ULTRA FLEX®350
For the Following Specs:
500237A-1 Pulse
•
OWNER’S MANUAL Number 430429-465 (Rev - 0)
Issued February 28, 2000
IMPORTANT: Readtheseinstructionsbeforeinstalling, operating,or servicing this system.
THERMAL ARC INC., TROY, OHIO 45373-1085, U.S.A.
430429-465
TABLE OF CONTENTS
INTRODUCTION 1
How To Use This Manual ..................................1-1
Equipment Identification ..................................1-1
Receipt Of Equipment ...................................1-1
SAFETY INSTRUCTIONS AND WARNINGS 2
DESCRIPTION OF EQUIPMENT 3
General ...........................................3-1
Specifications ........................................3-1
Duty Cycle .........................................3-2
Volt-Ampere Curves ....................................3-2
Description Of Controls And Features ...........................3-4
Protection Features .....................................3-5
Description of Control Panels ................................3-5
INSTALLATION 4
Location ...........................................4-1
Voltage Configuration ....................................4-1
Connecting The Welding Machine To Line Voltage ....................4-1
Use Of Engine-Generators For Input Power ........................4-2
Grounding ..........................................4-2
Welding Leads .......................................4-2
OPERATION 5
General ...........................................5-1
Power Up Sequence ....................................5-2
SMAW Operation ......................................5-2
LIFT GTAW Operation ...................................5-3
GTAW Operation ......................................5-4
GMAW/FCAW Operation ..................................5-6
Pulsed GMAW .......................................5-6
Optional Programming Pendant ..............................5-8
SAFE............................................5-8
MAINTENANCE 6
TROUBLESHOOTING 7
General ...........................................7-1
Fault Codes .........................................7-3
PARTS LIST 8
Equipment Identification ..................................8-1
How To Use This Parts List .................................8-1
DIAGRAMS
WARRANTY
February 28, 2000
INTRODUCTION
430429-465
INTRODUCTION
How To Use This Manual
This Owner’s Manual usually applies to just the
underlined specification or part numbers listed on
the cover. If none are underlined, they are all covered by this manual.
To ensure safe operation, read the entire manual,
including the chapter on safety instructions and
warnings.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay particular
attention to the information provided under these
headings. These special annotationsare easilyrecognized as follows:
WARNING gives information regarding possible personal injury. Warnings will be enclosed
in a box such as this.
CAUTION refers to possible equipment
damage. Cautions will be shown in bold
type.
NOTE offers helpful information concerningcertain operating procedures. Notes will
be shown in italics.
Equipment Identification
The unit’s identification number (specification or
part number), model, and serial number usually
appear on a nameplate attached to the control
panel. In some cases, the nameplate may be attached to the rearpanel. Equipment which does not
have a control panel such as gunand cable assemblies are identified only by the specification or part
number printed on the shipping container. Record
these numbers for future reference.
Receipt Of Equipment
When you receive the equipment, check it against
the invoice to make sure it is complete and inspect
theequipmentforpossible damage due to shipping.
If there is any damage, notify the carrier immediately to file a claim. Furnish complete information
concerning damage claims or shipping errors to
Thermal Arc, Order Department, 2200 Corporate
Drive, Troy, Ohio 45373-1085. Include all equipment identification numbers as described above
along with a full description of the parts in error.
Additional copies of this manual may be purchased by contacting Thermal Arc at the address
given above. Include the Owner’s Manual number
and equipment identification numbers.
February 28, 2000 1-1
430429-465
INTRODUCTION
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1-2 February 28, 2000
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
ARC WELDING can be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER
WEARERSKEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSETHESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does
not strictly observe all safety rules and take precautionary actions.
Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and
trainingbefore using this equipment. Anyone not having extensive training in welding and cutting practicesshould not attempt to weld. Certain
of the practices apply to equipment connected to power lines; other practices apply to engine driven equipment.
Safe practices are outlined in the American National Standard Z49.1 entitled:
other guides to what you should learn before operating this equipment are listed at the end of these safety precautions.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.
ELECTRIC SHOCK can kill.
Touchinglive electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electricallylive whenever the output is on. The input
power circuit and machine internal circuits are also
livewhenpowerison.Insemiautomaticorautomatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulatingmats
or covers.
4. Disconnect input power or stop engine before installing or servicing this equipment. Lock input power disconnect switch open,
or remove line fuses so power cannot be turned on accidentally.
5. Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
SAFETY IN WELDING AND CUTTING. This publication and
6. Turn off all equipment when not in use. Disconnect power to
equipment if it will be left unattended or out of service.
7. Use fully insulated electrode holders. Never dip holder in water
to cool it or lay it down on the ground or the work surface. Do not
touch holders connected to two welding machines at the same
time or touch other people with the holder or electrode.
8. Do not use worn, damaged, undersized, or poorly splicedcables.
9. Do not wrap cables around your body.
10. Ground the workpiece to a good electrical (earth) ground.
11. Do not touch electrode while in contact with the work (ground)
circuit.
12. Use only well-maintained equipment.Repairor replacedamaged
parts at once.
13. In confined spaces or damp locations, do not use a welder with
AC output unless it is equipped with a voltage reducer. Use
equipment with DC output.
14. Wear a safety harness to prevent falling if working above floor
level.
15. Keep all panels and covers securely in place.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
Arc rays from the welding process produce intense
heat and strong ultraviolet rays that can burn eyes
and skin. Noise from some processes can damage
hearing.
Eye protection filter shade selector for welding or cutting (goggles or helmet), from AWS A6.2-73.
Welding or Cutting
Operation
Torch soldering
Torch brazing
Oxygen cutting
Light
Medium
Heavy
Gas welding
Light
Medium
Heavy
Shielded metal-arc welding
(stick) electrodes
Electrode Size
Metal Thickness
or Welding Current
—
—
Under 1 in., 25 mm
1 to 6 in., 25-150 mm
Over 6 in., 150 mm
Under 1/8 in., 3 mm
1/8 to 1/2 in., 3-12 mm
Over 1/2 in., 12 mm
Under 5/32 in., 4 mm
5/32 to 1/4 in., 4 to 6.4 mm
Over 1/4 in., 6.4 mm
Filter
Shade
No.
2
3or4
3or4
4or5
5or6
4or5
5or6
6or8
10
12
14
1. Wear a welding helmet fitted with a proper shade of filter (see
ANSI Z49.1 listed in Safety Standards) to protect your face and
eyes when welding or watching.
2. Wear approved safety glasses. Side shields recommended.
3. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
4. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
5. Use approved ear plugs or ear muffs if noise level is high.
Welding or Cutting
Operation
Gas metal-arc welding (MIG)
Non-ferrous base metal
Ferrous base metal
Gastungsten arc welding (TIG)
Atomic hydrogen welding
Carbon arc welding
Plasma arc welding
Carbon arc air gouging
Light
Heavy
Plasma arc cutting
Light
Medium
Heavy
Electrode Size
Metal Thickness
or Welding Current
All
All
All
All
All
All
Under 300 Amp
300 to 400 Amp
Over 400 Amp
May 8, 1996 2-1
Filter
Shade
No.
11
12
12
12
12
12
12
14
9
12
14
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001
FUMES AND GASES can be hazardous
to your health.
Weldingproducesfumesand gases. Breathingthese
fumes and gases can be hazardous to your health.
1. Keep your head out of the fumes. Do not breath the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
WELDING can cause fire or explosion.
Sparks and spatter fly off from the welding arc. The
flying sparks and hot metal, weld spatter, hot workpiece, and hot equipment can cause fires and burns.
Accidental contact of electrode or welding wire to
metal objects can cause sparks, overheating, or fire.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc.
If this is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables, coatings, and
cleaners.
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks or drums.
8. Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
11. Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
FLYING SPARKS AND HOT METAL can
cause injury.
Chipping and grinding cause flying metal. As welds
cool, they can throw off slag.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas
cylinders are normally part of the welding process,
be sure to treat them carefully.
1. Protectcompressedgascylindersfromexcessiveheat,mechanical shocks, and arcs.
2. Install and secure cylinders in an upright position by chaining
themto a stationary supportorequipmentcylinderrack to prevent
falling or tipping.
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1. Wear approved face shield or safety goggles. Side shields recommended.
2. Wear proper body protection to protect skin.
3. Keep cylinders away from any welding or other electrical circuits.
4. Never allow a welding electrode to touch any cylinder.
5. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
6. Turn face away from valve outlet when opening cylinder valve.
7. Keep protective cap in place over valve except when cylinder is
in use or connected for use.
8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety
Standards.
ENGINES can be hazardous.
1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and away
from any building air intakes.
2-2 May 8, 1996
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001
ENGINE FUEL can cause fire or
explosion.
Engine fuel is highly flammable.
1. Stop engine before checking or adding fuel.
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can cut
fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and securely
in place.
2. Stop engine before installing or connecting unit.
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin.
Batteriescontainacidand generate explosive gases.
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
The coolant in the radiator can be very hot and under
pressure.
WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State
of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Sec. 25249.5 et seq.)
NOTE: Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields
The following is a quotation from the General Conclusions Section of the U.S. Congress, Officeof Technology Assessment,
of Power Frequency Electric & Magnetic Fields — BackgroundPaper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May
1989): “... there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and
people which clearly establish that low frequency magnetic fields can interactwith, and produce changes in, biologicalsystems. While most of
this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to
offer clear science-based advice on strategies to minimize or avoid potential risks.”
To reduce magnetic fields in the workplace, use the following procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
2. Do not add fuel while smokingor ifunit is near any sparksor open
flames.
3. Allow engine to cool before fueling. If possible, check and add
fuel to cold engine before beginning job.
4. Do not overfill tank — allow room for fuel to expand.
5. Do not spill fuel. If fuel is spilled, clean up before starting engine.
3. Have only qualified people remove guards or covers for mainte-
nance and troubleshooting as necessary.
4. To prevent accidentalstarting duringservicing, disconnectnega-
tive (-) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
6. Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery cables.
3. Do not allow tools to cause sparks when working on a battery.
4. Do not use welder to charge batteries or jump start vehicles.
5. Observe correct polarity (+ and –) on batteries.
1. Do not remove radiator cap when engine is hot. Allow engine to
cool.
2. Wear gloves and put a rag over cap area when removing cap.
3. Allow pressure to escape before completely removing cap.
Biological Effects
3. Do not coil or drape cables around the body.
4. Keep welding power source and cables as far away from body as
practical.
About Pacemakers:
The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
Safetyand Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
CuttingofContainersThat Have HeldHazardousSubstances,American Welding Society Standard AWS F4.1, from American Welding
Society, 550 N.W. LeJeune Rd., Miami, FL 33126.
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
May 8, 1996 2-3
PRINCIPAL SAFETY STANDARDS
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS
Instruction 830001
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2-4 May 8, 1996
PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
Instruction 830002
PRECAUTIONS DE SECURITE EN SOUDAGE A L′ARC
LE SOUDAGE A L′ARC EST DANGEREUX
PROTEGEZ-VOUS,AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES
ENFANTSS’APPROCHER,NI LES PORTEURSDE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTEUN MEDECIN).
CONSERVEZ CES INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU
ENTRETENIR CET EQUIPEMENT.
Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de mêmeque des dommages au reste du matériel
et à la propriété,sil’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.
En soudageet coupage, des pratiquessécuritaires se sont dévelop pées suite à l’expériencepassée. Ces pratiques doivent être apprises
parétudeou entraînement avant d’utiliserl’equipement. Toutepersonnen’ayantpas suiviun entraînementintensifen soudageet coupage
ne devrait pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres
s’adressent aux groupes électrogènes.
La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à
suivre. Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces
instructions de sécurité.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET
D’ESSAI.
L’ELECTROCUTION PEUT ETRE
MORTELLE.
