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OWNER`S MANUAL - Victor Technologies

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1. Description Qty 1 Nozzle refer to Table 8 4 Page 8 2 1 2 Contact tip refer to Table 8 3 Page 8 2 1 3 Gas diffuser refer to Table 8 2 Page 8 2 1 4 MS63 605 _ Conductor tube 1 5 N A O Ring Gun Handle 1 6 MS84 Handle kit includes items 7 8 9 22 amp 23 1 7 Insert amp screw refer to item 6 2 8 Handle refer to item 6 1 9 refer to item 6 1 10 ELC94 Trigger Lever 1 11 ELC94BL blades 1 12 Butt Splice insulateAd crimp link 1 5mm 2 13 ELC104 2 screw 1 14 MS210 Cable assembly Cablehoz 10ft 1 15 350 174H _ Connector Plug 2 16 44C Set screw 8 32 UNC 1 17 350174H F Connector plug 1 18 Conduit refer to Table 8 5 Page 8 2 1 22 hanger refer to item 6 1 23 Hanger screw refer to item 6 1 24 Locking Trigger not shown option Table 8 1 Mig Gun Components April 10 2000 10135 1 TWECO MIG GUN Gun Consumable Parts NOTE Denotes parts that are supplied as standard with TWECO gun a Gas Diffusers Part No HD52 11 slide on nozzles b Contact Tips Table 8 2 Mig Gun Gas Diffusers Table 8 5 Mig Gun Conduits STANDARD TAPERED Wire Size Part No Wi
2. lt socket positive for Flux Cored Wire Connect the GUN lead to the positive socket negative for Flux Cored Wire Position a gas cylinder on the rear tray and lock securely to the Power Supply cylinder bracket with the chain provided If this ar rangement is not used then ensure that the gas cylinder is secured to a building pillar wall bracket or otherwise securely fixed in an upright position Fix the cable stowage hook to the Power Supply cylinder bracket with the bolts pro vided Fit the gas Regulator Flowmeter to the gas cylinder Connect the gas hose from the rear of the Power Supply to the Flowmeter outlet Three dual groove feed rollers are supplied as standard with the Power Supply These can accommodate 0 6mm 024 0 8mm 030 0 9mm 035 and 1 2mm 045 diameter hard wires as well as 1 0mm 040 and 1 2mm 045 flux cored wires Select the roller required with the chosen wire size marking facing outwards Fit the electrode wire to the wire reel hub located behind the electrode wire com partment door Ensure that the drive dog pin engages the mating hole in the wire spool Push the clip into place to retain the wire spool securely The wire should feed from the bottom of the spool Fit the TWECO MIG gun to the wire feed unit by releasing the gun locking screw in the brass gun adaptor and pushing in the gun fitting until th
3. 409 062 i 0333 341M A LOW 1 Ob ya 8 XL 109 8 29 6 976804 894 9 5 HAINHOASNVAL 3 7109105 Of 16 6 gt m Y39914 a 19 1 12 z HOMOL lt Ya ZE 9 15 862 gt 5 95 9 o 88 1 1 9 OVA Sz WECRET 2 3YNIVY3AWIL Y3AO YZL Ave 5 lt 5 IM VIE avc TIM 06 WOO 6661 87 GIN OL FL 9503 5 LON ISNA VZ 5729875 IVISONSSHI LV l saze HMS 0 1009 N XJLIN TLIO 4 0190 OL ST 7802 970095 3 1 18 0 94 gg ee ee ee a A0 9 see 2 x T 93 5010 ee 8 354909 1040830 zT l 1011610 a te 8 1 828 3 HINYOISNVAL 209 ONIO TIM 9 67 IA 0121 00 Es Figure 13 1 Power Supply Schematic 13 1 April 10 2000 10135 1 270XSR SUPPLY CIRCUIT DIAGRAM This page intentionally left blank 13 2 April 10 2000 10135 1 PRINTED CIRCUIT BOARD CIRCUIT DIAGRAM PRINTED CIRCUIT BOARD CIRCUIT DIAGR
4. ek Glare gated beak al ke gle 7 4 Burnback Control feels Sh ee ee aoe aed Ba A elle a Be 7 4 Spool Gun Standard Switch a 7 5 Wirefeeder Drive Roller Pressure Adjustment 7 5 Wire Resl Brake 0 2 seis nn 7 5 10 2000 1 10135 1 TABLE OF CONTENTS TWECO MIG GUN T830788 2 a brad of GY pe autant Sera huge 8 1 TWECO MIG Gun Components 8 1 Gun Consumable Parts 8 2 Installing New Wire Conduit 8 3 MIG Gun Maintenance 8 3 BASIC WELDING TECHNIQUE 9 Setting Of The Power Supply 9 1 Postion oft MIG Gun hav as alert dla ht 9 1 Distance From The MIG Gun Nozzle To The Work Piece 9 1 Travel Speed da ee Ge a 9 1 Electrode Wire Size Selection 9 1 Stitch Welding Operation 9 2 Spot Welding Operation 9 2 MAINTENANCE amp INSPECTION 10 Improved Current Accuracy Calibration Procedure For The Digital Meter 10 1 TROUBLESHOOTING 11 Solving Problems Beyond the Welding Termi
5. 10135 1 BASIC WELDING TECHNIQUE 0 9 mm 035 Work Piece 1 2 mm 045 AY 7 Penetration comparison using the same current 200 for both electrode Figure 9 2 Wire Penetration Comparison This demonstrates that where the upper limit of current is limited by machine capacity and duty cycle higher deposition rates and therefore greater productivity will be achieved by using smaller elec trode wire The 270XSR is a particularly efficient MIG welder with the 0 9mm steel wire in spray transfer mode The savings from decreased welding time will more than cover the small cost penalty of the smaller electrode wire sizes 0 9mm 035 wire cost approx 10 more than 1 2mm 045 but is deposited approx 15 faster Higher current density or smaller diameter wire also gives deeper penetration as shown Figure 9 2 Stitch Welding Operation Stitch welding is normally used to bridge excessive gaps between panels or when welding very thin material to prevent heat build up and distortion Set the controls as follows for stitch welding a Coarse amp Fine Voltage Selector Switches and Wirespeed Control Set these controls to obtain the desired weld ing conditions for the wire and material being welded b Mode Selector Switch Set the MODE SELECTOR switch to STITCH c Spot Time Adjust the SPOT TIME control shaft for the desired weld or ON time while stitch welding d Dwell Time Adjust t
6. Input power supply voltage is ON Indicator light is not lit and welding arc can not be estab lished A B Primary fuse is blown Broken connection in primary circuit Replace primary fuse Have an Accredited DAIHEN Corporation Service Agent check primary circuit Input power indicator light is not lit but welding arc can be estab lished Indicator light is open circuit Have an Accredited DAIHEN Corporation Service Agent replace Indicator light Input power supply voltage is ON and Indicator light is lit but when the gun trigger switch is depressed nothing happens Gun trigger switch leads are disconnected Reconnect Input power supply voltage is ON no wire feed but gas flows from the MIG gun when the gun trigger switch is depressed A Electrode wire stuck in conduit liner or contact tip burn back jam Faulty control PCB or Tweco gun Check for clogged kinked MIG gun conduit or worn contract tip Replace faulty compo nent s Have an Accredited DAIHEN Corporation Service Agent in vestigate the fault Wire feeds when the gun trig ger switch is depressed but arc can not be established Poor or no work lead connec tion Clean work clamp area and en sure good electrical contact Wire continues to feed when the gun trigger switch is re leased The Mode Selector Switch has been set to 4T latch opera tion Set the Mode Selector Switc
7. Input Power supply voltages INPUT VOLTAGE SELECTION 208V 230V 208V lt 2 amp 70 DK BLU 208 208 CONNECT WIRE 230V 230V lt 78 amp 70 DK BLU TO 230V 208V lt 208 230V ess Figure 5 1 Voltage Settings For 270XSR Input Power Supply _ Input Power Machines Voltage Setting Supply Lead Size Input Power Outlet Size Fuse Size Duty Cycle 208V 8 0mm BAWG 40 Amp 80Amp 270XSR 270A See Figure 5 1 40 230V 8 0mm AWG 40 Amp 80Amp Motor start fuses or thermal circuit breakers are recommended for this application National Electrical Code Standards permits the rating of the fuse or thermal circuit breaker protecting the circuit conductors to be double the outlet current rating for any circuit used exclusively for an electric arc welder Check local requirements for your situation in this regard Table 5 2 Input Power Supply Lead Sizes For Alternative Input Power Supply Voltages April 10 2000 10135 1 SET UP FOR 270XSR SET UP FOR 270XSR a Remove all packaging materials CAUTION To obtain adequate air flow and cooling for the Power Supply components the four wheels must be fitted Alterna tively the Power Supply may be raised 140mm 5 5 from the floor using supports that do not restrict airflow b Connect the work lead to the negative
8. la propri t si l utilisateur n adh re pas strictement toutes les r gles de s curit et prend pas les pr cautions n cessaires En soudage et coupage des pratiques s curitaires se sont d velopp es suite pass e Ces pratiques doivent tre apprises par tude ou entra nement avant d utiliser l equipement Toute personne n ayant pas suivi un entra nement intensif en soudage coupage ne devrait pas tenter de souder Certaines pratiques concernent les quipements raccord s aux lignes d alimentation alors que d autres s adressent aux groupes lectrog nes La norme 249 1 de l American National Standard intitul e SAFETY IN WELDING AND CUTTING pr sente les pratiques s curitaires suivre Ce document ainsi que d autres guides que vous devriez conna tre avant d utiliser cet quipement sont pr sent s la fin de ces instructions de s curit SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D INSTALLATION DE REPARATION D ENTRETIEN D ESSAI L ELECTROCUTION PEUT ETRE 6 Arr tez tout quipement apr s usage Coupez l alimentation de MORTELLE l quipement s il est hors d usage ou inutilis 7 N utilisez que des porte lectrodes bien isol s Ne jamais plonger les porte lectrodes dans l eau pour les refroidir Ne jamais les laisser tra ner par terre ou sur les pi ces souder Ne touchez pas aux porte lectrodes raccord s deux sources de coura
9. 4 to 6 4 mm Light Under 300 Amp Over 1 4 in 6 4 mm Medium 300 to 400 Amp Heavy Over 400 Amp May 8 1996 2 1 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 FUMES AND GASES be hazardous to your health Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breath the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases 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 work piece and hot equipment can cause fires and burns Accidental contact of electrode or welding wire to metal objects can cause sparks overheating or fire Protect yourself and others from flying sparks and hot metal Do not weld where flying sparks can strike flammable material Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas 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 Shieldin
