Inverter Fusion FUSION 151 HF User manual

INSTRUCTION MANUAL
FUSION 151 HF Issue 02:Sept 2006
FUSION 151 PHF
FUSION 200 HF
FUSION 200 PHF
CAUTION: Ensure the operator of this equipment reads this information.
Additional copies can be obtained from your equipment supplier.
If you are not fully conversant with the principles of operation and safe working practices for
arc welding, we recommend that you read the HSE Booklet HSG204 (Health & Safety in Arc
Welding).
Do not attempt to install or operate this equipment until you have read and fully understood
the contents of this manual. If you do not fully understand any instruction, contact your
supplier for further information and advice before attempting any welding or installation
procedure.
Made in Britain
24pp A5 Instruction Manual.indd 1 28/9/06 3:33:09 pm

24pp A5 Instruction Manual.indd 2 28/9/06 3:33:09 pm

INDEX
Subject Page
EQUIPMENT INSTALLATION 1
DESCRIPTION OF CONTROLS 2
EQUIPMENT SPECIFICATIONS 3
MMA (Stick) WELDING FUNCTION & OPERATION 4
MMA (Stick) WELDING REMOTE CONTROL 4
HF TIG WELDING FUNCTION & OPERATION 5-6
LIFT TIG WELDING FUNCTION & OPERATION 7
TIG WELDING REMOTE CONTROL 7
TIG SPOT WELDING FUNCTION & OPERATION 8
REMOTE CONTROL CONNECTIONS 9
FUNCTION GUIDE 10-11
MMA (STICK) WELDING GUIDE 12
TIG WELDING GUIDE 13
INSULATION & PAT TESTING 14-15
WARRANTY INSTRUCTION 16-17
CARE & MAINTENANCE 18
TROUBLESHOOTING GUIDE 19
NOTICE:
Failure to adhere to the advice and instruction given in this manual or to the
implementation of the National/International Safety in the Workplace Regulations could
render the operator liable to danger that could be avoided. Inverter Fusion Limited
takes no responsibility for any accident that could occur from non-compliance of any
Safety Advice or the relevant Safety Standards.
24pp A5 Instruction Manual.indd 3 28/9/06 3:33:09 pm

INSTALLATION
Correct Installation can contribute materially to the satisfactory working of the welding inverter.
Each step in this section should be studied and adhered to as closely as possible.
A INSPECTION & PLACEMENT
1. Remove all packaging and inspect for any evidence of damage. Immediately notify the
supplier of any defects.
2. Check the unit for any loose parts. Ensure that air louvers are free from any packaging
material that could obstruct the airflow through the machine.
3. The components in the inverter operate at high temperatures and it is important that the fan
input and output louvers are not obstructed. Locate the unit in an open area allowing air to
circulate freely around the machine. The area around the machine should be relatively free
from dust and excessive heat.
4. Complete a risk assessment of the area to ensure that no danger to the Health & Safety of
the operator or any other person can be incurred during the equipment operation.
Consideration to noxious gases, fume, arc glare, fire risk and moisture should also be fully
considered.
B PRIMARY ELECTRICAL INPUT CONNECTION
WARNING
All possible measures should be taken to provide maximum protection against electrical shock.
Ensure the mains power is isolated before making any primary connections.
1. Ensure that an adequate mains power supply is available with a correct fuse rating, to
supply the machine at the duty cycle the operator requires to work within.
2. The machine is supplied with a two metre 3 core input power cable for connection to a
suitable single-phase power supply. The earth conductor in the power cable must at all times
be secured to ground earth.
3. Fit and use only plugs or circuit breakers that are designed for the level of primary input
voltage and input current required for the safe operation of the machine.
4. Extension cables may result in excessive voltage drops that will influence the welding output
of the machine. Use only industrial grade extension cables and ensure that the cable
conductor sizes are relevant to the required current draw.
C SECONDARY (WELDING OUTPUT) CONNECTIONS
WARNING
Before making any connections to the welding output terminals of the machine, ensure that the
mains power to the machine is switched off and the power cable is unplugged.
1. The machine is fitted with 35mm Dix style output connections; always use connection plugs of a
compatible size. Ensure that the connection plugs are free from damage and are fully locked
into the output terminals. Loose or damaged connections will cause the plugs to overheat
and will cause damage to the machine.
1
1
24pp A5 Instruction Manual.indd 4 28/9/06 3:33:09 pm

