Harris Powerbrazer User manual

POWERBrazer

OPERATING MANUAL

November, 2008

For use with machines having Code Numbers: 11535

Safety Depends on You

Harris Brazing, Soldering and cutting

equipment is designed and built with

safety in mind. However, your overall

safety can be increased by proper

installation ... and thoughtful opera-

tion on your part. DO NOT

INSTALL, OPERATE OR REPAIR

THIS EQUIPMENT WITHOUT

READING THIS MANUAL AND

THE SAFETY PRECAUTIONS

CONTAINED THROUGHOUT. And,

most importantly, think before you

act and be careful.

• Sales and Service through Subsidiaries and Distributors Worldwide •

4501 Quality Place, Mason, Ohio 45040 U.S.A. • Web Site: www.harrisproductsgroup.com

• World's Leader in Welding, Brazing, Soldering and Cutting Products •

IP21

a Division of Lincoln Electric

IM987

This manual covers equipment which is no

longer in production by The Lincoln Electric Co.

Specications and availability of optional

features may have changed.

POWERBrazer

SAFETY

BRAZING, SOLDERING AND OTHER METAL JOINING ACTIVITIES CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS

FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in

Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A

Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

Both ANSI Standard Z49.1 and Arc Welding Safety Booklet E205 are available at (WWW.lincolnelectric.com/community 1 safety)

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY

QUALIFIED INDIVIDUALS.

AUG 08

POWERBrazer

SAFETY

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks and

flame when brazing or observing

brazing. Headshield and filter lens

should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant

material to protect your skin and that of your helpers from

the heat and flame.

4.c. Protect other nearby personnel with suitable, non-flammable

screening and/or warn them not to nor expose themselves to hot

spatterormetal.

FUMES AND GASES

can be dangerous.

5.a. Brazing may produce fumes and gases haz

ardous to health. Do not breathe these

fumes and gases. When brazing, keep your

head out of the fume. Use enough

ventila-

tion and/or exhaust at the arc to keep

fumes

and gases away from the breathing zone.

When brazing with electrodes which

require special ventilation such as those containing

cadmium or fluorides (see instructions on container or

MSDS) or on lead or cadmium plated steel and other

metals or coatings which produce highly toxic fumes,

keep exposure as low as possible and below Threshold

Limit Values (TLV) using local exhaust or mechanical

ventilation. In confined spaces or in some circum-

stances, outdoors, a respirator may be required.

Additional precautions are also required when brazing

on galvanized steel.

5. b. Additional precautions for materials containing Cadmium

and Fluorides:

BRAZING MATERIALS MAY CONTAIN CADMIUM.-

FUMES ARE POISONOUS AN CAN KILL.

• Do not breathe fumes. Even brief exposure to high con-

centrations should be avoided.

• Use enough ventilation, exhaust at the arc, or both, to

keep fumes and gases from your breathing zone and gen-

eral area. If this cannot be done, use air supplied respira-

tors.

First Aid: If chest pain, shortness of breath, cough, or fever

develop after use, obtain medical help immediately.

BRAZING MATERIALS MAY CONTAIN FLUORIDES.

FUMES AND GASES CAN BE HAZARDOUS TO YOUR

HEALTH. BURNS EYES AND SKIN ON CONTACT. CAN

BE FATAL IF SWALLOWED.

• Avoid contact of flux with eyes and skin.

• Do not take internally.

First Aid: If contact in eyes, flush immediately with water for

at least 15 minutes. If swallowed, induce vomiting. Never

give anything by mouth to an unconscious person. Call a

physician..

5. c. The operation of brazing fume control equipment is affected

by various factors including proper use and positioning of

the equipment, maintenance of the equipment and the spe-

cific welding procedure and application involved. Worker

exposure level should be checked upon installation and

periodically thereafter to be certain it is within applicable

OSHA PEL and ACGIH TLV limits.

5.d. Read and understand the manufacturerʼs instructions for this

equipment and the consumables to be used, including the

material safety data sheet (MSDS) and follow your

employerʼs safety practices. MSDS forms are available from

your welding distributor or from the manufacturer.

