Lincoln electric Cwt gfm k3696-1 User manual

IM10501-A | Issue D ate Feb-22

For use with machines having Numbers:

K3696-1, K3697-1,

A0A0161, A0A0162

THANK YOU FOR SELECTING

A QUALITY PRODUCT BY

LINCOLN ELECTRIC.

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.

SAFETY DEPENDS ON YOU

Lincoln arc welding and cutting equipment is designed and built

with safety in mind. However, your overall safety can be increased

by proper installation ... and thoughtful operation 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.

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.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc.

Use corrective lenses if necessary

to stay a reasonable distance

away from the arc.

READ and obey the Safety Data

Sheet (SDS) and the warning label

that appears on all containers of

welding materials.

USE ENOUGH VENTILATION or

exhaust at the arc, or both, to

keep the fumes and gases from

your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be

adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away

from your face.

If you develop unusual symptoms, see your supervisor.

Perhaps the welding atmosphere and ventilation system

should be checked.

WEAR CORRECT EYE, EAR &

BODY PROTECTION

PROTECT your eyes and face with welding helmet

properly fitted and with proper grade of filter plate

(See ANSI Z49.1).

PROTECT your body from welding spatter and arc

flash with protective clothing including woolen

clothing, flame-proof apron and gloves, leather

leggings, and high boots.

PROTECT others from splatter, flash, and glare

with protective screens or barriers.

IN SOME AREAS, protection from noise may be appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

AT ALL TIMES.

SPECIAL SITUATIONS

DO NOT WELD OR CUT containers or materials which previously

had been in contact with hazardous substances unless they are

properly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special

precautions with ventilation have been taken. They can release

highly toxic fumes or gases.

Additional precautionary measures

PROTECT compressed gas cylinders from excessive heat,

mechanical shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an

electrical circuit.

REMOVE all potential fire hazards from welding area.

ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR

IMMEDIATE USE AND KNOW HOW TO USE IT.

WARNING

CAUTION

Safety 01 of 04 - 5/16/2018

SECTION A:

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

WARNING: Breathing diesel engine exhaust

exposes you to chemicals known to the State

of California to cause cancer and birth defects,

or other reproductive harm.

• Always start and operate the engine in a

well-ventilated area.

•If in an exposed area, vent the exhaust to the outside.

•Do not modify or tamper with the exhaust system.

•Do not idle the engine except as necessary.

For more information go to

www.P65 warnings.ca.gov/diesel

WARNING: This product, when used for welding or

cutting, produces fumes or gases which contain

chemicals known to the State of California to cause

birth defects and, in some cases, cancer. (California

Health & Safety Code § 25249.5 et seq.)

WARNING: Cancer and Reproductive Harm

www.P65warnings.ca.gov

ARC WELDING CAN BE HAZARDOUS. PROTECT

YOURSELF AND OTHERS FROM POSSIBLE SERIOUS

INJURY OR DEATH. KEEP CHILDREN AWAY.

PACEMAKER WEARERS SHOULD CONSULT WITH

THEIR DOCTOR BEFORE OPERATING.

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.

BE SURE THAT ALL INSTALLATION, OPERATION,

MAINTENANCE AND REPAIR PROCEDURES ARE

PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE POWERED

EQUIPMENT.

1.a. Turn the engine off before troubleshooting

and maintenance work unless the

maintenance work requires it to be running.

1.b. Operate engines in open, well-ventilated areas or vent the engine

exhaust fumes outdoors.

1.c. Do not add the fuel near an open flame welding

arc or when the engine is running. Stop the

engine and allow it to cool before refueling to

prevent spilled fuel from vaporizing on contact

with hot engine parts and igniting. Do not spill fuel when filling

tank. If fuel is spilled, wipe it up and do not start engine until

fumes have been eliminated.

1.d. Keep all equipment safety guards, covers

and devices in position and in good repair.

Keep hands, hair, clothing and tools away

from V-belts, gears, fans and all other

moving parts when starting, operating or

repairing equipment.

1.e. In some cases it may be necessary to remove safety guards to

perform required maintenance. Remove guards only when

necessary and replace them when the maintenance requiring

their removal is complete. Always use the greatest care when

working near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt to

override the governor or idler by pushing on the throttle control

rods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turning

the engine or welding generator during maintenance work,

disconnect the spark plug wires, distributor cap or magneto wire

as appropriate.

