200HF User Manual
Contents
1. INSTRUCTION MANUAL FUSION 151 HF Issue 02 Sept 2006 FUSION 151 PHF FUSION 200 HF FUSION 200 PHF Made in Britain CAUTION Ensure the operator of this equipment reads this information Additional copies can be obtained from your equipment supplier If you are not fully conversant with the principles of operation and safe working practices for arc welding we recommend that you read the HSE Booklet HSG204 Health amp Safety in Arc Welding Do not attempt to install or operate this equipment until you have read and fully understood the contents of this manual If you do not fully understand any instruction contact your supplier for further information and advice before attempting any welding or installation procedure 24pp A5 Instruction Manual indd 1 D 28 9 06 3 33 09 pm 24pp AS Instruction Manual indd 2 D 28 9 06 3 33 09 pm INDEX Subject Page EQUIPMENT INSTALLATION 1 DESCRIPTION OF CONTROLS 2 EQUIPMENT SPECIFICATIONS 3 MMA Stick WELDING FUNCTION amp OPERATION 4 MMA Stick WELDING REMOTE CONTROL 4 HF TIG WELDING FUNCTION amp OPERATION 5 6 LIFT TIG WELDING FUNCTION amp OPERATION 7 TIG WELDING REMOTE CONTROL 7 TIG SPOT WELDING FUNCTION amp OPERATION 8 REMOTE CONTROL CONNECTIONS 9 FUNCTION GUIDE 10 11 MMA STICK WELDING GUIDE 12 TIG WELDING GUIDE 13 INSULATION amp PAT TESTING 14 15 WARRANTY INSTRUCTION 16 17 CARE amp MAINTENANCE 18 TROUBLESHOOTING GUIDE 19 NOTICE Failure to a2. 5 Complete the welding application and set up procedure as detailed in HF TIG Welding Set Up in paragraphs 23 through to 26 6 TIG WELDING SET UP Remote Current Control 1 Connect the remote current control device to be used into the receptacle F12 F13 and complete the set up and operational instructions as detailed for HF TIG Welding Set Up in paragraphs 1 through to 18 2 Rotate control knob F8 clockwise until the text REMOTE CURRENT is displayed in the window F9 Rotate control knob F1 in either direction so that the text in window F9 reads FOOT CONTROL or TORCH CONTROL 3 Complete the welding application and set up procedure as detailed in HF TIG Welding Set Up in paragraphs 20 through to 26 4 If FOOT CONTROL is selected the machine will switch on and off when the foot switch is depressed and released The welding output current will increase and decrease as the footswitch regulation is varied Full depression of the footswitch will allow up to 99 of the welding current value as selected on the F2 display meter If the FOOT CONTROL option is selected then Start Current Up Slope Time Down Slope Time and Crater Current settings in the LCD window menu are disabled The operator will have full control of all the functions via the remote control foot pedal device 5 If TORCH CONTROL is selected this will allow the main welding output current to be controlled from a remote current adjustment co
3. 3 7 to 9 24pp AS Instruction Manual indd 7 D 28 9 06 3 33 11 pm TIG WELDING FUNCTION amp OPERATION 5 HF TIG WELDING SET UP Panel Control 1 Connect the work return cable into the positive Dix socket F4 Connect the TIG welding torch use a torch TIG adapter if required into the negative Dix socket F5 Attach the torch gas supply hose to the shielding gas outlet F10 Screw the torch switching control plug into the remote control socket F13 Fit the shielding gas supply hose to the gas inlet connection F11 Adjust the shielding gas inlet pressure and flow as required 2 Set the mains power switch F6 to the on position The welding output meter F2 will light up as will the LCD display F9 The welding mode as selected will also be shown on the LED display F3 and in the LCD menu display F9 3 Rotate the mode selection knob F7 in either direction until LED 3 is illuminated and TIG MODE is showing in the menu display window F9 At this point LED 4 may also be illuminated indicating that the HF start function is selected 4 Select the main welding output current required by rotating the control knob F1 The selected output will be displayed on the digital output meter F2 5 The menu selection control knob F8 is used to move through the welding function menu Using a swift motion rotate the menu selection control knob F8 clockwise approximately 90 Degrees The text in the display w
4. Estate Honiton Devon EX14 1BB England Tel 0 1404 549791 Fax 0 1404 46718 Email sales inverterfusion com Web www inverterfusion com 24pp AS Instruction Manual indd 24 D 28 9 06 3 33 18 pm
5. TIG welding mode and operation is explained in section 5 page 7 10 Rotate the control knob F8 clockwise until the text UP SLOPE TIME is displayed in window FQ Rotate control knob F1 to select the required up slope time 11 Rotate the control knob F8 clockwise until the text PULSE CURRENT is displayed in window F9 Rotate control knob F1 to select the required pulse base background current amps required Rotate the control knob F8 anticlockwise to switch the pulse mode off If the pulse current is adjusted to display off the pulse timers described in the following section will be disenabled 12 Rotate the control knob F8 clockwise until the text BASE TIME is displayed in window F9 Rotate control knob F1 to select the required base pulse time 24pp AS Instruction Manual indd 8 D 28 9 06 3 33 11 pm TIG WELDING FUNCTION amp OPERATION 13 Rotate the control knob F8 clockwise until the text PULSE TIME is displayed in window F9 Rotate control knob F1 to select the required high pulse time 14 Rotate the control knob F8 clockwise until the text DOWN SLOPE TIME is displayed in window F9 Rotate control knob F1 to select the required slope down time 15 Rotate the control knob F8 clockwise until the text CRATER CURRENT is displayed in window F9 Rotate control knob F1 to select the required crater amps level 16 Rotate the control knob F8 clock
