INSTRUCTIONS for HELIARC 250 HF . WELDING POWER SUPPLY PART NO. 678480 PUNEP PL Brass Senies ig” FEATURES/BENEFITS ‘= High Quality AC Tig Performance . . . Easily handles difficult aluminum welding jobs. = Electronic SCR Control . . . No output drift with line voltage or heat build up. Convenient Output Current Selection . . . A choice of AC, DCSP or DCRP welding current, with a simple turn of aknob, sets the best requirement for your application. '* Flexible Current Range Selection... Three widely over- lapping ranges of AC and DC output current permits ‘quick coarse adjustment by a simple turn of a knob. Solid State Current Control . . . Provides fine tuned current adjustment within the selected range for consis- tent welding performance. = Variable High Frequency Intensity Controls . . . M izes high frequency interference by allowing adjust- ment for optimum starts or for continuous are stability ‘depending on the welding application 12-964 December, 1982 @2H2 ofS RAC ZT BP BOR ORDER Chee medKed Feehan gee” SPECIFICATIONS ated Output @ 250 Amps @ 30 Volts 40% Duty Cycle cio ‘Open Gireuit Voltage 78 Volts AC/72 Volts DE ‘Gutout [Welding Mode AE 0e. current [~ SA Min. Bio 230 | St 230 Range in| 35 amp. Min. 3510 260 | 350260 Amperes_| 70.Amp. Mi. 70% 295 | 70 t0 260 Toput Voltage 7208/230/860 VAC, 1Ph., 60 Hs. tmput Current @ [Voge | 208 _[ 230 [460 Rated Load In Amps. | Full Load | 110 | 100, 30) Power Factor @ Rated Lood ‘Approx. 52 Percent ‘Dimensions: wit | 16:nenee 406 mm Depth | 264nehes 660mm Height | 224nches 559mm 276i. 125k0 * Post Flow Service Control . . Allows timed interval ‘of gas and water at the end of the weld to protect the weld area, extend tungsten life and help increase torch life. + Remote or Panel Control Features... Provides low vole tage circuitry to remote (optional) foot, hand or torch switch control for operator safety and convenience. * Highest Voltage Applied To Front Panel Components is 115 VAC . ... Conforms to various local codes and industry standards. + 10 Amp. 115 VAC Auxiliayy Outlet additional power to un grinders, drills, et. * Input Power Light . .. Confirms primary power status even when fan cannot be heard. 2” Access Terminals . . Output terminal studs are protectively mounted on the front panel for quick and easy connection of welding and ground cables. * Compact Size... Easy to move, takes little floor space. Convenient ‘These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for electric welding equipment, we urge you to read Linde’s free booklet, “Precautions and Safe Practices for Electric Welding and Cutting,” Form 52-529, Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions, If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions on page 2 before installing or operating this equipment. Sec ene maccocs Rec) Pes SSSaLINDE [UNION CARBIDESAFETY PRECAUTIONS WARNING: These Safety Precautions are for your protection. Before performing any installation or operating procedures, be sure to asd and follow the safety precautions listed below. Failure to observe these Sefety Precautions ean result in personal injury or death, 1 PERSONAL PROTECTION --Skin and eye burns from exposure to, rays from an elaetrieare oF hot metal een be more sevore than sun: burn, Therefor: 8. Use a face shield fitted with the correct filter and cover pl ‘to protect your eves, face, neck, and ears from sparks and rays ‘of the are when operating or observing operations. WARN by: “standors not to watch the are and not expose themselves to the rays of the olecti¢ are or hot meta. 'b, Wear flameproof gauntlet type gloves, heavy longalesve shirt, cuffless trousers, high-toppad shoes, and a welding helmet oF cap {or hair protection, to protect against are rays and hot sparks or hot metal, A flameproof apron may slo be desirable as protoe tion against radiated heat and sparks. ‘& Hot sparks oF metal can lodge in rolled up sleeves, trouser cuts, fr pockets, Sleeves and collars should be kept buttoned, and Dockets eliminated from the front of clothing 4, Protect other nearby personnel from are rays and hot sparks ‘witha suitable non-flammable partition. 2. Always wear sxfety glasses oF gogales whan in a work ‘safety alesis with sde shields or goggles when chipping sl ‘grinding. Chipped slag may be hot and can travel considerable tistances, Bystanders should also wear safety glasses or gogaes. 4. Some gouging and cutting processes produce excessively high noize levels and require ear protection. FIRE PREVENTION - - Hot slog or sparks con cause serious fires ‘when in contact with combustible solids, liquids or gases. There fore 2 Remove all combustible materials wll away from the work area for completely cover the materials with «protective nonlamma ble covering, Such combustible materials include wood, clothing, saurdust, gasoline, kerosene, paints, solvents, natural gas, acety: lone, propane, snd similar combustible eticles. b, Hot sperks or hot metal ean fall into cracks in floors or wall ‘openings and cause a hidden smoldering fir. Make certain that seh openings ate protected from hot sparks and rm ©. Do not weld, cut of perform other hot work until the workpiece has been completely cleaned so thet ther aro no substances on ‘the workpiece which might produce flammable oF toxie vapors. 