AUG 08

POWERBrazer

iii

SAFETY

iii

FOR ELECTRICALLY

powered equipment.

8.a. Turn off input power using the disconnect

switch at the fuse box before working on

the equipment.

8.b. Install equipment in accordance with the U.S. National

Electrical Code, all local codes and the manufacturerʼs

recommendations.

8.c. Ground the equipment in accordance with the U.S. National

Electrical Code and the manufacturerʼs recommendations.

Aug, 08

BRAZING SPARKS can

cause fire or explosion.

6.a.

Remove fire hazards from the brazing area.

If this is not possible, cover them to prevent

the sparks from starting a fire Remember

that brazing sparks and hot materials from

brazing and soldering can easily go through

small cracks and openings to adjacent

areas. Avoid working near hydraulic lines.

Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,

special precautions should be used to prevent hazardous

situations. Refer to “Safety in Welding and Cutting” (ANSI

Standard Z49.1) and the operating information for the

equipment being used.

6.c. Do not heat, cut or braze tanks, drums or containers until

the

proper steps have been taken to insure that such proce-

dures

will not cause flammable or toxic vapors from sub-

stances inside. They can cause an explosion even

though

they have been “cleaned”. For information, purchase

“Recommended Safe Practices for the

Preparation

for

Welding and Cutting of Containers and Piping That Have

Held Hazardous Substances”, AWS F4.1 from the American

Welding Society

(see address above).

6.d. Vent hollow castings or containers before heating, cutting or

brazing. They may explode.

6.e.

When brazing Wear oil

free protective garments such as

leather gloves, heavy shirt, cuffless trousers, high shoes and

a cap over your hair. Always wear safety glasses with side

shields.

6.f. Read and follow NFPA 51B “ Standard for Fire Prevention

During Welding, Cutting and Other Hot Work”, available

from NFPA,1 Batterymarch Park, PO box 9101, Quincy, Ma

022690-9101.

POWERBrazer

SAFETY

Mar. ʻ93

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions et

les précautions de sûreté specifiques qui parraissent dans ce manuel

aussi bien que les précautions de sûreté générales suivantes:

Sûreté Pour Soudage A LʼArc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours

tout contact entre les parties sous tension et la peau nue ou

les vétements mouillés. Porter des gants secs et sans trous

pour isoler les mains.

b. Faire trés attention de bien sʼisoler de la masse quand on

soude dans des endroits humides, ou sur un plancher met-

allique ou des grilles metalliques, principalement dans l e s

positions assis ou couché pour lesquelles une grande partie

du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble de

soudage et la machine à souder en bon et sûr état defonc-

tionnement.

d.Ne jamais plonger le porte-électrode dans lʼeau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension des

porte-électrodes connectés à deux machines à souder parce

que la tension entre les deux pinces peut être le total de la

tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions

pour le porte-électrode sʼapplicuent aussi au pistolet de

soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger

contre les chutes dans le cas ou on recoit un choc. Ne jamais

enrouler le câble-électrode autour de nʼimporte quelle partie du

corps.

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié ainsi

quʼun verre blanc afin de se protéger les yeux du rayon-

nement de lʼarc et des projections quand on soude ou quand

on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la peau

de soudeur et des aides contre le rayonnement de lʻarc.

c. Protéger lʼautre personnel travaillant à proximité au soudage

à lʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de lʼarc de soudage.

Se protéger avec des vêtements de protection libres de lʼhuile,

tels que les gants en cuir, chemise épaisse, pantalons sans

revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les

zones où lʼon pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de

prévenir tout risque dʼincendie dû aux étincelles.

7. Quandonnesoude pas, poser la pince à une endroit isolé de la

masse. Un court-circuit accidental peut provoquer un échauffe-

ment et un risque dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible de la

zone de travail quʼil est pratique de le faire. Si on place la masse

sur la charpente de la construction ou dʼautres endroits éloignés

de la zone de travail, on augmente le risque de voir passer le

courant de soudage par les chaines de levage, câbles de grue,

ou autres circuits. Cela peut provoquer des risques dʼincendie ou

dʼechauffement des chaines et des câbles jusquʼà ce quʼils se

rompent.