Une décharge électrique peut tuer ou brûler gravement. L’électrode et le circuit de soudage sont sous
tension dès la mise en circuit. Le circuit d’alimentation et les circuits internes de l’équipement sont
aussi sous tension dès la mise en marche. En
soudage automatique ou semi-automatique avec
fil, ce dernier, le rouleau ou la bobine de fil, le
logement des galets d’entrainement et toutes les
pièces métalliques en contact avec le fil de soudage
sont sous tension. Un équipement inadéquatement
installé ou inadéquatement mis à la terre est dangereux.
1. Ne touchez pas à des pièces sous tension.
2. Portez des gants et des vêtements isolants, secs et non troués.
3. Isolez-vous de la pièce à souder et de la miseà laterre au moyen
de tapis isolants ou autres.
4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez
le moteur avant de l’installer ou d’en faire l’entretien. Bloquezle
commutateuren circuit ouvertou enlevez lesfusibles de l’alimentation afin d’éviter une mise en marche accidentelle.
5. Veuillez à installer cet équipement et à le mettre à la terre selon
le manuel d’utilisation et les codes nationaux, provinciaux et
locaux applicables.
LE RAYONNEMENTDE L′ARC PEUT
BRÛLER LES YEUX ET LA PEAU; LE
BRUIT PEUT ENDOMMAGER L′OUIE.
L’arc de soudage produit une chaleur et des
rayons ultraviolets intenses, susceptibles de
brûler les yeux et la peau. Le bruit causé par
certains procédés peut endommager l’ouïe.
1. Portez une casque de soudeur avec filtre oculaire de nuance
appropriée (consultez la norme ANSI Z49 indiquéeci-après)
6. Arrêtez tout équipement après usage. Coupez l’alimentation de
l’équipement s’il est hors d’usage ou inutilisé.
7. N’utilisez que desporte-électrodesbienisolés.Nejamaisplonger
les porte-électrodes dans l’eau pour les refroidir. Ne jamais les
laisser traîner par terre ou sur les pièces à souder. Ne touchez
pas aux porte-électrodes raccordés à deux sources de courant
en même temps. Ne jamais toucher quelqu’un d’autre avec
l’électrode ou le porte-électrode.
8. N’utilisez pas de câbles électriques usés, endommagés, mal
épissés ou de section trop petite.
9. N’enroulez pas de câbles électriques autour de votre corps.
10. N’utilisez qu’une bonne prise de masse pour la mise à la terre
de la pièce à souder.
11. Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de
soudage (terre).
12. N’utilisez que des équipements en bon état. Réparez ou remplacez aussitôt les pièces endommagées.
13. Dans des espaces confinés ou mouillés, n’utilisez pas de source
de courant alternatif, à moins qu’il soit muni d’un réducteur de
tension. Utilisez plutôt une source de courant continu.
14. Portez un harnais de sécurité si vous travaillez en hauteur.
15. Fermez solidement tous les panneaux et les capots.
pour vous protéger le visage et les yeux lorsque vous soudez ou
que vous observez l’exécution d’une soudure.
2. Portez des lunettes de sécurité approuvées. Des écranslatéraux
sont recommandés.
3. Entourez l’aire de soudage de rideaux ou de cloisons pour
protéger les autres des coups d’arcoudel’éblouissement;
avertissez les observateurs de ne pas regarder l’arc.
4. Portez des vêtements en matériaux ignifuges et durables (laine
et cuir) et des chaussures de sécurité.
5. Portez un casque antibruit ou des bouchons d’oreilleapprouvés
lorsque le niveau de bruit est élevé.
8-V-96 2-1
PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
Instruction 830002
SELECTION DES NUANCES DE FILTRES OCULAIRES POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE
Opération
de
Coupage ou soudage
Brasage tendre au chalumeau
Brasage fort au chalumeau
Oxycoupage
mince
moyen
épais
Soudage aux gaz
mince
moyen
épais
Soudage à l’arc avec
electrode enrobées (SMAW)
Soudage à l’arc sous gaz
avec fil plein (GMAW)
métaux non-ferreux
métaux ferreux
Soudage à l’arc sous gaz
avec électrode de tungstène (GTAW)
Soudage à l’hydrogène
atomique (AHW)
Soudage à l’arc avec
électrode de carbone (CAW)
Soudage à l’arc Plasma (PAW)
Gougeage Air-Arc avec
électrode de carbone
mince
épais
Coupage à l’arc Plasma (PAC)
mince
moyen
épais
( selon AWS A 8.2-73 )
Dimension d’électrode ou
Epaisseur de métal ou
Intensité de courant
toutes conditions
toutes conditions
moins de 1 po. (25 mm)
de 1 à 6 po. (25 à 150 mm)
plus de 6 po. (150 mm)
moins de 1/8 po. (3 mm)
de 1/8 à 1/2 po. (3 à 12 mm)
plus de 1/2 po. (12 mm)
moins de 5/32 po. (4 mm)
de 5/32 à 1/4 po. (4 à 6.4 mm)
plus de 1/4 po. (6.4 mm)
toutes conditions
toutes conditions
toutes conditions
toutes conditions
toutes conditions
toutes dimensions
moins de 300 ampères
de 300 à 400 ampères
plus de 400 ampères
Nuance de
de filtre
oculaire
2
3 ou 4
2 ou 3
4 ou 5
5 ou 6
4 ou 5
5 ou 6
6 ou 8
10
12
14
11
12
12
12
12
12
12
14
12
14
9
LES VAPEURS ET LESFUMEES SONT
DANGEREUSES POUR LA SANTE.
Le soudage dégage des vapeurs et des fumées
dangereuses à respirer.
1. Eloignez la tête des fumées pour éviter de les respirer.
2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée ou que les fumées et les vapeurs sont aspirées à l’arc.
3. Si la ventilation est inadequate, portez un respirateur à adduc-
tion d’air approuvé.
4. Lisez les fiches signalétiques et les consignes du fabricant
relatives aux métaux, aux produits consummables, aux revêtements et aux produits nettoyants.
2-2 8-V-96
5. Ne travaillez dans un espace confiné que s’il est bien ventilé;
sinon, portez un respirateur à adduction d’air. Les gaz protecteurs de soudage peuvent déplacer l’oxygène de l’air et ainsi
causer des malaises ou la mort. Assurez-vous que l’air est
propre à la respiration.
6. Ne soudez pas à proximité d’opérations de dégraissage, de
nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc
peuvent réagir avec des vapeurs et former des gaz hautement
toxiques et irritants.
7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au
cadmium que si les zones à souder ont été grattées à fond, que
si l’espace est bien ventilé;sinécessaire portez un respirateur
à adduction d’air. Car ces revêtements et tout métal qui contient
cesélémentspeuvent dégager desfuméestoxiquesau moment
du soudage.
PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
Instruction 830002
LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION
L’arc produit des étincellies et des projections. Les
particules volantes, le métal chaud, les projections
de soudure et l’équipement surchauffé peuvent
causer un incendie et des brûlures. Le contact
accidentel de l’électrode ou du fil-électrode avec un
objet métallique peut provoquer des étincelles, un échauffement
ou un incendie.
1. Protégez-vous, ainsi que les autres, contre les étincelles et du
métal chaud.
2. Ne soudez pas dans un endroit où des particules volantes ou
des projections peuvent atteindre des matériaux inflammables.
3. Enlevez toutes matières inflammables dans un rayon de 10, 7
mètres autour de l’arc, ou couvrez-les soigneusement avec des
bâches approuvées.
LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT
CAUSER DES BLESSURES.
LES BOUTEILLES ENDOMMAGEES
PEUVENT EXPLOSER
Les bouteilles contiennent des gaz protecteurs
sous haute pression. Des bouteilles endommagées
peuvent exploser. Comme les bouteilles font normalement partie du procédé de soudage, traitezles avec soin.
1. Protégez les bouteilles de gaz comprimé contre les sources de
chaleur intense, les chocs et les arcs de soudage.
2. Enchainez verticalement les bouteilles à un support ou à un
cadre fixe pour les empêcher de tomber ou d’être renversées.
3. Eloignez les bouteilles de tout circuit électrique ou de tout
soudage.
4. Méfiez-vous des projections brulantes de soudage susceptibles
de pénétrer dans des aires adjacentes par depetites ouvertures
ou fissures.
5. Méfiez-vous des incendies et gardez un extincteur à portéede
la main.
6. N’oubliez pas qu’une soudure réalisée sur un plafond, un
plancher, une cloison ou une paroi peut enflammer l’autre côté.
7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.
8. Connectez le câble de soudage le plus près possible de la zone
de soudage pour empêcher le courant de suivre un long parcours inconnu, et prévenir ainsi les risques d’électrocution et
d’incendie.
9. Ne dégelez pas les tuyaux avec un source de courant.
10. Otez l’électrode du porte-électrode ou coupez le fil au tube-contact lorsqu’inutilisé après le soudage.
11. Portez des vêtements protecteurs non huileux, tels des gants
en cuir, une chemise épaisse, un pantalon revers, des bottines
de sécurité et un casque.
Le piquage et le meulage produisent des particules métalliques
volantes. En refroidissant, la soudure peut projeter du éclats de
laitier.
1. Portez un écran facial ou des lunettes protectrices approuvées.
Des écrans latéraux sont recommandés.
2. Portez des vêtements appropriés pour protéger la peau.
4. Empêchez tout contact entre une bouteille et une électrode de
soudage.
5. N’utilisez que des bouteillesde gaz protecteur, des détendeurs,
des boyauxs et des raccords conçus pour chaque application
spécifique; ces équipements et les pièces connexes doivent
être maintenus en bon état.
6. Ne placez pas le visage face à l’ouverture du robinet de la
bouteille lors de son ouverture.
7. Laissez en place le chapeau de bouteille sauf si en utilisation
ou lorsque raccordé pour utilisation.
8. Lisez et respectez les consignes relatives aux bouteilles de gaz
comprimé et aux équipements connexes, ainsi que la publication P-1 de la CGA, identifiée dans la liste de documents
ci-dessous.
LES GAZ D’ECHAPPEMENT DES
MOTEURS PEUVENT ETRE MORTELS.
Les moteurs produisent des gaz d’échappement
nocifs.
LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION.
Le carburant est hautement inflammable.
1. Arrêtez le moteur avant de vérifier le niveau de
carburant ou de faire le plein.
8-V-96 2-3
LES MOTEURS PEUVENT ETRE DANGEREUX
1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et
bien ventilées.
2. Si vous utilisez ces équipements dans un endroit confiné, les
fumées d’échappement doivent être envoyées à l’extérieur, loin
des prises d’air du bâtiment.
2. Ne faites pas le plein en fumant ou proche d’une source
d’étincelles ou d’une flamme nue.
3. Si c’est possible, laissez le moteur refroidir avant de faire le
plein de carburant ou d’en vérifier le niveau au début du
soudage.
4. Ne faites pas le plein de carburant à ras bord: prévoyez de
l’espace pour son expansion.
5. Faites attention de nepas renverser de carburant. Nettoyeztout
carburant renversé avant de faire démarrer le moteur.
PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC
Instruction 830002
DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES.
Despièces en mouvement, tels desventilateurs, des
rotors et des courroies peuvent couper doigts et
mains, ou accrocher des vêtements amples.
1. Assurez-vous que les portes, les panneaux, les capots et les
protecteurs soient bien fermés.
2. Avant d’installer ou de connecter un système, arrêtez le moteur.
DESETINCELLESPEUVENT FAIREEXPLOSER UN ACCUMULATEUR;
L’ELECTROLYTE D’UN ACCUMULATEUR PEUT BRULER LA PEAU ET
LES YEUX.
Les accumulateurs contiennent de l’électrolyte
acide et dégagent des vapeurs explosives.
LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS
PRESSION PEUVENT BRULER LA
PEAU ET LES YEUX.
Le liquide de refroidissement d’un radiateur peut
être brûlant et sous pression.