4. For five protection, have fre extinguishing equipment handy for instant use, such as a garden hose, water pal, sand bucket, 0 portable fire extinguisher. fe. After compiating operations, inspect the work area to make cr. ‘in thore are no hot eparks oF hot metal which could cause 3 or fire. sdditional information, refer to NFPA Standard 518, “Fire 1 in Use of Cutting end Wading Process”, wich is ‘rom the National Fire Protection Association, 470 Atlantic Ave., Boston, MA 02210. ELECTRICAL SHOCK - Contact with live electrical parts ean cause rovere burns to the body of fatal shock. Severity of electrical Shock ls determined by the path and amount of current through the body. Therefore Never allow live metal parts to touch bare skin or any wat clothing. Be sure gloves are dry. 'b, When standing on metal or operating in damp area, make cor tain that you are wall inaulsted. Wear dry gloves and rubber soled shows and stand on a dry board or platform. fe. Always ground the power supply by connecting « ground wire between the powor supply and an approved electrical ground 4. Do not use worn oF damaged cabes. Do not overload the cable, Use well maintained equipment. ©. When not operating, tin off the equipment, Accidental ground! {ng can eause overheating and creates fire hazard, Da not coll or {oop eable around parts ofthe body. Be sure the proper size ground cable is connected to the work piece os close to the work area at posible. Grounds connected to building framework or other remote locations from the work inerease the possibilty of output current passing through lifting chains, crane cables, or varius electrical paths 14. Koop everything dry, including elothing, work area, cables, ‘leetrode holder, nd power supply. Fix water leaks immediately. h, Refer to AWS Standard 249.1 in Item 6 below for specific {rounding recommendations. Do not mistake the work Toad for VENTILATION -. Fumes, particulary in confined space, can cause discomfort and physial harm. Do not breathe fumes. Therefor 2. At all times provide adequate ventilation in the work area by tatural or mechanical ventilation means, Do not weld, cut, oF {0Uge on materials such as galvanized zine, lead, beryllium, oF admium unless positivs mechanical ventilation is provided Do not breathe fumes from these matorias. 'b, Do not operate in locations clots to chlorinated hydrocarbon va- ‘ors coming from degreasing or spraying operations, The heat oF fre rays can act with solvent vapors to form phosgene, 2 highly toxic ges, and othe ieritant gases. {Hf you devolop momentary eye, nose, or throat irritation while operating, thie fz an indication that ventilation is not adequate ‘Stop work and take necessary steps to improve ventilation inthe work ates, Do not continue to operat If physical discomfort 44, Refer to AWS Standard 249.1 in Item 6 bolow for specific ontilation recommendations. EQUIPMENT MAINTENANCE - - Faulty or improperly maintained feavipment can result in poor work, but most importantly it can aus physical injury or death though fires or electrical shock, Theretor! 1. Aluayshave qualified personnel porform the instalotion, troubl shooting, and maintenance work. Do not perform any olectica ‘work unless you ate qualified to perform such work Before performing any maintenance work inside a power supp, disconnect the power supply {rom the electrical power source. . Maintein cables, grounding wire, connections, power cord, ‘and power supply in safe working order, Do not operate any ‘equipment in faulty condition. 1d, De not abuse any equipment oF accesrorier. Keep equipment ‘away from hent sourees such as furnaces, wot conditions such as water puddles, oi! or grease, corrosive atmospheres and inc ‘9. Keop all safety devices and cabinet covers in position and in ‘00d 4 Ure equipment for its intended purpose. Do not modify it in ADDITIONAL SAFETY INFORMATION -- For more information fon safe practices for setting up and operating electric welding and tatting eauipment and on good working habits, eek for free copy fof Linde's "Precautions nd Safe Practices for Electric Welding tnd Cutting”, Form 2523. The following publications which aro Srila from the Americon Welding Society, P. 0. Box 351040, Miami, FL 33135, ae recommended to you ‘Safety in Wolding and Cutting” - AWS 249.1 (ANSI) . “Recommended Safe Practices for GaeShielded Are Welding” AWS A6.1 “Recommended Safe Practices for the Proparation for Wa ‘and Cutting of Containers and Piping That Have Held Hazardous Substances” AWS F4.1 4. “Recommended Safe Practices for Plasma Are Cutting” AMS G3 “Recommended Safe Pration AWS C5.1 1. “Recommended Safe Practices for Air Carbon Are Gousing and Cutting” AWS €5.3. for Plasma Are Welding”|. INTRODUCTION ‘The HELIARC 250HE Welding Power Supply (P/N 678480) is a constant current AC/DC welding power source for quality tig and stick welding in both the AC and DC mode, ‘The unique characteristics of the magnetic and solid state circuits provide excellent arc conditions for al tig welding 48 well as high alloy