Lincoln Electric statiflex 200-m Operator's Manual
Operator’s Manual
Statiflex®200-M
For use with machines having Product Numbers:
K1654-4 - Single Arm Base Unit
K1654-5 - Dual Arm Base Unit
K1654-6 - High Efficiency Single Arm
Base Unit
Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10348 | Issue D ate Dec-16
© Lincoln Global, Inc. All Rights Reserved.
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use “Ask the Experts” at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com
THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELEC TRIC.
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.
SAFETY DEPENDS ON YOU
Lincoln arc welding and cutting equipment is designed and built
with safety in mind. However, your overall safety can be increased
by proper installation ... and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,
think before you act and be careful.
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.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc.
Use corrective lenses if necessary
to stay a reasonable distance
away from the arc.
READ and obey the Safety Data
Sheet (SDS) and the warning label
that appears on all containers of
welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to
keep the fumes and gases from
your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away
from your face.
If you de velop unusual symptoms, see your supervisor.
Perhaps the welding atmosphere and ventilation system
should be checked.
WEAR CORRECT EYE, EAR &
BODY PROTECTION
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.
PROTECT others from splatter, flash, and glare
with protective screens or barriers.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
Safety 01 of 04 - 06/15/2016
SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel Engines
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and other
reproductive harm.
Gasoline Engines
The engine exhaust from this product contains chemicals known
to the State of California to cause cancer, birth defects, or other
reproductive harm.
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.
SAFETY
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.
1.h. To avoid scalding, do not remove the radiator
pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS MAY
BE DANGEROUS
2.a. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF).
Welding current creates EMF fields around welding cables
and welding machines
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.
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.
Safety 02 of 04 - 06/15/2016
SAFETY
ELECTRIC SHOCK
CAN KILL.
3.a. The electrode and work (or ground) circuits are
electrically “hot” when the welder is on. Do
not touch these “hot” parts with your bare 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
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.
between the
ARC RAYS CAN BURN.
4.a. Use a shield with the proper filter and cover plates to protect your
eyes from sparks and the rays of the arc when welding or
observing open arc welding. Headshield and filter lens should
conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material
to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
CAN BE DANGEROUS.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these fumes and gases.
When welding, keep your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep fumes and gases
away from the breathing zone. When welding hardfacing
(see instructions on container or SDS) or on lead
or cadmium plated steel and other metals or
coatings which produce highly toxic fumes, keep
exposure as low as possible and within applicable
OSHA PEL and ACGIH TLV limits using local
exhaust or mechanical ventilation unless exposure
assessments indicate otherwise. In confined
spaces or in some circumstances, outdoors, a
respirator may also be required. Additional
precautions are also required when welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PEL and
ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon 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.
3.j. Also see It ems 6.c. and 8.
5.d. Shielding gases used for arc welding can displace air and
cause
injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
Safety 03 of 04 - 06/15/2016
SAFETY
WELDING AND CUTTING
SPARKS CAN CAUSE
FIRE OR EXPLOSION.
6.a. Remove fire hazards from the welding area. If
this is not possible, cover them to prevent the welding sparks
rom starting a fire. Remember that welding sparks and hot
f
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.
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,
tc. should be suitable for the application and
e
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, 14501 George Carter Way
Chantilly, VA 20151.
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.
6.I. Read and follow NFPA 51B “Standard for Fire Prevention During
Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
Safety 04 of 04 - 06/15/2016
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SAFETY
s a rule of thumb, for many mild steel electrode, if the air is
A
visibly clear and you are comfortable, then the ventilation is
generally adequate for your work. The most accurate way to
determine if the worker exposure does not exceed the applicable
exposure limit for compounds in the fumes and gases is to have
n industrial hygienist take and analyze a sample of the air you
a
are breathing. This is particularly important if you are welding with
stainless, hardfacing or Special Ventilation products. All Lincoln
MSDS have a maximum fume guideline number. If exposure to
total fume is kept below that number, exposure to all fume from
the electrode (not coatings or plating on the work) will be below
the TLV.