3. Seules des personnes qualifiées doivent démonter des protecteurs ou des capots pour faire l’entretien ou le dépannage
nécessaire.
4. Pour empêcher un démarrage accidentel pendant l’entretien,
débranchez le câble d’accumulateur à la borne négative.
5. N’approchez pas les mains ou les cheveux de pièces en mouvement; elles peuvent aussi accrocher des vêtements amples
et des outils.
6. Réinstallez les capots ou les protecteurs et fermez les portes
après des travaux d’entretien et avant de faire démarrer le
moteur.
1. Portez toujours un écran facial en travaillant sur un accumulateur.
2. Arrêtez le moteur avant de connecter ou de déconnecter des
câbles d’accumulateur.
3. N’utilisez que des outils anti-étincelles pour travailler sur un
accumulateur.
4. N’utilisez pas une source de courant de soudage pour charger
un accumulateur ou survolter momentanément un véhicule.
5. Utilisez la polarité correcte (+ et –) de l’accumulateur.
1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas
refroidi.
2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.
3. Laissez la pression s’échapper avant d’ôter complètement le
bouchon.
PRINCIPALES NORMES DE SECURITE
SafetyinWelding and Cutting,norme ANSI Z49.1, AmericanWelding
Society, 550 N.W. LeJeune Rd., Miami, FL 33128.
Safety and Health Standards, OSHA 29 CFR 1910, Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and
CuttingofContainers That Have HeldHazardousSubstances,norme
AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33128.
National Electrical Code, norme 70 NFPA, National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, document P-1,
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, norme CSA W117.2 Association canadienne de normalisation, Standards Sales, 276 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices for Occupation and Educational Eye and Face Protection, norme ANSI Z87.1, American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme 51B NFPA, National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
2-4 8-V-96
DESCRIPTION OF EQUIPMENT
DESCRIPTION OF EQUIPMENT
430429-465
General
The Ultra Flex®350 is a DC inverter power source
that can be used for Constant Current (CC), Constant Voltage (CV), and Pulse welding applications.
The DC output is produced by an inverter operating
at 20 kHz utilizing Insulated Gate Bipolar Transistors (IGBT). The output is rated for 350 amps at 34
volts and 60% duty cycle. The power source will
operate from either single or three phase input
power.
Controls for the following welding processes are
builtintotheUltraFlex
MetalArcWelding(Stick)with arc force control, Gas
Tungsten Arc Welding (TIG) with Lift-Arc, and Gas
Metal Arc Welding (MIG/MAG) with variable inductance control. The Ultra Flex
also has controls built in for pulsed Gas Metal Arc
®
350powersource: Shielded
®
350 Pulse machine
Specifications
Input Data For Three Phase
Output Volts
Output Amps
Duty Cycle
Line Volts
200 V
230 V
400 V
460 V
Input KVA
Efficiency
Power Factor
35 V
375 A
50 %
58 A
52 A
29 A
24 A
20.3 KVA
87 %
0.74
Welding. The pulse control includes 8 pre-programmed factory pulse schedules with the ability to
override any or all eight schedules using the optional programming pendant (204180A-1).
®
The Ultra Flex
several protection features to assure continued,
reliable operation. The features include: AC input
over and under voltage sensing and shutdown,
output overload shutdown, overtemperature shutdown, short circuit protection, ground fault current
shutdown for the remote receptacle, and s ingle/three phase detection. During the initial power
up sequence the input voltage and the inverter DC
capacitor voltage are sensed. If any voltage is not
correct the input circuit will be safely disabled protecting the inverter from damage.
34 V
350 A
60 %
Line Amps
52 A
48 A
26 A
22 A
18.6 KVA
86 %
0.74
350 power source also contains
31 V
275 A
100 %
38 A
36 A
19 A
17 A
13.9 KVA
85 %
0.72
Output Volts
Output Amps
Duty Cycle
Line Volts
200 V
230 V
400 V
460 V
Input KVA
Efficiency
Power Factor
February 28, 2000 3-1
Table 3-1 Input Data For Three Phase
Input Data For Single Phase
31 V
275 A
60 %
Line Amps
77 A
68 A
36 A
32 A
15.2 KVA
85 %
0.66
Table 3-2 Input Data For Single Phase
29 V
225 A
100 %
60 A
53 A
28 A
25 A
12.0 KVA
84 %
0.65
430429-465
DESCRIPTION OF EQUIPMENT
Duty Cycle
Theduty cycleratings fortheUltra Flex®350power
source are listed in Tables 3-1 and 3-2. The output
ratings are different for single and three phase
operation. The duty cycle is the percentage of a ten
minute period that the power source can be oper-
Output Data
Output Range For SMAW (Stick)
Output Range For GTAW (TIG)
Output Range for GMAW (MIG)
Overcurrent Shutdown
Maximum Short-Circuit Current
Maximum Pulse Current
Maximum Open-Circuit Voltage
Table 3-3 Output Data
Additional Specifications:
Allowable Line Voltage Variations: ±10 %
Operating Temperature Range: 0 – 40°C (32 – 104°F)
Line Regulation: ±1%
Load Regulation: ±1%
ated at a given output without overheating the machine. For example, the Ultra Flex
35 volts and 375 amps with a duty cycle of 50%.
This means that the machine can be operated for
five minutes at 35 Volts and 375 Amps, then itmust
be allowed to cool for the next five minutes at no
load.
Three Phase Single Phase
40 – 375 A
5 – 375 A
10 – 35 V
385 A
450 A
450 A
80 V
®
has a rating of
40 – 275 A
5 – 275 A
10 – 31 V
285 A
450 A
450 A
80 V
Volt-Ampere Curves
(See Figure 3-2)
Figure 3-2 shows the static operating characteristics for CC-Stick, CC-TIG, and CV-MIG modes.
3-2 February 28, 2000
Weight 92 lbs.
Figure 3-1 Overall Dimensions
430429-465
DESCRIPTION OF EQUIPMENT
February 28, 2000 3-3
Figure 3-2 Volt-Ampere Curves
430429-465
DESCRIPTION OF EQUIPMENT
Description Of Controls And
Features
(See Figure 3-3)
1 — Control Panel: The control panel consists of
a membrane switch and a digital display. See control panel descriptions for more details.
2 — Programming Pendant Plug: This plug is
used with the optional programming pendant
(204180A-1) to modify the eight Pulse MIG weld
programs.Any or all eight of the pulseprogramscan
be modified and the new data saved with the pendant.
3 — Output Negative Terminal: Connection
point for the negative welding lead.
4 — Output Positive Terminal: Connection
point for the positive welding lead.
5 — AC Power On/Off Switch: This switch is
used to control the single or three phase power
applied to the power source. When the switch is in
the ON position, the digital display should be lit.
6 — 19 Pin Remote Amphenol Receptacle:
This is the connection point for various remote
controls and wire feeders. It supplies 120 VAC
power as well as the control signals. The pinout is
as follows:
Pin A) Contactor Ckt. (+15 V)
Pin B) Contactor Ckt. (A-B closure turns power
source on)
Pin C) Arc Volts Signal (+1 V =+10 Arc Volts)
Pin D) Open
Pin E) 120 VAC
Pin F) 120 VAC Neutral
Pin G) Chassis Frame Ground
Pin H) Remote Control Maximum (High side of
remote potentiometer)
Pin J) Remote Control Input (Wiper of remote
potentiometer)
Scaling: 0 to ±10 V =0 - 375 Amps
0 to ±10 V =0 - 44 Volts
0 to ±10 V =0 - 440 For Pulse
Pin K) Remote Control Minimum (Low side of
remote potentiometer)
Pin L) Control Circuit Common
Pin M) Arc Established Signal (+12 V)
Pin N) Open
Pin P) Open
Pin R) 120 VAC Neutral
Pin S) Open
Pin T) Open
Pin U) Output Amps Signal (+1 V =100 Amps)
Pin V) Open
7 — Input Power Cable: A ten foot input cable
(4 conductor) is supplied standard with the machine.
3-4 February 28, 2000
Figure 3-3 Control and Rear Panel
8 — Voltage Select Switch: This switch is used
to select the line voltage that the machine is connected to.
Protection Features
TheUltra Flex®hasthe following built-inprotection
features designed to assure reliability. If the machine is shutdown because of one of the protection
circuits, the digital meter will display a fault code.
See the Troubleshootingchapter for an explanation
of the fault codes.
a. Output Short-Circuit Protection — The out-
put terminals of this machine can be short-circuited
for all modes of operation including Constant Voltage without damageto the machine. The protection
circuit instantly limits the output current to a safe
maximum value during short-circuit conditions.
b. Overcurrent Shutdown — If the average
welding amperage exceeds the overcurrent values
shown in Table 3-3, the machine will shut itself off
in less than four seconds. The purpose of the overcurrent shutdown is to protect the machine from
overheating if the maximum rated output amperage
is exceeded. The RED fault light will come on and
the digital meter will display a fault code indicating
that an overload has occurred. All function buttons
willalso be disabled. Toreset this condition itwill be
necessary to momentarily shut the main power
switch off.
430429-465
DESCRIPTION OF EQUIPMENT
e. Input Voltage Detection — If the inputvoltage
is too high or too low (see machine specifications
forrated line voltages) the machinewill notoperate.
Thiscondition will also be indicatedbytheREDfault
lightand fault code on the digital meter. To reset this
condition it will be necessary to momentarily shut
the main power switch off.
f. Ground Fault Protection — The ground fault
protection will disable the output of the machine if it
senses welding current flowing through the safety
ground wire in the 19 pin remote receptacle. This
conditionwillalso be indicated by the RED fault light
and fault code on the digital meter. To reset this
condition it will be necessary to momentarily shut
the main power switch off.
Description of Control Panels
(See Figure 3-4)
c. Overtemperature Shutdown — The machine
contains a thermostat to sense an overtemperature
condition. Overtemperature could occur because of
exceeding the duty cycle of the machine, high ambienttemperatures, blocked air flow, fanfailure,etc.
If an overtemperature condition is sensed, the RED
fault light will come on and the digital meter will
display a fault code indicating that an overtemperature has occurred. All function buttons will also be
disabled. To reset this condition it will be necessary
to momentarily shut the main power switch off.
d. Single/Three Phase Detector — The pur-
pose of this circuit is to sense whether the power
source is connected to single or three phase power
and set the maximum output scaling accordingly. If
the machine initially is powered up on three phase
andlaterdetects singlephase, the machine willshut
off and turn on the RED fault light. The digital meter
will also display a fault code and the user interface
will be disabled. This condition would most likely
occur because of a blown line fuse on one of the
three phases. To reset this condition it will be necessary to momentarily shut the main power switch
off.
Figure 3-4 Control Panels
GENERAL: The control panel consists of a mem-
brane switch and digital display. The control panel
will give both audible and visual feedback when a
button has been pressed. The UP and DOWN
buttons are used to adjust all of the preset values.
If the UP or DOWN button is held down for more
than two seconds the digital display will start to
scrollthe preset valuefaster, allowingformore rapid
changes. Pressing any of the other preset buttons
will activate that function, unless the function is not
allowedfor the weld processselected.Forexample,
the arc force function is only active during the
SMAW (Stick) process. When abutton isactive, the
LED adjacent to the button will be lit.
1 — AMPS LED INDICATOR: This indicator will
be lit whenever the digital meter is displayingeither
preset or actual weld AMPS.
2 — VOLTS LED INDICATOR: Thisindicator will
be lit whenever the digital meter is displayingeither
preset or actual weld VOLTS.
February 28, 2000 3-5
430429-465
DESCRIPTION OF EQUIPMENT
3 — FAULT LED INDICATOR: This indicator will
be lit whenever the digitalmeter is displayinga fault
code, and the power source has shut itself off because of a fault condition. See Troubleshooting
chapter for details on Fault codes.
4 — DIGITAL METER DISPLAY: The digitalmeteris used to display preset values, actualampsand
volts, fault codes, and user programmable values.
