PowCon PDVS-II Owner's Manual

Rev.
En.
w/Serial
I~A
,~/
Pow
Con
Processes
MIG
Flux
C
Number
(GMAW)
Cored
KH341356
Welding
(FCAW)
March
Welding
1997
4
x~n:~,
~
/
44
Description
Feeder
Wire
PDVS-II
4k
:
4k
2/
OWNERS
MANUAL
OM-171
892-C
TABLE
OF
CONTENTS
SECTION
1-1. 1-2.
1-3.
1-4. 1-5.
SECTION
1-1.
1-2.
1-3.
1-4.
1-5.
SECTION
2-1.
2-2. 2-3. 2-4.
2-5. 2-6.
2-7.
SECTION
3-1.
SECTION
4-1.
4-2.
4-3. 4-4.
SECTION SECTION
OPTIONS
WARRANTY
1
SAFETY
Symbol
Arc
Welding
Additional
Principal
EMF
Information
1
CONSIGNES
Signification
Dangers
Dangers
Ia
maintenance
et
Principales
Information
INSTALLATION
2
Typical
Installing
Gun
Recommendation
Connecting
Connecting
Connecting
Installing
3OPERATION
Controls
4MAINTENANCE
Routine
Overload
Calibrating
PRECAUTIONS
Usage
Hazards
Symbols
Standards
Safety
des
relatifs
au
supplOmentaires
normes
les
sur
Connections
And
Aligning
Welding
Shielding
Weld
And
Threading
Maintenance
Protection
Optional
Troubleshooting
ELECTRICAL
5
6
PARTS
LIST
AND
ACCESSORIES
For
Installation,
DE
SECURITE
symboles
soudage
de
sØcuritØ
champs
Wire
Table
Gun
Gas
Cable
Welding
&
TROUBLESHOOTING
1PM
DIAGRAM
-
READ
BEFORE
Operation,
AVANT
LIRE
a
Iarc
relation
en
avec
installation,
electromagnetiques
And
And
Guide
Voltage
Drive
Sensing
(Optional)
Wire
Meter
And
Roll
Lead
USING
Maintenance
IJTILISATION
le
fonctionnement
1
1 1
3 3
4
5
5
5
7
8 8
9
9
10
11
11
12 12 13 14
14
15
15 15 16
17 18 20
SECTION
1
-
SAFETY
PRECAUTIONS
-
READ
BEFORE
USING
som
nd_5/97
1-t..
a
Marks
A
Means
~
1~2
The
A
to
see
to
only
found
follow
Only
A
repair
A
During
circuits automatic
metal installed
Do
Wear
Insulate
or
work
Do
there
Use
If
unit.
Disconnect
servicing
to
Properly
Owners
Always
power
in
grounded
When
conductor
Frequently
replace
Turn
Do
Do
Symbol
Means hazards
shown
a
special
t~Jote~
Arc
symbols
attention
call
the
symbol,
avoid
a
summary
in
all
qualified
this
operation,
are
wire
touching
parts
or
improperly
touch
not
dry,
yourself
covers
or
ground.
not
use
is
a
AC
output
AC
output
OSHA
verify
cord
disconnect
making
cord
oft
all
not
use
not
drape
Usage.
Warning!
with
this
in
the
adjoining
safety
message.
safety
related.
not
Welding
shown
below
and
to
identity
watch
out,
the
of
Standards
Standards.
persons
keep
or
is
electrically
input
when
live
the
the
welding
grounded
electrical
insulating
from
work
enough
in
output
of
falling.
if
ONLY
required,
power
1910.147
and
ground
and
national,
the
supply
wire
that
box
or
outlet.
input
double-check
input
damaged,
cables
over
The
should
everybody,
live
severe
power
wire,
to
damp
required
use
ground
is
connections,
power
when
hazard.
the
the
Safety
Safety
unit.
ELEcTRIC.
Touching
shocks
circuit The
also
welding,
live
hole-tree
big
AC
danger
is
input
this
equipment.
CFR
29
install
Manual
ground
receptacle
first
inspect
immediatelyifdamaged
equipment
worn,
Out!
Watch
procedure!
The
symbols.