1.h. To avoid scalding, do not remove the radiator

pressure cap when the engine is hot.

ELECTRIC AND

MAGNETIC FIELDS MAY

BE DANGEROUS

2.a. Electric current flowing through any conductor

causes localized Electric and Magnetic Fields (EMF).

Welding current creates EMF fields around welding cables

and welding machines

2.b. EMF fields may interfere with some pacemakers, and

welders having a pacemaker should consult their physician

before welding.

2.c. Exposure to EMF fields in welding may have other health effects

which are now not known.

2.d. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure

them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work

cables. If the electrode cable is on your right side, the

work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as pos-

sible to the area being welded.

2.d.5. Do not work next to welding power source.

SAFETY

Safety 02 of 04 - 5/16/2018

ELECTRIC SHOCK

CAN KILL.

3.a. The electrode and work (or ground) circuits are

electrically “hot” when the welder is on. Do

not touch these “hot” parts with your bare skin or wet clothing.

Wear dry, hole-free gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.

Make certain the insulation is large enough to cover your full area

of physical contact with work and ground.

In addition to the normal safety precautions, if

welding must be performed under electrically

hazardous conditions (in damp locations or while

wearing wet clothing; on metal structures such as

floors, gratings or scaffolds; when in cramped

positions such as sitting, kneeling or lying, if there

is a high risk of unavoidable or accidental contact

with the workpiece or ground) use the following

equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,

electrode reel, welding head, nozzle or semiautomatic welding

gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical

connection with the metal being welded. The connection should

be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth)

ground.

3.f. Maintain the electrode holder, work clamp, welding cable and

welding machine in good, safe operating condition. Replace

damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode

holders connected to two welders because voltage

between the

two can be the total of the open circuit voltage of both

welders.

3.i. When working above floor level, use a safety belt to protect

yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS CAN BURN.

4.a. Use a shield with the proper filter and cover plates to protect your

eyes from sparks and the rays of the arc when welding or

observing open arc welding. 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 arc rays.

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

screening and/or warn them not to watch the arc nor expose

themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES

CAN BE DANGEROUS.

5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing these

fumes and gases. When welding, keep your head out of the fume.

Use enough ventilation and/or exhaust at the arc to keep fumes

and gases away from the breathing zone. When welding

hardfacing (see instructions on container or SDS)

or on lead or cadmium plated steel and other

metals or coatings which produce highly toxic

fumes, keep exposure as low as possible and

within applicable OSHA PEL and ACGIH TLV limits

using local exhaust or mechanical ventilation

unless exposure assessments indicate otherwise.

In confined spaces or in some circumstances,

outdoors, a respirator may also be required.

Additional precautions are also required when

welding

on galvanized steel.

5. b. The operation of welding fume control equipment is affected by

various factors including proper use and positioning of the

equipment, maintenance of the equipment and the specific

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.c. Do not weld in locations near chlorinated hydrocarbon vapors

coming from degreasing, cleaning or spraying operations. The

heat and rays of the arc can react with solvent vapors to form

phosgene, a highly toxic gas, and other irritating products.

5.d. Shielding gases used for arc welding can displace air and

cause

injury or death. Always use enough ventilation, especially in

confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the

Safety Data Sheet (SDS) and follow your employer’s safety

practices. SDS forms are available from your welding

distributor or from the manufacturer.

5.f. Also see item 1.b.

SAFETY

Safety 03 of 04 - 5/16/2018

WELDING AND CUTTING

SPARKS CAN CAUSE

FIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. If

this is not possible, cover them to prevent the welding sparks

from starting a fire. Remember that welding sparks and hot

materials from welding can easily go through small cracks and

openings to adjacent areas. Avoid welding 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. When not welding, make certain no part of the electrode circuit is

touching the work or ground. Accidental contact can cause

overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the

proper steps have been taken to insure that such procedures

will not cause flammable or toxic vapors from substances 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.e. Vent hollow castings or containers before heating, cutting or

welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free

protective garments such as leather gloves, heavy shirt, cuffless

trousers, high shoes and a cap over your hair. Wear ear plugs

when welding out of position or in confined places. Always wear

safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area

as practical. Work cables connected to the building framework or

other locations away from the welding area increase the

possibility of the welding current passing through lifting chains,

crane cables or other alternate circuits. This can create fire

hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

6.I. 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.