The preset values include amps, volts, arc force,
inductance,Pulse MIG schedulenumber,and Pulse
MIG pulse rate reference. For user programmable
values see the section under OPERATION on
“SAFE”. The display also incorporates a meter
“hold”function. For approximatelyfiveseconds after
theend ofaweld, themeterwilldisplaythe lastvalue
“held” for either amps or volts. To toggle between
“held” amps and “held” volts press the A/V button.
5 — INCREMENT UP: This button is used to increase the value of the selected parameter.
6 — DECREMENT DOWN: This button is used
to decrease the value of the selected parameter.
to toggle between the “held” values of amps and
volts.
10 — AF/IND (Arc Force/Inductance): Thisbutton has two functions dependent on which welding
process is being used. If stick welding is the selectedprocess, then this buttonis usedtoselect arc
force as the adjustable value on the digital meter.
Arc force has a value between 0 and 100, with 100
being maximum arc force. If MIG (GMAW) is the
selected welding process, then this button is used
to select inductance as the adjustable value on the
digital meter. Inductance also has a value between
0and 100, with 100beingthe maximum inductance.
IfTIG or Pulse MIG isthe selected welding process,
then pressing this button will do nothing. After arc
force or inductance has been selected, use the UP
and DOWN buttons to adjust the value.
11 — SMAW: This is one of the welding process
select buttons. Pressing this button will activate the
Stick (CC) welding mode. The LED next to the
SMAW switch will light. The process select buttons
can not be pressed when the contactor is on.
7 — REMOTE: This buttonis used to activatethe
remote amperage/voltage control feature of the
power source for use with a foot control, digital wire
feeder or other remote device. Pressing the switch
once activates remote control, pressing it again
de-activatesremotecontrol.Whenremote controlis
active, the LED indicator next to the switch will be
lit.
8 — CONTACTOR: This button is used to turnon
the output of themachine. Pressing the buttononce
will turn the machine on, pressing the button again
will turn the machine off. When the output of the
machine is energized, the LED on the switch willbe
lit. Whenever the LED is lit there will be voltage on
the output terminals of the power source. The process select buttons can not be pressed when the
contactor is on.
9 — A/V (Amps/Volts): This button has twomain
functions. Prior tostriking an arc, this button is used
to select AMPS, VOLTS, or PULSE rate reference,
as the adjustable value shown on the display. For
example, in Stick welding mode, pressing this buttonwouldbringupthepresetamps.After an arc has
been struck, this button is used to toggle between
actual amps and actual volts. The meter will “hold”
the last value of amps and volts for five seconds
after the end of a weld. The A/V button can beused
12 — LIFT GTAW: This is one of the welding
process select buttons. Pressing this button will
activate the Lift TIG (CC) welding mode. The LED
nextto the LIFT GTAW switch will light.Theprocess
select buttons can notbe pressedwhen the contactor is on.
13 — GMAW: This is one of the welding process
select buttons. Pressing this button will activate the
MIG (CV) welding mode. The LED next to the
GMAW switchwill light. The process select buttons
can not be pressed when the contactor is on.
14 — SCHEDULE: This button is used to select
the Pulse MIG schedule number. If this button is
pressed after GMAW PULSED has been selected
as the welding process, the display will show a
number between 1 and 8. This is the selected pulse
weld schedule number. To change the schedule
selection, use the UP and DOWN buttons. The
schedule selection can only be changed while not
welding. If this button is pressed with any other
selected weld process, nothing will happen.
15 — GMAW PULSED: This is one of the welding process select buttons. Pressing this button will
activate the Pulsed MIG mode of welding.The LED
next to the switch will be lit. The process select
buttons can not be pressed when the contactor is
on.
3-6 February 28, 2000
INSTALLATION
Location
For best operatingcharacteristics and longestunit
life, take care in selecting an installation site. Avoid
locations exposed to high humidity, dust, high ambienttemperature,orcorrosivefumes.Moisturecan
condense on electrical components, causing corrosionor shorting ofcircuits.Dirt oncomponentshelps
retain this moisture.
Adequate air circulation is needed at all times in
order to assure proper operation. Provide a minimum of 12 inches (305 mm) of free air space on all
sides of the unit. Make sure that the ventilator
openings are not obstructed. Ventilation air flow is
from rear to front.
Voltage Configuration
(See Figure 4-1)
For proper operation the machine must be configured for the correct line voltage. The voltage selection switch is located on the rear panel of the power
source next to the main power ON/OFF switch. For
operation on either 200 or 230VAC slide the switch
upwards to the 200/230V setting, for operation on
either 400 or 460VAC slide the switch down to the
400/460V setting
430429-465
INSTALLATION
Figure 4-1
Connecting The Welding
Machine To Line Voltage
The input power should be connected to the machine through a fused disconnect switch or other
suitable disconnecting means furnished by the
user. Table 4-1 provides minimal information for
selecting line fuses.
CAUTION: Make sure the main power
switch is in the OFF position before
making any changes to the voltage select switch. This switch should not be
switched with load on the machine.
Afour conductor power cable(6/4)is provided with
themachineforconnectionto theAC power source.
It is the responsibility of the user to provide the
proper plug or other means of connection to the
cable.
Three Phase
Line Volts Rated Line Amps Fuse Size
200
230
400
460
58
52
29
24
60
60
40
30
Single Phase
200
230
400
460
Table 4-1 Recommended Fuse Size
February 28, 2000 4-1
77
68
36
32
80
70
40
40
430429-465
INSTALLATION
For Single Phase Connection:
1. Connect the BLACK and WHITE wires to the
AC power source.
2. Connect the GREEN wire to the power system
safety GROUND.
For Three Phase Connection:
1. Connect the RED, WHITE, and BLACK wires
to the AC power source.
The generator used for power should have good
voltage and frequency regulation. If the generator’s
output voltage or frequency (engine speed) varies
excessivelywithload,thismay cause the protection
circuits for high or low line voltage to shut down the
welding machine and display a fault code. If this
happensfrequently, then the generator outputregulation is not satisfactory to use as a power supply
for this welding machine.
2. Connect the GREEN wire to the power system
safety GROUND.
DANGER: ELECTRIC SHOCK
CAN KILL. Open the disconnect switch, or breaker, and
determine that no voltage is
present, before connecting
wires between welding machine and power supply.
CAUTION: The method of installation,
conductor size, and overcurrent protection shall conform to the requirements
of the local electrical code, the National
Electrical Code, or other nationalcodes,
as applicable. All installation wiring and
machine reconnection shall be done by
qualified persons.
WARNING: Never connect the
safety ground screw to one of
thethreelinephases.This would
represent a serious electrical
shock hazard. The wiring to this
machine should be performed
by a qualified person only.
Use Of Engine-Generators For
Input Power
This welding power source may be powered by
engine driven generators. The generatormust have
an adequate output powerrating(20KVA minimum)
to power the unit. Make sure that the generator’s
output voltage, frequency and phase ratings are
correct by checkingthe nameplate of the generator
or by measurement by a qualified electrician. To
connectthewelding machine to the generatorfollow
theinstructions in“Connectingthe WeldingMachine
to Line Voltage.”
Grounding
The frame of this welding machine should be
grounded for personnel safety, and to assure operationoftheovercurrentprotection.Thegrounding
method, and the equipment grounding conductor
size and type shall conform to local and national
codes.
For the National Electrical Code, the equipment
grounding conductor shall be green, green with a
yellow stripe, or bare.
If flexible power cable isused, use a cableassembly which includes the equipment grounding conductor. If metallic armored cable or conduit is used,
the metal sheathing or conduit must be effectively
grounded per local and national codes.
Rubber-tire mounted equipment shall be
grounded to conform to local and national codes.
The grounding assists in providing protection
against line voltage electrical shock and static
shock.The grounding serves to discharge thestatic
electric charge which tends to build up on rubbertire mounted equipment. This static charge can
cause painful shock and lead to the erroneous
conclusionthatanelectricalfault exists in the equipment.
If a system ground is not available, consult the
electrical code enforcement body for instructions.
The welding machine should be connected to an
adequate driven ground rod, or to a water pipe that
enters the ground not more than 10 feet (3 meters)
from the machine.
Welding Leads
Connect the welding leads to the output terminals
of the power source. Selection of the proper size of
welding leads should be based upon both the rated
ampacity of the wire as well as the voltage drop on
the cable. For Pulsed-GMAW welding, it is often
more important to sizethewelding leads for voltage
drop. If the voltage drop is excessive on the leads,
the power source will have difficulty producing the
peak pulse current with the correct voltage at the
4-2 February 28, 2000
arc. When considering voltage drop, the entire loop
(electrode plus work lead) must be considered.
Refer to Table 4-2 as a basic guideline to the
required copper cable sizes. For Pulsed-GMAW
welding,thecablesizeshould be selectedbasedon
peak pulse current rather than average welding
amps. The peak pulse current will vary with the
different welding schedules.
As a general rule, the welding cables should be
keptas short as possible and placedclose together.
When Pulse-GMAW weld ing with long cables
430429-465
INSTALLATION
(greater than 100 feet total length), try to avoid
coiling up the cables if possible. A damaged or
frayed cable should not be used, and all connections must be properly tightened.
To attach the plugs onthe welding cables, refer to
Figure 4-2. Strip the insulation off of the welding
cable for about 1/2". Insertthe cable into the rubber
boot first, and then insert the stripped end into the
metallic sleeve. Insert the sleeve and cable into the
plug full and tighten the set screw. Slide the rubber
boot onto the plug.
TOTAL LENGTH OF LEAD CIRCUIT IN FEET (AND METERS)
Avg. Welding
Amps or Peak
Pulse Amps
100
150
200
250
300
350
50 Feet
(15.2 M)
#1/0
#2/0
(ELECTRODE LEAD PLUS WORK LEAD)
100 Feet
(30.5 M)
#4
#3
#2
#1
#4
#3
#2
#1
#1/0
#2/0
150 Feet
(45.7 M)
#2
#1
#1/0
#2/0
#3/0
#4/0
NOTE: Lead size shown is for 90°C (194°F) insulation, 30°C (86°F) ambient, and not over 4.5 volts
lead drop.
Table 4-2
February 28, 2000 4-3
Figure 4-2
430429-465
INSTALLATION
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4-4 February 28, 2000
OPERATION
430429-465
OPERATION
General
Readand understand the safety instructions at the
beginning of this manual prior to operating this
machine.
WARNING: Be sure to put on
proper protective clothing and
eye safeguards (welding coat,
apron, gloves, and welding helmet, with proper lenses installed). See Safety Instructions
and Warnings chapter included
in this manual. Neglect of these
precautions may result in personal injury.
WARNING: Make all connectionstothepowersource including electrode and work cables,
aswell asremote controlcables,
with the power source turned
off. These connections could be
electrically live with the power
switch ON.
This first section on the operation of the machine
will describe the general operation of the control
panel and digital display. Most of this information is
the same no matter what type of welding is being
done. Following sections give specific instructions
for each welding process or mode of operation.
The bottom group of four buttons on the control
panel are used to select the welding process or
modeofoperation.For the UltraFlex
following modes are available: SMAW, LIFT
GTAW, GMAW, and GMAW PULSED. The first
step would be toselect the correct modedepending
on the welding process to be used. To select aweld
mode, momentarily press the appropriate button.
The light next to the switch should come on indicating that it is now the active mode.
The A/V button is used to select amps or volts as
the adjustable value shown on the display. To preset amps or voltsfirst press the A/V button and then
®
350Pulsethe
use the UP and DOWN buttons to set the value. If
the UP or DOWN button is held for more than two
seconds, the display will scroll at a more rapid rate.
During welding the A/V button is used to toggle
between actual weld amps and actual weld volts.
To adjust amps or volts while welding use the UP
or DOWN buttons. The display will automatically
switch to showing the set amps or set volts.