There are steps that you can take to identify hazardous
substances in your welding environment. Read the product label
and material safety data sheet for the electrode posted in the work
place or in the electrode or flux container to see what fumes can
be reasonably expected from use of the product and to determine
if special ventilation is needed. Secondly, know what the base
metal is and determine if there is any paint, plating, or coating that
could expose you to toxic fumes and/or gases. Remove it from the
metal being welded, if possible. If you start to feel uncomfortable,
dizzy or nauseous, there is a possibility that you are being
overexposed to fumes and gases, or suffering from oxygen
deficiency. Stop welding and get some fresh air immediately.
Notify your supervisor and co-workers so the situation can be
corrected and other workers can avoid the hazard. Be sure you
are following these safe practices, the consumable labeling and
MSDS to improve the ventilation in your area. Do not continue
welding until the situation has been corrected.
NOTE: The MSDS for all Lincoln consumables is available on Lincoln’s web-
site: www.lincolnelectric.com
Before we turn to the methods available to control welding fume
exposure, you should understand a few basic terms:
Natural Ventilation is the movement of air through the
workplace caused by natural forces. Outside, this is usually the
wind. Inside, this may be the flow of air through open windows
and doors.
Mechanical Ventilation is the movement of air through the
workplace caused by an electrical device such as a portable fan
or permanently mounted fan in the ceiling or wall.
Source Extraction (Local Exhaust) is a mechanical device used
to capture welding fume at or near the arc and filter contaminants out of the air.
The ventilation or exhaust needed for your application depends
upon many factors such as:
• Workspace volume
• Workspace configuration
• Number of welders
• Welding process and current
• Consumables used (mild steel, hardfacing, stainless, etc.)
• Allowable levels (TLV, PEL, etc.)
• Material welded (including paint or plating)
• Natural airflow
Your work area has adequate ventilation when there is enough
ventilation and/or exhaust to control worker exposure to
hazardous materials in the welding fumes and gases so the
applicable limits for those materials is not exceeded. See chart of
TLV and PEL for Typical Electrode Ingredients, the OSHA PEL
Permissible Exposure Limit), and the recommended guideline, the
(
ACGIH TLV (Threshold Limit Value), for many compounds found in
welding fume.
Ventilation
There are many methods which can be selected by the user to
provide adequate ventilation for the specific application. The
following section provides general information which may be
helpful in evaluating what type of ventilation equipment may be
uitable for your application. When ventilation equipment is
s
installed, you should confirm worker exposure is controlled within
applicable OSHA PEL and/or ACGIH TLV. According to OSHA
regulations, when welding and cutting (mild steels), natural
ventilation is usually considered sufficient to meet requirements,
provided that:
1. The room or welding area contains at least 10,000 cubic feet
(about 22' x 22' x 22') for each welder.
2. The ceiling height is not less than 16 feet.
3. Cross ventilation is not blocked by partitions, equipment, or
other structural barriers.
4. Welding is not done in a confined space.
Spaces that do not meet these requirements should be equipped
with mechanical ventilating equipment that exhausts at least 2000
CFM of air for each welder, except where local exhaust hoods or
booths, or air-line respirators are used.
Important Safety Note:
When welding with electrodes which require special
ventilation such as stainless or hardfacing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings which
produce hazardous fumes, keep exposure as low as
possible and below exposure limit values (PEL and TLV)
for materials in the fume using local exhaust or
mechanical ventilation. In con ned spaces or in some
circumstances, for example outdoors, a respirator may
be required if exposure cannot be controlled to the PEL
or TLV. (See MSDS and chart of TLV and PEL for Typical
Electrode Ingredients.) Additional precautions are also
required when welding on galvanized steel.
6
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BIBLIOGRAPHY AND SUGGESTED READING
NSI, Standard Z49.1, Safety in Welding, Cutting and Allied
A
Processes. Z49.1 is now available for download at no charge at
NSI Z87.1, Practice for Occupational and Educational Eye and
A
Face Protection, American National Standards Institute, 11 West
42nd Street, New York, NY 10036.