6. are secure and that no kinking or twisting of the supply cable has occurred m Check the machine outer casings for any sign of cracking or breakage m Inspect welding and work return leads for any breakdown in insulation Ensure connection plugs welding torch electrode holder and earth clamp assemblies are damage free and secure m Check for any signs of overloading or improper use and that no unauthorized modifications have been carried out to the equipment m Make sure that the mains power on off switch is functioning correctly MEASUREMENT OF INSULATION RESISTANCE Depending on National and Company Standards insulation testing should be completed and carried out to the relevant safety laid down criteria For full instruction and guidance on this subject contact either the supplier or the manufacturer of the unit OPEN CIRCUIT VOLTAGE Testing the open circuit voltage of the unit should be carried out in accordance to the Standard EN60974 1 Copies of which can be obtained from the National Standards Authority or the equivalent Authority in the country the equipment is being used If outside the EU contact the standards authority for that region FUNCTION TEST A periodic function test of the equipment should be completed to ensure the unit performs and operates in line with the original specification for the unit as supplied CAUTION Only spares which are of Inverter Fusion Limited origin will be deemed fit for purpose Any other m
7. at optimum performance when supplied with a suitable mains input supply as specified 2 MAINS POWER CONNECTION On applying power to the unit the inverter will perform a self setting check This will be indicated by all displays briefly flashing on then off Following this LED 1 will stay lit to indicate that mains power is present and the unit is ready for operation MMA STICK WELDING SET UP Panel Control 1 Connect the electrode amp work return supply cables into the Dix sockets F4 amp F5 Check the consumable manufacturers specification for the correct polarity required 2 Set the mains power switch F6 to the on position The welding output meter F2 will light up as will the LCD display F9 The selected welding mode LED MMA TIG will also be lit in the LED display F3 3 Ensure that at no time the electrode holder and work return clamp come into contact as this could cause the machine to arc and could result in personal injury 4 Rotate the mode selection knob F7 in either direction until LED 2 is illuminated and MMA MODE is displayed in the menu display window F9 5 Select the output current required by rotating the control knob F1 The selected output will be displayed in the digital output meter F2 6 Using a swift motion Rotate control knob F8 clockwise until the text REMOTE CURRENT is displayed in the window F9 Rotate control knob F1 in an anti clockwise direction until the text in
8. correct sized Uncontrollable earth returns work lead components are fitted and that the Welding Arc connection welding torch is in good condition Ensure that all connections are secure and that there is a good earth return connection with the work piece Machine Overheats The machine working duty cycle has been exceeded Check and ensure that there is no restriction in the machine fan in and output ducts Also ensure that there is adequate ventilation space around the machine WARNING higher rated fuses If any fuses need to be changed these must be replaced by ones of the same value No warranty claims will be accepted in respect of damage caused or resulting from the use of Under no circumstances should any attempt be made to operate the equipment with any of the machine casings removed or in a dangerous condition The machine operates at very high voltages and serious personal injury could be incurred if unqualified persons make any repair attempt If in any doubt immediately disconnect the unit and contact the supplier 24pp A5 Instruction Manual indd 22 28 9 06 3 33 17 pm 19 24pp AS Instruction Manual indd 23 D 28 9 06 3 33 18 pm If at anytime further information is required regarding the safe operation or servicing of any Inverter Fusion Limited products please contact us at the address provided below Inverter Fusion Limited Heathpark Way Heathpark Industrial
9. fully locked into the output terminals Loose or damaged connections will cause the plugs to overheat and will cause damage to the machine 24pp AS Instruction Manual indd 4 D 28 9 06 3 33 09 pm DESCRIPTION OF CONTROLS FUSION HF amp PHF FUSION HF amp PHF Front View Rear View F10 F13 F12 CONTROL FUNCTION Mains Power Indicator F1 Current Adjustment MMA Mode Indicator F2 Output Display Meter Lift TIG Indicator F3 LED Function Display HF TIG Indicator F4 Positive Output Dix Socket Meter Hold Indicator F5 Negative Output Dix Socket Overheat Indicator F6 Mains Power On Off Switch F7 Mode Selector TIG amp MMA Torch Switch Plug Connection F8 Program Selection Control Connect the torch switch leads to pins 1 F9 Program LCD Menu Display amp 2 in the remote connection plug F10 Gas Output Connection supplied F11 Gas Input Connection Remote Current Plug Connection F12 Remote Control Socket 3 Wire Refer to the diagram on Page 14 for F13 Remote Control Socket 5 Wire connection instructions NOTE The equipment is supplied as standard with a 5 wire remote control receptacle for torch switching and current control A 3 wire remote control option is available upon request It is not possible to fit both 3 amp 5 wire options simultaneously Dead Man Safety Feature A dead man safety feature is installed in the HF amp PHF units to reduce the danger from the torch arcing accidentally on surfaces other than
10. of any authorised warranty claim work the product will be returned to the original claimant at the cost of Inverter Fusion Limited UK Customers Only Failure to comply with the above procedure could invalidate or delay the completion of any warranty work Improper use abuse or any attempt to repair the product by an unauthorised third party will invalidate any warranty claim Any parts or consumables fitted or used in conjunction with the Inverter Fusion Limited product which affect the equipment operation which are deemed by Inverter Fusion Limited to be of inferior quality or not fit for that purpose will be regarded as abuse and will invalidate the warranty claim Limited Warranty Effective 1 September 2004 This limited warranty supercedes all previous Inverter Fusion Limited warranties and applies to sales of Inverter Fusion Limited equipment in the UK only Warranty Terms amp Conditions Subject to the following Terms and Conditions Inverter Fusion Limited warrants to the original retail purchaser that new Inverter Fusion Limited equipment sold in the UK after the effective date of this limited warranty is free of defects in material and workmanship at the time of it s dispatch from Inverter Fusion Limited Within the warranty period as listed Inverter Fusion Limited will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Inverter Fusion Limited must be notifie