TheAF/IND buttonisused toselectarc forcewhen
Stick welding and inductance when MIG welding.
Both arc force and inductance have a range of 0 to
100,with100 being the maximum setting.Tosetarc
force or inductance first press the AF/IND button
and then use the UP and DOWN buttons to set the
value. Arc force and inductance can also be adjusted while welding.
The SCHEDULE button on the Ultra Flex
Pulse machine is used to select one of the eight
available Pulse MIG schedules. To select the
schedule, first press the SCHEDULE button and
then use the UP and DOWN buttons to set the
schedule number on the display. The schedule
number can not be changed while welding.
The REMOTE button is used to select remote
amperage/voltage control through the 19pinreceptacleon the rearofthemachine. Pressingthebutton
once will toggle remote control on, pressing the
buttonagainwilltoggle remote control off.Whenthe
lightnext to the switchison, remote controlisactive.
For all modes except TIG, the remote control will
allow full scale adjustment of the output. For TIG
modes it is necessary to first set the maximum
welding amperage using the front panel of the machine. The remote control will then have control
from zero to this maximum setting.
The CONTACTOR button is used to energize the
output of the power source. There really is no contactor being energized, the solid state control uses
the signal to “turn” the output on. Pressing the
button once will turn the outputon. Pressing it again
will turn the output off. When the output is on, the
light next to the CONTACTOR button will be lit.
Normally the CONTACTOR button would be used
for Stick or TIG welding when a torch switch or foot
pedal is not beingused. If aremote control, such as
a hand pendant, is being used then the contactor
can be controlled at the remote control. Whenever
®
350
February 28, 2000 5-1
430429-465
OPERATION
this light is on, there will be open circuit voltage on
the output terminals of the machine.
®
The Ultra Flex
350 will “remember” all of the
control panel settings even after power has been
removed from the machine. The next time power is
applied the machine will come up with the same
settings. The Ultra Flex
®
350 will “remember” different setting for each process. For example, the amperage could be set to 100 Amps for SMAW and 75
Amps for GTAW. When the power source is
switchedbetween the two modes, thesetamperage
will automatically change to the correct value.
SMAW Operation
(See Figure 5-1)
1. Connect the welding leads tothe power source
with the correct polarity. Figure 5-1 shows typical
connections for DCEP welding. Make sure connections are properly tightened and that ground clamp
is securely attached to the workpiece.
2. Turn AC power switch to the ON position. The
initial power up sequence will be complete in approximately three seconds.
3. Press the SMAW button on the control panel.
This will select the Stick or SMAW process.
Power Up Sequence
Topower up themachineturnthe AC power switch
(located on the rear of the machine) to the ON
position. The machine will perform s ome selfchecks during the power up sequence. The power
up sequence takes about 3 seconds to complete.
The digital display will show the following during
power up:
1. “350A” indicating the rating of the machine of
350 Amps.
2. “PULS” indicates the type of machine.
3. “1PH” or “3PH” indicating whether the input
AC power connected to the machine is single or
three phase. If the machine recognizes single
phase, the display will read “1PH”. If the machine
recognizesthreephase,thedisplaywill read “3PH”.
4. Preset amps or volts will then be displayed
depending on the weld process. At this point the
machine is ready to weld.
4. ForLOCALorfront panel current control, make
sure the REMOTE light is off. Pressing the REMOTE button will toggle the light on and off.
5. To set welding AMPS using front panel, first
press the A/V button and then use the UP and
DOWN buttons to adjust amperage.
6. For REMOTE current control, connect the remote control to the 19 pin amphenol receptacle on
the rear of the machine. Make sure that the REMOTE light is on, by pressing the REMOTE button
if necessary. Adjust amperage using remote potentiometer. The digital meter will display preset amperage.
7. To adjust arc force, press the AF/IND button.
Use the UP and DOWN buttons to adjust the arc
force value. The range is 0 to 100 with 0 being no
arc force, and 100 being maximum arc force. Maximum arc force will increase the short circuit current
considerably, giving the arc more drive for out of
position welding. Arc force can be adjusted while
welding, or during standby.
5-2 February 28, 2000
Figure 5-1
430429-465
OPERATION
8. To energize the output of the machine, press
theCONTACTOR button so that the light comeson.
If a remote control is being used, the contactor can
be energized remotely using the switch on the remote control.
CAUTION: ONCE THE CONTACTOR IS
ENERGIZED THERE WILL BE OPEN
CIRCUIT VOLTAGE ON THE OUTPUT
TERMINALS OF THE MACHINE. TO
AVOID ELECTRIC SHOCK DO NOT
HANDLE EXPOSED CONDUCTORS ATTACHED TO THE POWER SOURCE
TERMINALS WITHOUT PROPER PROTECTIVE CLOTHING AND GLOVES.
9. The power source is now ready to weld. After
the weld is complete, shut the CONTACTOR off to
remove open circuit voltage from the output terminals of the machine.
While welding, the digital meter will show either
actual amps or actual volts. To toggle between
actual amps andactual volts use the A/V button. To
adjust amperage while welding, use the UP and
DOWNbuttons. The digitaldisplay willautomatically
change to the preset amperage. After the adjustments are made, themeter will automatically switch
back to showing actual amps or actual volts. To
adjustarc force while welding,firstpress the AF/IND
button, then use the UP and DOWN buttons. The
digitalmeter willchangetoshowthe preset arc force
setting. Afterthe adjustment is complete, the meter
will automatically switch back to showing either
actual amps or actual volts.
LIFT GTAW Operation
(See Figure 5-2)
The purpose of Lift GTAW is to allow for striking
the arc by momentarily touching the torch to the
workpiece. The lift circuit functions to reduce the
amperage during the arc start to a low level to give
a good soft start.
1. Connect the work lead and torch lead to the
powersource. Figure5-2showstypical connections
for DCEN (straight polarity). This is the normal
connection for TIG welding.
2. Providesuitableshielding gas connections and
controls to the torch. The power source does not
provide connections for the shielding gas.
3. Selectthepropertungstensizeandtypeforthe
job. Table 5-1 gives a basic guideline to the amperage ranges of various tungstens.
4. If a remote controlsuch as a foot pedalor hand
control is going to be used, connect the remote
control to the 19 pin amphenol receptacle on the
rear of the machine.
5. Turn AC power switch to the ON position. The
initial power up sequence will be complete in approximately three seconds.
6. Press the LIFT GTAW button on the control
panel. This will select the Lift TIG process.
7. To set welding amps, use the UP and DOWN
buttons. For local control, the display will show the
preset welding amperage. For remote control, the
display will show the preset maximum amperage.
Thefoot pedal or hand control will have controlfrom
0 to this maximum setting.
February 28, 2000 5-3
Figure 5-2
430429-465
OPERATION
Electrode
Diameter
Inches
DCEN DCEP
Using pure or thoriated tungsten electrodes
.020 5-35 ———
.040 30-100 ———
1/16 70-150 10-20
3/32 150-225 15-30
1/8 200-275 25-40
5/32 250-350 40-55
Table 5-1 Typical Current Ranges for
Tungsten Electrodes
NOTE: When using a remote control such
as foot pedal, momentarily switch the front
panel back to LOCAL control to view the
preset maximum amperageon the display.
When ready to weld, switch back to REMOTE by pressing the REMOTE button on
the front panel.
8. Tostrike an arc, first energize the power source
by depressing the foot pedal, or using the torch
switch, or by using the CONTACTOR button on the
front panel.
9. Make sure gas flow has been initiated.
10. Gently rest the cup of the torch on the workpiece.
11. Rock the torch until the tungsten briefly contacts the work; this will initiate the “LIFT-ARC” feature of the power source. Lift or rock the tungsten
backoff of theworkto initiatethewelding arc.During
the time the tungsten is touching the work, the
power source will automatically limit the output current to 20 amps. As the arc is initiated, the current
will automatically change to the preset value. To
minimize the heating of the end of the tungsten, it
should be left in contact with the work only briefly.
12. Toend the weld, releasethefoot pedal, or turn
contactor switch off. Turn off shielding gas supply.
GTAW Operation
(Non-Lift)
GTAW mode is intended to be us ed for
non-contact arc starting such as with the use of an
optional capacitor discharge arc starter. GTAW
mode can also be used for scratch start TIG. This
mode can be made active on the Ultra Flex
CC/CV Pulse unit through the SAFE. If an optional
arc starter is to be used, be sure to make all con-
®
350
Welding Current, Amps
nections to the arc starter with the power off. The
arc starter will connect to the 19 pin amphenol
receptacleon the rear of the power source.The foot
pedal or remote control will then connect to the arc
starter. If an optional pulser control is also used, it
willneed to be connected tothearc starter, and then
the foot pedal connected to the pulser control.
1. Figure 5-3 shows typical connections for an
Optional Arc Starter Box.
2. Providesuitableshielding gas connections and
controls to the torch or Arc Starter Box. The power
source does not provide connections for the shielding gas.
3. Selectthepropertungstensizeandtypeforthe
job. Table 5-1 gives a basic guideline to the amperage ranges of various tungstens.
4. Turn AC power switch to the ON position. The
initial power up sequence will be complete in approximately three seconds.
5. Press the GTAW button on the control panel.
This will select the TIG process.
6. To set welding amps, use the UP and DOWN
buttons. For local control, the display will show the
preset welding amperage. For remote control, the
display will show the preset maximum amperage.
Thefoot pedal or hand control will have controlfrom
0 to this maximum setting.
NOTE: When using a remote control such
as foot pedal, momentarily switch the front
panel back to LOCAL control to view the
preset maximum amperage on the display.
When ready to weld, switch back to REMOTE by pressing the REMOTE button on
the front panel.
7. Make sure gas flow has been initiated.
5-4 February 28, 2000
8. To strike an arc, depress the foot pedal, or use
the torch switch. Open circuit voltage will now be
present on the output of the power source. If a
capacitor discharge arc starter is being used, hold
the torch in close proximity to the workpiece while
430429-465
OPERATION
pressing the foot pedal. The high voltage will jump
the gap to the workpiece and the arc will follow.
9 To end the weld, release the foot pedal, or turn
torch switch off. Turn off shielding gas supply.
February 28, 2000 5-5
Figure 5-3
430429-465
OPERATION
GMAW/FCAW Operation
The GMAW mode on the Ultra Flex®350 power
source provides a constant voltage output characteristic. Variable inductance is also provided.
source to condition the end of the wire for the next
weld. The wire conditioningcircuit will tend to leave
thewire with a verysmallballon the end of thewire,
thus making the next start easier.
To operate proceed as follows:
1. Connectthewirefeeder to the 19 pin amphenol
receptacle on the rear of the power source.
2. Connect the weldingleads to the power source
and wire feeder, make sure connections are tight
and polarity is correct.
3. Turn AC power switch to the ON position. The
initial power up sequence will be complete in approximately 3 seconds.
4. Press the GMAW button to select the GMAW
process. The light next to the button should be on
indicating that GMAW is now the active process.
5. For LOCAL control make sure the REMOTE
light is off by pressing the REMOTE button if necessary. The light should toggle on and off as the
REMOTE button is pressed repeatedly.
6. To adjust output voltage first press the A/V
button and then use the UP and DOWN buttons to
adjust the voltagesetting. For remote control, make
sure that thelight next to the REMOTE button is on,
by pressing the REMOTEbutton if necessary. Then
use the voltage control on the wire feeder to preset
output voltage.
7. To adjust the INDUCTANCE setting first press
theAF/IND button, and then use the UPand DOWN
buttons to set an inductance value between 0 and
100. The minimum inductance setting is 0. 100 is
the maximum setting. Lower values give a faster
cooling puddle with a “harsher” type of arc. Higher
inductancesettingsgive a very soft arcand a slower
cooling puddle. As a general rule, most materials
can be welded with a setting around 50. Mild steel
normally runs best from minimum to mid range,
stainless steel normally runs best from mid range to
maximum.