stick electrodes. The non-satuating current limiting reactors probibit high current. surges inherent with saturable reactors or solid state SCR control alone, therefore reducing spatter on stick electrodes as well as tungsten spitting on tig welding. The electronic firing circuit utilizes a voltage compensating cireuit which ‘compensates for line voltage variations. Through its unique design, the Heliarc 250 combines all of the latest state-of-the-art magnetic and solid state con. cepts to provide the wide rango(s) voltampere cue characteristics needed for a constant current AC/DC power supply ~ see Figure 1. — Pie Fig, 1- Volt Ampere Curves Ml, DUTY CYCLE Duty cycle is defined as the ratio of Ioad time to the total time. Standard current ratings ace based on a ten minute cycle. This machine is rated at 40 percent duty cycle which means the rated load (250 amps.) is applied for four ‘minutes and shut off for six minutes. However, if the weld- ing current is decreased, the duty cycle can be increased, Figure 2 enables the operator to determine the safe output, Of the power supply at various duty cycles. t ' t 200 + q ' & 1 5 aso 4 Se ' g 1 § t ' : v ' 1 ° 0” ajaon) poly aceon ato % bury eveLe, Fig. 2- Duty Cyclo Chart MIL. INSTALLATION Proper installation can contribute materially to the satis: factory and troublefiee operation of the power supply. is suggested that each step in this section be studied care- fully and followed as closely as possible. ‘A. UNPACKING AND PLACEMENT 1. Immediately upon receipt of the power supply, it should be inspected for damage whictt may have occurred in (ransit, Notify the carrier of any defects or damage at once, 2. After removing the power supply from the shipping container, check the container for any foose parts. Remove all packing materials, NOTE: A strain relief coupling, for the input cable entrance hole, is attached to the fan shroud inside ihe power supply, Remove the right side panel to locate and install this trem. 43. Check sir passages at front, bottom and rear of cabinet for any packing materials that may obstruct air flow tdirough the power supply. 4. If the machine is not to be installed immediately, store itina ry, well-ventilated area, 5. The location of the welding machine should be carefully selected to insute satisfactory and dependable service. Using the lifting eyebolt, or a Forklift truck, place the power supply in the desired location. Choose a location relatively close to a properly fused source of electrical power. 6. The machine components are maintained at proper operating temperatures by forced air which is drawn through the cabinet by the fan unit on the rear panel, The power supply is designed to operate at up toa 40°€ (104° F) ambient temperature, For this reason, locate the machine in an open atea where air can circulate freely at front, bottom and rear openings. Leave at least two feet of clearance between the rear of the power supply and wall or other obstruction. IMPORTANT: Output ratings are designed and based on ‘an unobstructed supply of cooling air drawn ‘over its internal components. Do not use {filters on this unit. B. PRIMARY (INPUT) ELECTRICAL CONNECTIONS This welding power supply is a single-phase unit and must be connected to a single-phase power source. Although designed with line voltage compensation, itis suggested the unit be operated on a separate circuit to assure that the performance of the machine is not impaired due to an overloaded circuit. $46 6 + WARNING © oo oe Precautionary measures should be taken to provide maxi- mum protection against electrical shock. Be sure that all ower is off by opening the line (wall) disconnect switch when primary electrical connections are made to the power supply. To be doubly safe, check your input leads with a voltmeter to make sure that all power is OFF. 1. A line (wall) disconnect switch, with fuses or circuit breakers should be provided at the main power panel (Gee Fig. 4). The primary power input must have three insulated copper conductors (two power leads and one ground wire). The wires may be heavy rubber-covered cable, or may be run ina solid or flexible conduit. Refer to the following table for Recommended Input Condue tors And Line Fuse sizes. Do not connect the input conductors until step 3. Recommended Sizes for Input Conductors and Line Fuses Input Requirements Input & Gnd. | Fuse Conductor* | Size Volts Amps. cU/AWG Amps. 200 (208) | 110 No. 2 160 230 100 No. 2 150 460 50 No.6 70 “sized per National Electric Code for 75° C rated con- ‘ductors @ 30° C ambient. Not more than three conduc- tors in raceway or cable, Local codes should be follow- ed if they specify sizes other than those listed above 2. For access to input terminal board, remove the serews which secure the right side panel of the power supply. ‘The input terminal board, Figure 3, is clearly marked to show the available primary voltage connections which may be used. Set the voltage links, on this board, to ‘match your actual incoming voltage (208, 230, or 460 volt single-phase. 