9. Assurer une ventilation suffisante dans la zone de soudage. Ceci

est particuliérement important pour le soudage de tôles gal-

vanisées plombées, ou cadmiées ou tout autre métal qui produit

des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant

dʼopérations de dégraissage, nettoyage ou pistolage. La chaleur

ou les rayons de lʼarc peuvent réagir avec les vapeurs du solvant

pour produire du phosgéne (gas fortement toxique) ou autres pro-

duits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir le

code “Code for safety in welding and cutting” CSA Standard W

117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR

LES MACHINES À SOUDER À

TRANSFORMATEUR ET À

REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de

lʼélectricité et aux recommendations du fabricant. Le dispositif de

montage ou la piece à souder doit être branché à une bonne

mise à la terre.

2. Autant que possible, Iʼinstallation et lʼentretien du poste seront

effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à

lʼinterrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

Thank You

for selecting one of our QUALITY products. We want you to take

pride in operating this product ••• as much pride as we have in

bringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it

handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.

The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

CAUTION

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims

for material damaged in shipment must be made by the purchaser against the transportation company at the

time the shipment is received.

Please record your equipment identification information below for future reference. This information can be

found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code (if available)______________________________________________________

Serial Number (if available)__________________________________________________________________

Date Received___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you

have recorded above.

CUSTOMER ASSISTANCE POLICY

The business of our company is manufacturing and selling high quality welding equipment. Our challenge is to

meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask us for

advice or information about their use of our products. We respond to our customers based on the best informa-

tion in our possession at that time. We are not in a position to warrant or guarantee such advice, and assume no

liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any

warranty of fitness for any customerʼs particular purpose, with respect to such information or advice. As a matter

of practical consideration, we also cannot assume any responsibility for updating or correcting any such informa-

tion or advice once it has been given, nor does the provision of information or advice create, expand or alter any

warranty with respect to the sale of our products.

We are a responsive manufacturer, but the selection and use of specific products sold by us is solely within the

control of, and remains the sole responsibility of the customer. Many variables beyond our control affect the

results obtained in applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing.

POWERBrazer

SAFETY ..............................................................................................................................................................i-iv

INSTALLATION ....................................................................................................................................SECTION A

Technical Specifications .................................................................................................................................A-1

Safety Precautions ..........................................................................................................................................A-2

Location.............................................................................................................................................................A-2

Procedures to Install Drive Rolls and Wire Guides ....................................................................................A-2

_____________________________________________________________________________________

OPERATION..........................................................................................................................................SECTION B

Safety Precautions ..........................................................................................................................................B-1

User Serviceability...........................................................................................................................................B-1

General Description.........................................................................................................................................B-1

Recommended Processes and Equipment..................................................................................................B-1

Case Front Controls ........................................................................................................................................B-2

Internal Controls ..............................................................................................................................................B-3

Rear Controls ...................................................................................................................................................B-4

_____________________________________________________________________________________

ACCESSORIES ....................................................................................................................................SECTION C

Drive Roll Kits, Steel Wire..............................................................................................................................C-1

_____________________________________________________________________________________

MAINTENANCE....................................................................................................................................SECTION D

Safety Precautions ..........................................................................................................................................D-1

Routine Maintenance ......................................................................................................................................D-1

Periodic Maintenance .....................................................................................................................................D-1

Calibration Specifications ...............................................................................................................................D-1

_____________________________________________________________________________________

TROUBLESHOOTING GUIDE............................................................................................................SECTION E

How to Use the Troubleshooting Guide .......................................................................................................E-1

Troubleshooting Guide....................................................................................................................................E-2

_____________________________________________________________________________________

WIRING DIAGRAM AND DIMENSIONS ...........................................................................................SECTION F

_____________________________________________________________________________________

PARTS PAGES ................................................................................................................................P-589 SERIES

_____________________________________________________________________________________

TABLE OF CONTENTS vi

A-1

POWERBrazer

A-1 INSTALLATION

TEMPERATURE RANGE

OPERATION: -40°F to 104°F (-40°C to 40°C)