DESCRIPTION OF CONTROLS
FUSION HF & PHF FUSION HF & PHF
Front View Rear View
CONTROL FUNCTION
F1 Current Adjustment
F2 Output Display Mete
r
F3 LED Function Display
F4 Positive Output Dix Socket
F5 Negative Output Dix Socket
F6 Mains Power On/Off Switch
F7 Mode Selector TIG & MMA
F8 Program Selection Control
F9 Program LCD Menu Display
F10 Gas Output Connection
F11 Gas Input Connection
F12 Remote Control Socket 3 Wire **
F13 Remote Control Socket 5 Wire**
LED 1 Mains Power Indicato
r
LED 2 MMA Mode Indicato
r
LED 3 Lift TIG Indicato
r
LED 4 HF TIG Indicator
LED 5 Meter Hold Indicator
LED 6 Overheat Indicator
Torch Switch Plug Connection
Connect the torch switch leads to pins 1
& 2 in the remote connection plug
supplied.
Remote Current Plug Connection
Refer to the diagram on Page 14 for
connection instructions.
NOTE:
**The equipment is supplied as standard with a 5-wire remote control receptacle for torch
switching and current control. A 3-wire remote control option is available upon request. It is not
possible to fit both 3 & 5 wire options simultaneously.
Dead Man Safety Feature.
A dead man safety feature is installed in the HF & PHF units to reduce the danger from the torch
arcing accidentally on surfaces other than the welding fixture.
In the TIG Welding Mode, if the arc fails to establish after 3 seconds (Not including any pre-gas
time if selected) the unit is programmed to switch off. To re-start the arc release the torch switch
and recommence the welding start sequence.
If at any time during the TIG welding sequence of operation the arc is accidentally broken the
machine is programmed to switch off. If a down-slope time has been selected the machine will
remain inoperative until both the down slope, crater and post gas times as selected have
expired.
2
2
24pp A5 Instruction Manual.indd 5 28/9/06 3:33:10 pm

SPECIFICATION DETAIL
EQUIPMENT
P/No. 000633 Fusion 151 HF 110V- 150 Amp MMA/LT/HF TIG Inverter.
P/No. 000634 Fusion 151 PHF 110V - 150 Amp MMA/LT/PHF TIG Inverter.
P/No. 000485 Fusion 200 HF 230V - 200 Amp MMA/LT/HF TIG Inverter.
P/No. 000200 Fusion 200 PHF 230V - 200 Amp MMA/LT/PHF TIG Inverter.
OPTIONAL ACCESSORIES
P/No. 000537 150 Amp GP17 Air Cooled TIG Welding Torch, Fitted with 4 Metre Hose
Assembly, Plugs & Handle Mounted On/Off Switch. P/No. 000561 150 Amp
GP17R Air Cooled TIG Welding Torch, Fitted with 4 Metre Hose
Assembly, Plugs & Handle Mounted On/Off Switch & Thumb Wheel for
Remote Current Control. P/No. 000111 GP17 Torch Accessory Kit.
Including Long Back Cap, Collet Bodies,
Collets and Tungsten Electrodes. P/No. 000320 Footswitch for Remote
Current Control & On/ff Switching, Fitted with 3 Metre
Cable & Plug. P/No. 000313 Argon Gas Supply Hose, 3 Metre Fitted with 1/4-
3/8" BSP Fittings. P/No. 000080 Electrode Holder, Fitted With 3 Metre Power Cable & 35mm
Male Dix Plug. P/No. 000079 Earth Clamp, Fitted With 3 Metre Power Cable & 35mm Male
Dix Plug.
SPECIFICATIONS Fusion
151 HF
Fusion
151 PHF
Fusion
200 HF
Fusion
200 PHF
Input Volts 50/60Hz +/-15% 110V AC 110V AC 230V AC 230V AC
Typical Input Fuse Rating 32A Slow
Blow
32A Slow
Blow
22A Slow
Blow
22A Slow
Blow
Power Transformer Rating 5KVA 5KVA - -
Power Generator Rating 7KVA 7KVA 7KVA 7KVA
MMA Power Output Amps 20-120 20-120 20-180 20-180
TIG Power Output Amps 10-150 10-150 5-200 5-200
100% Duty Cycle MMA Amps 120 120 160 160
100% Duty Cycle TIG Amps 150 150 180 180
Max Open Circuit Voltage 92 Volts 92 Volts 92 Volts 92 Volts
Power Factor @ 100% 0.71 0.71 0.71 0.71
Efficiency® 100% 0.96 0.96 0.96 0.96
Enclosure Class IP 23 IP 23 IP 23 IP 23
Application Class S S S S
Ambient Temperature -10 <>+40 Degrees C
Cooling Method Forced Fan
Standard IEC 60974 CE Marked
Warranty 24 Months Full Parts & Labour
Wei
g
ht 9 K
g
9 K
g
9 K
g
9 K
g
Dimensions L 365mm x H 360mm x W 220mm
3
3
24pp A5 Instruction Manual.indd 6 28/9/06 3:33:10 pm