NOTE: The inductance control is primarily
used for the short-circuiting transfer mode
of MIG welding. For globular and spray
transfer modes, the inductance control has
minimal effect.
8. The power source is now ready to weld. To
initiatethe weld,activatethe torchswitchon the MIG
torch.
9. To end the weld, release the torch switch while
holdingthe torch in place at the end of the weld.This
will allow the wire conditioning circuit in the power
Pulsed GMAW
General
Pulsed-GMAW (referred to as Pulse-MIG) is a
welding process that involves the pulsing of the
welding current from a high value (peak current) to
alowvalue (background current) to produce a clean
spatter-free weld. The intent of this manual is not to
present a comprehensive coverage of this welding
process, but to give an explanation of the terms
used and how they apply to the Ultra Flex
power source.
Explanation of Terms: (See Figure 5-4)
: Istis the amplitude of theinitial pulse ofcurrent
I
st
during the arc starting interval.
I
isthe amplitude of the high pulse of welding
pk:Ipk
current (peak current). The current is forced to this
high value by the power source for a brief time
(T
). The peak current melts the wire and forms
peak
a droplet. This droplet is then propelled to the weld
pool.
V
: Vpkis the amplitude of the arc voltage during
pk
the high pulse of weld current.
T
: Tpkis the amount of time that is spent at the
pk
peak current. This time must be sufficient to form a
droplet.
I
bak: I
(background current) is the low value of
bak
the weld current. The background current serves to
preheat the wire and maintain the arc between the
wire and the workpiece. The background current
must not be allowed to go too low, or the arc
becomes unstable and difficult to maintain.
V
bak: V
is the amplitude of the arc voltage
bak
during the background time.
bak:T
T
(backgroundtime) istheamount oftime
bak
that the weld current is at the low value. Normally,
this would be a larger amount of time than is spent
at peak current.
Pulse Rate: The pulse rate is the number of
pulsesof currentthat are produced per second. The
Ultra Flex
®
350 allows a pulserate ofapproximately
30–300 pulses per second.
Pulsing Frequency: Pulsing frequency is the
same as pulse rate. A pulse rate of 60 Hz means
thatthe power source produces 60 pulses ofcurrent
per second.
®
350
5-6 February 28, 2000
Figure 5-4 Pulse Waveforms
Ibak (min): I
(min) refers to a minimum back-
bak
ground current level. If the current falls below this
minimum level, it becomes difficult to maintain a
stable arc.
Arc Length: The distance between the end of the
wire electrode (the wire being fed through the torch
or gun) and the weld pool. This distance is usually
set to give a smooth, spatter-free weld.
The Ultra Flex
®
350 Pulse machine comes with 8
pre-programmed weld schedules for use in the
Pulsed MIG mode. Each schedule was developed
around the particular wire/gas combination given in
tables 5-2. These schedules should give good results for most applications. It is possible to use a
number of other wire and gas combinations other
then those listed. It will be necessary, however, for
theuser to determine theoptimum weldscheduleto
use.
SCHEDULE
STD
1
2
3
4
5
6
7
8
WIRE TYPE
Mild Steel
Mild Steel
Stainless Steel
Stainless Steel
Aluminum
Aluminum
Metal Core
Nickel
WIRE
SIZE
(inches)
.035 350 300 2.5 20.0
.045 450 350 2.5 20.0
.035 350 276 2.6 18.0
.045 400 326 2.8 19.0
.035 400 224 1.4 17.0
3/64 450 274 1.4 17.0
.045 450 400 1.5 16.0
.035 350 276 2.6 18.0
I
st
(Amps)
430429-465
OPERATION
For welding applications where none of the 8
schedules will give adequate results, any or all 8
schedules can be changed by the operatorto fit the
application. In order to change them, an optional
Programming Pendant (204180A-1) is required.
The programming pendant plugs into the PROGRAMMING PENDANT connector located on the
front of the Ultra Flex
®
(Item 2, Figure 3-3). Using
the Pendant, a schedule can easily be modified by
changing I
pk,Tpk
, and V
to give the proper weld
BAK
characteristics.
1. Connect the wire feeder to the power source
using the 19 pin amphenol receptacle onthe rear of
the power source.
2. Connect the welding leads tothe power source
and wire feeder.
I
pk
(Amps)
T
pk
(msec)
V
Bak
(Volts)
GAS MIXTURE
92% Ar 8% CO
92% Ar 8% CO
81% Ar 1% CO
81% Ar 1% CO
100% Ar
100% Ar
92% Ar 8% CO
75% Ar 25% He
2
2
2 18% He
2 18% He
2
February 28, 2000 5-7
Table 5-2 Pulse MIG Schedules
For The Ultra Flex
®
350
430429-465
OPERATION
3. Turn AC power switch to the ON position. The
initial power up sequence will be complete in approximately three seconds.
4. Press the GMAW PULSED buttonto select the
pulsed MIG process. The light next to the button
shouldbeonindicatingthat GMAW PULSEDis now
active.
5. Press the SCHEDULE button andthen use the
UP and DOWN buttons to select one of the eight
schedules. See the chart in this manual or the
sticker on the machine for schedule information.
Optional Programming Pendant
An optional programming pendant allows any or
all eight of the factory pulse schedules to be overridden. To use the pendant, turn the power source
OFF, and plug the pendantinto thependant plug on
the front of the power source. Then turn the power
source back ON. To work properly, the pendant
mustonlybe pluggedinto the power source with the
power source turned off.
1. Select the GMAW PULSED mode on the front
panel.
6. For LOCAL control make sure the REMOTE
light is off by pressing the REMOTE button if necessary. The light should toggle on and off as the
REMOTE button is pressed repeatedly.
7. To set the output proceed as follows: First set
the wire feed speed at the wire feeder. As in conventional MIG welding, the wire feeder will control
theaverageamperage or heat input. Second set the
correct arc length by adjusting the output of the
powersource. Press theA/Vbuttonto selectvoltage
as the adjustable value. The meter will display a
“reference number” between 0 and 440. The higher
the “reference number” the higher the pulsing rate
and arc voltage. (The actual number of pulses per
second will vary between approximately30 and 300
asthe referencenumbervariesbetween 0and440.)
To increase arc length, increase the “reference
number” setting. To decrease arc length, decrease
the “reference number” setting. This is essentially
the same as adjusting voltagefor conventional MIG
welding. As with conventional MIG welding, the
power source must be adjusted to correspond with
the correct heat input for a given wire feed speed
setting.
8. For REMOTE control make sure the REMOTE
light is on by pressing the REMOTE button if necessary. Now the arc voltagecan be controlled at the
wire feeder (if the feeder is equipped with a voltage
control). See Step 6for an explanation ofhow to set
the output of the power source. If the wire feeder is
equipped with a digital meter, it will also display the
preset “reference number”, however it will show a
decimal point. For example, if the wire feeder displays 23.5 the power source will display 235.
9. The power source is now ready to weld. To
initiatethe weld,activatethe torchswitchon the MIG
torch.
10. To end the weld, release the torch switch. As
with conventional MIG welding, a wire conditioning
sequence will leave the wire with a very small ball
on the end, thus making the next arc strike easier.
2. Selectthe scheduleto be over-ridden bypressing the SCHEDULE button and then using the UP
and DOWN buttons. The schedule number will appear on the programming pendant.
3. Select the parameter to be adjusted on the
pendant. The parameters are I
st,Tpk,Ipk
, and V
bak
4. Use the increase and decrease buttons to adjust the value.
NOTE: It is not the intent of this manual to
try to describe how to arrive at the correct
values for a “good” schedule. This manual
just provides the procedure.
5. Select the next parameter to be changed.
6. Afterallparameters have been changed, press
the SAVE button on the pendant. This will “permanently” save the new data into the memory on the
power source. It will retain the new data even after
power has been removed from the machine. The
new data can still be over-ridden with the programming pendant.
7. To restore the factory settings for the selected
schedule, press the RESETbutton on the pendant.
8. After all changes have been made, the power
source should be turned off and the pendant removed.
SAFE
SAFE (Special Application Function Environment)
is a mode of operation that the Ultra Flex
welding power sources can enter in order to customize the welder for a special application. In most
cases this power source feature can be ignored.
The factory default settings are expected to be
sufficient for most of our customers. In the few
cases that the factory default settings are not adequate, the Ultra Flex
®
can be programmed to meet
special specifications.
®
series of
.
5-8 February 28, 2000
There are two separate safes, one for single
phase operation and one for three phase operation. These safes are independent of each other,
and are accessed automatically when the ma-
OPTION
OPTION FACTORYDEFAULT DISPLAY
NUMBER
0
RESET THE SYSTEM.
This option resets all SAFE parameters to their factory default
settings. “nO” means do not reset the system to factory default
while “rES” means reset the system to factory default settings.
Only the single phase settings will be reset if the machine is
hookedup to single phase power. Likewise, only the three phase
settings will be reset when hooked to three phase power.
NOTE: THE SAVE BUTTON MUST BE DEPRESSED WHEN
EXITINGTHE SAFE IN ORDERFOR THE RESET TO OCCUR.
1
WIRE SHARP VOLTAGE SETTING.
This is the voltage that will be present on the wire following a
GMAW or Pulsed GMAW weld. This feature “sharpens” the wire
by burning off the ball of filler metal that often forms on the end
of the wire following a GMAW weld. The voltage can be set to
any value between 0 and 20 volts in increments of 1 volt.
2
WIRE SHARP TIME.
Wiresharptime is the length of time following a GMAW or Pulsed
GMAW weld that the wire sharp voltage will remain on the filler
wire. This variable time is adjustable between 0 and 1 second in
increments of 0.01 seconds. Longer times will give more of a
burnback effect.
3
MAXIMUM SELECTABLE AMPERAGE.
Maximum selectable amperage is the largest amperage value
thatthe user is capable of setting inSMAW,LiftGTAW, or GTAW
local mode. This feature is effective when the user would like to
insure that the amperage is never set above a particular
amperage level. The range of values permitted is 5-275 amps
(single phase) and 5-375 amps (three phase). The maximum
selectable amperage is never permitted to be set less than the
minimum selectable amperage.
4
MINIMUM SELECTABLE AMPERAGE.
Minimumselectableamperageis thelowestamperage valuethat
the user is capable of setting in SMAW, Lift GTAW, or GTAW
local mode. This feature is effective when the user would like to
insure that the amperag e is never set below a particular
amperage level. The range of values permitted is 5-275 amps
(single phase) and 5-375 amps (three phase). The minimum
selectable amperage is never permitted to be set greater than
the maximum selectable amperage.
5
MAXIMUM SELECTABLE VOLTAGE.
Thisvoltage is the largest value that the user is capable of setting
inGMAW local weldingmode. Voltagesabove thisvalue can not
be entered by the user in local mode. This voltage value can be
exceeded in remote by using a feeder with voltage setting
capability. The range of values permitted is 10-31 volts (single
phase) and 10-35 volts (three phase). The maximum selectable
voltage is never permitted to be set less than the minimum
selectable voltage.
430429-465
OPERATION
chine is powered up in either the single or three
phase mode. Any changes to one will not affect
the other.
1 PHASE 3 PHASE
FORMAT
nO nO 0XXX
10 10 1_XX
.25 .25 2XXX
275 375 3XXX
5 5 4XXX
31.0 35.0 5XX.X
February 28, 2000 5-9
430429-465
OPERATION
OPTION
NUMBER
6
Thisvoltage is the lowest valuethat the useris capableof setting
in GMAW localwelding mode. Voltages below this value cannot
be entered by the user in local mode. This voltage value can be
overridden in remote by using a feeder with voltage setting
capability. The range of values permitted is 10-31 volts (single
phase) and 10-35 volts (three phase). The minimum selectable
voltage is never permitted to be set greater than the maximum
selectable voltage.