3. Thread the input conductor cables from the wall dis- connect switch through the (strain relief) hole in the rear panel (see Fig, 3). Secure the cables with the strain relief coupling provided, and then connect conductors to terminals L1 and L2 (on the input terminal board) using UL listed pressure wire connectors. Connect the ground wire to the grounding stud provided on the chassis base near the input terminal board. CAUTION: I is of the wimost importance that the chassis ‘be connected to an approved electrical ground to prevent accidental shocking. Take care not 0 connect the ground wire to any of the pri- mary leads. Customer's Input Cable Connection * DOUBLE LINKS PROVIDED Fig, 3 Input Terminal Board 4. Recheck all connections to make sure that they are tight, well insulated, and that the proper connection has been made, C, EXTERNAL POWER/CONTROL/HOSE CONNEC- TIONS CAUTION: Verify that all electrical connections comply with local electrical codes and especially with requirements established in booklet F-11-831 ‘High Frequency Stabilized Are Welding Equip- ‘ment,’ which is packed with power supply. Refer to Interconnection Diagram, Figure 4, for typical primary input, secondary output, process gas and water, and torch connections that are required for this unit's welding applications+4 ee) WARNING ¢ oe Before making any connections to the power supply’s output terminals, make sure that all primary input power to the machine is deenergized (off) at the customers discon: rect switch, The proper operation of the welding machine depends to a ‘great extent on the use of output cables that are insulated ‘copper, adequately sized, in good condition and properly connected to the machine using UL listed pressure wire ‘connectors. It is recommended that the output cables be kept as short as possible (this is particularly important for tig applications using ACHF), and be of adequate current carrying capacity. The resistance of the output cables and. connections cause a voltage drop which is added to the voltage of the arc. Excessive cable resistance may result in overloading as well as reducing the maximum current ‘output of which the power supply is capable. The welding output terminals are located on the front panel and are protected by a hinged cover. The following table will prove useful for selecting the recommended output cable Recommended Welding Cable Sizes ‘Welding | Total Length (Feet) of Cable in Weld Circuit” Curent | 60 | 100 | 150 | 200 | 250 700 6 4 3 2 1 150 4 3 1 | 10 | 20 200 3 1 | vo | 20 | 30 250 2 | wo | 20 | 30 | 40 300 1 | 2 | 30 | vo | 40 “Total cable length includes work and electrode cables. Cable size is based on direct current, insulated copper conductors, 100% duty eyele and a voltage drop of 4 or less volts, The welding cable insulation must have a Voltage rating that is high encugh to withstand the open circuit voltage of the machine. ‘Customer's Fused Line Disconnect Switey (Hose, 2075676 - 30m) Remote Contactor Control | Remote Current Control noe. 1184. eco. INPUT TERMINAL BOARD custom Phos Comets (need Peeegee eer Sonecton & waren SUPPLY (How, 40V76- 121/240) Ci) | Sindee ronch cas CONNECTOR -11N16 IG TORCH (ir Cooled) POWER CABLES ‘GAs SUPPLY (Hose, 0v77 - 12:1/24) 1— work CABLE 210 Min 4/0 Max. ADAPTORS. AY Tig TORCH (Water Cooled) Foor conrRot, Fo4.676154 ——»| Mes REMOTE CONTACTOR TORCH SW. 674038 i TORCH WATER CONNECTOR - 1116 |» 25 waren onain (owe, 40V76- 1247240) | REMOTE CURRENT HAND CONTROL -674209 Fig, 4 Interconnection DiagramD. ACCESSORIES 1. FC-4 Remote Control Foot Switch, P/N 676154. This device provides the operator with remote control of cursent and contactor operation at the welding static Interconnection of these control functions to the main unit is provided by a pair of mating 25-foot cable/plug assemblies. By depressing the foot pedal, the weld-start sequence circuit will energize, and the welding current will increase or decrease within the range preset on the ower supply Current Control potentiometer. 2. Torch Switch Assembly, P/N 674038, This device is designed to be attached to any tig welding torch, and Provides the operator with remote contactor opera: don at the welding station, Interconnection to the Power supply is provided by its 12-1/2t. cable/plug asiembly. The torch switch button must be depressed during the entire welding cycle for all tig welding opera- tions, 3. Current Hand Control, P/N 674209. This accessory operates in series with the power supply’s Current Control potentiometer to provide remote (up to 25-ft.) ‘current rogulation. The hand control potentiometer’s ‘current adjustment is always controlled by and limited to the range that is preset on the power supply Current Control potentiometer. This lightweight, low voltage control can be hand-held, or attached to any canvenient steel structure with its integrally mounted magnets, 4, WC-SA Water Cooler, P/N 953564. A self contained, 3 ‘gallon capacity water cooler suitable for most water- ‘cooled torch applications. The unit circulates 1 gallon per minute at 40 ps and operates from 115 volt, 60 Hz, 1 phase (5.6 amp) input. 