11. window F9 reads PANEL CONTROL 7 Using the correct safety equipment to protect the body and eyes fit an electrode in the holder and connect the work return cable to the work piece Strike the electrode on the work piece to establish the welding arc To end the welding application quickly lift the electrode away from the work piece 8 At the end of the weld LED 5 will be illuminated indicating that the welding output meter hold feature is activated The hold feature displays the last welding current used This will re set on welding re start or if the output current is adjusted 9 When the welding application is completed place the mains switch F6 in the off position and disconnect the unit from the mains power supply MMA STICK WELDING SET UP Remote Current Control 1 Connect the remote current control device into the receptacle F12 F13 Follow the MMA set up procedure as described in paragraph 3 1 to 5 2 Rotate control knob F8 until the text REMOTE CURRENT is displayed in the window F9 Rotate control knob F1 in a clockwise direction so that the text in window F9 reads either FOOT CONTROL or TORCH CONTROL as required for the type of remote control device to be used 3 The welding current is now adjustable with the remote control device between the machines minimum output and the main welding current output as selected on the digital meter F2 Complete the welding process as detailed in paragraph
12. 06 3 33 11 pm TIG WELDING FUNCTION amp OPERATION LIFT TIG WELDING SET UP Panel Control 1 To use the machine for LIFT TIG applications follow the instruction as described and detailed for HF TIG Welding Set Up in paragraphs 1 through to 8 2 Rotate the control knob F8 clockwise until the text HF START is displayed in window F9 Rotate control knob F1 anticlockwise to switch the HF start off When the HF start is switched off the LED 4 will not be illuminated The machine will now operate in a Lift TIG mode and no HF will be present at the start of the welding sequence 3 Continue to complete the program sequence set up as described for HF TIG Welding Set Up In section 4 paragraphs 10 through to 21 4 Using the correct safety equipment to protect the body and the eyes rest the torch gas shroud on the work piece at an angle of 45 degrees to the work piece Depress the torch switch this will start the shielding gas to flow still resting the torch gas shield on the work piece rotate the torch forward until the tungsten electrode touches the work piece then lift gently away approximately 4mm This will cause the arc to establish and the welding application can be commenced The method of starting the arc in the Lift TIG mode requires that the electrode is made to momentary make contact with the work piece practice will provide the individual operator with the best method of completing this task
13. R HI POT TEST DO NOT PERFORM EARTH LEAKAGE TESTING 14 24pp AS Instruction Manual indd 17 D 28 9 06 3 33 16 pm INSULATION PAT TESTING PROCEDURE DO NOT FLASH OR HI POT TEST WELDERS Some PAT testers are marketed as do it all units and incorporate hi pot or flash tests Such tests are not only superfluous to the requirements of PAT testing but can be damaging to otherwise satisfactory equipment If a PAT tester that incorporates hi pot flash testing as part of a programmed test routine is to be used for the insulation resistance test then the hi pot flash test function must be disabled Dielectric strength testing is performed by Inverter Fusion Limited during product manufacture and is not required as an in service test DO NOT PERFORM EARTH LEAKAGE TESTING ON WELDERS An earth continuity test is not required on Class II welding equipment as such equipment does not rely on a protective earth connection to the welding circuit for electrical safety There are no exposed conductive parts on the Marvel welders that are directly connected to earth WARNING The welder in common with all solid state power converters operates with high earth leakage current An earth connection is essential before connecting the mains supply to the welder 3 Functional Checks To check that the equipment is functioning correctly confirm that the unit operates and functions in accordance with the operator s instruction manual supplied
14. able amp Plug P No 000313 Argon Gas Supply Hose 3 Metre Fitted with 1 4 3 8 BSP Fittings P No 000080 Electrode Holder Fitted With 3 Metre Power Cable amp 35mm Male Dix Plug P No 000079 Earth Clamp Fitted With 3 Metre Power Cable amp 35mm Male Dix Plug SPECIFICATIONS Fusion Fusion Fusion Fusion 151 HF 151 PHF 200 HF 200 PHF Input Volts 50 60Hz 15 110V AC 110V AC 230V AC 230V AC Typical Input Fuse Rating 32A Slow 32A Slow 22A Slow 22A Slow Blow Blow Blow Blow Power Transformer Rating SKVA SKVA Power Generator Rating 7KVA 7KVA 7KVA 7KVA MMA Power Output Amps 20 120 20 120 20 180 20 180 TIG Power Output Amps 10 150 10 150 5 200 5 200 100 Duty Cycle MMA Amps 120 120 160 160 100 Duty Cycle TIG Amps 150 150 180 180 Max Open Circuit Voltage 92 Volts 92 Volts 92 Volts 92 Volts Power Factor 100 0 71 0 71 0 71 0 71 Efficiency 100 0 96 0 96 0 96 0 96 Enclosure Class IP 23 IP 23 IP 23 IP 23 Application Class S S S S Ambient Temperature 10 lt gt 40 Degrees C Cooling Method Forced Fan Standard IEC 60974 CE Marked Warranty 24 Months Full Parts amp Labour Weight 9 Kg 9 Kg 9 Kg 9 Kg Dimensions L 365mm x H 360mm x W 220mm 24pp A5 Instruction Manual indd 6 D 28 9 06 3 33 10 pm MMA Stick WELDING FUNCTION amp OPERATION 1 GENERAL The Fusion range of digital welding inverters is designed to operate
15. akes or type used in any repair or servicing procedure will render any and all statutory rights invalid 18 24pp AS Instruction Manual indd 21 D 28 9 06 3 33 17 pm TROUBLESHOOTING GUIDE FAULT CAUSE REMEDY No Power On LED Lamp No mains power available Ensure that the machine is connected to a suitable live mains power source and switched on The LED amp Meter Display Is Not Lit Up The machine power switch is turned off Ensure that the machine power switch located on the rear of the machine is switched to the on position No Welding Output Incorrect mode setting Check that the correct welding MMA TIG mode is selected in the LED display Machine Does Not Operate With TIG Torch Switch Broken torch lead or faulty torch switch In correctly fitted remote connection plug Use a meter to check that the torch switch is functioning and check that the remote control plug is wired correctly No Shielding Gas Empty gas cylinder or in correctly adjusted gas flow rate Replace amp adjust as required Check that no kinks are present in the gas and torch supply hose Welding Operation Is Incorrect welding current Check that the current level is correct Erratic Or Not As selected Faulty or damp for the application Select an Required electrodes alternative electrode Erratic Or Faulty welding torch or bad Check that the