7
This reference is the largest value that the user is capable of
setting in PulsedGMAW local welding mode. References above
this value can not be entered by the user in local mode. The
reference value can be exceeded in remote by using a feeder
with voltage setting capability. Therange of values permitted are
between 0 and 440 inincrements of 1. The maximum selectable
reference is never permitted to be set less than the minimum
selectable reference.
8
Minimum reference is the lowest value that the user is capable
of setting in Pulsed GMAW local welding mode. A reference
value less than the minimum reference can not be entered by
the user in local mode. This reference value can be overridden
in remote by using a feeder with voltage setting capability.
Minimum selectable reference can have a range of values
between 0 and 440 in increments of 1. The minimum selectable
reference is never permittedto be set greaterthan the maximum
selectable reference.
9
The purpose of Lift GTAW is to allow for striking the arc by
momentarily touching the electrode to the workpiece. The lift
circuit functions to reduce the amperage during the arc start to
a low level to give a good soft start. This initial start amperage is
adjustable between 5 and 100 amps in increments of 1 amp.
A
Meter hold time is the time following a successful arc that the
actual weld amps and volts are held in memory and displayed
(Use the A/V button to toggle between amps and volts). This
parameteris adjustablebetween 0 and60secondsin increments
of 1 second. A time of 0 seconds disables meter hold.
B
AVC (Automatic Voltage Control) is available in the Ultra Flex
350 Pulse unit. By turning on this function an additional 8 AVC
schedules are made available in addition to the 8 standard
schedules.
C
Lift GTAW ON/OFF changes Lift GTAW into standardGTAW. In
the ON mode, Lift GTAW is operational. In the OFF mode,
depresson of theLift GTAW process selection switch will put the
UltraFlex
have to be done with an external arc starter or by scratch
methods.
OPTION FACTORY DEFAULT DISPLAY
MINIMUM SELECTABLE VOLTAGE.
MAXIMUM SELECTABLE REFERENCE.
MINIMUM SELECTABLE REFERENCE.
LIFT START INITIAL AMPS VALUE.
METER HOLD TIME
AVC ON/OFF
LIFT GTAW ON/OFF
®
inGTAW mode with thelift circuit disabled.Starts will
1 PHASE 3 PHASE
10.0 10.0 6XX.X
440 440 7XXX
0 0 8XXX
20 20 9XXX
5 5 A_XX
OFF OFF BXXX
®
ON ON CXXX
FORMAT
5-10 February 28, 2000
OPTION
NUMBER
D CODE
OPTION FACTORY DEFAULT DISPLAY
Code is the password code that the user must enter prior to
entering the SAFE. The acceptable range of values is
between 0 and 999.
NOTE: In the case that you change and forget the code,
contact Thermal Arc for instructions on how to access the
SAFE and retrieve/change the code.
430429-465
OPERATION
1 PHASE 3 PHASE
FORMAT
350 350 DXXX
The following parameters are programmable in
the SAFE:
To enter the SAFE, press the button labeled A/V
within several seconds of turning on the power to
the Ultra Flex
®
. Continue to press the button until
the meter displaysthe word “SAFE”. “COdE” willbe
displayed for two seconds upon releasing the A/V
button, followed by “0” being displayed. The SAFE
is waiting for the correct password code to be entered using the up and down arrow buttons. The
correct code (350 by factory default) must be entered and remain on the display for five seconds.
This code insures that inadvertent access to the
SAFE is not possible. A correct code will cause the
Ultra Flex
®
to display “OPEn”“SAFE”.
Access to the SAFE has now been established.
The meter will display a series of flashing and
non-flashing digits. The first digit, reading left to
right, is the option number of the parameter that is
currently being set. It will not flash. An explanation
and description of this option can be found in the
preceding table. The following three digits correspond to the parameter values. These digits will
flash. Changes to the displayed parameter value
can be made by pressing the UP or DOWN arrow
buttons.
To gain access to the next option number press
the CONTACTOR button. The CONTACTOR button will always advance to the next option. At each
option proceed as described in the previous paragraph.
After all changes have been made to the SAFE,
the REMOTE button must be pressed in order to
save the new parameters and restart the system. A
successful saving of the information will be indicated by “SAVE” being displayed for 1 second
followed by the Ultra Flex
®
re-starting and entering
into the “normal” weld mode. Failure to save will
cause all changes to be lost. A power down prior to
savingwillalso cause all changes madewhile in the
SAFE to be lost.
February 28, 2000 5-11
Figure 5-5
430429-465
OPERATION
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5-12 February 28, 2000
MAINTENANCE
430429-465
MAINTENANCE
If this equipment does not operate properly, stop
work immediately and investigate the cause of the
malfunction. Maintenance work must be performed
by an experienced, qualified person only. Any electrical work must be performed by an electrician or
other person properly trained in servicing electrical
equipment. Do not permit untrained persons to inspect, clean or repair this equipment. Use only
recommended replacement parts when servicing
this machine.
DANGER: HIGH VOLTAGE may be present internallyeven with the powerswitchinthe OFF position.
Before inspecting, cleaning, or servicing, disconnect and lock out input power to the power source.
For uninterrupted, satisfactory service from this
welding machine, it is necessary to keep the machine clean, dry, and well ventilated. At least every
threemonths, or more often as necessary, wipeand
blow out all dirt from the machine’s interior, with air
pressure of not over 25 psi.
As normal preventive maintenance, at the time of
the three-month cleaning, a full inspection of the
welding machine and setup should be performed.
Check warning labels on the machine for readability; replace if necessary. Check input and output
connections as well as frame ground connections
to the machine to insure that they are tight and the
wires are not frayed or overheated. Inspect internal
wiring of machine for loose or frayed connections;
tighten or repair as necessary. It would also be
advisable to check connections to wire feeders,
fixtures, etc., at this time. Any damaged cables or
hoses should be replaced.
February 28, 2000 6-1
430429-465
MAINTENANCE
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6-2 February 28, 2000
TROUBLESHOOTING
WARNING: Disconnect the
power source from the input
power source before carrying
out any service or repair work.
Hazardous voltages can be present in the machine whenever
input power is connected.
430429-465
TROUBLESHOOTING
lead’s conductor and should be crimped to the
lead’s insulation. The mating surfaces of the connection should be clean and free of oxidation or
debris.
Do not pull on leads or cables to disassemble
connections. Firmly grasp each lug or connector.
Use appropriate tools to enhance leverage if
needed. Pulling on leads and cables for disassembly can damage the integrity of the connection and
cause future malfunctions.
WARNING: ALL SERVICE
SHOULD BE PERFORMED BY
TRAINED PERSONNEL ONLY.
General
1. Safety Practices, Precautions,
and Warnings.
Cautionshould be used when troubleshooting and
working inside inverter power supplies. Many circuits inside the machine handle high voltages or
currents. Some circuits will retain their charge for
several seconds after power to the machine has
been turned off. Before touching, diagnosing, or
servicing the machine or its subsystems, measure
the circuit in question for decaying voltage levels.
Do not touch, service, or attempt to diagnose any
part of the machine unless you are certain of the
function of the circuit and the voltage level present
in the circuit.
During certain machine failures, abnormally high
voltagelevelsmay be present in circuits thatusually
contain low voltage levels. Check the voltage level
in the circuit before touching or servicing the circuit.
2. Wiring.
Prior to disassembly or servicing of the machine,
note the wiring and connections in the machine.
Reassembling should place the wires in the same
location and routing as received from the factory.
Keepwires andleadsaway from hotpartsand sharp
edges. Keepthe primary sideof the machine(input
power side) away from thesecondary side (welding
and control circuits).
Examine connections for proper assembly and
contact. Lugs should be in tight contact with the
3. PC Board Handling and Checking.
Most of the PC boards in the machine contain
staticsensitivecomponents. Use a grounding strap
or other suitable grounding means before attempting to service PC boards. When a PC board is
removed from the machine, it should be immediately placed on a grounded anti-static mat for examination or placed in an anti-static bag for
transportation or further handling.
Before replacing a suspect PC board, disconnect
all wires and cables from the board. Firmly reconnect the board and retest the machineto determine
iftheproblempersists. Faultyconnectionsorwiring
problems are often the source of poor PC board
performance.
Ifa PC board replacementhasappearedto correct
a problem, the machine should be retested with the
old PC board to recreatethe problem. If theoriginal
symptoms reappear, then the original PC board
created the problem. If the original symptoms do
not reappear, then it is likely that the wiring or
connections were the source of the problem and
these, or other sources, should be examined to
insure that the problem doesn’t reappear later.
4. Optional Equipment or
Accessories.
Disconnect any optional or compatible equipment
to verify that the power source is creating the problem. Disconnectanywirefeedersfromthemachine
and trigger the power source on from the back
Amphenol or use the SMAW mode to verify proper
power source triggering. Disc onnect optional
equipment or accessories to determine if they are
placing excessive demands on the power source’s
auxiliary supplies.
February 28, 2000 7-1
430429-465
TROUBLESHOOTING
5. Troubleshooting Hints.
Carefully note all operating conditions and problem symptoms for effective troubleshooting diagnosis. During problem analysis, bear in mind that the
total welding system includes not only the power
source but may also include a wire feeder, control
cables, welding gun or torch, gun liner, gun contact
tip, gun trigger, remote controls, water coolers,
ground cables and connections, electrode cables
andconnections,electrodes, shielding gas type and
flow, weld plate quality and composition, weld process, control settings, chassis grounding, input cables and connections, inputfuses or breakers, input
voltage, and effects of nearby equipment.
Are the power source’s accessory circuit
breakers tripped?
Are accessories in good condition and
properly set? Is the wire feed speed correct? Does the wire feed smoothly? Is the
contact tip or gun liner worn? Are the drive
rolls properly tensioned? While welding, is
the gun cable kinked?
Are the ground cables and connections in
good condition and of the correct size?
Are the electrode cables and connections
in good condition and of the correct size?
Troubleshootingshouldbeginwith an assessment
of the welding process and control settings being
used. Are they appropriate for the weldment? Is
the correct electrode and gas being used? Is the
optimal technique being used?
Next,an examination ofthewelding system should
be made to determine thatall equipment iscompatible and connected correctly. Determine that all
input fuses are intact and that the input power is
correct. Examine cables and connections for possible faults.
Examine and eliminate external equipment as the
problem source. Are the wire feeder drive rolls
tight? Is the gun liner worn or plugged? Does the
gun trigger work? Are thecontrol cables connected
correctly and in good condition? Disconnect as
much external equipment as possible to determine
its’ impact on the problem.
Examine the power source externally and internally for signs of possible damage. Inspect the
wiring and connections.
Lastly, begin diagnosis of the machine and it’s
sub-systems.
An effective troubleshooting approach is often to
eliminate symptoms or possible causes by determining what is working correctly.
A few typical questions whose answers might be
of benefit in troubleshooting are:
Is the input voltage correct? Are fuses
blown?
Does the machine have the proper input
voltage for what the machine is configured
for, or vice versa?
Are accessories connected properly?
Are accessories compatible with the power
source?
Is the welding procedure being used within
the capabilities of the machine? Does the
welding duty cycle match the powe r
source’s duty cycle?
Will adjustments in the control settings
eliminate the problem?
Will adjustments intorch or electrode stickout,angle, ormovementeliminate theproblem?
Does the problem exist in all operating
modes?
If appropriate, does the problem persist
with wire feeders and other equipment disconnected from the machine?
Which indicators are on and which are off
as a result of this problem?
What are all of the control panel settings
during the problem?
How often and in what manner is the machine serviced or maintained?
Is the machine clean and dry? Does moisture condense in or on the machine during
operation or during idle?
Is air flow inand around themachine unobstructed?
Has the machine been dropped?
Does the problem consistently occur at the
same time of dayor when other equipment
is operated?
Afew minutes spent assessing the condition ofthe
welding system and symptoms of the problem can
greatly facilitate the troubleshooting process.