Hazards
used
are
and
safety
more
SHOCK..can
electrical
power
wire
wire
equipment
parts.
gloves
and
prevent
areas,
remote
or
stop
Lockout/tagout
(see
properly
cord
not
undersized,
your
throughout
possible
the
follow
information
complete
in
listed
install,
especially
parts
The
burns.
live
whenever
circuit
is
on.
drive
reel,
are
electrically
and
using
ground
physical
any
if
movement
for
the
output
engine
Safety
this
equipment
and
state,
check
connected
is
connected
plug
attach
connections.
for
cord
in
use.
body.
operate,
and
welding
Standards).
damage
bare
or
There
are
possible
hazards.
related
given
safety
Section
1-4.
maintain,
children,
icl~
can
electrode
the
machine
semiautomatic
In
roll
housing,
live.
isahazard.
protection.
body
insulating
dry
contact
is
process.
control
before
input
power
according
local
codes.
and
be
sure
to
ground
proper
or
wiring
spliced
poorly
possible
hazards
output
are
manual
this
When
instructions
cause
you
below
Information
Read
and
and
away.
fatal
work
and
is
on.
internal
and
Incorrectly
mats
with
confined,
if
or
present
installing
according
to
that
input
terminal
to
a
properly
grounding
bare
wiring
kill.
can
cables.
all
the
on
or
its
Watch
This ELECTRIC Consult
actions
If with
is
Do
or
Use
parts
Wear
Keep
Clamp
or
Insulate
contact
Do
single
SIGNIFICANT
input
Turn
capacitors
before
if
Keep
If
remove
or
If
Read
manufacturers
cleaners,
Work
wearing
person
lower
breathing
Do
operations.
form
Do
cadmium
weld
wearing
containing
of
group
SHOCK,
symbols
avoid
to
earth
grounding
a
separate
touch
not
another
well-maintained
only
at
once.
a
safety
all
panels
work
worktable
work
with
not
connect
weld
power
Oft
inverter,
touching
your
inside,
welding
ventilation
the
in
a
an
nearby.
the
weld
not
highly
weldoncoated
not
area,
an
symbols
MOVING
related
and
hazards.
the
of
the
cable
electrode
Maintain
harness
and
as
near
clamp
metal
any
more
DC
inverters.
on
from
covers
with
the
when
terminal.
VOLTAGE
disconnect
electrode
cable
output
according
parts.
any
~JM~
Welding
fumes
these
health.
of
out
head
ventilate
and
the
fumes
is
poor,
Material
instructions
degreasers.
confined
use
space
air-supplied
Welding
level
oxygen
safe.
air
is
locations
in
The
heat
toxic
and
steel,
plated
the
area
air-supplied
elements
these
means
Warning!
PARTS,
instructions
workpiece
do
not
use
it
are
you
different
a
equipment.
unit
according
if
working
securely
metal-to-metal
good
weld
as
connected
not
object.
than
one
input
instructions
to
GASES
AND
produces
and
gases
fumes.
the
and/or
area
and
gases.
an
approved
Data
Safety
for
only
respirator.
fumes
causing
near
degreasing,
rays
of
gases.
and
irritating
metals,
the
unless
is
well
ventilated,
respirator.
can
and
is
required,
work
in
contact
machine.
Repair
to
floor
above
in
place.
practical.
electrodeorwork
exists
power,
in
can
fumes
can
Do
not
use
air-supplied
Sheets
metals,
consumables,
if itiswell
Always
and
gases
injury
the
arc
can
such
as
coating
and
The
coatings
off
toxic
give
Out!
HOT
PARTS
below
for
grounditdirectly
work
or
clamp
with
the
work,
or
replace
manual.
level.
to
contact
to
workpiece
cable
after
removal
and
discharge
Maintenance
be
hazardous.
and
gases.
be
hazardous
breathe
the
exhaust
at
respirator.
(MSDS5)
ventilated,
have
trained
a
can
displace
death.
or
cleaning,
with
react
galvanized,
is
removed
if
necessary,
and
fumes
possible
hazards.
necessary
cable.
ground,
damaged
workpiece
to
prevent
to
Section
Breathing
to
fumes.
the
arc
and
coatings,
or
watch-
air
Be
sure
or
spraying
vapors
lead,
from
metals
any
if
welded.
any
of
input
your
to
the
while
and
the
to
or
the
while
OM-171
892
Page
1
Wear
your
and
Wear
helmet.
Use
glare;
Wear
material
and
burns.
cause
is
area
Protect
Do
Remove
this
Be
easily
Watch
Be
can
Do
unless
Safety
Connect
practical
unknown
Do
Remove
contact
Wear
shirt,
Remove
from
ARC
Arc visible
that
weld.
a
welding
face
and
listed
Z87.1
approved
protective
others
warn
protective
(leather
Accidental
explosion,
sparks,
before
safe
yourself
weld
is
cause
not
go
for
weld
where
flammables
all
possible,
that
welding
through
fire,
that
fireonthe
on
are
they
not
alert
aware
not
Standards).
work
to
prevent
paths
welder
not
use
stick
when
tip
oil-free
cuffless
any
person
your
RAYS
from
rays
invisible
and
burn
can
fitted
helmet
when
eyes
in
Safety
glasses
safety
barriers
or
screens
not
watch
to
clothing
and
wool)
WELDING
Welding
drums,
can
hot
on
or
pipes,
from
off
fly
workpiece,
contact
overheating,
doing
any
others
and
sparks
flying
within
tightly
sparks
cracks
small
keep
on a
hidden
containers
a
and
welding
closed
properly
cable
the
to
welding
and
causing
thaw
to
electrode
in
not
use.