STORAGE: -40°F to 122°F (-40°C to 50°C)

INPUT VOLTAGE and CURRENT

TECHNICAL SPECIFICATIONS –

POWERBrazer (K2772-1)

HEIGHT WIDTH DEPTH WEIGHT

14.8 in 8.7 in 23.2 in 30 lbs

(376 mm) (221 mm) (589 mm) (13.6 kg)

PHYSICAL DIMENSIONS

INPUT VOLTAGE

1 phase 60 Hz 120 VAC

INPUT AMPERES

GEARING - WIRE FEED SPEED RANGE-WIRE SIZE

WFS RANGE

20-120 ipm

(0.51 – 3.1m/min)

WIRE SIZES

1/16” – 3/32”

(0.6 – 1.6mm)

GEARING

Extra torque

K2772-1

A-2

A-2 INSTALLATION

POWERBrazer

SAFETY PRECAUTIONS

ELECTRIC SHOCK CAN KILL.

• Only qualified personnel should

perform this installation.

• Only personnel that have read and

understood the POWERBrazer

Operating Manual should install

and operate this equipment.

• The POWERBrazer must be plugged into a recep-

tacle which is grounded per any national, local or

other applicable electrical codes.

• The POWERBrazer power switch is to be in the

OFF (“O”) position when connecting the power

cord to the input power.

------------------------------------------------------------------------

LOCATION

For best wire feeding performance, place the

POWERBrazer on a stable and dry surface. Keep

the wire feeder in a vertical position. Do not operate

the wire feeder on an angled surface of more than

15 degrees.

Do not submerge the POWERBrazer.

The POWERBrazer is rated IP21 and is suitable for

indoor use.

The handle of the POWERBrazer is intended for

moving the wire feeder about the workplace only.

WARNING

PROCEDURE TO INSTALL DRIVE ROLLS

AND WIRE GUIDES

ELECTRIC SHOCK CAN KILL.

• Turn the input power OFF at the

POWERBrazer before installation

or changing drive rolls and/or

guides.

• Do not operate with covers, panels or guards

removed or open.

• Only qualified personnel should perform mainte-

nance work.

------------------------------------------------------------------------

1. Turn power off at the POWERBrazer.

2. Release the idle roll pressure arm.

3. Remove the outer wire guide by turning the knurled

thumbscrews counter-clockwise to unscrew them

from the feedplate.

4. Rotate the triangular lock and remove the drive

rolls.

5. Remove the inner wire guide.

6. Insert the new inner wire guide, groove side out,

over the two locating pins in the feed plate.

7. Install a drive roll on each hub assembly secure

with the triangular lock.

8. Install the outer wire guide by aligning it with the

pins and tightening the knurled thumbscrews.

9. Close the idle arm and engage the idle roll pressure

arm. Adjust the pressure appropriately.

WARNING

POWERBrazer

B-1

FUMES AND GASES can be

dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to

remove fumes from breathing

zone.

BRAZING MATERIALS MAY CONTAIN CADMIUM. FUMES

ARE POISONOUS AN CAN KILL.

• Do not breathe fumes. Even brief exposure to high concen-

trations should be avoided.

• Use enough ventilation, exhuast at the arc, or both, to keep

fumes and gases from your breathing zone and general

area. If this cannot be done, use air supplied respirators.

----------------------------------------------------------------------------------------

• Do not wear gloves when threading or

changing wire spool.

• Keep hands, hair, clothing and tool away

from rotating equipment.

----------------------------------------------------------------------------------------

FLAME and BRAZING SPARKS

can cause fire or explosion.

• Keep flammable material

away.

------------------------------------------------------------------------------

OPERATION

WARNING

GENERAL DESCRIPTION

The POWERBrazer is a specially engineered wire

feeder for brazing materials. As part of a patent

pending process, the POWERBrazer brings

productivity and efficiency gains to brazing

customers. A simple press of a button on the gun

feeds brazing wire at a controlled speed.