7-2 February 28, 2000
Fault Codes
The Ultra Flex®350 power source has several
standard protection circuits designed to assure the
reliability of the machine. Whenever one of these
circuits senses a fault, it will shut the output of the
power source off and display a fault code on the
digital display. The fault light next to the display will
also come on. To clear a fault, it will be necessary
to reset the machine by turning the main power
switch off briefly.
Prior to resetting the machine, make sure that the
cause of thefault has beenidentified and corrective
action taken where appropriate. The following is an
explanation of the fault codes.
“E008”—Overtemperature. This fault code indicates that the overtemperature thermostat has operated. Overheating of the machine could occur
because of exceeding the duty cycle rating, excessive high ambient temperature,blocked airflow, fan
failure, etc.
“E012”—GroundFault.This faultcode indicates
that excessive current was flowing through the
chassis frame ground wire in the amphenol receptacle. This would normally be caused by welding
current flowing through this connection because of
improper grounding of the workpiece being welded
on. Check all connections from the power source
terminals to the work and wire feeder. Check to
make sure that feed head at the wire feeder is not
shorted out to ground or to the control box.
“E014”—Inverter bus voltage too high or too
low. This could be caused by the AC input voltage
being too high, too low, or improper setting on the
voltage select switch. It could also be caused by
“spikes” or “sags” on the AC line. Check AC line
voltage. If line voltage is ok, reset the machine by
turning the main power switch off and back on. If
430429-465
TROUBLESHOOTING
voltage is ok and machine will not reset, service will
be required.
“E015”—Over/undervoltage oftheAC line. This
fault code is caused by an input AC voltage that is
too high or too low. Check AC line voltage. Reset
the machine by turning the main power switch off
and back on.
“E016”—Could not “read” setup. This is an internal fault to the machine. Reset power source by
turning the main power switch off and back on. If
fault persists, machine will require service.
“E017”—Couldnot save data. This isaninternal
faultto the machine.Reset powersource by turning
the main power switch off and back on. If fault
persists, machine will require service.
“E018”—Overcurrent. This fault code is caused
by excessive welding current. If the welding current
exceeds the overcurrent values shown in Table 3-3
for a couple of seconds, the machine will shut off.
The overcurrent limit is lower for single phase than
itis for three phase.Reduce wirefeedspeed and/or
welding amperage. Reset the machine.
“E019”—Single phase error. This fault code
means that the power source has senseda change
inthe inputpower,from three phasetosinglephase.
Check line fuses. Check AC voltage at the power
source.
“E020”—Machine ID error. At power up the
Ultra Flex
®
senses the type of machine, CCCV or
PULSE. If thepower sourcesenses a change in the
ID of the machine after power up, it will shut down.
Check all connections internally for loose connections at the PC boards.
“E999”—General Fault. If the power source is
not able to identify the specific fault, it will signal a
generalfault.Reset the power source by turning the
main power switch off.
February 28, 2000 7-3
430429-465
TROUBLESHOOTING
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7-4 February 28, 2000
PARTS LIST
430429-465
PARTS LIST
Equipment Identification
All identification numbers as described in the Introductionchaptermustbefurnishedwhenordering
partsormakinginquiries.Thisinformationis usually
found on the nameplate attached to the equipment.
Be sure to include any dash numbers following the
Specification or Assembly numbers.
How To Use This Parts List
The Parts List is a combination of an illustration
(Figure Number) and a corresponding list of parts
which contains a breakdown of the equipment into
assemblies, subassemblies, and detail parts. All
partsof theequipmentare listedexceptfor commercially available hardware, bulk items such as wire,
cable, sleeving, tubing, etc., and permanently attached items which aresoldered,riveted, or welded
to another part. The part descriptions may be
indented to show part relationships.
Todetermine the part number,description,quantity,or application of an item,simplylocatethe item
in question from the illustration and refer to that
item number in the corresponding Parts List.
An“ApplicationCode” is used to distinguish parts
that are applicable only to certain Specifications
and/or Assemblies. Thiscode is found in the rightmostcolumn ofthePartsList. Ifanitemin theParts
ListappliestoallSpecificationsorAssemblies,the
word “ALL” will be inthe ApplicationCode column.
Refer to the following list to determine the appropriate Application Codes for the Specifications or
Assemblies covered by this manual. If only the
assemblyor specification number is listed, the use
of an Application Code does not apply to this
manual.
SPEC NUMBER
500237A-1
February 28, 2000 8-1
430429-465
PARTS LIST
8-2 February 28, 2000
Figure 8-1 Ultra Flex®Welder Assembly
Parts List for Figure 8-1
Item Part Description Qty
No Number per
430429-465
PARTS LIST
500237A-1 Welder - Ultra Flex®(Pulse) 1
Assy
1 205189 . Wrapper 1
2 204036 . Label - Precautionary 1
3 205120A . Label - Programs 1
4 . Deleted
5 . Deleted
6 205149 . Brace - Endcaps 2
7 205141 . Cover - Handle, Plastic 2
8 205143 . Panel - Endcap, Front 1
9 205006A-3 . Switch - Overlay, Membrane 1
10 204982 . Board - PC, Pendant Interconnection 1
11 205118-2 . Cable - 16 Pin, Ribbon Assy. (9") 2
12 . Deleted
13 408049-1 . Connector - Locking 2
14 205785-1 . Connector - Male 1
15 204841 . Board - Display 1
16 205019-1 . Fan 1
17 205147 . Plate - MTG. Fan 1
18 205144 . Panel - Endcap, Rear 1
19 205091-1 . Nut - Strain Relief 1
20 204943-1 . Bushing - Strain Relief 1
21 205123 . Cable - Power Input 1
22 203163-3 . Switch - Rotary, Power 1
23 205089 . Board - PC Assy. Auto Link Relay 1
24 204826 . Board - PC Amphenol, Interface 1
25 171370-2 . Cable - 16 Pin Ribbon Assy. 1
— 205128A . Label - Rear 1
26 205058 . Tray - Upper 1
27 205077B . Board - PC Assy., Auto Link Control (Rear) 1
28 401972-3 . Fuse - MDX, 3 Amp, 250 V, FL 1
29 204996 . Board - PCAssy. Weld Control (Front Bottom)1l
30 204777 . Board - PC Assy. MIG Circuit (Front Top) 1
31 204979 . Board - PC Assy. Pulse MIG (Front Top) 1
32 404460-1 . Support - PC Board 24
33 205118-1 . Cable - 16 Pin Ribbon Assy. (4") 3
34 409990-2 . Spacer - Board, PC 1
35 830786 . Switch - Voltage Select 1
— Not Illustrated
February 28, 2000 8-3
430429-465
PARTS LIST
8-4 February 28, 2000
Figure 8-2
Parts List for Figure 8-2
Item Part Description Qty
No Number per
Assy
500237A-1 Welder - Ultra Flex®(Pulse) (Continued) Ref.
1 202258-6 . Suppressor - W/Lug Assy. 3
2 205005-1 . Rectifier - Power 1
3 204944 . Heat Sink 1
4 203205 . Diode - Ultra Fast Recovery 4
5 205115 . Bus - Plate 1
6 205139 . Board - PC, Suppressor 1
7 203199-2 . Spacer - Board PC 1
8 404044-7 . Thermostat - OverTemperature 1
9 205136 . Bus - Bar 1
430429-465
PARTS LIST
10 205116 . Bus - Bar 1
11 409838 . Grommet - MTG. Nylon 4
12 409837 . Spacer - MTG. Nylon 4
13 204919 . Bracket - Left Side 1
14 205146 . Bus - Bar, Current Sensor 1
15 205018-1 . Current - Sensor 1
16 205074 . Board - PC Assy, Power IGBT 2
17 404915-2 . Stand - Off 12
18 405362-1 . Bushing - Snap 2
19 830116 . Label - Frame Ground 1
20 205048 . Bracket - Right Side 1
21 205062 . Bracket - Transformer 1
22 205043-1 . Transformer - Control 1
23 205092 . Choke 1
24 205134 . Bus - Bar 1
25 204918 . Base 1
26 205095 . Transformer - Power 1
27 205121-1 . Bracket - Capacitor 2
28 205016-1 . Capacitor - Electrolytic 2
29 368705-38 . Capacitor - W/Leads 2
30 830000 . Capacitor - Assembly, W/Leads 1
31 830104 . Support - Tray 4
February 28, 2000 8-5
430429-465
PARTS LIST
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8-6 February 28, 2000
STATEMENT OF WARRANTY
LIMITED WARRANTY: Thermal Arc®, Inc., A Thermadyne Company, warrants that its products will be free of defects in workmanship
ormaterial. Should any failure to conform to this warranty appear within thetime period applicable to the Thermal Arc products as stated
below, Thermal Arc shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and
maintained in accordance with Thermal Arc’s specifications, instructions, recommendations and recognized standard industry practice,
and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal
Arc’s sole option, of any components or parts of the product determined by Thermal Arc to be defective.
THERMAL ARC MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF
ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY
PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: Thermal Arc shall not under any circumstances be liable for special or consequential damages, such as,
but not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”)
for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Arc with respect to any
contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery,
resale, or use of any goods covered by or furnished by Thermal Arc whether arising out of contract, negligence, strike tort, or under
any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is
based. No employee, agent, or representative of Thermal Arc is authorized to change this warranty in any way or grant any other
warranty.
PURCHASER’SRIGHTSUNDER THIS WARRANTY AREVOID IF REPLACEMENTPARTSORACCESSORIESAREUSED WHICH
IN THERMAL ARC’S SOLE JUDGMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT.
PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY
NON-AUTHORIZED PERSONS.
Except with regards to the products listed below, this warranty shall remain effective three (3) years from the date Thermal Arc’s
authorized distributor delivers the product to Purchaser, but in no event more than (4) years from the date Thermal Arc delivers the
product to the authorized distributor.
Shorter warranty periods apply to the products listed below. On these products, the warranty is effective for the time stated below
beginning on the date that the authorizeddistributor delivers the products to the Purchaser. Notwithstanding the foregoing, in no event
shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the
authorized distributor.
ALL OTHER P-WEE, PRO-LITE
POWER SUPPLIES POWER SUPPLIES PRO-PLUS, PRO-WAVE LABOR
MAIN POWER MAGNETICS (STATIC & ROTATING) 3 YEARS 2 YEARS 1 YEAR
ORIGINAL MAIN POWER RECTIFIER 3 YEARS 2 YEARS 1 YEAR
CONTROL PC BOARD 3 YEARS 2 YEARS 1 YEAR
ALLOTHER CIRCUITSANDCOMPONENTS INCLUDING 1 YEAR 1 YEAR 1 YEAR
BUT NOT LIMITED TO, CONTACTORS, RELAYS,
SOLENOID, PUMPS, POWER SWITCHING SEMI-CONDUCTORS
ENGINES: ENGINES ARE NOT WARRANTED BY THERMAL ARC, ALTHOUGH MOST ARE WARRANTED BY THE ENGINE
MANUFACTURER. SEE THE ENGINE MANUFACTURES WARRANTY FOR DETAILS
CONSOLES, CONTROL EQUIPMENT, HEAT 1 YEAR 1 YEAR 1 YEAR
EXCHANGES, AND ACCESSORY EQUIPMENT
TORCH AND LEADS 180 DAYS 180 DAYS 180 DAYS
REPAIR/REPLACEMENT PARTS 90 DAYS 90 DAYS 90 DAYS
Warranty repairs or replacement claimsunderthis limited warrantymustbe submitted to ThermalArcby an authorized Thermal Arc®repair
facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to
sendproducts to anauthorized warrantyrepairfacilityshallbethe responsibilityofthe customer. Allreturned goods shallbe at the customer’s
risk and expense. This warrantysupersedes all previous ThermalArc warranties.
.
Thermal Arc®is a Registered Trademark of Thermadyne Industries Inc.
Thermal Arc Inc. Effective January 4, 1999
Troy, Ohio 45373 830538
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