6.j. Do not use a welding power source for pipe thawing.

CYLINDER MAY EXPLODE IF

DAMAGED.

7.a. Use only compressed gas cylinders containing

the correct shielding gas for the process used

and properly operating regulators designed for

the gas and pressure used. All hoses, fittings,

etc. should be suitable for the application and

maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to

an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected

to physical damage.

• A safe distance from arc welding or cutting operations

and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other

electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet

when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight

except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders,

associated equipment, and CGA publication P-l, “Precautions for

Safe Handling of Compressed Gases in Cylinders,” available from

the Compressed Gas Association, 14501 George Carter Way

Chantilly, VA 20151.

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 manufacturer’s recommendations.

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

Electrical Code and the manufacturer’s recommendations.

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

SAFETY

Safety 04 of 04 - 5/16/2018

ELECTROMAGNETIC

COMPATIBILITY (EMC)

CONFORMANCE

Products displ ying the CE m rk re in conformity with Europe n

Community Council Directive. It w s m nuf ctured in conformity

with n tion l st nd rd th t implements h rmonized st nd rd: EN

60974-10 Electrom gnetic Comp tibility (EMC) Product St nd rd for

Arc Welding Equipment. It is for use with other Lincoln Electric

equipment. It is designed for industri l nd profession l use.

INTRODUCTION

All electric l equipment gener tes sm ll mounts of electrom gnetic

emission. Electric l emission m y be tr nsmitted through power

lines or r di ted through sp ce, simil r to r dio tr nsmitter. When

emissions re received by other equipment, electric l interference

m y result. Electric l emissions m y ffect m ny kinds of electric l

equipment; other ne rby welding equipment, r dio nd TV reception,

numeric l controlled m chines, telephone systems, computers, etc.

WARNING: This Cl ss A equipment is not intended for use in

residenti l loc tions where the electric l power is provided by the

public low-volt ge supply system. There m y be potenti l difficulties

in ensuring electro-m gnetic comp tibility in those loc tions, due to

conducted s well s r di ted disturb nces.

INSTALLATION AND USE

The user is responsible for inst lling nd using the welding

equipment ccording to the m nuf cturer’s instructions.

If electrom gnetic disturb nces re detected then it sh ll be the

responsibility of the user of the welding equipment to resolve the

situ tion with the technic l ssist nce of the m nuf cturer. In some

c ses this remedi l ction m y be s simple s e rthing (grounding)

the welding circuit, see Note. In other c ses it could involve

constructing n electrom gnetic screen enclosing the power source

nd the work complete with ssoci ted input filters. In ll c ses

electrom gnetic disturb nces must be reduced to the point where

they re no longer troublesome.

NOTE: The welding circuit m y or m y not be e rthed for s fety

re sons. Follow your loc l nd n tion l st nd rds for inst ll tion nd

use. Ch nging the e rthing rr ngements should only be uthorized

by person who is competent to ssess whether the ch nges will

incre se the risk of injury, e.g., by llowing p r llel welding current

return p ths which m y d m ge the e rth circuits of other

equipment.

ASSESSMENT OF AREA

Before inst lling welding equipment the user sh ll m ke n

ssessment of potenti l electrom gnetic problems in the

surrounding re . The following sh ll be t ken into ccount:

) other supply c bles, control c bles, sign ling nd telephone

c bles; bove, below nd dj cent to the welding equipment;

b) r dio nd television tr nsmitters nd receivers;

c) computer nd other control equipment;

d) s fety critic l equipment, e.g., gu rding of industri l equipment;

e) the he lth of the people round, e.g., the use of p cem kers

nd he ring ids;

f) equipment used for c libr tion or me surement;

g) the immunity of other equipment in the environment. The user

sh ll ensure th t other equipment being used in the

environment is comp tible. This m y require ddition l

protection me sures;

h) the time of d y th t welding or other ctivities re to be

c rried out.

The size of the surrounding re to be considered will depend on

the structure of the building nd other ctivities th t re t king

pl ce. The surrounding re m y extend beyond the bound ries

of the premises.