5. TRAIL Truck, P/N 600437. Provides complete mobility for power supply or welding outfit and includes handle and gas eylinder bracket. JV. CONTROL FUNCTIONS ‘A. Ready-Off Switch (ROS). In the OFF position, the power supply is electrically shut down;however, elect cal input power is sil present in the unit (at the input terminal board, primary and secondary of the main transformer power and 115.volt control winding, the main bridge, and at the ROS toggle) ~ unless the custo- mers line switch is off. In the READY position, this switch provides 115-volts to energize the control and cooling fan circuitry and also prepares the ready-to-veld status of the unit, as determined by the positioning of the Tig-Stick switch S2 (see Item B. following). B. TigStick Mode Switch ($2). This two-position toggle switch sets the operational modes which can be use. In the STICK position (and the ROS toggle in Ready), the solid-state contactor circuits immediately energize and welding power is continuously present at the output terminals. Inthe TIG position, the solid-state contactor and other tig sequencing circuits are controlled by 2 remote device (foot or torch switeh) through the Re- mote Contactor receptacle P7 (see Item C. following). . Remote Contactor Receptacfe (P7). The cable connector from the remote Foot Control or Torch Switch acces- sories plugs into this low-voltage receptacle 10 control the conducting sequence of the bridge SCR’s to make or break the Tig welding output power. D. Current Selector Switch (CSS). A three-position switeh offers a choice of AC, DCSP, or DCRP output curcent 10 suit your particular welding applications. This switch provides a means of selecting the desired welding output, without the necessity of physically changing the secon- dary cable connections. Placing the switch in its DCSP ‘mode causes the output terminals to assume the follow- ing polarities; work is positive, and torch/electrode is negative. Conversely, when the switch isin DCRP; work is negative and torch/electrode is positive. Do aot change the position of this switch while welding or under load. E, Range Selector Switch (RSW), This three-position switch permits quick coarse selection of the output current ranges which can be used. The current ranges are marked S-Amp, Min,, 35-Amp Min,, and 70-Amp. Min, The S.amp. mode provides exceptional cleaning action for All low current tig applications. For higher curren! tig welding, always try to select the appropriate minimum current” range that adequately covers your welding requitements. Similarly for stick electrode welding, ‘always position the switch to cover the lowest current level required for a given electrode (e.g. for 1/4sinch 7O18, select the 70amp. min,; for a 1/16nch 308L16, select either the 5 or 35-amp, min.). Do mot change the position of this switch while welding or under foad F. Current Control Potentiometer (CCP). This potentio- meter provides fine adjustment of welding current with- in the range selected on the Range Switch (RSW). The panel-faced dial provides an accurate reference for resetting andjor adjusting the potentiometer. G.Curent Control Mode Switch (S4), and Receptacle (P6). This two-position toggle switch determines the location from which welding curcent will he operated: ‘ithe locally from the power supply ~ PANEL position; or, from a REMOTE location by plugging the optional FC4 Foot or Hand Control into Receptacle P6. When the foot or hand (and toreh switch) controls are used; the remote contiol() will energize the contactor circuit and then vaty the welding current, but only within the range preset_on the power supply Current Contzc? Potentiometer (CCP). H. High Frequency (and Gas/Water Solenoids) Selector Switch ($3). A three position toggle switch contols thigh frequency and, shielding gas and cooling wate in the welding operat ‘The functional positions are: Off ~ no high frequency and, gas and water solenoid valves are deenergized (this is the normal position for all stick welding); Con- tinuous frequency and, shielding gas and cooling water ( used) are provided throughout the entire welding cycle (this is the normal position for all AC Tig welding); and, Start -- high frequency initiates immediately and cuts off when the arc is established, gasand water solenoids energize and remain on throughout the welding cycle (this last position is normal for most DC Tig welding applications). 1. High Frequeney Intensity Control (HFI). This rheostat, with pancl-faced dial, sets and regulates the output intensity of the high frequency generator circuit J, Post Flow Control (PF). This potentiometer provides a timed (from 3 t0 30 sezonds) post-flow of shielding gxs and cooling water after the welding arc is broken. K. Auxiliary 115-Volt Receptacle (12). This receptacle can be utilized to supply 115-volt power for auxiliary equip- ment, and is fuse protected for up to 10.ampere loads. L. Input “Power On” Indicating Light. The “red” Input Power indicator will light immediately after the custo- mer’s primary disconnect switch is closed ~ indicating that primary power is present in the welder. M. Gas and Water Torch Connections. A pair of connectors are provided for each of these services. They are thread- ed to accept standard CGA “B" size inert gas (r.h.) and water (Lh) hose connection nuts. V. SEQUENCE OF OPERATION CAUTION: Never, under any circumstances, operate the power supply without its panels in place. In addition to the safety hazard, improper cooling ‘may cause overheating which will damage the internal components, Also, make sure you are adequately protected before you start welding = welding helmet, gloves and ear protection should always be worn, A. STICK ELECTRODE WELDING 1. Connect all welding cables to workpiece and electrode holder as shown on the Interconnection Diagram, Fig. 4. 