MMA (Stick) WELDING FUNCTION & OPERATION
1. GENERAL
The Fusion range of digital welding inverters is designed to operate at optimum
performance when supplied with a suitable mains input supply, as specified.
2. MAINS POWER CONNECTION
On applying power to the unit, the inverter will perform a self-setting check. This will
be indicated by all displays briefly flashing on then off. Following this, LED 1 will stay
lit to indicate that mains power is present and the unit is ready for operation.
3. MMA (STICK) WELDING SET UP (Panel Control)
(1) Connect the electrode & work return supply cables into the Dix sockets (F4 & F5)
Check the consumable manufacturers specification for the correct polarity required.
(2) Set the mains power switch (F6) to the on position. The welding output meter (F2) will
light up as will the LCD display (F9). The selected welding mode LED (MMA/TIG) will
also be lit in the LED display (F3).
(3) Ensure that at no time the electrode holder and work return clamp come into contact
as this could cause the machine to arc and could result in personal injury.
(4) Rotate the mode selection knob (F7) in either direction until LED 2 is illuminated and
'MMA MODE' is displayed in the menu display window (F9).
(5) Select the output current required by rotating the control knob (F1). The selected
output will be displayed in the digital output meter (F2).
(6) Using a swift motion, Rotate control knob (F8) clockwise until the text 'REMOTE
CURRENT is displayed in the window (F9). Rotate control knob (F1) in an anti
clockwise direction until the text in window (F9) reads 'PANEL CONTROL'.
(7) Using the correct safety equipment to protect the body and eyes fit an electrode in the
holder and connect the work return cable to the work piece. Strike the electrode on the
work piece to establish the welding arc. To end the welding application, quickly lift the
electrode away from the work piece.
(8) At the end of the weld, LED 5 will be illuminated, indicating that the welding output
meter hold feature is activated. (The hold feature displays the last welding current
used) This will re-set on welding re-start or if the output current is adjusted.
(9) When the welding application is completed, place the mains switch (F6) in the off
position and disconnect the unit from the mains power supply.
4. MMA (STICK) WELDING SET UP (Remote Current Control)
(1) Connect the remote current control device into the receptacle (F12/F13). Follow the
MMA set up procedure as described in paragraph 3 (1 to 5).
(2) Rotate control knob (F8) until the text 'REMOTE CURRENT' is displayed in the
window (F9). Rotate control knob (F1) in a clockwise direction so that the text in
window (F9) reads either 'FOOT CONTROL' or TORCH CONTROL' as required for
the type of remote control device to be used.
(3) The welding current is now adjustable with the remote control device between the
machines minimum output and the main welding current output as selected on the
digital meter (F2). Complete the welding process as detailed in paragraph 3 (7 to 9).
4
24pp A5 Instruction Manual.indd 7 28/9/06 3:33:11 pm