16. aped joints are not allowed d The outer sheath of the cable is effectively secured where it enters the plug or the equipment Obvious evidence of damage would be if the coloured insulation of the internal cable cores were showing e The equipment has not been subjected to conditions for which it is not suitable eg it is wet or excessively contaminated f There is no damage to the external casing of the equipment or there are no loose parts or screws g There is no evidence of overheating burn marks or discolouration 2 Insulation Resistance Testing To check that electrical resistances between the mains terminals and the user accessible terminals are greater than 2MQ the following test instrument and test procedure is required Test instrument The resistance tester should apply a test voltage of approximately 500Vdc The tester should be capable of maintaining this test voltage with a load resistance of 0 5MQ Alternatively a PAT tester that can measure resistance with 500Vdc applied voltage can be used Procedure a The phase and neutral conductors are to be connected together This connection is best made with a dedicated test socket with phase and neutral connected together b Connect one test lead to the phase neutral pair Connect the other test lead in turn to each of the welding output terminals and the gas port on the front of the enclosure and check that the resistance is greater than 2MQ Note DO NOT FLASH O
17. d within 3 working days of any such defect of failure so that the procedure for a warranty claim can be followed 16 24pp AS Instruction Manual indd 19 D 28 9 06 3 33 16 pm WARRANTY INSTRUCTION amp PROCEDURE Inverter Fusion Limited shall honour all warranty claims on warranted equipment as listed below in the event of such a failure within the warranty time period All warranty time periods start on the date the equipment was delivered to the original retail purchaser and are as follows The period as detailed in the equipments original manual and specification issued at the time of purchase Extended Warranty may be purchased Details are available and supplied on application Inverter Fusion Limited Warranty shall not apply to Goods supplied by Inverter Fusion Limited but manufactured by others such as trade accessories These items will be covered by the manufacturers warranty if any Consumable components electrodes contactors and relays Equipment that has been modified by a third party equipment that has been improperly installed misused improperly operated or used in a manor that does not comply with an industry standard Any equipment that has been used for a purpose outside the specifications for that equipment or any equipment that has not been maintained in a condition that would make it suitable for use In the event of a valid warranty claim being made on any Inverter Fusion Limited pro
18. dhere to the advice and instruction given in this manual or to the implementation of the National International Safety in the Workplace Regulations could render the operator liable to danger that could be avoided Inverter Fusion Limited takes no responsibility for any accident that could occur from non compliance of any Safety Advice or the relevant Safety Standards 24pp AS Instruction Manual indd 3 D 28 9 06 3 33 09 pm INSTALLATION Correct Installation can contribute materially to the satisfactory working of the welding inverter Each step in this section should be studied and adhered to as closely as possible A INSPECTION amp PLACEMENT 1 Remove all packaging and inspect for any evidence of damage Immediately notify the supplier of any defects 2 Check the unit for any loose parts Ensure that air louvers are free from any packaging material that could obstruct the airflow through the machine 3 The components in the inverter operate at high temperatures and it is important that the fan input and output louvers are not obstructed Locate the unit in an open area allowing air to circulate freely around the machine The area around the machine should be relatively free from dust and excessive heat 4 Complete a risk assessment of the area to ensure that no danger to the Health amp Safety of the operator or any other person can be incurred during the equipment operation Consideration to noxious gases fume a
19. duct the exclusive remedies shall be at the discretion of Inverter Fusion Limited and shall be one of the following Repair Replacement Where authorised by Inverter Fusion Limited the reasonable cost of a repair carried out by a third party Payment for or a credit for the purchase price of the Inverter Fusion Limited product Less reasonable depreciation based on actual usage In each case the product must be returned to Inverter Fusion Limited or to it s authorised service centre at the claimants own risk and expenditure No compensation or reimbursement for transport costs of any kind will be allowed To the extent permitted by Law the remedies provided herein are the sole and exclusive remedies Inverter Fusion Limited liability under this warranty shall not exceed the cost of correcting the defect In no event shall Inverter Fusion Limited be liable for direct indirect special incidental or consequential damages including loss of profit whether based on contract tort or any other legal theory Any express warranty not provided herein and any implied warranty guarantee or representation as to the performance and any remedy for breach of contract tort or any other legal theory which but for this provision might arise by implication operation of Law Custom of Trade or course of dealing including and implied warranty or merchantability for a particular purpose with respect to any and all equipment furnished by In