protective
trousers,
combustibles,
FLYING
garments
high
before
doing
METAL
Welding,
cause
sparks
can
they
Wear
approved
shields
bum
can
the
welding
(ultraviolet
skin.
and
eyes
with
a
proper
or
welding
watching
Standards).
with side
to
protect
the
arc.
from
made
and
foot
protection.
cause
can
closed
containers,
cause
can
the
welding
and
hot
equipment
of
electrode
or
welding.
from
flying
can
ft
35
(10.7
them
cover
materials
and
hot
and
openings
fire
extinguisher
floor,
ceiling,
side.
such
prepared
from
according
workasclose
from
current
electric
frozen
pipes.
holderorcut
such
and
shoes,
such
as
a
welding.
any
can
and
oft
wire
flying
slag.
chipping,
throw
safety
under
even
eyes
process
Sparks
shade
durable,
fire
them
arc.
to
Check
fire.
sparks
strike
m)
with
as
tanks,
to
traveling
shock
as
a
butane
injure
brushing,
metal.
your
and
produce
and
infrared)
fly
filter
of
(see
shields
from
others
flame-resistant
or
explosion
such
blow
to
The
flying
can
metal
and
and
hot
flammable
of
the
welding
approved
from
to
adjacent
nearby.
bulkhead,
drums,
AWS
to
the
welding
long,
and
fire
off
welding
leather
gloves,
cap.
lighter
eyes
and
As
glasses
welding
skin
intense
off
from
to
protect
ANSI
Z49.1
under
flash
as
tanks,
Sparks
up.
sparks,
cause
objects
be
sure
metal.
material.
covers.
welding
areas.
or
partition
or
F4.1
area
possibly
hazards.
wire
or
matches,
grinding
welds
with
helmet.
rays
the
your
and
fires
can
the
If
arc.
can
pipes,
(see
as
at
heavy
cool,
side
Protect
mechanical
Install
support
Keep
Never
Never
Never
Use
fittings
associated
Turn
Keep
use
Read
associated
Standards.
BUILDUP
1
HOT
I
MAGNE1IG
NOISE
Noise
damage
CYLINDERS
Shielding
pressure. Since
process,
compressed
shocks,
cylinders
or
cylinder
cylinders
a
drape
allow
a
welding
weld
on
correct
only
designed
parts
face
away
protective
connected
or
follow
and
equipment,
Shutoff
shielding
Always
approved
PARTS
touch
not
Do
Allow
cooling
torch.
Pacemaker
Wearers
near
going
welding
can
from
hearing.
Wear
approved
high.
gas
If
cylinders
gas
be
gas
slag,
in
an
upright
to
rack
from
away
torch
welding
electrode
a
pressurized
shielding
for
the
specific
in
good
from
valve
in
place
cap
for
use.
instructions
and
GAS
OF
gas
ventilate
confined
air-supplied
cause
can
hot
parts
before
period
FIELDS
should
wearers
arc
can
consult
welding,
operations.
some
processes
ear
protection
can
explode
cylinders
damaged,
are
normally
to
treat
sure
cylinders
flames,
open
position
fallingortipping.
prevent
welding
any
a
over
gas
touch
to
cylinder
cylinders,
gas
application;
condition.
when
outlet
valve
over
on
compressed
CGA
publication
can
injure
when
supply
spaces
respirator.
severe
handed.
bare
working
affect
keep
away.
their
gouging,
hearing
or
contain
a
cylinder
part
them
carefully.
excessive
from
sparks,
securing
by
electrical
other
or
cylinder.
cylinder.
any
explosion
regulators,
maintain
opening
when
except
P-i
or
in
not
use.
or
use
burns~
on
or
gun
pacemakers
before
doctor
or
spot
equipment
if
noise
If
damag~d
gas
can
of
and
to
will
cylinder
gas
listed
can
level
is
under
high
explode.
the
welding
heat,
arcs.
a
stationary
circuits.
result.
and
hoses,
them
and
valve.
is
cylinder
cylinders,
in
Safety
in
OM-17i
892
Page
2
I
-3~
Do is
not
properly
Additional
FIRE
Do
combustible
Do
overload
sized,
building
rated,
Symbols
OR
EXPLOSION
install
not
install
not
wiring
and
or
place
surfaces.
unit
near
be
sure
protected
For
Installation,
hazard
unit
on,
over,
flammables.
supply
power
handle
this
to
unit.
near
or
system
Operation,
And
MOVING
Maintenance
PARTS
away
all
and
from
doors,
securely
Keep Keep
closed
~an
moving
panels,
in
place.
cause
parts
covers,
injury
suchasfans.
and
guards
FALLING
Use
gear,
Use
support
If
using
long
unit.