10. ARD SPOOL GUN selector switch which is located inside the wire drive compartment of the power supply This switch allows either the built in wire drive system STANDARD mode or the SPOOL GUN mode to operate NOTE When in the SPOOL GUN mode the internal gas control and the internal wire feed system of the power supply are dis abled Wirefeeder Drive Roller Pressure Adjustment The moveable roller applies pressure to the grooved roller via screw adjustable spring pressure The adjustable spring screw should be adjusted to a minimum pressure that will provide satisfactory wire feed without slippage If slipping occurs and inspection of the wire contact tip reveals no wear distortion or burn back jam the conduit liner should be checked for kinks and clogging by metal flakes and swarf If this is not the cause of slipping the feedroll pressure can be increased by rotating the adjustable spring screw clockwise The use of ex cessive pressure may cause rapid wear of the feed roller motor shaft and motor bearings NOTE Genuine TWECO contact tips and liners should be used Many non genuine liners use inferior materials which can cause wire feed problems Wire Reel Brake The wire reel hub incorporates a friction brake which is adjusted during manufacture for optimum braking If it is considered necessary adjustment can be made by turning the large nut inside the open end of the wire reel hub Clockwise rotat
11. Le carburant est hautement inflammable 1 Arr tez le moteur avant de v rifier le niveau de carburant ou de faire le plein Portez un cran facial ou des lunettes protectrices approuv es Des crans lat raux sont recommand s Portez des v tements appropri s pour prot ger la peau Emp chez tout contact entre une bouteille et une lectrode de soudage N utilisez que des bouteilles de gaz protecteur des d tendeurs des boyauxs et des raccords con us pour chaque application sp cifique ces quipements et les pi ces connexes doivent tre maintenus en bon tat Ne placez pas le visage face l ouverture du robinet de la bouteille lors de son ouverture Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccord pour utilisation Lisez et respectez les consignes relatives aux bouteilles de gaz comprim et aux quipements connexes ainsi que la publica tion P 1 de la CGA identifi e dans la liste de documents ci dessous Utilisez l quipement l ext rieur dans des aires ouvertes et bien ventil es Si vous utilisez ces quipements dans un endroit confin les fum es d chappement doivent tre envoy es l ext rieur loin des prises d air du b timent Ne faites pas le plein en fumant ou proche d une source d tincelles ou d une flamme nue Si c est possible laissez le moteur refroidir avant de faire le plein de carbura
12. intensity of radiation entering the eye thus filtering out harmful infra red ultra violet radiation and a percentage of the visible light Such filter lenses are incorporated within face shields To prevent dam age to the filter lenses from molten or hard particles an additional hard clear glass or special plastic external cover lens should be used This cover lens should always be kept in place and replaced before the damage impairs your vision while welding Welding Protection It is recommended to use a welding helmet con forming to the local relevant Standards when elec tric arc welding Use a welding helmet in serviceable condition with the correct filter lens fitted as per Table 3 1 Approximate range of Filter lens welding current required for MIG Up to 150 Shade 10 150 250 Shade 11 250 300 Shade 12 300 350 Shade 13 Over 350 Shade 14 Table 3 1 Filter Lens Size Verses Welding Current User Responsibility This equipment will perform as per the information contained herein when installed operated main tained and repaired in accordance with the instruc tions provided This equipment must be checked periodically Defective equipment including weld ing leads should not be used Parts that are broken April 10 2000 3 1 10135 1 GENERAL INFORMATION missing plainly worn distorted or contaminated should be replaced immediately Should such re pairs or r
13. tal qui contient ces l ments peuvent d gager des fum es toxiques au moment du soudage 2 2 8 V 96 PRECAUTIONS DE SECURITE SOUDAGE L ARC Instruction 830002 LE SOUDAGE PEUT CAUSER UN IN CENDIE O UNE EXPLOSION L arc produit des tincellies et des projections Les particules volantes le m tal chaud les projections de soudure et l quipement surchauff peuvent causer un incendie et des br lures Le contact accidentel de l lectrode ou du fil lectrode avec un objet m tallique peut provoquer des tincelles un chauffement ou un incendie Prot gez vous ainsi que les autres contre les tincelles et du m tal chaud Ne soudez pas dans un endroit o des particules volantes ou des projections peuvent atteindre des mat riaux inflammables Enlevez toutes mati res inflammables dans un rayon de 10 7 m tres autour de l arc ou couvrez les soigneusement avec des b ches approuv es M fiez vous des projections brulantes de soudage susceptibles de p n trer dans des aires adjacentes par de petites ouvertures ou fissures M fiez vous des incendies et gardez un extincteur port e de la main N oubliez pas qu une soudure r alis e sur un plafond un plancher une cloison ou une paroi peut enflammer l autre c t Ne soudez pas un r cipient ferm tel un r servoir o un baril Connectez le c ble de soudage le plus pr s possible de la zone de soudage
14. 0 5 Cubic Feet per minute Check for gas leaks between the regulator cylinder connection and in the gas hose to the Power Supply Ensure the hose from the solenoid valve to the Mig gun adaptor has not fractured and that it is con nected to the Mig gun adaptor Shield the weld area from the wind or increase the gas flow Clean contaminates off the plate Keep the distance between the MIG gun nozzle and the work piece to a minimum Refer to Distance From The MIG Gun Nozzle To The Work Piece in Chapter 8 Ensure that the gas holes are not blocked and gas is exiting out of the gun nozzle Refer to WARNING Do not restrict gas flow by allowing spatter to build up inside the Mig gun nozzle Check that the MIG gun O rings are not damaged WARNING Disengage the drive roll when testing for gas flow by ear b Inconsistent wire feed Wire feeding problems can be reduced by checking the following points 1 Wire spool brake is too tight Feed roller driven by motor in the cabinet will slip April 10 2000 11 1 10135 1 TROUBLESHOOTING 2 Wire spool brake is too loose 3 Worn or incorrect feed roller size 4 Mis alignment of inlet outlet guides 5 Liner blocked with debris 6 Incorrect or worn contact tip 7 Poor work lead contact to work piece 8 Bent liner Welding Problems Wire spool can unwind and tangle Use U groove drive feed roller matched to the aluminum w
15. Harris BLVD West Charlotte North Caroline 28269 USA Phone 1 704 597 8240 Fax 1 704 333 9790 Upon contact advise MODEL and MANUAL NO
16. Increase the gun travel speed the voltage selection switches position or increase the wire and or reduce welding current by reducing the voltage selec tion switches position or reduc ing the wire feed speed 11 2 April 10 2000 10135 1 TROUBLESHOOTING FAULT CAUSE REMEDY 2 Lack of penetration Welding current too low Joint preparation too narrow or gap too tight Shielding gas incorrect Increase welding current by in creasing wire feed speed and increasing voltage selection switch position Increase joint angle or gap Change to a gas which gives higher penetration 3 Lack of fusion Voltage too low Increase voltage by increasing voltage selection switches po sition 4 Excessive spatter Voltage too high Voltage too low Lower voltage by reducing the voltage selection switches or increase wirespeed control Raise voltage by increasing the voltage selection switches or reduce wirespeed control 5 Irregular weld shape Incorrect voltage and current settings Convex voltage too low Concave voltage too high Wire is wandering Incorrect shielding gas Insufficient or excessive heat input Adjust voltage and current by adjusting the voltage selection switches and the wirespeed control Replace contact tip Check shielding gas Adjust the wirespeed control or the voltage selection switches 6 Weld cracking Weld bea
17. inductance settings These inductance terminals are the positive welding termi nals Inductance selection can effect the spatter level and penetration characteristics of the weld The correct choice depends upon the shielding gas transfer mode and the material type CO2 High Inductance is used for Carbon Dioxide shielded welding Dip transfer with 1 2mm 045 wires Carbon Dioxide or mixed gas Gives a hotter weld in DIP transfer MIXED GASES Low Inductance is used for Spray transfer Aluminum and Flux Cored wires Gives a cooler weld in DIP transfer NOTE If in doubt use the high inductance setting Wirespeed Control The Wirespeed Control knob controls the welding current via the electrode wire feed rate ie the speed of the wire feed motor Mode Selector Switch The Mode Selector switch selects the method of welding mode a CONTINUOUS This mode of welding is used 2T to weld two or more com ponents together with a con tinuous weld b SPOT This mode of welding is used to weld two plates together at a desired location by melting the top amp bottom plates together to form a nugget between them The spot time period is set by the SPOT TIME control shaft located in the electrode wire compartment NOTE A spot nozzle should be used on the MIG gun to obtain consistent spot welds c STITCH This mode of welding is used to weld two or more com ponents together with a st