2, Place the power supply’s Ready-Off and High Frequency Selector switches to their OFF positions. 3. Close the main (wal) disconnect switch or circuit break- er to provide input power to the power supply -- the In- put Power pilot light should come “on”. 4, Place the Current Selector switeh to either AC, DCSP, ‘or DCRP depending on your welding application, CAUTION: Do not chenge the position of this switch under load. 5, Place the Tig Stick togge switch to its (STICK) position. 6. Leave the High Frequency Selector switeh in its OFF (STICK) position. 7. Place the Current Range Selector to one of the three Current Range positions to suit your welding applica- tion. For best control, always operate in the lowest ‘minimum current range which will do the job. CAUTION: Do not chenge the position of this switch while welding. 8. Adjust the Current Control potentiometer for the ap- proximate desired welding current. 10. 10. ) Place the Ready-Off switch to its READY position. ‘This will immediately energize the power supply up to the output terminals and the electrode holder. Com- ‘mence welding by touch or scratch starting. If necessary, readjust the Current Control potentiometer to obtain the exact welding condition required 3. TIG WELDING. |. Make the necessary welding power and service connec- tions as shown on the Interconnection Diagram, Fig. 4. . Set the Ready-Off switch to its OFF position. Place the Tig-Stick switch in its TIG position. Remember this mode requires that a torch switch or foot control be plugged into the Remote Contactor Receptacle (P7) in order to make and break the welding sequence. | Close the main (wall) disconnect switch or circuit break- er to provide input power to the power supply -- the In- put Power pilot light should come “on”. Place the Current Selector switch in either AC, DCSP, ‘or DCRP position. The AC position is primarily used for welding of aluminum and magnesium. The DCSP posi tion will normally be used to cover all of the remaining metals (steel, copper, refractory, etc.) and alloys. The DCRP position produces a shallow weld, which makes it suitable for joining thin sheets of metal (e.., magne- foil, ete.), CAUTION: Do not change the position of this switch under load, Set the Current Control “Panel-Remote” toggle switch to its REMOTE position. Remember, the tig mode requites that the optional Hand, or Foot Control be plugged into its Receptacle (P6) in order to provide remote current regulation. Further, welding current can only be regulated up to the limit preset on the power supply’s Main Current Control Potentiometer. Place the Current Range Selector to one of the three Current Range positions to suit your welding applica- tion. For best control always operate in the lowest ‘minimum current range which will do the job. CAUTION: Do not change the position of this switch while welding, . Adjust the Current Control Potentiometer for the ap» proximate welding current desired. Remember, that the setting placed on this potentiometer will be the maxi- mum current which can be regulated from the re- mote Foot or Hand Control, Place the High Frequency Selector Switch in either START or CONTINUOUS - - this will also energize the gis and water solenoid valves. The Continuous position is generally used for a.c. welding applications; whereas the Start position is for d.c. welding, although individual instances may dictate other usage. Set the High Frequency Intensity Control to secure the tensity which provides the best results (try starting at midpoint).11, Set the POSTFLOW control to provide the desired interval of postflow shielding gas and/or water cooling (fom 3 up to 30 seconds) after the welding arc is broken. 12, To establish the welding are, position the torch electrode near the workpiece and close the Remote Torch Switch for Foot Control. This will energize the solid state contactor and provide the high frequency to initiate the 13, If necessary, readjust the Current Control or High Fre- queney Intensity Control until you secure the exact conidition desired. VI. MAINTENANCE If this equipment does not operate properly, stop work immediately and te the cause of the malfunction. Maintenance work must be performed by an experienced Porson, and electrical work by 2 trained electrician. Do not armit untrained persons to inspect, clean, oF repair this equipment. Use only recommended replacement parts #4 6 6 6 WARNING + 8 #4 6 Be sure that the wall disconnect switch or circuit breaker is, ‘open before attempting any inspection or work on the inside of the power supply. A. CLEANING Since there are no moving