20. e and down slope time as selected Once the spot time is completed the post flow gas will operate for the time as programmed 12 Complete the welding application as required making parameter adjustments as necessary 13 When the welding application is completed turn the power switch F6 to the off position and disconnect the unit from the mains power supply 24pp AS Instruction Manual indd 11 D 28 9 06 3 33 12 pm REMOTE CONTROL CONNECTION FIVE WIRE REMOTE CONTROL CONNECTION For 5 wire remote control connection the remote control receptacle F13 is installed as detailed Any 5 wire remote control device should be connected as follows TIG Torch Switch Pin 1 Trigger Switch Pin 2 Trigger Switch Pin 3 Not Used Pin 4 Pot Start Bottom Pin 5 Pot Wiper Pin 6 Pot End Top Pin 7 Ground The remote source for the control is ratio metric Any potentiometer with a value between 1K amp 10K Ohms can be used for the Remote Potentiometer control current increase gt m THREE WIRE REMOTE CONTROL CONNECTION For 3 wire remote control connection the remote control receptacle F12 is installed as detailed Any 3 wire remote control device should be connected as follows Remote Potentiometer FREE Pin 1 Pot End Top amp Pot Wiper Pin 2 Trigger Switch amp Pot Start Bottom Pin 3 Not Used Pin 4 Not Used Pin 5 Not Used Pin 6 Trigger Switch TIG Torch Switch Pi
21. e selected level at the end of the completed right up to the edge of the weld sequence component 10 24pp A5 Instruction Manual indd 13 28 9 06 3 33 13 pm FUNCTION GUIDE Control Function Explanation aa ea 5 Crater This controls the time that the arc will As described for Crater Control Current be maintained at the selected crater Time current level aS Hele ke eee spre te Mid Post Flow Controls the length of time the To prevent contamination of the weld puddle Gas Time shielding gas flows after the arc is and to also allow the tungsten and welding switched off torch to cool down 2 Touch Signals the machine to start and end When the torch switch is depressed the Torch the welding sequence weld sequence will begin When the switch Control is released the weld sequence will be signalled to end HE Fer ree eee ete ee ee 4 Touch Signals the machine to start and step Allows for easy control at the start and end Torch through the welding sequence of the welding application Control Remote Provides method of adjusting the The remote control device will allow 0 100 Control welding current output using either a adjustment of the current as selected on the foot or hand operated device main current display FUNCTION SEQUENCE Main Welding Current Up Slope Down Slope Time Time Z Base Welding Arc Start Crater Current Current Current Arc i i Off Pre High Pu
22. for the relative model under test For any further information or advice regarding the Pat Testing of the Fusion Product range please contact our Technical Department Tel 0 1404 549791 Fax 0 1404 46718 Or Write To Inverter Fusion Limited Heathpark Way Heathpark Industrial Estate Honiton Devon EX14 1BB England 15 24pp AS Instruction Manual indd 18 D 28 9 06 3 33 16 pm WARRANTY INSTRUCTION amp PROCEDURE GENERAL The Warranty Registration Card enclosed must be completed and returned at the time of purchase in order to register the new product with Inverter Fusion Limited In the event of a claim the claimant must first contact Inverter Fusion Limited for a warranty claim authorisation number Following this the Warranty Claim form as printed on the reverse side of this page should be completed with all the details as requested and forwarded to Inverter Fusion Limited along with the faulty product and a copy of the original purchase receipt The claimant will be responsible for all carriage insurance and transportation costs in returning the product to Inverter Fusion Limited Upon receipt and inspection of the product the product will be repaired or replaced at the discretion of Inverter Fusion Limited In the event of a chargeable repair or a repair being required that is not considered to be a warranty issue the claimant will be contacted for his further instruction Following the completion
23. indow F9 will change and display the next function in the menu By repeating this operation the complete menu sequence can be stepped through and welding parameter adjustments can be made as required using the control knob F1 The selected menu function will be displayed for twenty seconds after which the display widow F9 will return to a datum point and display TIG MODE At any time during the menu set up the display can be signalled to return to the datum point by pressing and releasing the torch on off switch The selection control knob can be rotated in either direction to move both forward and backward through the welding sequence program 6 The menu display function and operations as described in the following instructions 7 8 10 11 12 13 15 amp 16 are only available on the Fusion PHF models 7 Rotate the control knob F8 clockwise until the text PRE GAS TIME is displayed in window FQ Rotate control knob F1 to select the required pre gas time 8 Rotate the control knob F8 clockwise until the text START CURRENT is displayed in window FQ Rotate control knob F1 to select the required start current amps 9 Rotate the control knob F8 clockwise until the text HF START is displayed in window F9 Rotate control knob F1 to switch the HF start on When the HF start is switched on the LED 4 will be illuminated When the HF start is switched off the machine will operate in the Lift TIG mode The Lift
24. ith each _ 2mm type of electrode being manufactured for specific types of metal and VID LG applications At Not Fouling Prep During the welding process the flux is used to provide a gaseous shroud around the weld puddle in order to provide protection to the molten metal from atmospheric contamination After the welding application is complete the slag residue encasing the weld bead should be removed Always check the electrode manufacturers specification for the Vy Wi recommended amperage setting and connection polarity for the electrode to be used Fouling Sides Of Prep Incorrect Electrode Size WELDING TECHNIQUE To strike the arc the electrode should be directed at an angle of 90 degrees and moved on the plate in a motion similar to striking a match Care should 75 be taken to avoid lengthening the arc once struck as this will cause porosity T in the weld puddle UD bak F Direction Of Travel It is essential with normal welding electrodes that an arc length of no greater than 2 0mm is visible at any time during welding Once the arc is struck the electrode should be drawn along the plate at an angle of approximately 75 degrees at a continuous speed that allows the VIP molten weld puddle to fill the weld joint as required 7 4 During welding a horse shoe pattern will be seen to form behind the molten J Preparation weld pool caused as the molten metal freezes and this should be kept as uniform in width as pos