18. nuance Portez un casque antibruit ou des bouchons d oreille approuv s appropri e consultez la norme ANSI Z49 indiqu e ci apr s lorsque le niveau de bruit est lev 8 V 96 2 1 PRECAUTIONS DE SECURITE SOUDAGE A L ARC Instruction 830002 SELECTION DES NUANCES DE FILTRES OCULAIRES POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE Op ration de Coupage ou soudage Brasage tendre au chalumeau Brasage fort au chalumeau Oxycoupage mince moyen pais Soudage aux gaz mince moyen pais Soudage l arc avec electrode enrob es SMAW Soudage l arc sous gaz avec fil plein GMAW m taux non ferreux m taux ferreux Soudage l arc sous gaz avec lectrode de tungst ne GTAW Soudage l hydrog ne atomique AHW Soudage l arc avec lectrode de carbone CAW Soudage Plasma PAW Gougeage Air Arc avec lectrode de carbone mince pais Coupage Plasma PAC mince moyen pais selon AWS 8 2 73 Dimension d lectrode ou Epaisseur de m tal ou Intensit de courant toutes conditions toutes conditions moins de 1 po 25 mm de 1 6 po 25 150 mm plus de 6 po 150 mm moins de 1 8 po 3 mm de 1 8 1 2 po 12 mm plus de 1 2 po 12 mm moins de 5 32 po 4 mm de 5 32 1 4 po 4 6 4 mm plus de 1 4 po 6 4 mm toutes conditions toutes conditions toutes conditions toutes conditions toutes conditions tou
19. ou mouill s n utilisez pas de source le moteur avant de l installer ou d en faire l entretien Bloquez le de courant alternatif moins qu il soit muni d un r ducteur de commutateur en circuit ouvert ou enlevez les fusibles de tension Utilisez plut t une source de courant continu tation afin d viter une mise en marche accidentelle Portez un harnais de s curit si vous travaillez en hauteur Veuillez installer cet quipement et le mettre la terre selon Fermez solidement tous les panneaux et les capots le manuel d utilisation et les codes nationaux provinciaux et locaux applicables pour vous prot ger le visage et les yeux lorsque vous soudez ou que vous observez l ex cution d une soudure Portez des lunettes de s curit approuv es Des crans lat raux LE RAYONNEMENT DE L ARC PEUT BRULER LES YEUX ET LA PEAU LE BRUIT PEUT ENDOMMAGER Entourez l aire de soudage de rideaux de cloisons pour de soudage produit une chaleur et des prot ger les autres des coups ou de l blouissement rayons ultraviolets intenses susceptibles de avertissez les observateurs de pas regarder l arc br ler les yeux et la peau Le bruit caus par Portez des v tements en mat riaux ignifuges et durables laine certains proc d s peut endommager et cuir et des chaussures de s curit 1 Portez une casque de soudeur avec filtre oculaire de
20. pour emp cher le courant de suivre un long par cours inconnu et pr venir ainsi les risques d lectrocution et d incendie Ne d gelez pas les tuyaux avec un source de courant Otez l lectrode du porte lectrode ou coupez le fil au tube con tact lorsqu inutilis apr s le soudage Portez des v tements protecteurs non huileux tels des gants en cuir une chemise paisse un pantalon revers des bottines de s curit et casque Le piquage et le meulage produisent des particules m talliques volantes En refroidissant la soudure peut projeter du clats de LES ETINCELLES ET LES PROJEC TIONS BRULANTES PEUVENT CAUSER DES BLESSURES LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER Les bouteilles contiennent des gaz protecteurs sous haute pression Des bouteilles endommag es peuvent exploser Comme les bouteilles font nor malement partie du proc d de soudage traitez les avec soin Prot gez les bouteilles de gaz comprim contre les sources de chaleur intense les chocs et les arcs de soudage Enchainez verticalement les bouteilles un support o un cadre fixe pour les emp cher de tomber ou d tre renvers es Eloignez les bouteilles de tout circuit lectrique ou de tout soudage MISE EN GARDE LES GAZ D ECHAPPEMENT DES MOTEURS PEUVENT ETRE MORTELS Les moteurs produisent des gaz d chappement nocifs LE CARBURANT PEUR CAUSER UN IN CENDIE OU UNE EXPLOSION
21. s identification number specification or part number model and serial number usually appear on a nameplate attached to the machine Equipment which does not have a nameplate at tached to the machine is identified only by the specification or part number printed on the shipping container Record these numbers for future refer ence Receipt Of Equipment When you receive the equipment check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping If there is any damage notify the carrier immedi ately to file a claim Furnish complete information concerning damage claims or shipping errors to DAIHEN Inc Order Department 5311 W T Harris BLVD West Charlotte NC 28269 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 pur chased by contacting DAIHEN Inc at the address given above Include the Owner s Manual number and equipment identification numbers April 10 2000 1 1 10135 1 INTRODUCTION This page intentionally left blank 1 2 April 10 2000 WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR DO NOT LOSE THESE INSTRUC
22. the results are complex Current scientific understanding does not yet allow us to interpret the evidence 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 3 Do not coil or drape cables around the body 2 Arrange cables to one side and away from the operator 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 PRINCIPAL SAFETY STANDARDS Safety in Welding and Cutting ANSI Standard 249 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis High way Suite 501 Arlington VA 22202 Safety and Health Standards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washington D C 20402 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 Recommended Safe
23. 0 Seconds Stitch on Time 0 to 4 0 Seconds Stitch off Time 0 to 4 0 Seconds Burnback Time Range 0 to 0 40 Seconds Power Supply Contents 270XSR Power Supply Owner s Manual 3 Meter 10ft Work Lead Cable Stowage Hook Regulator Flowmeter TWECO MIG Gun 250A Feed Roller 0 6 0 8 Hard Feed Roller 0 9 1 2 Hard Feed Roll 1 0 1 2 1 4 1 6 Flux Cored Set Of Contact Tips KR SSE Re 4 2 June 20 2000 Revised 10135 1 SPECIFICATIONS Optional Accessories Catalogue Description 270XSR Number T600119 Digital Meter Kit MS412116 400A Spraymaster Gun fits 270XSR adaptor 110 6120 Feed Roll 0 6 0 8 Hard Wire T10 6151 Feed Roll 0 9 1 2 Hard Wire 110 6121 Feed Roll 1 0 1 2 Hard Wire 110 6179 Feed Roll 0 8 0 9 Soft Wire 110 6134 Feed Roll 1 0 1 2 Wire 110 6180 Feed Roll 0 8 0 9 Flux Cored 110 6022 Feed Roll 1 0 1 2 1 4 1 6 Flux Cored v ELC96L Spraymaster Mig Gun Trigger Lock Tweco Gun T10 4209 Regulator Gas June 20 2000 Revised 4 3 10135 1 SPECIFICATIONS This page intentionally left blank 4 4 June 20 2000 Revised 10135 1 INSTALLATION RECOMMENDATIONS INSTALLATION RECOMMENDATIONS Environment The 270XSR is NOT designed fo
24. 0 to 270A Rated Output Duty Cycle 270A 40 270A 40 100 Duty Cycle Output Rating 180A 180A Duty Cycle Period 10 minutes June 20 2000 Revised 10135 1 SPECIFICATIONS 270XSR Number Of Output Voltage Values 16 Wire Size Range 0 6mm 024 1 2mm 045 Hard 0 9mm 035 1 2mm 045 Soft 0 8mm 030 1 2mm 045 Fluxcored The Rated Input Current should be used for the determination of cable size amp supply requirements CAUTION The method of installation conductor size and overcurrent protection shall con form to the requirements of the local electrical code the National Electrical Code or other national codes as applicable All installation wiring and persons machine reconnection shall be done by qualified Generator Requirements at the Rated Output Duty Cycle Wire Drive Specifications Motor Supply Voltage 6 Motor Supply VA 216VA Control Supply Voltage 24VAC Control Supply VA Minimum Wire Speed 1m per minute 40 Maximum Wire Speed 20m per minute 787 ipm Wire Diameter Mild Steel Aluminum Flux Cored Stainless Steel 0 6mm 024 0 8mm 030 0 9mm 035 1 0mm 040 1 2mm 045 0 8mm 030 0 9mm 035 0 9mm 035 1 0mm 040 1 0 8mm 030 0 9mm 035 1 Wire Spool Size 15 33lb Maximum Spot Time Range 0 to 4
25. 135 1 TROUBLESHOOTING This page intentionally left blank 11 18 April 10 2000 10135 1 VOLT AMP GRAPHS VOLT AMP GRAPHS 270XSR 230V 260 270 C24 20V F4 T il 230V SUPPLY C24 29V Fa 1 1 1 1 1 180 1 1 1 1 1 1 1 1 00 1 1 St es As sae ey Amps Figure 12 1 Volt Amp Curves Of The 270XSR 12 1 April 10 2000 10135 1 VOLT AMP GRAPHS This page intentionally left blank 12 2 April 10 2000 10135 1 270XSR SUPPLY CIRCUIT DIAGRAM 270XSR SUPPLY CIRCUIT DIAGRAM 035019 SLOVLINOD X 035012 SLOVINOD G3Y3ENNN 1 X x X x x EX x x x x x x rx x X X x xix X 2 X X X x x x x x 91 vla 214 01418 9 4 NOILISOd 9l tl lola 8 9 2 NOILISOd us 53 1 ot of HOLIMS i 5 13 5 5 HOLIMS J Z HOLMS 389909 H LMS 03193NN09 LON 3078 Nya SOLOW 1 HOLON
26. AM C444 10nCD SNA 148 45 10nCD x2 RIK 47400 ie SPOT DWELL 500R TRIMROT BURNBACK RVS Loh RK11K114400k 25 46 BX2 6 ToncD ew MR301 24VBC 1 TRIG LE _IRIGGER LATCH 80R 0 5 0 10 STITCH DRIVE 13 6 OMS WI 12 T 1046 MODE SWITC T4 R38 T0nCD gt Toc 2 2 2 ul TRIGGER INPUT J 9v ca lt ulCD uiCD 022 fra IN4148 D 2 X24 R54 1 2 TRIGGER NORMAL TRIGGER LATCH D21 D23 1 4148 21148 26 D25 R50 026 147 400 R46 4 X26 fx Re NC contact connects to ot COM contact connects to QC2 OVERLOAD 2 sh F NORMAL 2 gt 4 40106 Tag 40106 15 5 7 RLY3 MR301 24VDC REA 22u 20V Ton 24VAC DPDT THERMAL OVERLOAD RELAY TRIGGER LATCH RESET Remove link J1 to es 12 test fan on deman OVA0PZ SAYL 20 SONVAVATO _ STITCH CONTROL FOR CONTACTOR RELAY STITCH DRIVE IC3F 3 EX PS D 4 k i 4541 16 49 CH I 1080 817 Figure 14 1 Circuit Diagram For Control 600041 April 10 2000 14 1 10135 1 PRINTED CIRCUIT BOARD CIRCUIT DIAGR
27. AM This page intentionally left blank 14 2 April 10 2000 Publications Refer to the following standards or their latest revisions for more information 1 10 11 12 13 14 15 OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 ANSI Standard Z49 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 NIOSH SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 ANSI Standard Z87 1 SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard 241 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard 249 2 FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROC ESSES obtainable from American National Standards Institute 1430 Broadway New York NY 10018 AWS Standard A6 0 WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTI BLES obtainable from American Welding Society 550 N W LeJeune Rd Miami FL 33126 NFPA Standard 51 OXYGEN FUEL GAS SYSTEMS FOR WELDING CUTTING AND ALLIED PROCESSES obt