parts (other than the fan) in the. power supply, maintenance consists mainly of keeping the interior of the cabinet clean, Periodically remove the cover, from the eabinet and blow accumulated dust and dirt from the air passages and the interior components, using clean ow pressure air. It is imperative that the air passages, to the interior of the unit, be kept free of dirt accumulation to Insure adequate circulation of cooling air, especially over, the rectifier bridge plates, The length of time between cleaning will depend on the location of the unit, and the amount of dustin the atmosphere, 8. LUBRICATION Fan motors with oil tubes requite lubrication after one year of service. Motors without oil tubes are permanently lubsi- cated and do not require any attention. . SPARK GAP SERVICING ‘This component is part of the high frequency assembly. ‘The spark gaps are normally set for 007 inches at che factory. J will probably be necessary to readjust these ‘gaps after extended operation, or if erratic high Trequency ‘operation is noted. It is important that the gaps be adjusted with a feeler gauge rather than by eye. Cleaning and dress- ing of spark gap points is not recommended since the point is tungsten and difficult to file, All four (4) points (P/N 673578) should be replaced when replacement is necessary. D. SPARK GAP ADJUSTMENT Generally, the high frequency output of the unit increases as the gap setting is increased. Maximum output is generally, obtained when the gap is adjusted between .008 and .010-n, Never set the gap above .010%n., because high-frequency radiation increases as the gap inereases. It is suggested that Settings between .004 and .007-in., where these are consis- tent with good welding operation be used. Refer to Fig. 5 and do the following: 1. Loosen retaining screws ‘A’ only enough to free spark gap points ‘C’ for adjustment. 2. Place feeler geuge of propor thickness between gaps ‘B’ 3. Apply slight pressure against spark gap polnts'C’ in end heat sinks ‘D’ so the feelor gauge is held firmly in the gaps. Tighten retaining screws‘ Fig. 5 - Spark Gap Adjustment E. TESTING AND REPLACING BRIDGE ASSY. COMPONENTS ‘SCR's and silicon diodes are devices which allow current to flow in only one direction, and block eurrent in the other direction, The SCR's and silicon diodes used in this power supply are designed to provide long trouble-free operation; however, should a failure occur, they may require replace- ment. Tho testing procedures to determine defective com- ponents follow: 1. Silicon Diode Rectifier, D1-D4. Disconnect the power lead to the diode, to provide an ‘open-circuit across the component to be tested. Using an ‘ohmmeter set to the Rx 1 seale, check the resistance in the forward and reverse directions. A good diode will ead high in the reverse direction, and low in the forward, direction, When replacing defective diodes, make sure mounting surfaces are clean. Coat mounting surfaces with Dow- Coming No, 340 silicon heat sink compound, or equi valent, Replaced diode (nuts) should be tightened only until firm, and then torqued tight (recommended range is 100 jnok tbs. min, to 125 inch Ibs, max.) 2, Silicon Controlled Rectifier - SCR, Disconnect the SCR wiring (but do not unclamp) to break continuity and provide an open-circuit across the component to be tested. Using an ohmmeter set to the Rx I scale, check the resistance across the SCR in both, directions. A good SCR will read high in both ditections, If the reading is fow or zero in either direction, the SCR is defective. When replacing defective SCR's, make sure the mounting surfaces aro clean, Coat the mounting surfaces wi Alcoa No. 2 electrical joint compound, available fromLinde in 8 o2. cOntainers under P/N 73585002. Make certain that the polarity on the replacement SCR is the same as on the unit being replaced. Place the top clamp piece over the bolts and tighten each nut hard finger tight. The clamp piece should be parallel to the top plate. Then tighten each nut approx. 1/4 tum at a time (alternately), for two complete revolutions. Holding that nut in place with an open end wrench, proceed to tighten the second nut down upon it in order to lock it VII, TROUBLESHOOTING 244 © WARNING + oo oo Be sure that all primary power to the machine has been externally disconnected. Open wall disconnect switch or circuit breaker before attempting inspection or work inside of the power supply If power supply is operating improperly, the following ‘troubleshooting information may be used to locate the source of the trouble. Check the problem against the symptoms in the following troubleshooting guide. The remedy may be quite simple. If the cause cannot be quickly located, open up the unit ‘and perform a simple visual inspection of all the compo: nents and wiring. Check for secure terminal connections, loose or burned wiring or components, bulged or leaking capacitors, or any other sign of damage or discoloration. TROUBLE SYMPTOM GUIDE A. SYMPTOM: Fan does not run when Ready-Off switch is, in READY. 1, Check ROS switch. 