Arc Welding and Your Health: A Handbook of Health Information
for Welding. Published by The American Industrial Hygiene
Association, 2700 Prosperity Avenue, Suite 250, Fairfax, VA
2031-4319.
2
NFPA Standard 51B, Cutting and Welding Processes, National Fire
Protection Association, 1 Batterymarch Park, P.O. Box 9146,
Quincy, MA 02269-9959.
OSHA General Industry Standard 29 CFR 1910 Subpart Q. OSHA
Hazard Communication Standard 29 CFR 1910.1200. Available
from the Occupational Safety and Health Administration at
http://www.osha.org or contact your local OSHA office.
The following publications are published by The American Welding
Society, P.O. Box 351040, Miami, Florida 33135. AWS publications may be purchased from the American Welding society at
http://www.aws.org or by contacting the AWS at 800-443-9353.
LISTED BELOW ARE SOME TYPICAL INGREDIENTS IN WELDING ELECTRODES AND
THEIR TLV (ACGIH) GUIDELINES AND PEL (OSHA) EXPOSURE LIMITS
INGREDIENTS CAS No. TLV mg/m3PEL mg/m
Aluminum and/or aluminum alloys (as AI)***** 7429-90-5 1.0 15
Aluminum oxide and/or Bauxite***** 1344-28-1 1. 0 5**
Barium compounds (as Ba)***** 513-77-9 0.5 0.5
Chromium and chromium alloys or compounds (as Cr)***** 7440-47-3 0.5(b) 0.5(b)
Hexavalent Chromium (Cr VI) 18540-29-9 0.05(b) .005(b)
Copper Fume 7440-50-8 0.2 0.1
Cobalt Compounds 7440-48-4 0.02 0.1
Fluorides (as F) 7789-75-5 2.5 2.5
Iron 7439-89-6 10* 10*
Limestone and/or calcium carbonate 1317-65-3 10* 15
Lithium compounds (as Li) 554-13-2 15 10*
Magnesite 1309-48-4 10 15
Magnesium and/or magnesium alloys and compounds (as Mg) 7439-95-4 10* 10*
Manganese and/or manganese alloys and compounds (as Mn)***** 7439-96-5 0.02 5.0(c)
Mineral silicates 1332-58-7 5** 5**
Molybdenum alloys (as Mo) 7439-98-7 10 10
Nickel***** 7440-02-0 0.1 1
Silicates and other binders 1344-09-8 10* 10*
Silicon and/or silicon alloys and compounds (as Si) 7440-21-3 10* 10*
Strontium compounds (as Sr) 1633-05-2 10* 10*
Zirconium alloys and compounds (as Zr) 12004-83-0 5 5
http://www.lincolnelectric.com/community/safety/ or at the AWS
website http://www.aws.org.
AWS F1.1, Method for Sampling Airborne Particulates Generated
by Welding and Allied Processes.
AWS F1.2, Laboratory Method for Measuring Fume Generation
ates and Total Fume Emission of Welding and Allied Processes.
R
AWS F1.3, Evaluating Contaminants in the Welding Environment: A
Strategic Sampling Guide.
AWS F1.5, Methods for Sampling and Analyzing Gases from
Welding and Allied Processes.
AWS F3.2, Ventilation Guide for Welding Fume Control
AWS F4.1, Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers and Piping That Have Held
Hazardous Substances.
AWS SHF, Safety and Health Facts Sheets. Available free of charge
from the AWS website at http://www.aws.org.
3
Supplemental Information:
(*) Not listed. Nuisance value maximum is 10 milligrams per cubic
meter. PEL value for iron oxide is 10 milligrams per cubic meter.
TLV value for iron oxide is 5 milligrams per cubic meter.
(**) As respirable dust.
(*****) Subject to the reporting requirements of Sections 311, 312,
and 313 of the Emergency Planning and Community Rightto-Know Act of 1986 and of 40CFR 370 and 372.