28. IQUE BASIC WELDING TECHNIQUE Setting Of The Power Supply The setting of the 270XSR requires some practice by the operator the welding Power Supply having two control settings that have to balance These are the Wirespeed control and the Voltage Control switches The welding current is determined by the Wirespeed control the current will increase with increased Wirespeed resulting in a shorter arc Less wire speed will reduce the current and lengthen the arc Increasing the welding voltage hardly alters the welding current level but lengthens the arc By decreasing the voltage a shorter arc is obtained with little change in welding current When changing to a different electrode wire di ameter different control settings are required A thinner electrode wire needs more Wirespeed to achieve the same current level A satisfactory weld cannot be obtained if the wire speed and voltage switch settings are not adjusted to suit the electrode wire diameter and dimensions of the workpiece If the Wirespeed is too high for the welding voltage stubbing will occur as the wire dips into the molten pool and does not melt Welding in these conditions normally produces a poor weld due to lack of fusion If however the welding voltage is too high large drops will form on the end of the electrode wire causing spatter The correct setting of voltage and Wirespeed can be seen in the shape of the weld deposit and heard by a smooth re
29. MANUAL 10135 1 Tech Pub Ref 430429 455 DAIHEN Conporattan OWNER S MANUAL FOR 270XSR MODEL CPTXS 270 P10135 DO NOT DESTROY IMPORTANT Read and understand the entire contents of this manual with special emphasis on the safety material throughout the manual before installing operating or maintaining this equipment This equipment and this manual are for use only by persons trained and experienced in the safety operation of welding equipment Do not allow untrained persons to install operate or maintain this equipment Contact your distributor if you do not fully understand this manual DAIHEN CORPORATION WELDING PRODUCTS DIVISION AA June 20 2000 Upon contact advise MODEL and MANUAL NO 10135 1 TABLE OF CONTENTS INTRODUCTION 1 How To Use This Manual 1 1 Equipment Identification 1 1 Receipt Of Equipment 5 1 1 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS 2 GENERAL INFORMATION 3 SACs etd Re EAN ame wick 3 1 Protective Filter Lenses 3 1 Welding Protection 3 1 User Responsibility se pue re 3 1 Cycles keg Ste 3 2 SPECIFICATIONS 4 MIG Gun Specifications 4 1 Machine Specification
30. Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances Ameri can Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safe Practices for Occupation and Educational Eye and Face Pro tection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 National Electrical Code NFPA Standard 70 from National Fire Protection Association Batterymarch Park Quincy MA 02269 Cutting and Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 May 8 1996 2 3 WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 This page intentionally left blank 2 4 May 8 1996 PRECAUTIONS DE SECURITE SOUDAGE L ARC Instruction 830002 PRECAUTIONS DE SECURITE EN SOUDAGE A L ARC MISE EN GARDE LE SOUDAGE A L ARC EST DANGEREUX PROTEGEZ VOUS AINSI QUE LES AUTRES CONTRE LES BLESSURES GRAVES POSSIBLES O LA MORT NE LAISSEZ PAS LES ENFANTS S APPROCHER NI LES PORTEURS DE STIMULATEUR CARDIAQUE A MOINS QU ILS N AIENT CONSULTE UN MEDECIN CONSERVEZ CES INSTRUCTIONS LISEZ LE MANUEL D OPERATION OU LES INSTRUCTIONS AVANT D INSTALLER UTILISER OU ENTRETENIR CET EQUIPEMENT Les produits et proc d s de soudage peuvent sauser des blessures graves ou la mort de m me que des dommages au reste du mat riel et
31. TCH 4T Spot timer control MIN STANDARD SPOT s Dwell timer control Mode selector switch Figure 7 2 Internal 270XSR Controls April 10 2000 7 1 10135 1 POWER SUPPLY CONTROLS INDICATORS AND FEATURES Value displayed for 157 Amp 5 Value displayed for 23 4 Volts Figure 7 3 Examples Of The Digital Read Outs Standby Switch With In built Indicator Light The indicator light is provided to indicate when the 270XSR is connected to the input power supply voltage With the switch in the STANDBY position the auxiliary power and the fan are turned off WARNING When the light is lit the machine is connected to the input power supply voltage and the internal electrical compo nents are at input power voltage potential Coarse Voltage Control Switch And Fine Voltage Control Switch The Coarse Voltage Control sets the voltage level to the welding terminals as it is rotated in the clock wise direction The Fine Voltage Control switch increases the voltage in smaller increments than the Coarse switch as it is rotated in the clockwise direction CAUTION The Coarse amp Fine Voltage Control switches MUST NOT BE SWITCHED during the welding process Digital Ammeter And Voltmeter optional Where fitted an average reading ammeter and voltmeter is provided to allow accurate monitoring 5 tolerance of welding current and voltmeter to facilitates precise we
32. TIONS READ OPERATING INSTRUC TION 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 training before using this equipment Anyone not having extensive training in welding and cutting practices should 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 249 1 entitled SAFETY IN WELDING AND CUTTING This publication and 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 Turn off all equipment when not in use Disconnect power to equipment if it will be left unattended or out of service 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 power circuit and machine internal circuits are also ee live when power is sem
33. ainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 70 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 51B CUTTING AND WELDING PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 CGA Pamphlet P 1 SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 CSA Standard W117 2 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 NWSA booklet WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 American Welding Society Standard AWSF4 1 RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 ANSI Standard Z88 2 PRACTICE FOR RESPIRATORY PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 DAIHEN DAIHEN Corporation 5 1 Minamisenrioka Settsu shi Osaka 566 0021 Japan Phone 81 6 6317 2506 Fax 81 6 6317 2583 DAIHEN INC 5311
34. ains ou les cheveux de pi ces mou vement elles peuvent aussi accrocher des v tements amples et des outils R installez les capots ou les protecteurs et fermez les portes apr s des travaux d entretien et avant de faire d marrer le moteur Portez toujours un cran facial en travaillant sur un accumu lateur Arr tez le moteur avant de connecter ou de d connecter des c bles d accumulateur N utilisez que des outils anti tincelles pour travailler sur accumulateur N utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentan ment v hicule Utilisez la polarit correcte et de l accumulateur N tez pas le bouchon de radiateur tant que le moteur n est pas refroidi Mettez des gants et posez un torchon sur le bouchon pour l ter Laissez la pression s chapper avant d ter compl tement le bouchon PRINCIPALES NORMES DE SECURITE Safety in Welding and Cutting norme ANSI 249 1 American Welding 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 Cutting of Containers That Have Held Hazardous Substances norme AWS F4 1 American Welding Society 550 LeJeune Rd Miami FL 33128 National Electrical Code norme 70 NFPA Na
35. an burn eyes and skin Wear a welding helmet fitted with a proper shade of filter see NOISE can damage hearing ANSI 249 1 listed in Safety Standards to protect your face and eyes when welding or watching Wear approved safety glasses Side shields recommended Arc rays from the welding process produce intense Use protective screens or barriers to protect others from flash heat and strong ultraviolet rays that can burn eyes and glare warn others not to watch the arc de pith Noise from some processes can damage Wear protective clothing made from durable flame resistant 9 material wool and leather and foot protection Use approved ear plugs or ear muffs if noise level is high Eye protection filter shade selector for welding Electrode Size i Electrode Size Welding or Cutting Metal Thickness Welding or Cutting Metal Thickness Operation or Welding Current Operation or Welding Current Torch soldering Gas metal arc welding MIG Torch brazing Non ferrous base metal All Oxygen cutting Ferrous base metal All Light Under 1 in 25 mm Gas tungsten arc welding TIG All Medium 1 to 6 in 25 150 mm Atomic hydrogen welding All Heavy Over 6 in 150 mm Carbon arc welding All Gas welding Plasma arc welding All Light Under 1 8 in 3 mm Carbon arc air gouging Medium 1 8 to 1 2 in 3 12 mm Light Heavy Over 1 2 in 12 mm Heavy Shielded metal arc welding Under 5 32 in 4 mm Plasma arc cutting stick electrodes 5 32 to 1 4 in
36. ds too small Weld penetration narrow and deep Excessive weld stresses Excessive voltage Cooling rate too fast Decrease travel speed Reduce current and voltage and increase Mig gun travel speed or select a lower pene tration shielding gas Increase weld metal strength or revise design Decrease voltage by reducing the voltage selection switches Slow the cooling rate by pre heating part to be welded or cool slowly April 10 2000 11 3 10135 1 TROUBLESHOOTING FAULT CAUSE REMEDY 7 Cold weld puddle Faulty rectifier unit Loose welding cable connec tion Low Primary Voltage Have an Accredited DAIHEN CORPORATION Service Agent to test then replace the faulty component Check all welding cable con nections Contact supply authority Arc does not have acrisp sound that short arc exhibits when the wirefeed speed and voltage are adjusted correctly The MIG gun has been con nected to the wrong voltage po larity on the front panel Connect the MIG gun to the positive welding terminal for solid wires and gas shielded flux cored wires Refer to the electrode wire manufacturer for the correct polarity Power Supply Problems FAULT CAUSE REMEDY Indicator light is ON but welding arc can not be established Voltage switch in standby posi tion Switch the voltage selection switches to a welding setting