The heart of the POWERBrazer is the 2 roll

MAXTRAC™ drive. The patented features on the

wire drive offer tool-less changing of the drive rolls

and wire guides for quick spool changes. A

tachometer controlled motor powers the patent

pending drive rolls for smooth, steady feeding

without slippage.

With only one printed circuit board, the

POWERBrazer is designed to be simple, reliable

and easy to service.

RECOMMENDED PROCESSES

AND EQUIPMENT

K1500-1 Gun Bushing Installed

RECOMMENDED PROCESSES

• Semi-Automatic Brazing

PROCESS LIMITATIONS

• The POWERBrazer is intended for brazing only.

It cannot be used for arc welding.

EQUIPMENT LIMITATIONS

• The maximum spool size is 45lbs.(20.4Kg.),

12”(305mm) diameter.

• Maximum gun length is 15 ft.(4.6m).

SAFETY PRECAUTIONS

READ AND UNDERSTAND ENTIRE SECTION

BEFORE OPERATING MACHINE

USER SERVICEABILITY

The serviceability of a product or structure utilizing the

POWERBrazer is and must be the sole responsibility

of the builder/user. Many variables beyond the control

of the Harris Products Group affect the results

obtained in using the POWERBrazer. These variables

include, but are not limited to, brazing procedure,

plate chemistry and temperature, joint design, fabrica-

tion methods and service requirements. The available

range of the POWERBrazer may not be suitable for all

applications, and the builder/user is and must be sole-

ly responsible for welding settings.

B-2

B-2 OPERATION

ITEM

DESCRIPTION

Wire Feed Speed Knob

5-pin gun trigger connector

Triggers on pins A and C

Power Switch

CASE FRONT CONTROLS

POWERBrazer

B-3 B-3

OPERATION

ITEM

DESCRIPTION

Pressure Adjustment Knob

Spool Retainer

Spindle Brake

Socket Head Cap Screw for Gun Bushing

Drive Hubs

Inlet Bushing

Cold Feed Pushbutton

PURPOSE

The pressure arm controls the amount of force the

drive rolls exert on the wire. Too much pressure

will distort the brazing wire. Too little pressure

allows the drive rolls to slip. Most brazing wires

feed best with the pressure arm set between 2

and 4.

Holds the spool in place. Remove by squeezing

the steel piece.

Used to set moderate friction to keep the spool

from unwinding.

Holds the gun in place.

Hold the drive hubs.

Guides the wire into the wire drive.

Used to jog the wire.

POWERBrazer

INTERNAL CONTROLS

B-4

B-4 OPERATION

POWERBrazer

REAR CONTROLS

ITEM

DESCRIPTION

Circuit Breaker

Power Cord

C-1

ACCESSORIES

PBKT-062

PBKT-094

PBGN-062

PBGN-094

1/16” gun, Drive Rolls and wire guides

3/32” gun, Drive Rolls and wire guides

1/16” gun

3/32” gun

KITS AVAILABLE

C-1

POWERBrazer

ELECTRIC SHOCK can kill.

• Only qualified personnel

should perform this installa-

tion.

• Only personnel that have read and under-

stood the POWERBrazer Operating Manual

should install and operate this equipment.

• The POWERBrazer must be plugged into a

receptacle which is grounded per any nation-

al, local or other applicable electrical codes.

• The POWERBrazer power switch is to be in

the OFF (“O”) position when connecting the

power cord to the input power.

--------------------------------------------------------------------

ROUTINE MAINTENANCE

• Check cords and the brazing gun for cuts and

damage.

• Clean and tighten all weld terminals.

PERIODIC MAINTENANCE

• Clean the drive rolls and inner wire guide and

replace if worn.

• Blow out or vacuum the inside of the feeder.

CALIBRATION SPECIFICATION

Wire Feed Speed Validation:

Calibration of the POWERBrazer may be required

when the printed circuit board, wire feed speed

potentiometer or motor is replaced or serviced.

Calibration matches the scale on the name plate to

the actual wire feed speed.

Tools required:

• RPM meter

• 7/16” open end wrench.