(b) The PEL for chromium (VI) is .005 milligrams per cubic meter as
an 8 hour time weighted average. The TLV for water-soluble
chromium (VI) is 0.05 milligrams per cubic meter. The TLV for
insoluble chromium (VI) is 0.01 milligrams per cubic meter.
(c) Values are for manganese fume. STEL (Short Term Exposure
Limit) is 3.0 milligrams per cubic meter. OSHA PEL is a ceiling
value.
(****) The TLV for soluble barium compounds is 0.5 mg/m
TLV and PEL values are as of October 2013. Always check Safety
Data Sheet (SDS) with product or on the Lincoln Electric website at
http://www.lincolnelectric.com
7
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TABLE OF CONTENTS
INSTALLATION ...........................................................................................................................SECTION A
TECHNICAL SPECIFICATIONS ...........................................................................................................A-1
GENERAL DESCRIPTION ...................................................................................................................A-2
COMPONENTS .................................................................................................................................A-3
NPACKING .....................................................................................................................................A-3
U
INSTALLATION .................................................................................................................................A-4
STATIFLEX 200-M(/HE) SINGLE ARM................................................................................................A-4
STATIFLEX 200-M DUAL ARM..........................................................................................................A-6
OPERATION ................................................................................................................................SECTION B
USERS ............................................................................................................................................B-2
INTENDED USE ................................................................................................................................B-2
MODIFICATIONS...............................................................................................................................B-2
OPERATION .....................................................................................................................................B-2
PRODUCT COMBINATIONS ...............................................................................................................B-4
USE ............................................................................................................................................B-4
FILTER MAINTENANCE INDICATOR...................................................................................................B-4
OPTIONS ................................................................................................................................SECTION C
MAINTENANCE ......................................................................................................................................
DISPOSAL
MAINTENANCE...........................................................................................................................SECTION D
PERIODIC MAINTENANCE.................................................................................................................D-1
FILTER REPLACEMENT ....................................................................................................................D-2
TROUBLESHOOTING ..................................................................................................................SECTION E
WIRING DIAGRAM ......................................................................................................................SECTION F
Parts List .........................................................................................................parts.lincolnelectric.com
Content/details may be changed or updated without notice. For most current Instruction Manuals, go to
parts.lincolnelectric.com.
STATIFLEX®200-M
28.74 in (730 mm)
35.43 in
(900 mm)
25.20 in
(640 mm)
31.89 in
(810 mm)
5.12 in (130 mm)
5.12 in (130 mm)
Ø7.67 in
(Ø195 mm)
Ø6.10 in
(Ø155 mm)
teChniCal sPeCiFiCations -
K1654-4 - Single Arm Base Unit
K1654-5 - Dual Arm Base Unit
1654-6 - High Efficiency Single Arm Base Unit
K
INSTALLATION
GENERAL
EIGHT
W
OPERATING CAPACITY
6 LBS (30 KGS)
6
EXTRACTOR TYPE LOW VACUUM; HIGH VOLUME
AIRFLOW RATE
STATIFLEX 200-M(/HE)
SINGLE ARM
MAX. 735 CFM (1,250 M3/H)
MAX. 1,200 CFM (2,040 M3/H) AT
STATIFLEX 200-M DUAL ARM
SIMULTANEOUS USE OF TWO
SF2400
FILTER TYPE
STATIFLEX 200-M SINGLE/
DUAL ARM BASE UNIT:
STATIFLEX 200-M/HE
SINGLE ARM BASE UNIT:
FILTER CLASS (ACCORDING TO ASHRAE 52.2)
STATIFLEX 200-M SINGLE/DUAL ARM
DISPOSABLE CELLULOSE
LONGLIFE FILTER CARTRIDGE
WITH PRECOAT
DISPOSABLE CELLULOSE /
POLYESTER BLEND
LONGLIFE FILTER
UNTREATED: MERV 11
TREATED: MERV 14
STATIFLEX 200-M/HE SINGLE ARM MERV 16
FILTER SURFACE AREA
538 FT2(50 M2)
AMBIENT CONDITIONS
MINIMUM TEMPERATURE 41ºF (5ºC)
NOMINAL 68º F (20º C)
MAXIMUM TEMPERATURE 113ºF (45ºC)
MAXIMUM RELATIVE HUMIDITY 80%
DIMENSIONS
A-1
STATIFLEX®200-M
INSTALLATION
general desCriPtion
This instruction manual describes three base units:
• K1654-4 Statiflex 200-M Single Arm stationary filter unit with
disposable filter cartridge - filter class MERV 11 (untreated);
ERV 14 (treated)
M
K1654-5 Statiflex 200-M Dual Arm stationary filter unit with
•
disposable filter cartridge - filter class MERV 11 (untreated);
MERV 14 (treated)
• K1654-6 Statiflex 200-M/HE Single Arm stationary filter unit with
high efficiency disposable filter cartridge - filter class MERV 16
STATIFLEX 200-M(/HE) SINGLE ARM
The K1654-4 Statiflex 200-M and K1654-6 Statiflex 200-M/HE
Single Arm wall-mounted filter unit provides filtration for use with
one extraction arm and one fan.