OVERUSE
Allow
Reduce
starting
Do
STATIC
Put
handling
Use
store,
MOVING
Keep
Keep
rolls.
WELDING
Do
so.
Do
other
welding
UNIT
lifting
eye
cylinders,
gas
equipment
unit.
forks
lift
enough
can
cooling
current
weld
to
block
not
(ESD)
on
grounded
boards
proper
move,
PARTS
from
away
away
WIRE
not
press
not
point
people,
wire.
can
cause
lift
unit
to
or
any
of
adequate
to
move
cause
or
unit,
beyond
follow
reduce
to
extend
period;
again.
filter
airflow
or
can
damage.
wrist
or
parts.
static-proof
PC
ship
cm
boards.
cause:
or
moving
from
pinch
points
can
cause
trigger
gun
toward
gun
or
any
any
metal
injury
NOT
only,
other
capacity
be
running
accessories.
to
forks
sure
opposite
OVERHEATING
rated
duty
duty
cycle
unit.
to
boards;
pc
BEFORE
strap
and
bags
boxes
Injii~,
parts.
such
as
injury
instructedtodo
until
of
the
part
when
threading
lift
and
are
of
side
cycle.
before
to
drive
body,
The
promptly
installation.
notified
If
equipment
Have
Keep keep
shielding
To
reduce
possible,
Locate
tronic
Be
sure
according
If
interference
such
using
HF.
RADiATI~Ncant~seiiiterferen~e~
High-frequency
navigation,
communications
Have electronic
is
user
responsible
correct
any
the
FCC
by
at
once.
the
installation
high-frequency
spark
to
at
gaps
minimize
ARC
WELDING
Electromagnetic
sensitive
computers
suchasrobots.
Be
sure
electromagnetically
possible
close
welding
interference,
together,
operation
equipment.
this
welding
this
manual.
to
still
occurs,
moving
filters,
the
or
shielding
as
line
safety
only
qualified
equipment
for
interference
about
regularly
source
correct
setting,
the
possibility
electronic
and
all
equipment
and
down
100
machine
the
machine,
welding
the
interfere
can
(H.F.)
services,
computers,
equipment.
persons
perform
familiar
this
havingaqualified
problem
interference,
checked
doors
can
energy
resulting
and
maintained.
and
panels
and
use
of
interference.
cause
can
stop
tightly
grounding
Interference
interfere
equipment
computer-driven
in
the
welding
compatible.
weld
such
low,
from
installed
must
using
area.
take
cables
as
sensitive
any
and
extra
shielded
on
keep
meters
is
user
work
with
radio
and
with
installation.
electrician
from
the
the
using
shut,
and
with
such
as
equipment
is
area
short
as
the
as
floor.
elec
grounded
measures
cables,
1-4.
in
Safety
Welding
Safetyand
dent
D.C.
Recommended
Cutting
American
Welding
National
Protection
Society,
of
Documents,
20402.
of
Society,
Principal
and
Welding
Health
Containers
Welding
Electrical
Association,
Cutting,
N.W.
550
Standards,
U.S.
Safe
Practices
Society
N.W.
550
Code,
Batterymarch
That
Safety
ANSI
LeJeune
OSHA
Government
for
Have
Standard
LeJeune
Standard
NFPA
Standards
Standard
Rd,
29
the
Held
Rd,
Z49.
Miami
CFR
1910,
Printing
Preparation
Hazardous
AWS
F4.1,
Miami,
70,
Park,
Quincy,
1,
FL
33126
from
Office,
for
FL
33126
from
MA
from
American
Superinten
Washington,
Welding
Substances,
from
American
National
02269.
and
Fire
Safe
Handling
from
P-i,
Highway,
Code Canadian
for
Suite
Safety
Boulevard,
Safe
Practices
Protection,
Institute,
Cuffing
Fire
1430
And
Protection
of
Compressed
Compressed
501,
Arlington,
in
Welding
Standards
Rexdale,
ANSI
Ontario,
For
Standard
Broadway,
Welding
Association,
Gases
Gas
Association,
VA
and
Cutting,
Association,
Canada
Occupation
Z87.i,from
New
York,
Processes,
Batterymarch
22202.
Standards
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NY
NFPA
in
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1235
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1
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10018.
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Park,
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Sales,
Eye
National
51
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Quincy,
OM-171
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17.2,
178
And
Standards
from
MA
892
Davis
from
Rexdale
Face
National
02269.
Page
3
1-5
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OM-171
892
Page
4
SECTION
1-1
Signification
-
1
CONSIGNES
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OM-171
892
Page
6
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