METHODS OF REDUCING EMISSIONS

Public Supply System

Welding equipment should be connected to the public supply system

ccording to the m nuf cturer’s recommend tions. If interference

occurs, it m y be necess ry to t ke ddition l prec utions such s

filtering of the system. Consider tion should be given to shielding

the supply c ble of perm nently inst lled welding equipment, in

met llic conduit or equiv lent. Shielding should be electric lly

continuous throughout its length. The shielding should be

connected to the welding power source so th t good electric l

cont ct is m int ined between the conduit nd the welding power

source enclosure.

Maintenance of the Welding Equipment

The welding equipment should be routinely m int ined ccording to

the m nuf cturer’s recommend tions. All ccess nd service doors

nd covers should be closed nd properly f stened when the

welding equipment is in oper tion. The welding equipment should

not be modified in ny w y except for those ch nges nd

djustments covered in the m nuf cturer’s instructions. In

p rticul r, the sp rk g ps of rc striking nd st bilizing devices

should be djusted nd m int ined ccording to the m nuf cturer’s

recommend tions.

Welding Cables

The welding c bles should be kept s short s possible nd should

be positioned close together, running t or close to the floor level.

Equipotential Bonding

Bonding of ll met llic components in the welding inst ll tion nd

dj cent to it should be considered. However, met llic components

bonded to the work piece will incre se the risk th t the oper tor

could receive shock by touching these met llic components nd

the electrode t the s me time. The oper tor should be insul ted

from ll such bonded met llic components.

Earthing of the Workpiece

Where the workpiece is not bonded to e rth for electric l s fety, nor

connected to e rth bec use of its size nd position, e.g., ship’s hull

or building steelwork, connection bonding the workpiece to e rth

m y reduce emissions in some, but not ll inst nces. C re should be

t ken to prevent the e rthing of the workpiece incre sing the risk of

injury to users, or d m ge to other electric l equipment. Where

necess ry, the connection of the workpiece to e rth should be m de

by direct connection to the workpiece, but in some countries

where direct connection is not permitted, the bonding should be

chieved by suit ble c p cit nce, selected ccording to n tion l

regul tions.

Screening and Shielding

Selective screening nd shielding of other c bles nd equipment in

the surrounding re m y llevi te problems of interference.

Screening of the entire welding inst ll tion m y be considered for

speci l pplic tions. 1

1 Portions of the receding text are contained in EN 60974-10

“Electromagnetic Com atibility (EMC) roduct standard for arc welding

equi ment.”

L10093 D

Table of Contents

1.0 OVERVIEW..................................................................................................................... 1

1.1 DESCRIPTION .............................................................................................................................................1

1.2 BENEFITS ....................................................................................................................................................1

1.3 FEATURES...................................................................................................................................................1

1.4 MECHANICAL SPECIFICATIONS .............................................................................................................1

1.5 SENSOR SPECIFICATIONS ......................................................................................................................2

1.6 MODELS .......................................................................................................................................................2

1.7 OPTIONAL ACCESSORIES .......................................................................................................................2

2.0 INSTALLATION.............................................................................................................. 3

2.1 OPTIONS......................................................................................................................................................3

2.2 GAS LINE HOOKUP ....................................................................................................................................3

2.3 OPTIONAL GAS LINE FILTERS.................................................................................................................3

2.4 CABLE HOOKUP .........................................................................................................................................4

2.5 GAS FLOW LIMITS......................................................................................................................................5

2.6 GAS FLOW VOLUME..................................................................................................................................5

3.0 OPERATION................................................................................................................... 6

3.1 FIRMWARE VERSION ................................................................................................................................6

3.2 PROGRAM LIMITS ......................................................................................................................................6

3.3 PARAMETERS.............................................................................................................................................7

4.0 SETTING GAS FLOW CONTROL LIMITS ................................................................. 10

4.1 DESCRIPTION .......................................................................................................................................... 10

4.2 SETUP ....................................................................................................................................................... 10

5.0 GAS FLOW SURGE “PEAK” MEASUREMENT ....................................................... 11

5.1 DESCRIPTION .......................................................................................................................................... 11

5.2 SETUP ....................................................................................................................................................... 11

6.0 GAS FLOW USAGE LOG ........................................................................................... 12

6.1 DESCRIPTION .......................................................................................................................................... 12

6.2 SETUP ....................................................................................................................................................... 12