25. ium and Gas Flow hydrogen may be used for special applications The TIG welding process is ideal for thin gauge materials and also for quality Tungsten work such as stainless steel applications for the food and chemical process Electrode industries Smm There is no flux used in the TIG welding process so the finished weld requires Length Controls Bead Width the minimum of cleaning afterwards Wide ranges of gas shrouds are available that allow access into difficult weld positions The selected filler material should be an ideal match for the parent material to be welded WELDING TECHNIQUE Two normal methods of striking an arc are either with an HF arc starter or by the Lift TIG method With the HF method when the machine is signalled to start a high voltage spark jumps from the electrode to the work to establish the welding arc With the Lift TIG method it is necessary to momentary allow the electrode to make contact with the work piece Once the arc is established the welding torch is pointed in the direction of the weld joint and filler material as required is added to the weld puddle The travel Filler Rod amp speed for the torch is adjusted to match the time needed to melt the joint Weld Puddle For optimum arc striking when welding with DC power the electrode should be ground to a sharp point The welding arc length is controlled by the operator and should be between 2mm and 5mm Sharpened The shielding gas flowing th
26. ll also be illuminated 5 Select the main welding output current required by rotating the control knob F1 The selected output will be displayed on the digital output meter F2 6 Rotate the control knob F8 clockwise until the text PRE GAS TIME is displayed in window F9 Rotate control knob F1 to select the required pre gas time 7 Rotate the control knob F8 clockwise until the text SPOT TIME is displayed in window F9 Rotate control knob F1 to select the required spot weld time 8 Rotate the control knob F8 clockwise until the text DOWN SLOPE TIME is displayed in window F9 Rotate control knob F1 to select the required time 9 Rotate the control knob F8 clockwise until the text POST GAS is displayed in window F9 Rotate control knob F1 to select the required post gas time 10 Itis not necessary to adjust the welding sequence parameters in the order as described Any parameter can be individually adjusted by rotating the control knob F8 in either direction until the required area of the program is displayed in the window F9 and the adjustment made as required using control knob F1 11 Using the correct safety equipment to protect both the body and the eyes position the spot welding torch as required Depress the torch switch the gas will start to flow and a HT spark will jump from the tungsten to initiate the welding arc The arc will remain established to complete the spot welding tim
27. lse Base Pulse Remote Crater Post Gas Time Time Current Control Time Gas 11 24pp AS Instruction Manual indd 14 D 28 9 06 3 33 13 pm MMA STICK WELDING GUIDE The following notes are aimed at providing the operator with a basic overview of MMA welding techniques and do not provide instruction or explanation of welding theory or welding practice PREPERATION All materials to be welded should be clean and free from rust and grease The joint to be welded should be suitably prepared and clamped in position All welding processes produce fume and full consideration to this should be given before any welding is commenced as should any risk of fire explosion and danger to either the operator or any other personnel The welding arc produces harmful ultra violet and infrared rays that can cause serious eye damage and burns to the skin Ensure that the correct safety equipment is worn to provide optimum protection from both the welding rays and to protect against hot Arc metal burns a Length ELECTRODE SELECTION 2mm MMA Stick welding is still probably the most commonly known and Va recognised method of joining most metals To achieve optimum results it is VTA important that the correct type and size of electrode is selected for the material to be welded Correct Size Electrodes are manufactured using a core rod that is encased in a flux Electrode material The type of core rod and flux material used can be varied w
28. mp Allows the welding current to be gently Timer up from the start current setting to the increased in the weld puddle selected main welding output current Pulse If turned to minimum the pulse is Allows a controllable high current level Mode switched off If a current level is to be used for the welding application Selection selected the machine will pulse without the risk of burn through It also between the level selected and the allows for a wide weld bead to be current level displayed on the main amp completed on thin gauge material display meter Base Pulse Controls the time that the base Allows the base low current pulse time Time current selected is operational to be adjusted so that burn through or excessive current is not used in the welding application Peak Pulse Controls the time that the peak main Allows the main high pulse current time Time current selected is operational to be adjusted so that optimum weld penetration is maintained during the welding application Down Controls the time the arc takes to ramp Allows the weld current to be gently Slope down from the main welding current to reduced as required allowing weld Time the crater final current if selected or to overlaps to be completed without excess switch off weld bead material build up Crater When a crater current level is To maintain the arc at the end of the Current selected the weld output will ramp down weld sequence allowing welds to be Control to th