STATIFLEX 200-M DUAL ARM
The K1654-5 Statiflex 200-M Dual Arm wall-mounted filter unit
provides filtration for use with two extraction arms and two fans.
STATIFLEX 200-M SINGLE/DUAL ARM
The Statiflex 200-M features an aluminum prefilter and a square
disposable cellulose LongLife filter cartridge. This LongLife filter
cartridge is provided with a precoat (ExtraCoat) to extend the
lifespan and increase initial operating efficiency of the filter.
The Statiflex 200-M is used for filtering fume which is released
during the most common welding processes, such as:
•
MIG/MAG Solid Wire (GMAW)
•
MIG/MAG Flux Cored Wire (FCAW)
•
TIG (GTAW) Welding
•
Stick Welding (MMA or SMAW)
•
Autogeneous Welding
The Statiflex 200-M is designed for light to medium duty, intermittent welding applications listed above.
The Statiflex 200-M Single Arm system is recommended for
annual consumable use of approximately*:
•
1500 lbs. (700 kg) GMAW or FCAW or GTAW
•
1100 lbs. (500 kg) MMA or SMAW or Autogeneous
The Statiflex 200-M Dual Arm system is recommended for annual
consumable use per workstation of approximately*:
•
750 lbs. (350 kg) GMAW or FCAW or GTAW
•
550 lbs. (250 kg) MMA or SMAW or Autogeneous
* Variables such as coatings (e.g. oil), base material, weld
process, humidity and welding procedures can affect filter life and
performance.
Unspecified amount and type of smells and odors, e.g. ozone (O3),
can be captured with optional Activated Carbon Filter used within
Statiflex 200-M unit.
STATIFLEX 200-M/HE SINGLE ARM
he Statiflex 200-M/HE features an aluminum prefilter and a high
T
efficiency square disposable cellulose/polyester blend LongLife
filter cartridge.
The Statiflex 200-M/HE is used for filtering fume which is released
during the most common welding processes, such as:
•
MIG/MAG Solid Wire (GMAW)
•
MIG/MAG Flux Cored Wire (FCAW)
•
TIG (GTAW) Welding
•
Stick Welding (MMA or SMAW)
•
Autogeneous Welding
The Statiflex 200-M /HE is designed for light to medium duty,
intermittent welding applications listed above.
The Statiflex 200-M/HE Single Arm system is recommended for
annual consumable use of approximately*:
•
500 lbs (250 kg) GMAW or FCAW or GTAW
•
385 lbs (175 kg) MMA or SMAW or autogeneous
* Variables such as coatings (e.g. oil), base material, weld process
and welding procedures can affect filter life and performance.
Unspecified amount and type of smells and odors, e.g. ozone (O3),
can be captured with optional Activated Carbon Filter used within
Statiflex 200-M/HE unit.