6.3 RESET LOG MODE CLOCK.................................................................................................................... 12

6.4 RESET LOG MODE VOLUME................................................................................................................. 13

7.0 GFM CONNECTOR PIN ASSIGNMENT .................................................................... 14

7.1 AUX CONNECTOR................................................................................................................................... 14

8.0 POWER OPTIONS AND BATTERY SPECIFICATION/CHANGING ........................ 15

8.1 POWER OPTIONS ................................................................................................................................... 15

8.2 BATTERY SPECIFICATIONS.................................................................................................................. 16

8.3 CHANGING THE BATTERY .................................................................................................................... 17

9.0 MODEL SPECIFICATIONS ......................................................................................... 18

9.1 120/240 VAC PORTABLE GFM SYSTEM P/N: A0A0161 ..................................................................... 18

9.2 120/240 VAC IN-LINE GFM SYSTEM P/N: A0A0162 ............................................................................ 19

10.0 GFM ENCLOSURE SPECIFICATIONS P/N: A3A0277 ............................................ 20

10.1 GFM ENCLOSURE PARTS LIST ............................................................................................................ 20

10.2 GFM MOUNTING DIMENSIONS............................................................................................................. 21

11.0 CABLE SPECIFCATIONS .......................................................................................... 23

11.1 GFM AUX CABLE P/N: A3W0418 ........................................................................................................... 23

12.0 MODBUS SCPECIFICATIONS................................................................................... 24

12.1 GFM MODBUS REGISTER DATA .......................................................................................................... 24

12.2 MODBUS COILS CR [1..16] ..................................................................................................................... 24

12.3 MODBUS REGISTER REG [1..10] .......................................................................................................... 25

12.4 MODBUS SERIAL PORT CONNECTIONS............................................................................................ 25

1.0 OVERVIEW

1.1 Description

The Gas Flow Monitor (GFM) is designed to precisely measure the flow rates of

welding shielding gases. WARNING – DO NOT USE WITH ANY FLAMMABLE

GASES. The unit comes in both "portable" and "in-line" models and is software

configurable for English or Metric units of measure. The portable version can be

used to check the gas flow rates directly at the welding torch. The unit is battery

powered (and rechargeable) which allows it to be carried throughout the shop. This

version is ideal for use by maintenance personnel to correctly set and verify shielding

gas flow rates at the welding torch. The GFM has 6 selectable gas settings,

ARGON, Argon/ CO2(90/10), Argon/ CO2(80/20), Argon/ CO2(75/25), Helium,

and CO2. The GFM can be custom ordered and configured for additional gas

mixtures.

1.2 Benefits

The "in-line" version is designed to be permanently installed in a welding fixture to

continuously monitor the gas flow rate. When used in this manner the GFMcan

provide "sure-flow" gas testing by setting upper and lower control limits for the user

defined gas flow rates. An internal fault relay can be used to warn or interrupt the

welding process if an out-of-limits condition is detected.

1.3 Features

Some of the features contained in the unit are the capability to limit test, provide an

accumulated gas usage and peak flow rates as well as displaying on-going gas flow

rates. The unit also provides an analog output voltage representing measured gas

flow rates. The GFM also has a Modbus® RS-485 serial port. The sensor can

communicate with third party controllers via the Modbus® protocol. The sensor

defines 16 coils and 10 Registers for use with the Modbus® serial port. See the serial

communications section for further descriptions of the feature. The GFM uses an

OLED graphic display panel to display the gas flow rates, to provide programming

menus and user defined optional parameter display.

1.4 Mechanical Specifications

Dimensions

2-13/16"W x 3-1/2"H x 2-13/16”L (71.4 mm W x 88.9 mm H x 71.4 mm L)

Weight

19 oz. (539 gm)

Pipe Fittings

3/8" NPT with 3/8" hose barb fittings recommended max torque 15 in. lbs.

1.5 Sensor Specifications

Measurement Range

5 - 255 CFH (2 - 120 LPM)

Display Resolution

±1 CFH (± 1 LPM)

Accuracy

±3 % of full-scale ±1 digit

Operating Pressure

50-PSI maximum (344 KPA)

Fault Relay Output

Opto-Isolated Solid State Relay (N.O. Contacts)

Relay Rating

48 vac @ 0.5 amps non-inductive

48 vdc @ 1.0 amps non-inductive

Analog Sensor Output

0 - 2.55 vdc @ 10 ma.