29. n 7 Ground For 3 wire remote control connection a potentiometer value of 10K Ohms must be used 24pp AS Instruction Manual indd 12 D 28 9 06 3 33 12 pm FUNCTION GUIDE Control Function Explanation Pre Flow Controls the length of time that the Allows sufficient shielding gas to be Gas Time shielding gas flows before the arc is present in the weld area to avoid any started contamination in the welding puddle Start Controls the power output amps that The size and type of tungsten electrode Current the arc will start and strike in at used will determine the optimum start Control current level 1 0mm_ electrodes will require a minimum of 10amps 2 4mm 20amps and for larger sizes the current would be increased as required Lift TIG Provides a method of starting the arc Allows the arc to be established by Start without the use of HF touching the electrode on the work piece Operation and then lifting away avoiding the necessity to scratch the electrode and reduces the potential for the electrode to stick down and contaminate HFTIG Provides method of starting the arc Allows the arc to be established without Start using a high frequency generated the necessity of touching the electrode Operation spark on the work piece A high voltage spark jumps from the electrode to the work piece ionising the shielding gas allowing the arc to establish Up Slope Controls the time the arc takes to ra
30. ntrol device The welding output current will increase and decrease as the remote regulation is varied and will allow variation of the welding output current value as selected on the F2 display meter The machine welding sequence will be switched On amp Off as detailed in HF TIG Welding Set Up paragraph 18 When a remote current device is adjusted the output current as selected will be displayed in the F2 meter All other available LCD menu options will be fully functional 24pp AS Instruction Manual indd 10 D 28 9 06 3 33 12 pm TIG SPOT WELDING FUNCTION amp OPERATION 7 TIG SPOT WELDING 1 The TIG SPOT welding menu function option is only available on the Fusion PHF models 2 Connect the work return cable into the positive Dix socket F4 Connect an appropriate TIG Spot Welding Torch use a TIG torch adapter if required into the negative Dix socket F5 Attach the torch gas supply hose to the shielding gas outlet F10 Screw the torch switch control plug into the remote control socket F13 Fit the shielding gas supply hose to the gas inlet connection F11 Adjust the shielding gas pressure and flow as required 3 Set the mains power switch F6 to the on position The welding output meter F2 will light up as will the LCD display F9 4 Rotate the mode selection knob F7 in either direction until LED 3 is illuminated and SPOT MODE is showing in the program display window F9 At this point LED 4 wi
31. rc glare fire risk and moisture should also be fully considered B PRIMARY ELECTRICAL INPUT CONNECTION WARNING All possible measures should be taken to provide maximum protection against electrical shock Ensure the mains power is isolated before making any primary connections 1 Ensure that an adequate mains power supply is available with a correct fuse rating to supply the machine at the duty cycle the operator requires to work within 2 The machine is supplied with a two metre 3 core input power cable for connection to a suitable single phase power supply The earth conductor in the power cable must at all times be secured to ground earth 3 Fit and use only plugs or circuit breakers that are designed for the level of primary input voltage and input current required for the safe operation of the machine 4 Extension cables may result in excessive voltage drops that will influence the welding output of the machine Use only industrial grade extension cables and ensure that the cable conductor sizes are relevant to the required current draw c SECONDARY WELDING OUTPUT CONNECTIONS WARNING Before making any connections to the welding output terminals of the machine ensure that the mains power to the machine is switched off and the power cable is unplugged 1 The machine is fitted with 35mm Dix style output connections always use connection plugs of a compatible size Ensure that the connection plugs are free from damage and are
32. rough the torch as well as providing protection from Electrode atmospheric contamination also assists in cooling the welding torch head For standard gas shrouds when welding materials between 1 6mm and 6 0mm a A gas flow rate should be set for between 5 and 8 Litres per min 6 When the arc is switched off the shielding gas continues to flow for several G seconds during this time the torch should be held in position over the molten NG metal to prevent weld puddle contamination Direction Of Weld 13 24pp AS Instruction Manual indd 16 D 28 9 06 3 33 15 pm INSULATION PAT TESTING PROCEDURE All electrical insulation within the Inverter Fusion Limited welding inverters provides Class II protection in accordance with the international standard for arc welding power sources IEC60974 Portable Appliance Testing PAT as detailed in the IEE Code of Practice for In service Inspection and Testing of Electrical Equipment when applied to Inverter Fusion Limited welders providing Class II protection requires the following tests and inspection 1 Visual Inspection 2 Insulation Resistance Testing 3 Functional Checks 1 Visual Inspection To visually check that the equipment is in sound condition check the following a There is no damage apart from light scuffing to the cable sheath b The plug is not damaged the casing is not cracked or split and the pins are not bent c There are no inadequate joints in the cable t
33. sible 4 Butt Weld i H V Fillet Weld YW V Preparation 12 I 24pp AS Instruction Manual indd 15 D 28 9 06 3 33 15 pm TIG WELDING GUIDE The following notes are aimed at providing the operator with a basic overview of TIG welding techniques and do not provide an instruction or explanation of welding theory or welding practice PREPERATION All materials to be welded should be clean and free from rust and grease The joint to be welded should be suitably prepared and clamped in position All welding processes produce fume and full consideration should be given to this before any welding is commenced as should any risk of fire explosion and danger to either the operator or any other personnel The welding arc produces harmful ultra violet and infrared rays that can cause serious eye damage and burns to the skin Ensure that the correct safety equipment is worn to provide optimum protection from both the welding rays and to protect against hot metal burns TIG WELDING PRINCIPLES TIG Tungsten Inert Gas welding uses an arc between the tungsten electrode EEL and the work to fuse the joint The electrode is not melted and filler metal to Body build up the weld profile is added separately Collet Shroud The molten metal in the weld puddle together with the electrode and the tip of the filler material used are protected from atmospheric contamination by a shield of inert gas Normally argon gas is used but mixes of hel