A-2
C
E
D
J
B
H
G
A
Front View
Back View -
Filter Cover Removed
I
I
F
STATIFLEX®200-M
INSTALLATION
ComPonents
The Statiflex 200-M(/HE) Single and Dual Arm housing consists of
the following main components and features (See Figure A.1):
A. Outlet Opening (2)
B. Filter Cover
C. Filter Cover Plate
D. Prefilter
E. LongLife filter cartridge
F. Latch (3)
G. Bottom Housing
H. Filter Maintenance Indicator
I. Inlet Opening (2)
J. Wall Mounting Bracket
ATTENTION
• The installer is responsible for following
federal, state and local safety codes and
regulations.
• Before drilling, verify locations of existing
gas, water or electrical conduits.
unPaCKing
Check that the product package is complete. The package should
contain:
STATIFLEX 200-M(/HE) SINGLE ARM
(1) Complete filter unit, with prefilter and filter cartridge installed
•
• (1) Mounting bracket
• (1) 8 in. Diameter Connection hose, length 4.9 ft.
• (2) 8 in. Diameter Hose clamps
• (2) Screws
• (1) Sealing Ring
• (1) Reducer
• (3) Sheet metal screws
• (1) Instruction manual
STATIFLEX 200-M DUAL ARM
• (1) Complete filter unit, with prefilter and filter cartridge installed
• (1) Mounting bracket
• (2) 8 in. Diameter Connection hoses, length 4.9 ft.
• (4) 8 in. Diameter Hose clamps
• (2) 8 in. Diameter Non-return valves
• (2) Reducers
• (2) Sealing Rings
• (2) Screws
• (12) Sheet metal screws
• (1) Instruction manual
If parts are missing or damaged, contact Lincoln Electric
Automation Service 888-935-3878.
FIGURE A.1
A-3
STATIFLEX®200-M
INSTALLATION
INSTALLATION
For information on installation of fume extraction arm(s) and extraction fan(s), refer to the
corresponding manuals.
OTE: Mount the Statiflex 200-M, extraction fan(s) and fume
N
extraction arm(s) as close as possible to the source of welding.
ATTENTION
Use adequate mounting hardware for
installing the unit, corresponding with the
ype of wall. Be aware, the weight of the
t
unit when unpacked is approx. 66 lbs (30
kg). As filter saturates it will increase in
weight.
statiFlex 200-m(/he) single arm
NOTE: In the standard configuration of the Statiflex 200-M(/HE)
Single Arm system, the filter unit is positioned on the right side of
the fan. However, it may be mounted on either side, as long as the
connection hose reaches from the outlet of the fan to the inlet of
the Statiflex 200-M(/HE).
Installation Steps:
FIGURE A.3
BOTTOM HOUSING
INLET
3. Using a multi-purpose power saw, cut open one two outlets of
the filter cover See Figure A.4. The outlet shall be on the same
side as the inlet, on base See Figure A.3.
FIGURE A.4
OUTLET OPENING
CAUTION
If the base is not completely disassembled, it may be
possible that some plastic residue will get stuck in filter
after step 1.
1. Loosen latches and remove the filter cover. See Figure A.2.
FIGURE A.2
LATCH
FILTER COVER
4. Secure the mounting bracket to the wall. See Figure A.5.
Fasteners not included.
5. Secure the bottom housing onto the mounting bracket. See
Figure A.5.
FIGURE A.5
MOUNTING
BRACKET
FASTENERS
(NOT INCLUDED)
2. Using a multi-purpose power saw, cut open through the scribe
mark on the left (or right) inlet of bottom housing; 8 in. (200
mm). See Figure A.3. If using a 6 in. diameter hose, cut open
through the scribe mark on the 6 in. side of the left (or right) inlet
of bottom housing.
BOTTOM
HOUSING
A-4
STATIFLEX®200-M
FAN OUTLET
8 in. DIAMETER
CONNECTION HOSE
8 in. HOSE CLAMP
REDUCER 6.4 in. - 8 in.
INSTALLATION
NOTE: The installation may be made permanent by running two
crews in through the bottom housing against the mounting
s
bracket. See Figure A.6.