37. e plastic gun casing meets the brass adaptor Tighten the gun locking screw securely Remove the contact tip from the gun Connect the two black gun trigger leads to the gun trigger terminals Lift up the wire feeder pressure lever and pass the electrode wire through the inlet guide between the rollers through the outlet guide and into the gun Lower the pressure lever and with the gun lead reasonably straight feed the wire through the gun Fit the appropriate contact tip WARNING The electrode wire will be at welding voltage poten tial while it is being fed through the system April 10 2000 10135 1 SET UP FOR 270XSR This page intentionally left blank 6 2 April 10 2000 10135 1 POWER SUPPLY CONTROLS INDICATORS AND FEATURES POWER SUPPLY CONTROLS INDICATORS AND FEATURES Thermal overload light Optional meter Standby switch amp indicator light Coarse voltage switch FO TA Fin Fine voltage switch 70 270 XSR Brass Gun adaptor Spool gun TO G2 215 7 control socket N A N vay A Des y A S S fs Negative welding terminal 5 Oe Positive welding Torch polarity lead current terminal Figure 7 1 270XSR Controls Burnback control BURNBACK Spool gun switch MODE SELECTOR SWITCH TI
38. elding power Supply circuitry To make connections align keyway insert plug and rotate threaded collar fully clockwise The socket information is included in the event the sup plied cable is not suitable and it is necessary to wire a plug or cable to interface with the SPOOL GUN 14 pin receptacle Figure 7 4 Spool Gun 14 Pin Receptacle Socket Pin Function A Input Supply 24VAC 1 0A with respect to Socket G circuit common B Output to energize the power supply contactor 24VAC contact closure is provided between socket pins A and B to energize the contractor Not Used D Not Used Not Used F Not Used G 24 Circuit Common H Not Used l Not Used J Not Used K Not Used L Not Used M Not Used N Not Used April 10 2000 7 3 10135 1 POWER SUPPLY CONTROLS INDICATORS AND FEATURES Thermal Overload The critical component for thermal protection isthe rectifier stack which is fitted with a thermal overload cut out device If the overload operates then the machine should be left to cool for approximately 15 minutes before resuming welding The thermal overload will not operate and there will be no danger of transformer damage if the Power Supply is operated within its duty cycle refer to Chapter 3 Page 3 2 for an explanation of duty cycle and Chapter 4 for the specifications Choice Of Inductance Setting The 270XSR has two
39. electrode wire The following instructions detail how to correctly set up the welder and give guide lines on gaining the best production efficiency from the Power Supply Please read these instructions thoroughly before using your 270XSR welder Safety The following basic safety rules should always be followed Ensure the machine is correctly installed if necessary by a qualified electrician Ensure the Power Supply is grounded correctly electrically in accordance with local regu lations iii Excessive heat in the welding cables may cause fire Never weld with poor electrical connections damaged welding cables or exceed the welding cable current rating as this will produce excessive heat and may cause a fire iv Always wear the correct protective clothing for protection from sparks molten parti cles and arc rays v When welding in confined spaces always ensure adequate ventilation and constant observation of the operator vi Keep combustible materials away from the welding area Have a suitable fire extin guisher handy vii Never watch the welding arc with naked eyes Always use and wear a welding mask fitted with the correct filter lens viii not stand on damp ground when welding ix For more complete safety advice please read the safety literature included with the equip ment before starting to weld Protective Filter Lenses Protective filter lenses are provided to reduce the
40. en viewing the 270XSR from the front iii Select maximum voltage switch positions Coarse 19 23V Fine 4 270XSR iv Switch the input power supply voltage to the 270XSR ON Ensure the DIGITAL METER is selected to read current vi Short circuit the GUN TRIGGER termi nals to energize output welding terminals CAUTION Do not allow the 270XSR to remain ON under load for more than ONE minute vii Determine the output current as given by the DC AMMETER April 10 2000 10 1 10135 1 MAINTENANCE amp INSPECTION viii Adjust SHUNT CAL potentiometer on DIGITAL METER to read identically with DC AMMETER xiv If the above is not met offset the SHUNT CAL potentiometer such that both the min imum and maximum values are within 2 ix Open circuit the GUN TRIGGER terminals xv The improved accuracy for DIGITAL ME to deactivate output welding terminals TER is now complete x _ Select minimum voltage switch positions xvi Where fitted position the meter cover Coarse 15 17V Fine 1 270XSR over the hexagonal brass spacers taking care not to trap loom wiring xi Short circuit the GUN TRIGGER terminals to energize output welding terminals xvii Fitthe M3 flat washers and M3x1 0 screws Refer to CAUTION on page 10 1 through the meter cover and into the hex i agonal brass spacers xvi ii Close wire feeder compartment or replace side panel xiii Co
41. eplacements become necessary it is rec ommended that such repairs be carried out by appropriately qualified persons approved by DAI HEN Inc Advice in this regard can be obtained by contacting DAIHEN Inc This equipment or any of its parts should not be altered from standard specification without prior written approval of DAIHEN Inc The purchaser of this equipment shall have the sole responsibility for any malfunction which results from improper use or unauthorized modification from standard specifica tion faulty maintenance damage or improper repair by anyone other than appropriately qualified per sons approved by DAIHEN Inc Duty Cycle percentage 100 Duty Cycle The rated duty cycle of a welding Power Supply is the operating time it may be used at its rated output current without exceeding the temperature limits of the insulation of the component parts To explain the ten minute duty cycle period the following exam ple is used Suppose a welding Power Supply is designed to operate at 40 duty cycle 270 am peres at 27 volts This means that it has been designed and built to provide the rated amperage 270A at the rated load voltage 27V for 5 0 minutes out of every 10 minute period 50 of 10 minutes is 5 0 minutes During the other 5 0 min utes of the 10 minute period the Power Supply must idle and be allowed to cool The thermal cut out will operate if the duty cycle is exceeded 160 180 200 220 210 We
42. g gas cylinders contain gas under high pres sure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks and arcs Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping amp WARNING ENGINE EXHAUST GASES can kill Engines produce harmful exhaust gases Read the Material Safety Data Sheets MSDSs and the manu facturer s instruction for metals consumables coatings and cleaners 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 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 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 Be aware that welding on a ceiling floor bul
43. gular arc sound Position of MIG Gun The angle of MIG gun to the weld has an effect on the width of the weld run Refer to Figure 9 1 Forehand Figure 9 1 MIG Gun Angle Distance From The MIG Gun Nozzle To The Work Piece The electrode stick out from the MIG Gun nozzle should be between 2 0mm 5 64 to 5 0mm 13 64 This distance may vary depending on the type of joint that is being welded Travel Speed Speed at which a weld travels influences the width of the weld and penetration of the welding run Electrode Wire Size Selection The choice of electrode wire size in conjunction with shielding gas used depends on a Thickness of the metal to be welded b Type of joint c Capacity of the wire feed unit and power supply d The amount of penetration required e The deposition rate required f The bead profile desired g The position of welding and h Cost of the electrode wire Weld metal deposition rate is proportional to cur rent density Current density is defined as the cur rent per cross sectional area of the electrode wire and is normally expressed as amps per example is tabled below Electrode Wire Size Current Amps Current Density Deposition Rate Ibs hour 0 9mm 035 200 314 7 0 1 2mm 045 200 177 6 2 Table 9 1 0 9mm 035 1 2mm 045 Wire Deposition Rate April 10 2000
44. h has been set to 2T normal operation 11 4 April 10 2000 10135 1 TROUBLESHOOTING FAULT CAUSE REMEDY 8 Jerky wire feed Worn or dirty contact tip Replace B Worn feed roll Replace Excessive back tension Reduce brake tension on spool wire reel hub hub Worn kinked or dirty conduit D Clean or replace conduit liner liner 9 No gas flow Gas hose is cut Replace or repair Gas passage contains Disconnect gas hose from the ties rear of 270XSR or then raise gas pressure and blow out the impurities Gas regulator turned off 10 Gas flow continues after the Gas valve has jammed open Have an Accredited DAIHEN gun trigger switch has been due to impurities in the gas or Corporation Service Agent released the gas line repair or replace gas valve Parts List Equipment Identification Allidentification numbers as described in the Intro duction chapter must be furnished when ordering parts or making inquiries This information is 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 parts of the equipme