34. splayed in the window F9 and the adjustment made as required using control knob F1 21 When all required parameters have been set in the sequence menu program the unit will store the data until any further adjustment is made The data will also be stored ready for future use even when the mains power is switched off 22 Using the correct safety equipment to protect both the body and the eyes hold the torch at an angle of 45 degrees so that the tungsten electrode is approximately 2 3 mm away from the work piece Depress the torch switch the gas will start to flow and a HF spark will jump from the tungsten to initiate the welding arc 23 Once the welding arc is established the unit will operate as programmed At any time in the 2T switch mode the welding arc can be stopped by releasing the torch switch In the 4T switch mode the arc is stopped by pressing and releasing the torch switch 24 Complete the welding application as required making output and control parameter adjustments as necessary 25 Ifat any time the welding arc is broken prior to signalling the machine to switch off the dead man device installed in the machine will be activated and it will not be possible to re strike the arc until the post flow gas time has completed 26 When the welding application is completed turn the power switch F6 to the off position and disconnect the unit from the mains power supply 24pp AS Instruction Manual indd 9 D 28 9
35. the welding fixture In the TIG Welding Mode if the arc fails to establish after 3 seconds Not including any pre gas time if selected the unit is programmed to switch off To re start the arc release the torch switch and recommence the welding start sequence If at any time during the TIG welding sequence of operation the arc is accidentally broken the machine is programmed to switch off If a down slope time has been selected the machine will remain inoperative until both the down slope crater and post gas times as selected have expired 24pp AS Instruction Manual indd 5 D 28 9 06 3 33 10 pm SPECIFICATION DETAIL EQUIPMENT P No 000633 Fusion 151 HF 110V 150 Amp MMA LT HF TIG Inverter P No 000634 Fusion 151 PHF 110V 150 Amp MMA LT PHF TIG Inverter P No 000485 Fusion 200 HF 230V 200 Amp MMA LT HF TIG Inverter P No 000200 Fusion 200 PHF 230V 200 Amp MMA LT PHF TIG Inverter OPTIONAL ACCESSORIES P No 000537 150 Amp GP17 Air Cooled TIG Welding Torch Fitted with 4 Metre Hose Assembly Plugs amp Handle Mounted On Off Switch P No 000561 150 Amp GP17R Air Cooled TIG Welding Torch Fitted with 4 Metre Hose Assembly Plugs amp Handle Mounted On Off Switch amp Thumb Wheel for Remote Current Control P No 000111 GP17 Torch Accessory Kit Including Long Back Cap Collet Bodies Collets and Tungsten Electrodes P No 000320 Footswitch for Remote Current Control amp On ff Switching Fitted with 3 Metre C
36. verter Fusion Limited is excluded and disclaimed by Inverter Fusion Limited 17 24pp AS Instruction Manual indd 20 D 28 9 06 3 33 17 pm CARE amp MAINTENANCE Under normal circumstances the Freeman range of welding inverter machines are virtually maintenance free However certain points should be observed to ensure the trouble free operation of the machine Amongst these are regular checks as described below the frequency of these checks will depend on the type of environment the unit will be operated within and the overall usage of the equipment CAUTION Any internal inspection testing or repairs to the equipment should only be carried out by personnel trained and qualified to do so The following description of tests either visual or any other are extracts of various Standards regarding the safe servicing and maintenance of electrical equipment The following recommendations are for guidance only and we suggest that they are completed at least once every 12 months or in the case of excessively high use more often as required VISUAL CHECKS The unit should be inspected externally for visible faults without opening the unit In the course of this inspection the following points should be checked and if necessary service and repair should be arranged immediately m Any damage to the mains supply plug or cable Examine for any signs of faulty insulation scorching of pressure marks Ensure all cable glands and fittings
37. wise until the text CRATER TIME is displayed in window F9 Rotate control knob F1 to select the required crater current time 17 Rotate the control knob F8 clockwise until the text POST GAS is displayed in window F9 Rotate control knob F1 to select the required post gas time 18 Rotate the control knob F8 clockwise until the text TIG SWITCH is displayed in window F9 Rotate control knob F1 to select either 2T or 4T touch operation In 2T operation the weld sequence will start and stop as selected when the torch switch is depressed and released In 4T operation when the torch switch is depressed the arc will strike in and hold at the start current level when the switch is released the arc will upslope to the main welding current level When the switch is again depressed the arc will down slope and hold at the crater current level when the switch is released the arc will switch off If the torch switch is released during the down slope time the weld will switch of at that point 19 Rotate control knob F8 clockwise until the text REMOTE CURRENT is displayed in the window F9 Rotate control knob F1 in an anticlockwise direction so that the text in window F9 reads PANEL CONTROL 20 Itis not necessary to adjust the welding sequence menu parameters in the order as described Any parameter can be individually adjusted by rotating the control knob F8 in either direction until the required area of the program is di
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