FIGURE A.6
6. Replace the filter cover and fasten latches.
7. 8 in. hose gets clamped to the 8 in. side of the reducer with hose
clamp. Then the 6.4” side of reducer goes over the outlet of the
fan and secured with 3 sheet metal screws. See Figure A.7
FIGURE A.7
9. Slide the 8 in. diameter connection hose over the sealing ring on
he inlet by placing the hose all the way over the sealing ring.
t
Secure with a 8 in. diameter hose clamp. See Figure A.8.
FIGURE A.8
INLET
8 in. DIAMETER CONNECTION HOSE
NOTE: When installing in combination with the SF4200 fan, first
mount flexible outlet with steel bushing (included with SF4200
fan package) on the fan housing.
8. Install the 8 in. sealing ring on the inlet side of the hose.
.
ATTENTION
In case the filter unit is mounted left of the
SF2400 fan, the SF2400 will be in reverse
position, resulting in centerpoints of fan
outlet and Statiflex 200-M(/HE) inlet not
aligning. This will not affect system performance.
A-5
STATIFLEX®200-M
10. in.
(250 mm)
38-43.5 in.
(965-1105 mm)
9.06 in.
(230 mm)
5 ft (1525 mm)
9
Recommended
Minimum
Recommended
ft
(2745 mm)
8.5 ft
(2600 mm)
INSTALLATION
statiFlex 200-m dual arm
NOTE: The Statiflex 200-M Dual Arm should be mounted between
two SF2400 extraction fans.
Installation Steps:
FIGURE A.9
ATTENTION
The SF 2400 which is mounted right of the
Statiflex 200-M filter unit will be in reverse
position, resulting in centerpoints of fan
outlet and filter inlet not aligning. This will
not affect system performance.
1. Loosen latches and remove the filter cover. See Figure A.10.
FIGURE A.10
LATCH
FILTER COVER
2. Using a multi-purpose power saw cut open through the scribe
marks both inlets of bottom housing; cutouts to be Ø 8 in. (200
mm). See Figure A.11.If using a 6 in. diameter hose, cut open
through the scribe mark on the 6 in. side of the inlets of bottom
housing.
FIGURE A.11
BOTTOM
HOUSING
INLET
A-6
STATIFLEX®200-M
INSTALLATION
3. Using a multi-purpose power saw, cut open both outlets of the
ilter cover. See Figure A.12.
f
IGURE A.12
F
OUTLET OPENING
4. Secure the mounting bracket to the wall. See Figure A.13.
Fasteners not included.
FIGURE A.13
FIGURE A.14
INLET
HOSE CLAMP
8 in. DIAMETER CONNECTION HOSE
9. Fit the other ends of the 8 in. connection hoses over the 8 in.
diameter non-return valves (See Diagram Page F-7) and secure
them with a 8 in. diameter hose clamp. See Figure A.15
FIGURE A.15
5. Secure the bottom housing onto the mounting bracket.
See Figure A.13.
NOTE: The installation may be made permanent by running two bolts
in through the bottom housing against the mounting bracket (See
Figure A.13).
6. Replace the filter cover and fasten latches.
7. Install the 8 in. sealing rings on both inlets of the base.
8. Fit the 8 in. diameter connection hoses over the sealing rings on
the inlets and secure them with a 8 in. diameter hose clamp. See
Figure A.14.
HOSE CLAMP
8 in. DIAMETER CONNECTION HOSE
8 in. DIAMETER NON-RETURN VALVE
NOTE: Be aware of the airflow direction from fan to filter unit. If non-
return valves are installed backwards, airflow will be blocked.
See Figure F-7
10. Fit the 8 in. side of the reducer to the non-return valve and
secure with 3 sheet metal screws. Slide the 6.4 in. side of the
reducer over the outlet of the fan and sealing ring, then secure
with 3 sheet metal screws. See Figure A.16
FIGURE A.16
6.3 - 8 in. REDUCER
8 in. DIAMETER
NON-RETURN VALVE
FAN
A-7
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