TIG WELDING FUNCTION & OPERATION
5. HF TIG WELDING SET UP (Panel Control)
(1) Connect the work return cable into the positive Dix socket (F4). Connect the TIG welding
torch (use a torch TIG adapter if required) into the negative Dix socket (F5). Attach the
torch gas supply hose to the shielding gas outlet (F10). Screw the torch switching control
plug into the remote control socket (F13). Fit the shielding gas supply hose to the gas
inlet connection (F11). Adjust the shielding gas inlet pressure and flow as required.
(2) Set the mains power switch (F6) to the on position. The welding output meter (F2) will
light up as will the LCD display (F9). The welding mode as selected will also be shown on
the LED display (F3) and in the LCD menu display (F9).
(3) Rotate the mode selection knob (F7) in either direction until LED 3 is illuminated and 'TIG
MODE' is showing in the menu display window (F9). At this point LED 4 may also be
illuminated indicating that the HF start function is selected.
(4) Select the main welding output current required by rotating the control knob (F1). The
selected output will be displayed on the digital output meter (F2).
(5) The menu selection control knob (F8) is used to move through the welding function menu.
Using a swift motion rotate the menu selection control knob (F8) clockwise approximately
90 Degrees. The text in the display window (F9) will change and display the next function
in the menu. By repeating this operation the complete menu sequence can be stepped
through and welding parameter adjustments can be made as required using the control
knob (F1). The selected menu function will be displayed for twenty seconds, after which
the display widow (F9) will return to a datum point and display TIG MODE'. At any time
during the menu set up, the display can be signalled to return to the datum point by
pressing and releasing the torch on/off switch. The selection control knob can be rotated
in either direction to move both forward and backward through the welding sequence
program.
(6) The menu display function and operations as described in the following instructions
(7),(8),(10),(11),(12),(13,(15) & (16) are only available on the Fusion PHF models.
(7) Rotate the control knob (F8) clockwise until the text 'PRE GAS TIME' is displayed in
window (F9). Rotate control knob (F1) to select the required pre-gas time.
(8) Rotate the control knob (F8) clockwise until the text 'START CURRENT is displayed in
window (F9). Rotate control knob (F1) to select the required start current amps.
(9) Rotate the control knob (F8) clockwise until the text 'HF START is displayed in window
(F9). Rotate control knob (F1) to switch the HF start on. When the HF start is switched on
the LED 4 will be illuminated. When the HF start is switched off the machine will operate
in the Lift TIG mode. The Lift TIG welding mode and operation is explained in section (5)
page (7).
(10) Rotate the control knob (F8) clockwise until the text 'UP SLOPE TIME' is displayed in
window (F9). Rotate control knob (F1) to select the required up slope time.
(11) Rotate the control knob (F8) clockwise until the text 'PULSE CURRENT is displayed in
window (F9). Rotate control knob (F1) to select the required pulse base (background)
current amps required. Rotate the control knob (F8) anticlockwise to switch the pulse
mode off. If the pulse current is adjusted to display off, the pulse timers described in the
following section will be disenabled.
(12) Rotate the control knob (F8) clockwise until the text 'BASE TIME' is displayed in window
(F9). Rotate control knob (F1) to select the required base pulse time.
5
5
24pp A5 Instruction Manual.indd 8 28/9/06 3:33:11 pm

TIG WELDING FUNCTION & OPERATION
(13) Rotate the control knob (F8) clockwise until the text 'PULSE TIME' is displayed in window (F9).
Rotate control knob (F1) to select the required high pulse time.
(14) Rotate the control knob (F8) clockwise until the text 'DOWN SLOPE TIME' is displayed in window
(F9). Rotate control knob (F1) to select the required slope down time.
(15) Rotate the control knob (F8) clockwise until the text 'CRATER CURRENT is displayed in
window (F9). Rotate control knob (F1) to select the required crater amps level.
(16) Rotate the control knob (F8) clockwise until the text 'CRATER TIME' is displayed in window
(F9). Rotate control knob (F1) to select the required crater current time.
(17) Rotate the control knob (F8) clockwise until the text 'POST GAS' is displayed in window (F9).
Rotate control knob (F1) to select the required post gas time.
(18) Rotate the control knob (F8) clockwise until the text 'TIG SWITCH' is displayed in window (F9).
Rotate control knob (F1) to select either 2T or 4T touch operation. In 2T operation the weld
sequence will start and stop as selected when the torch switch is depressed and released. In 4T
operation when the torch switch is depressed the arc will strike in and hold at the start current
level, when the switch is released the arc will upslope to the main welding current level. When
the switch is again depressed the arc will down-slope and hold at the crater current level, when the
switch is released the arc will switch off. If the torch switch is released during the down slope time
the weld will switch of at that point.
(19) Rotate control knob (F8) clockwise until the text 'REMOTE CURRENT' is displayed in the window
(F9). Rotate control knob (F1) in an anticlockwise direction so that the text in window (F9)
reads 'PANEL CONTROL'
(20) It is not necessary to adjust the welding sequence menu parameters in the order as described.
Any parameter can be individually adjusted by rotating the control knob (F8) in either direction until
the required area of the program is displayed in the window (F9) and the adjustment made as
required using control knob (F1)
(21) When all required parameters have been set in the sequence menu program, the unit will store
the data until any further adjustment is made. The data will also be stored ready for future use
even when the mains power is switched off.
(22) Using the correct safety equipment to protect both the body and the eyes, hold the torch at an
angle of 45 degrees so that the tungsten electrode is approximately 2-3 mm away from the work
piece. Depress the torch switch, the gas will start to flow and a HF spark will jump from the
tungsten to initiate the welding arc.
(23) Once the welding arc is established the unit will operate as programmed. At any time in the 2T
switch mode the welding arc can be stopped by releasing the torch switch. In the 4T switch mode
the arc is stopped by pressing and releasing the torch switch.
(24) Complete the welding application as required making output and control parameter adjustments
as necessary.
(25) If at any time the welding arc is broken prior to signalling the machine to switch off, the dead man
device installed in the machine will be activated and it will not be possible to re-strike the arc until
the post flow gas time has completed.
(26) When the welding application is completed, turn the power switch (F6) to the off position and
disconnect the unit from the mains power supply.
6
6
24pp A5 Instruction Manual.indd 9 28/9/06 3:33:11 pm