To verify if calibration is necessary:

1. Turn power OFF.

2. Set the wire feed speed to 100 in/min.

3. Remove the plastic cover from the lower portion

of the wire drive with a 7/16” wrench.

4. Turn power ON.

5. Measure the motor rpm when the COLD FEED

button is pressed.

6. Verify the rpm is within 16 – 19 rpm.

WARNING

SAFETY PRECAUTIONS

MAINTENANCE

To change the wire feed speed calibration:

(See Figure D.1)

Tools required:

• 5/16" nut driver

• RPM meter

• Shorting plug. The shorting plug shorts pins 4 and 8 of

connector J3 on the printed circuit board. J3 is an 8

pin molex connector.

1. Unplug the POWERBrazer.

2. Remove the (4) screws holding the rear cover inside

the feeder and remove the cover.

3. Open the idle arm.

4. Set the wire feed speed to 100 in/min.

5. Disconnect the fan connector from J3.

6. Plug in the POWERBrazer and turn power ON.

7. Insert the shorting plug into connector J3 on the print-

ed circuit board.

8. Remove the shorting plug.

9. Turn power OFF.

10. Reconnect the fan connector into J3.

11. Replace the cover and secure with the screws.

FIGURE D.1

D-1 D-1

POWERBrazer

TROUBLESHOOTING

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

This Troubleshooting Guide is provided to help you

locate and repair possible machine malfunctions.

Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMP-

TOMS)”. This column describes possible symptoms

that the machine may exhibit. Find the listing that

best describes the symptom that the machine is

exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists

the obvious external possibilities that may contribute

to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the

Possible Cause, generally it states to contact your

local Authorized Field Service Facility.

If you do not understand or are unable to perform the

Recommended Course of Action safely, contact your

local Authorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

Service and Repair should only be performed by Factory Trained Personnel. Unauthorized repairs

performed on this equipment may result in danger to the technician and machine operator and will

invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all

safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

WARNING

Observe all Safety Guidelines detailed throughout this manual

E-1 E-1

POWERBrazer

E-2 E-2

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

The feeder does not power up: no

cold feed.

Inconsistent wire feeding or wire not

feeding but drive rolls turning.

The wire feed speed is fast (maxi-

mum) and there is no change when

the wire feed speed knob is adjust-

ed.

The POWERBrazer stops feeding

after a few seconds. After a while, it

will begin to feed again when it has

been retriggered.

1. The PowerBrazer is unplugged.

2. The power switch is turned off.

3. The circuit breaker tripped.

4. The motor is not receiving power.

1. The gun cable is kinked and/or

twisted.

2. The wire is jammed in the gun and

cable.

3. The gun liner is dirty or worn.

4. The filler wire is corroded or dirty.

5. Improper gun liner, tip, drive rolls

and/or inner wire guide.

6. Incorrect tension arm pressure on

the drive rolls.

7. The spindle brake is too tight.

8. Worn drive roll.

1. The tachometer is connected

improperly.

2. The tachometer has failed.

1. The motor has gone into thermal

overload.

1. Plug in the PowerBrazer.

2. Turn on the power switch.

3. Check cords for damage. Verify

the brazing wire easily feeds

through the gun. Consult a trained

repair person if the circuit breaker

repeatedly trips.

4. Consult a trained repair person.

1. Keep the gun cable as straight as

possible. Avoid sharp corners or

bends in the cable.

2. Remove the gun from the wire

feeder and pull the jammed wire

out of the gun and cable.

3. Blow dirt out of the liner with low

pressure (40psi or less). Replace

the liner if worn.

4. Use only clean electrode. Use

quality electrode from the Harris

Products Group.

5. Verify the proper parts are

installed.

6. Most filler wires feed well with the

pressure arm set between “2” and

“4”.

7. Verify the spool of wire moves

with minimal effort.

8. Replace the drive rolls if worn or

filled with dirt.

1. Verify all of the tachometer leads

are properly connected.

2. Replace the motor and tachome-

ter assembly.

1. Verify that the filler wire can be

easily pulled through the gun

when the pressure arm is open.

Output Problems

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

POWERBrazer

WIRING DIAGRAM F-1

F-1

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on