45. he DWELL TIME control shaft for the desired interval or OFF time while stitch welding Spot Welding Operation Fit a spot welding nozzle to the MIG Gun for consistent spot welding operations The 270XSR will operate effectively using 0 8mm 030 elec trode wire when spot welding Penetration depth is limited when using 0 6mm 024 electrode wire for spot welding Set the controls as follows for spot welding a Coarse amp Fine Voltage Selector Switches and Wirespeed Control Select higher Voltage Selector switch posi tions and set the Wirespeed Control between 354 to 590 ipm 9 to 15 meters minute for maximum penetration b Mode Selector Switch Set the MODE SELECTOR switch to SPOT c Spot Time Adjust the SPOT TIME control shaft for the desired weld or ON time for spot welding d Dwell Time The DWELL TIME control shaft has no affect in this mode of operation April 10 2000 10135 1 MAINTENANCE amp INSPECTION MAINTENANCE amp INSPECTION The only routine maintenance required for the 270XSR is a thorough cleaning and inspection with the frequency depending on the usage and the operating environment WARNING Disconnect the 270XSR from the Input Power supply voltage before disas sembling Special maintenance is not necessary for the con trol unit parts in the Power Supply If these parts are damaged for any reason replacement is recom mended CAUTION Do not blow ai
46. hen working on a battery Do not use welder to charge batteries or jump start vehicles Observe correct polarity and on batteries Batteries contain acid and generate explosive gases STEAM AND PRESSURIZED HOT Do not remove radiator cap when engine is hot Allow engine to COOLANT can burn face eyes and cool skin Wear gloves and put a rag over cap area when removing cap The coolant in the radiator can be very hot and under Allow pressure to escape before completely removing cap 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 amp 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 Office of Technology Assessment Biological Effects of Power Frequency Electric amp Magnetic Fields Background Paper 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 interact with and produce changes in biological systems While most of this work is of very high quality
47. iautomatic or automatic 4 peop wire welding the wire wire reel drive roll housing Do notuse worn damaged undersized or poorly spliced cables and all metal parts touching the welding wire are Do not wrap cables around your body electrically live Incorrectly installed or improperly Ground the workpiece to a good electrical earth ground grounded equipment is a hazard Do not touch electrode while in contact with the work ground Do not touch live electrical parts circuit Wear dry hole free insulating gloves and body protection Use only well maintained equipment Repair or replace damaged Insulate yourself from work and ground using dry insulating mats parts at once or covers In confined spaces or damp locations do not use a welder with Disconnect input power or stop engine before installing or serv AC output unless it is equipped with a voltage reducer Use icing this equipment Lock input power disconnect switch open equipment with DC output or remove line fuses so power cannot be turned on accidentally Wear a safety harness to prevent falling if working above floor Properly install and ground this equipment according to its level Owner s Manual and national state and local codes Keep all panels and covers securely in place Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input ARC RAYS c
48. il 10 2000 10135 1 TROUBLESHOOTING Parts List for Figure 11 4 Item Part Description Qty No Number per T830623 1 Nut Nylok T406807 6 Knob 1 T830618 2 Panel Interior 1 2 T83061 7 2 Bracket Reel Lug 1 3 T830496 Washer Friction 1 4 T10 6018 Hub Spool 1 5 T830534 Clip Retaining 6 TW11242 27 Washer Flat 7 T10 6132 Washer Tension 8 9 June 20 2000 Revised 11 13 10135 1 TROUBLESHOOTING SCALE 115 Figure 11 5 April 10 2000 11 14 10135 1 TROUBLESHOOTING Parts List for Figure 11 5 Item Part Description Qty No Number per 1 TW 11166 10 Fuse AGC 3 Amp 1 2 T402658 Holder Fuse 2 3 T600093 Resistor 1 4 T600042 Contactor 1 5 T600037 Transformer Aux 1 6 T830612 2 Panel Baffle 1 7 T600041 Board PC Control 1 8 T600107 Support PC Board 16 6mm 1 9 TW 11166 1 Fuse AGC 2 Amp 1 June 20 2000 Revised 11 15 10135 1 TROUBLESHOOTING Figure 11 6 11 16 April 10 2000 10135 1 TROUBLESHOOTING Parts List for Figure 11 6 Item Part Description Qty No Number per 1 T830648 Transformer Power Assy 250 1 2 T10 6131 Capacitor Electrolitic 5 3 T400828 7 Tie Cable 5 4 T830589 Bar Bus 1 5 T10 6127 Socket 25mm 3 6 T830592 Link Output 1 7 T830591 Link Capacitor 1 8 T600040 Rectifier Output 1 9 830593 Link Ind Output 1 10 T830590 Link Capacitor 1 11 830651 1 Assy Inductor 1 June 20 2000 Revised 11 17 10
49. ion will tighten the brake Correct adjustment will result in the wire reel circumference continuing no further than 20mm 0 75 after release of the Gun trigger switch The wire should be slack without becoming dislodged from the reel CAUTION Excessive tension on the brake will cause rapid wear of mechani cal wire feed parts overheating of elec trical componentry and possibly an increased incidence of wire Burnback into the contact tip April 10 2000 10135 1 POWER SUPPLY CONTROLS INDICATORS AND FEATURES This page intentionally left blank 7 6 April 10 2000 10135 1 TWECO MIG GUN TWECO MIG GUN Torch T830788 Introduction The TWECO 250A gun fitted to the 270XSR offers robust construction unparalleled reliability and easy replacement of consumable parts The TWECO 250A has an operating capacity in excess of the capacity of the 270XSRs and can be expected to give trouble free service TWECO MIG guns may be fitted to many different types of MIG welding Power Supplies so that your whole shop can be converted to TWECO Not only will this give greater reliability and hence greater productivity but it will reduce stockholding of consumable parts See your DAIHEN distributor for details 8 9 mi 4 18 17 16 15 Figure 8 1 Exploded View Of MIG Gun TWECO MIG Gun Components
50. ire size you are welding Use V groove drive feed roller matched to the steel wire size you are welding Use knurled V groove drive feed roller matched to the flux cored wire size you are welding Wire will rub against the mis aligned guides and reduces wire feedability Debris is produced by the wire passing through the feed roller if excessive pressure is applied to the pressure roller adjuster Debris can also be produced by the wire passing through an incorrect feed roller groove shape or size Debris is fed into the liner where it accumulates thus reducing wire feedability The contact tip transfers the weld current to the electrode wire If the hole in the contact tip is to large then arcing may occur inside the contact tip resulting in the electrode wire jamming in the con tact tip When using soft electrode wire such as aluminum it may become jammed in the contact tip due to expansion of the wire when heated A contact tip designed for soft electrode wires should be used If the work lead has a poor electrical contact to the work piece then the connection point will heat up and result in a reduction of power at the arc This will cause friction between the wire and the liner thus reducing wire feedability FAULT CAUSE REMEDY 1 Undercut Welding arc voltage too high Reduce voltage by reducing feed speed Incorrect gun angle B Adjust angle C Excessive heat input C
51. itch weld The SPOT TIME shaft controls the welding or ON time while the DWELL TIME shaft controls the inter val or OFF time for stitch welding d LATCH This mode of welding is 4T mainly used for long weld runs as the operator need only press the trigger to ac tivate the weld then press the trigger again to stop This obviates the need for the operator to depress the trigger for the complete length of the weld run Spot Timer When the MODE SELECTOR switch is switched to the SPOT position the SPOT TIME shaft controls the duration of a single spot weld When the MODE SELECTOR switch is switched to the STITCH position the SPOT TIME shaft con trols the welding or ON time while stitch welding Dwell Timer The DWELL TIME shaft controls the interval or OFF time while stitch welding Burnback Control Burnback time is the difference between the wire feed motor stopping and switching off of the welding current The Burnback time allows the electrode wire to burn out of the molten metal weld pool The Burnback time is factory set for optimum perform ance Burnback time is adjusted by placing a flat bladed screwdriver into the Burnback adjustment access hole and adjusting the trim potentiometer Clock wise adjustment increases Burnback time April 10 2000 10135 1 POWER SUPPLY CONTROLS INDICATORS AND FEATURES Spool Gun Standard Switch The 270XSR comes ready with a STAND
52. khead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks or drums 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 Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Wear approved face shield or safety goggles Side shields rec ommended Wear proper body protection to protect skin Keep cylinders away from any welding or other electrical circuits Never allow a welding electrode to touch any cylinder Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders asso ciated equipment and CGA publication P 1 listed in Safety Standards ENGINES can be hazardous 1 2 Use equipment outside in open well ventilated areas If used in a closed area vent engine exhaust outside and away from any b
53. lding Current amps Figure 3 1 270XSR Duty Cycle Curves April 10 2000 10135 1 SPECIFICATIONS SPECIFICATIONS MIG Gun Specifications Gun Catalog Number T830788 Gun Type TWECO 250A Spray Master Consumables Gun Cable Length 3 6 meters 12 ft Machine Specifications 270XSR Unit Assembly P10135 Unit Weight 103kg 227108 Unit Dimensions including wheels and cylinder carrier H 910mm x W 365mm x D 900mm H 35 8 x W 14 4 x D 35 5 Power Supply CPTXS 270 Power Supply Weight 93kg 205lbs Power Supply Dimensions including wheels and cylinder carrier H 800mm x W 355mm x D 820mm H 31 5 x W 14 0 x D 32 3 Primary Input Voltage 208V 230V Number Of Phases 18 Frequency 60 Hz Rated Input Current 100 Duty V36A V 32A Cycle Rated 100 Duty Cycle 8 KVA 8 KVA Maximum Input Current 55A 50A Generator Requirements amp 12 amp 12 Supply VA no load 1170 VA 1060 VA Supply Watts no load 660W 660W Supply VA max output 11 5kVA 11 5kVA Supply Watts max output 9450W 9450W Machine Efficiency max output 58 58 Power Factor max output 0 85 0 85 Recommended Input Power Outlet Size 40A 40A Recommended Fuse Size 80 80A Open Circuit Voltage Range 17 9 to 43 1V 18 8 to 42 9V Output Current Range 30 to 270A 3