TIG WELDING FUNCTION & OPERATION
5. LIFT TIG WELDING SET UP (Panel Control)
(1) To use the machine for LIFT TIG applications follow the instruction as described and
detailed for' HF TIG Welding Set Up' in paragraphs (1) through to (8)
(2) Rotate the control knob (F8) clockwise until the text 'HF START is displayed in window
(F9). Rotate control knob (F1) anticlockwise to switch the HF start off. When the HF start is
switched off the LED 4 will not be illuminated. The machine will now operate in a Lift TIG
mode and no HF will be present at the start of the welding sequence.
(3) Continue to complete the program sequence set up as described for 'HF TIG Welding Set
Up' In section 4 paragraphs (10) through to (21)
(4) Using the correct safety equipment to protect the body and the eyes, rest the torch gas
shroud on the work piece at an angle of 45 degrees to the work piece. Depress the torch
switch, this will start the shielding gas to flow, still resting the torch gas shield on the work
piece, rotate the torch forward until the tungsten electrode touches the work piece, then lift
gently away approximately 4mm. This will cause the arc to establish and the welding
application can be commenced. The method of starting the arc in the Lift TIG mode
requires that the electrode is made to momentary make contact with the work piece,
practice will provide the individual operator with the best method of completing this task.
(5) Complete the welding application and set up procedure as detailed in 'HF TIG Welding Set
Up' in paragraphs (23) through to (26).
6. TIG WELDING SET UP (Remote Current Control)
(1) Connect the remote current control device to be used into the receptacle (F12/F13) and
complete the set up and operational instructions as detailed for HF TIG Welding Set-Up in
paragraphs (1) through to (18).
(2) Rotate control knob (F8) clockwise until the text 'REMOTE CURRENT' is displayed in the
window (F9). Rotate control knob (F1) in either direction so that the text in window (F9)
reads 'FOOT CONTROL' or TORCH CONTROL'
(3) Complete the welding application and set up procedure as detailed in 'HF TIG Welding Set
Up' in paragraphs (20) through to (26).
(4) If 'FOOT CONTROL' is selected the machine will switch on and off when the foot switch is
depressed and released. The welding output current will increase and decrease as the
footswitch regulation is varied. Full depression of the footswitch will allow up to 99% of the
welding current value as selected on the (F2) display meter. If the 'FOOT CONTROL'
option is selected then Start Current, Up-Slope Time, Down-Slope Time and Crater Current
settings in the LCD window menu are disabled. The operator will have full control of all the
functions via the remote control foot pedal device.
(5) If TORCH CONTROL' is selected this will allow the main welding output current to be
controlled from a remote current adjustment control device. The welding output current will
increase and decrease as the remote regulation is varied and will allow variation of the
welding output current value as selected on the (F2) display meter. The machine welding
sequence will be switched On & Off as detailed in HF TIG Welding Set Up paragraph (18).
When a remote current device is adjusted, the output current as selected will be displayed
in the (F2) meter. All other available LCD menu options will be fully functional.
7
7
24pp A5 Instruction Manual.indd 10 28/9/06 3:33:12 pm