2. Fan blade loose. B. SYMPTOM: Fan runs but output is not enerpized, 1, Tig-Stick switch in tig position. C. SYMPTOM: No voltage or current in the DC mode. 1, Check all diodes. (see VI-E-1) 2. Check AC-DC switch. D. SYMPTOM: No output control in AC or DC. 1. Check silicon controlled rectifiers. (see VI-E-2) 2. Replace firing circuit P.C. board. E, SYMPTOM: No flow of gas or water. I. High Frequency switch must be either start or con- tinuous. 2. Check valves for proper connections. F. SYMPTOM: No high frequency output or weak high frequency. WARNING: Voltage on secondary is 3,000 volts RMS. 1. Check spark gaps. Set between .004 and .010. 2. Adjust adjustable rheostat HIFI to increase or decrease hhigh frequency intensity. G.SYMPTOM: High frequeney operated continuously when mode switch is set on start only. 1. Check relay. 2. Check rectifier DS. 3. Check resistor H, SYMPTOM: Ematic output, low current. 1. Pilot reactor fuses open. Check 100 ampere fuse on SCR plate and 15 ampere fuse on front panel. VIII, REPLACEMENT PARTS DATA 1. All replacement parts are keyed on the as shown on illus fon the unit nameplate. 3. Indicate any special shipping instructions. 4. Order replacement parts from the lustrations which follow. Order replacement parts by number and part name, tions, DO NOT ORDER BY PART NUMBER ALONE. 2. Always state the series or serial number of the machine on which the parts 1 to be used, The serial number is stamped inde office or distributor nearest you.(WFD) HIGH FREO. INTENSITY RREOSTAT- 099420 (2) HIGH FREO. SELECTOR Su. 620702 Rorecnee cover srs me SILKSCREENED FRONT ——. (ROS) READY.OFF Sw..673213, le7) RemoTe cONTACTOR RECEPT..e4ws1 \c28,20) CAPACITOR 677948 152) TIGSTICK Sw, -694515 (css) CURRENT WARNING DECAL: 995227 re RIGHTSIDE PANEL 678646 fevos 200217 (asm nana (s4) CURRENT PaneL. StuecTon sn fremore oH, eon oe 20071 (2) TERMINAL ASSY 676701 a2 aux. 18 voLT LEFT SIDE PANEL - 670647 (2) Fuse aa 679000 (PF) posTFLOW (PL POWER ON PILOT (coe) current conrnoy PorenTiomeTER 672206 HEAR 2sone (@o) REMOTE CURRENT RECEPTACLE - 99110, (25, 28,27) caraciTon 60/9 1 Bane SILKSCREENED HINGEO PNL. 678006, (4) FUSE 184-2990) (Sv) WATER SOLENOID “Replaces tit becoae HOLDER. 634700 VALVE 626306 ‘hcetsaly worm ois or [2H ADAPTORS. 11N16 shen easing pal) (6SV) GASSOLENOID VALVE 636005 (2)RM. ADAPTORS 24875. Fig. 6- HELIARC 250 HF Front View (F/C) FIRING CIRCUIT SCR CONTROL-8D. ASSY - 678051 REAR PANEL - 678645 ————»y (GR) BRIDGE ASSY (Also Seo Figs. 8 & 9) 678486 Includes: (01, D2} Fwo. ploves 672164 —I (2) STANDOFF - 672225: (C11, C13) CAPACITOR - 672348 FAN MOTOR 678083, FAN BLADE - 678064 FAN SHROUD - 678193. HIGH FREQ. ASSY. (See V| Fig 9) 678006; (PR) PILOT REACTOR - 676055: (HFC) HIGH FREQ. AIR CORE TRANSF. 678075: (io) INDUCTOR -678054 Fig, 7 - HELIARC 250 HF Left Side View 10(cB) COMPONENT BD. ASSY (See Fig. 9) 678498 REF. PLUG “PA” (F(T) FILTER/TINER P.C. 8D ‘ASSY - 678062 (4R) MAIN REACTOR -678056 (@R) BRIDGE ASSY (Also See Figs. 7 & 9) 678486 Includes: (03, D4) REV. DIODE -672159, (2) STANDOFF - €72225 (C10, C12) CAPACITOR - 672348 (MTR) MAIN TRANSF. ASSY -678053, (175) THERMOSTAT 2062211 (78) INPUT TERMINAL 8D. ASSY -678576 (GND) GROUND LUG TERMINALS - 647361 Fig. 8 HELIARC 250 HF Right Side View (Sch-1, 2) SCR ASSY, 2 COND W/SHIELD -678527 includes: SCR RECTIFIER - 678058 (C33, 34) CAPACITOR - 995514 (F23, 24) RESISTOR - 17110110 (2) ScR CLAMP ASSY 678506. (BTS) THERMAL SWITCH. 2062372 (F1) FUSE LINK, 1008 -678061 perce opes COMPONENT BO. ASSY -678498 Includes: (C2) CAPACITOR -672772 (K1) CONTAGTOR- 678069 [c14) CAPACITOR - 950380 [R4, Top) RESISTOR - 17250010 (22, Bottom) RESISTOR - 17250115, {c30, 31) CAPACITOR -950380 (MOV) METAL OXIDE VARISTOR - 950428 HIGH FREQ, ASSY -678496 Includes (86) SPARK GAP ASSY -673582 Includes CENTER HEATSINK -673580 2) ENDHEATSINK. 673670 |4) SPARK GAP POINTS - 673578, (HVT) HIGH VOLT, TRANSF. - 635017 (C15, 16) CAPACITOR -672348 (a7) RESISTOR - 17135222 (05) BRIDGE RECTIFIER -635152| (ka) RELAY - 678076 (C1) MICA CAPACITOR - 950256: |—\c5, 6) CAPACITOR - 678070 (6) RESISTOR - 17140010 (ca) CAPACITOR -950360 (25) RESISTOR - 17235160, (c3) CAPACITOR - 678067 Fig, 9- HELIARC 250 HF Top View (Cover Removed) "cear-673305 ROLL PIN 62350821 POTENTIOMET Te Com Terminol —~——— SwiTCH-674592 Wat) To contactor Contel Five RACK: 676187 MOUNTING BRACKET-676207 (4) Foor-te2wiz CONTAGTOR CONTROL 1.098 0%.438") Pug “sswaa) 7 ware = Jen | 8x9 Fr @r Els eh. Terminal eorrom view CURRENT CONTROL PLUG-98WIT STRAIN RELIEF-95485 Fig. 10- FC-4 Remote Foot Switch, P/N 676154 (Optional) MAGNETIC CATCH- 99W77. (One each end} / B0x-OSNI! CONNECTOR isow3e 25 F1,3/C CABLE PLUG Py KNOB - 92065 RCP-POTENTIOMETER, 639541 VIEW LOOKING INTO BACK OF COVER (Ref.) RUBBER “O" RING RETAINERS B6we2 SWITCH-996059 PLuG.95w44 (Ref.) TYPICAL TIG TORCH HANDLE Fig, 12- Remote Torch Switch Assembly, P/N 674038 (Optional) 2 Fig, 12- Remote Current Hand Control, P/N 674209 (Optional) TCs Fee’ Con Ol Pox7€oG =aewaa/aanea WOME PS lweabelq oneweyog 4H SZ ONVITZH “EL “Bld Gna winoa/m eno9/2nat/naa bon? /e02 8DETAILIE Fig, 15- HALIARC 250 HF Wiring Diagram (Sheet 2)UNION CARBIDE CORPORATION LINDE DIVISION L12.964 92.0062 12/62 SM Printed in US.A Box F-6000, Florence, SC 29501