54. lding condition adjustment Refer to Improved Current Accuracy Calibration Procedure for the Digital Meter in Chapter 10 Page 10 1 The Digital Meter will display both welding current and voltage To toggle between the current and voltage readings depress the push button switch mounted below the meters display See Figure 7 3 for an example of current and voltage display The Digital Meter will hold the last reading at completion of welding for 10 seconds to allow for easy operator setup Gun Polarity Lead This lead selects the welding voltage polarity of the electrode wire Plug it into the positive welding terminal when using steel stainless steel or aluminum electrode wire Plug the Gun Polarity Lead into the negative welding terminal when using gasless electrode wire If in doubt consult the manufacturer of the electrode wire for the correct polarity Positive And Negative Welding Terminals Welding current flows from the Power Supply via heavy duty DINSE terminals It is essential how ever that the male plug is inserted and turned securely to achieve a sound electrical connection CAUTION Loose welding terminal con nections can cause overheating and re sult in the male plug being fused in the bayonet terminal 7 2 April 10 2000 10135 1 POWER SUPPLY CONTROLS INDICATORS AND FEATURES Z 14 Spool Gun Control Socket The SPOOL GUN 14 pin receptacle is used to connect a spool gun to the w
55. nals 11 1 Welding Problems 11 2 Power Supply Problems 11 4 Parts List Pr 11 5 VOLT AMP GRAPHS 12 270XSR SUPPLY CIRCUIT DIAGRAM 13 PRINTED CIRCUIT BOARD CIRCUIT DIAGRAM 14 PUBLICATIONS Page 2 April 10 2000 10135 1 INTRODUCTION 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 cov ered by this manual To ensure safe operation read the entire manual including the chapter on safety instructions and warnings Throughout this manual the word WARNING CAUTION and NOTE may appear Pay particular attention to the information provided under these headings These special annotations are easily rec ognized as follows WARNING A procedure which if not properly followed may cause injury to the operator or others in the operating area Warnings will be enclosed in a box such as this CAUTION A procedure which if not properly followed may cause damage to the equipment Cautions will be shown in bold type NOTE An operation procedure or back ground information which requires addi tional emphasis or is helpful in efficient operation of the system Notes will be shown in italics Equipment Identification The unit
56. nfirm the minimum DIGITAL METER reading is within 2 of DC AMMETER 10 2 April 10 2000 10135 1 TROUBLESHOOTING TROUBLESHOOTING The basic level of troubleshooting is that which can be performed without special equipment or knowledge and without removing the covers from the Power Supply If major components are faulty then the Power Supply should be returned to an Accredited DAIHEN CORPORATION Service Agent for repair Solving Problems Beyond the Welding Terminals The general approach to fix Gas Metal Arc Welding GMAW problems is to start at the wire spool then work through to the MIG gun There are two main areas where problems occur with GMAW a Porosity When there is a gas problem the result is usually porosity within the weld metal Porosity always stems from some contaminant within the molten weld pool which is in the process of escaping during solidification of the molten metal Contaminants range from no gas around the welding arc to dirt on the work piece surface Porosity can be reduced by checking the following points 1 Gas cylinder contents and flow meter 2 Gas leaks 3 Internal gas hose in the Power Supply 4 Welding in a windy environment 5 Welding dirty oily painted oxidized or greasy plate 6 Distance between the MIG gun 7 Maintain the MIG gun in good working order Ensure that the gas cylinder is not empty and the flow meter is correctly adjusted to 15 liters per minute
57. nt en m me temps Ne jamais toucher quelqu un d autre avec ou le porte lectrode Une d charge lectrique peut tuer ou br ler grave ment L lectrode et le circuit de soudage sont sous tension d s la mise en circuit Le circuit d alimenta tion et les circuits internes de l quipement sont aussi sous tension d s la mise en marche En soudage automatique semi automatique avec 4 4 fil dernier le rouleau ou la bobine de fil le N utilisez pas de c bles lectriques us s endommag s mal logement des galets d entrainement et toutes les piss s ou de section trop petite pi ces m talliques en contact avec le fil de soudage pas de cables lectriques autour de votre corps sont sous tension Un quipement inad quatement N utilisez qu une bonne prise de masse pour la mise la terre install ou inad quatement mis a la terre est dangereux de la pi ce a souder Ne touchez pas des pi ces sous tension Ne touchez pas l lectrode lorsqu en contact avec le circuit de Portez des gants et des v tements isolants secs et non trou s soudage terre Isolez vous de la pi ce souder et de la mise la terre au moyen N utilisez que des quipements en bon tat R parez ou rem de tapis isolants ou autres placez aussit t les pi ces endommag es D connectez la prise d alimentation de l quipement ou arr tez Dans des espaces confin s
58. nt are listed except for commer cially available hardware bulk items such as wire cable sleeving tubing etc and permanently at tached items which are soldered riveted or welded to another part The part descriptions may be in dented to show part relationships To determine the part number description quantity or application of an item simply locate the item in question from the illustration and refer to that item number in the corresponding Parts List An Application Code is used to distinguish parts that are applicable only to certain Specifications and or Assemblies This code is found in the right most column of the Parts List If an item in the Parts List applies to all Specifications or Assemblies the word ALL will be in the Application Code column Refer to the following list to determine the appropriate Application Codes for the Specifications or Assem blies covered by this manual If only the assembly or specification number is listed the use of an Applica tion Code does not apply to this manual PART NUMBER 10135 1 April 10 2000 11 5 10135 1 TROUBLESHOOTING THIS PAGE IS IN TROUBLESHOOTING CHAPTER June 20 2000 Revised 11 5 10135 1 TROUBLESHOOTING Figure 11 1 11 6 April 10 2000 10135 1 TROUBLESHOOTING Parts List for Figure 11 1 Item Part Description Qty No Number per CPTXS 270 270XSR 1 1 T830616 2 Base Welder 1 2 T830614 2 Doo
59. nt ou d en v rifier le niveau au d but du soudage Ne faites pas le plein de carburant ras bord pr voyez de l espace pour son expansion Faites attention de ne pas renverser de carburant Nettoyez tout carburant renvers avant de faire d marrer le moteur 8 V 96 2 3 PRECAUTIONS DE SECURITE SOUDAGE A L ARC Instruction 830002 DES PIECES EN MOUVEMENT PEU VENT CAUSER DES BLESSURES Des pi ces en mouvement tels des ventilateurs des rotors et des courroies peuvent couper doigts et mains ou accrocher des v tements amples 1 Assurez vous que les portes les panneaux les capots et les protecteurs soient bien ferm s 2 Avant d installer ou de connecter un syst me arr tez le moteur DES ETINCELLES PEUVENT FAIRE EX PLOSER UN ACCUMULATEUR L ELECTROLYTE D UN ACCUMU LATEUR PEUT BRULER LA PEAU ET LES YEUX Les accumulateurs contiennent de l lectrolyte acide et d gagent des vapeurs explosives LA VAPEUR ET LE LIQUIDE DE RE FROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX Le liquide de refroidissement d un radiateur peut tre br lant et sous pression Seules des personnes qualifi es doivent d monter des protec teurs ou des capots pour faire l entretien ou le d pannage n cessaire Pour emp cher un d marrage accidentel pendant l entretien d branchez le c ble d accumulateur la borne n gative pas les m
60. of welding fumes can be harmful ensure that the welding area is effectively ventilated Input Power Supply Voltage Requirements The input power supply voltage should be within 10 of the rated input power supply voltage Too low a voltage may cause poor welding performance or the wirefeeder malfunction Too high a supply voltage will cause components to overheat and possibly fail The 270XSR is supplied with an input lead to which an appropriate plug should be fitted Install a power outlet for each Power Supply and fit fuses as per the Machine Specifications WARNING DAIHEN Copora tion advises that your 270XSR be electrically connected by a qualified electrician The 270XSR Power Supply is factory connected rain for the following input power supply voltages Machine Input Power Supply Lead Current Lead Machine _ Lead Size Rating Length Voltage Setting Cycle 270XSR 8 AWG 40 Amps meters 10ft 230V 270A 40 Table 5 1 Factory Fitted Input Power Supply Leads Fitted To The 270XSR Power Suppy April 10 2000 10135 1 INSTALLATION RECOMMENDATIONS WARNING The 270XSR input power supply leads should be replaced with leads as specified in section Alternative Input Power Supply Voltages when the 270XSR input power supply voltage is changed Alternative Input Power Supply Voltages The Power Supplies are suitable for the following
61. r L H 1 3 T830615 2 Side R H 1 4 T830613 3 Panel Front 1 5 T83061 1 2 Panel Top 1 6 T800071 Mat Top 1 7 T600069 Handle End Moulding 2 8 T10 6305 Cap Axle 2 9 T10 6261 Wheel 2 10 T10 6146 Castor Swivel 2 11 T830622 Cable Torch Assy 1 12 T10 6155 Switch Range 2 13 T600047 Switch STBY 1 14 T600046 Indicator OVLD 1 15 T406806 3 Knob 1 16 T401428 5 Potentiometer Wire Feed Speed 1 17 T600070 Moulding Front 18 T600074 Handle Bar 1 19 T830788 Torch Spraymaster 1 20 T830551 Latch Slide 2 21 T830620 1 Clamp Work Assy 1 22 T830721 Label OTC 2 June 20 2000 Revised 11 7 10135 1 TROUBLESHOOTING EE DETAIL WIRE DRIVE DETAIL WIRE DRIVE SCALE 1 5 Figure 11 2 11 8 April 10 2000 10135 1 TROUBLESHOOTING Parts List for Figure 11 2 Item Part Description Qty No Number per 1 T10 6150 Drive Motor Assy 1 2 T10 6039 Adaptor Gun Assy 1 3 T10 6187 Screw Locking Mig Torch 1 4 T10 6040 Output Liner 5 T10 6144 Input Guide 1 June 20 2000 Revised 10135 1 TROUBLESHOOTING Figure 11 3 11 10 April 10 2000 10135 1 TROUBLESHOOTING Parts List for Figure 11 3 Item Part Description Qty No Number per T830619 3 Panel Rear T600049 1 Fan Assy T600045 Valve Gas T401840 3 Cable Input Power Not Illustrated June 20 2000 Revised 11 11 10135 1 TROUBLESHOOTING SCALE 1 5 Figure 11 4 11 12 Apr
62. r into the Power Supply during cleaning Blowing air into the Power Supply can cause metal particles to interfere with sensi tive electronic components and cause damage to the Power Supply To clean the Power Supply disconnect it from the input power supply voltage then open the enclosure and use a vacuum cleaner to remove any accumu lated dirt and dust The Power Supply should also be wiped clean If necessary solvents that are recommended for cleaning electrical apparatus may be used Troubleshooting and repairing the 270XSR should be carried out only by those who are familiar with electrical equipment WARNING Donotattemptto di agnose or repair unless you have had training in electronic measurement and troubleshoot ing techniques Improved Current Accuracy Calibration Procedure For The Digital Meter WARNING This calibration procedure should be carried out by a qualified electrical trades person The following procedure will give a current meas urement accuracy of better than the factory stand ard of approximately 5 Equipment Required 270XSR DC Ammeter 300A certified up to 1 accuracy LOAD RESISTANCE of 0 12 8kW Output Connecting Leads Procedure With the 270XSR switched off connect the LOAD RESISTANCE and DC AMMETER to the output terminals ii Open the wirefeeder compartment door or remove the left hand side cover wh
63. r use in ments with increased hazard of electric shock a Examples of environments with increased hazard of electric shock are In locations in which freedom of move ment is restricted so that the operator is forced to perform the work in a cramped kneeling sitting or lying position with physical contact with conductive parts ii In locations which are fully or partially limited by conductive elements and in which there is a high risk of unavoidable or accidental contact by the operator or iii In wet or damp hot locations where humid ity or perspiration considerable reduces the skin resistance of the human body and the insulation properties of accesso ries b Environments with increased hazard of elec tric shock do not include places where elec trically conductive parts in the near vicinity of the operator which can cause increased hazard have been insulated Location Be sure to locate the Power Supply according to the following guidelines a In areas free from moisture and dust b In areas from oil steam and corrosive gases wa c In areas not subjected to abnormal vibration or shock d In areas not exposed to direct sunlight or Place at a distance of 30cm 1ft or more from walls or similar that could restrict natural air flow for cooling f The minimum ground clearance for these products is 140mm 5 5 Ventilation Since the inhalation
64. re Size Part No 0 6mm 024 11 23 0 6mm 024 11HT 23 0 8mm 030 11H 30 0 8mm 030 11HT 30 0 9mm 035 11 35 0 9mm 035 11HT 35 1 0mm 040 11H 40 1 0mm 040 11HT 40 1 2mm 045 11H 45 1 2mm 045 11HT 45 1 2mm 045 Alum 11AH 364 Table 8 3 Mig Gun Contact Tips c Nozzles Bore Size Part No 9 5mm 3 8 HD22 37 9 5mm 3 8 HD22 37F 12 7mm 1 2 HD22 50 12 7mm 1 2 HD22 50F 15 9mm 5 8 HD22 62 15 9mm 5 8 HD22 62F F Flush Tip Table 8 4 Mig Gun Nozzles d Conduits HARD ELECTRODE WIRE SOFT ELECTRODE WIRE Wire Size Part No Wire Size Part No 0 6 mm 024 42 23 15 035 045 0 9 1 2mm 42N 3545 15 0 8 0 9 mm 030 0 35 42 3035 15 1 0 1 2 mm 040 045 42 4045 15 8 2 April 10 2000 10135 1 TWECO MIG GUN Installing New Wire Conduit a Be sure the MIG Gun cable is arranged in a straight line free from twists when installing or removing a wire conduit Remove the old conduit by first removing the MIG guns noz zle contact tip and gas diffuser Then loosen Allen screws in the conductor tube and con nector plug and pull the old wire conduit out of the cable assembly from the connector plug end To install a new wire conduit first inspect the o ring gas seal on the conduit for cuts or damage Start from the connector plug end of the assembly and begin pushing the con duit through the connector plug cable as sembly and in
65. s 4 1 Wire Drive Specifications 4 2 Power Supply Contents 4 2 Optional Accessories 4 3 INSTALLATION RECOMMENDATIONS 5 Environment da AM BO ee 5 1 LOCATION BRA ete 5 1 she a sens Go ings eB Mt A Se Soe BAe 5 1 Input Power Supply Voltage Requirements 5 1 Alternative Input Power Supply Voltages 5 2 SET UP FOR COMPACT 270XSR 6 POWER SUPPLY CONTROLS INDICATORS AND FEATURES 7 Standby Switch With In built Indicator Light 7 2 Coarse Voltage Control Switch And Fine Voltage Control Switch 7 2 Digital Ammeter And Voltmeter optional 7 2 G n Polarity Lead teem ae Ete en he ie ee ee 7 2 Positive And Negative Welding Terminals 7 2 Spool Gun Control Socket 7 3 se es dus d A RE LUE 7 4 Choice Of Inductance Setting 7 4 Wirespeed Control 7 4 Mode Selector Switch 7 4 SpOt TIME ee Obl ee PUS a Oe ee A A a eee 7 4 Dwell ice
66. tes dimensions moins de 300 amp res de 300 400 amp res plus de 400 amp res Nuance de de filtre oculaire LES VAPEURS ET LES FUMEES SONT 5 Ne travaillez dans un espace confin que s il est bien ventil DANGEREUSES POUR LA SANTE Le soudage d gage des vapeurs et des fum es dangereuses respirer 1 Eloignez la t te des fum es pour viter de les respirer l int rieur assurez vous que de soudage est bien ven til e ou que les fum es et les vapeurs sont aspir es l arc Si la ventilation est inadequate portez un respirateur adduc tion d air approuv Lisez les fiches signal tiques et les consignes du fabricant relatives aux m taux aux produits consummables aux rev te ments et aux produits nettoyants sinon portez un respirateur adduction d air Les gaz protec teurs de soudage peuvent d placer l oxyg ne de et ainsi causer des malaises ou la mort Assurez vous que l air est propre la respiration Ne soudez pas proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir avec des vapeurs et former des gaz hautement toxiques et irritants Ne soudez des t les galvanis es ou plaqu es au plomb ou au cadmium que si les zones a souder ont t gratt es a fond que si l espace est bien ventil si n cessaire portez un respirateur adduction Car ces rev tements et tout m
67. tional 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 Asso ciation canadienne de normalisation Standards Sales 276 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices for Occupation and Educational Eye and Face Pro tection norme ANSI 787 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 10135 1 GENERAL INFORMATION GENERAL INFORMATION The 270XSR is a semi automatic Gas Metal Arc Welders GMAW commonly MIG with either inte grated or separate wire feed unit The Power Sup plies are designed to meet the broad operating needs of the metal fabrication industry where pro duction efficiency is vital They are designed and manufactured to IEC974 1 and CE The 270XSR range gives excellent performance on mild steel stainless steel aluminum silicon bronze and some hard facing with Argon based shielding gases The Power Supplies also give excellent results on mild steel using Carbon Dioxide shielding gas The 270XSR range is supplied as a complete package ready to weld apart from gas cylinder and
68. to the gun If the conduit should lodge along the way gently whip or work the cable assembly to aid forward movement When the wire conduit stop meets the end of the connector plug and the new raw end extends through the end of the conductor tube the Allen screw in the connector plug must be securely tightened onto the conduit to prevent its backward movement Conductor tube conduit NOTE When the conduit is fully inserted into the cable assembly and the conduit stop is firmly against the Connector Plug the raw end of the conduit will protrude out of the open end of the gun conductor tube Trim the conduit as shown in Figure 8 2 The trimmed end which seats in the Gas Diffuser must be filed and reamed smooth on the inside and outside radii so wire feed will not be obstructed 2 Replace Gas Diffuser Contact Tip and Nozzle Tighten the Allen the conductor tube CAUTION Do not over tighten the conductor tube screw as this action will result in the distortion of the con duit and will lead to wire feedability problems MIG Gun Maintenance Remove dust and metallic particles from the gun conduit forcing clean dry compressed air into the conduit once a week This will minimize wire feeding problems Figure 8 2 Conduit Trim Length April 10 2000 10135 1 TWECO MIG GUN This page intentionally left blank 8 4 April 10 2000 10135 1 BASIC WELDING TECHN
69. uilding 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 Do not add fuel while smoking or if unit is near any sparks or open flames Allow engine to cool before fueling If possible check and add fuel to cold engine before beginning job Do not overfill tank allow room for fuel to expand Do not spill fuel If fuel is spilled clean up before starting engine Have only qualified people remove guards or covers for mainte nance and troubleshooting as necessary To prevent accidental starting during servicing disconnect nega tive battery cable from battery Keep hands hair loose clothing and tools away from moving parts Reinstall panels or guards and close doors when servicing is finished and before starting engine SPARKS can cause BATTERY GASES TO EXPLODE BATTERY ACID can burn eyes and skin Always wear a face shield when working on a battery Stop engine before disconnecting or connecting battery cables Do not allow tools to cause sparks w

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