Analog Scaling

0.01 vdc = 1 CFH (0.01 V = 1 LPM)

Power Requirement

12 - 28 vdc @ 100 ma.

Operating Temperature

14° to 140° F (-10° to 60° C)

Battery Charger

120 vac 60 hz @ 300 ma (220 VAC 50 hz @ 300 ma)

Battery Life

Approximately 24 hours with full charge

(User configurable English / Metric units of measurement)

Note: Specifications subject to change without notification.

1.6 Models

The following models are covered in this document:

Part No.

Description

A0A0161

120/240 VAC Portable GFM System

A0A0162

120/240 VAC In-Line GFM System

1.7 Optional Accessories

Part No.

Description

A3W0418

AUX Cable for GFM (3 meters)

2.0 INSTALLATION

2.1 Options

The GFM can be used as a portable or in-line gas flow monitor. If the unit was

purchased as a portable monitor, it will be equipped with a rubber gas cone. When

installing the rubber hose and gas cone on the GFM make sure the hose is installed

on the side of the GFM marked gas inlet. The cone is designed to fit standard torch

gas cups and allows the GFM to measure the actual gas flow at the torch. To install,

simply press the GFM gas cone onto the welding torch gas cup. Make sure that the

cone is fitted snugly to the gas cup. The GFM uses a custom MEM sensor that is

calibrated to measure Air. The GFM has 6 selectable gas settings, ARGON,

Argon/ CO2(90/10), Argon/ CO2(80/20), Argon/ CO2(75/25), Helium, and CO2.

The GFM can be custom ordered and configured for additional gas mixtures.

By default the Argon gas type is enabled. To change the gas type, refer to the

Section 3: Operations.

2.2 Gas Line Hookup

The GFM may also be installed into the gas line and used to permanently monitor the

gas-flow rate. This model is supplied with barbed 3/8 ID hose fittings. The sensor will

accept any 3/8” NPT pipefitting. The user may hard plumb the sensor if desired. DO

NOT USE PIPE DOPE OR TEFLON TAPE ON THE PIPE FITTINGS. The sensor

should be located between the welding-gas solenoid and the torch. DO NOT

INSTALL THE SENSOR ON THE INLET SIDE OF THE GAS SOLENOID. If the

sensor is installed on the inlet pressure side of the gas solenoid, the maximum

operating pressure (50 psi) of the transducer may be exceeded.

WARNING: Do not over tighten fittings as it may damage the sensor. The maximum

recommended torque for fittings is 15 in. lbs or 1.7 newton meters

2.3 Optional Gas Line Filters

Dust particle contamination may be present in some applications. Ensure

appropriate measures are taken to minimize the effect of particulate contamination.

Although the sensor naturally repels dust, some dust and contamination can still

collect on the microstructure. Dust adherence to chip edges and channel surfaces

can be prevented by using a simple filter. A disposable five micron filter used in

series on the upstream side of the airflow divide will provide adequate filtering in most

applications.

Recommended Filter Suppliers

Manufacture

Model

Function

Pall Corporation

www.pall.com

Acro 50

•The filter may be used at a common mode pressure of

0.17 MPa (24.6 psi) at a temperature of 80 °C [176 °F]

•May be used with swag lock compression fittings

•Approximate pressure drop is 5 kPA at 1 SLPM of flow

Pall Corporation

www.pall.com

Acro Cap

•May be used at an operating temperature of 55 °C

[131 °F] and common mode pressure of 30 psi

•Sensors connections are1/4 barb fittings

Pall Corporation

www.pall.com

General

Gas Filter

•Pressure drop is 1 psi with a flow of 15 SLPM

•Fittings are 1/8 barbed tubing

Parker Balston

www.balstonfilters.com

9933-05

•US and EMEA only sales offices

•May be used at common mode pressures up to 125

psi and operating temperature to 135 °C [275] °F

•Sensor connections are 1/4 tube

2.4 Cable Hookup

The GFM provides an analog voltage, which will represent gas flow. This analog

voltage can be monitored by using the Auxiliary cable and connecting the plug to the

"AUX" connector on the bottom panel. The output voltage will have the following

relationship:

2.55 volts = 255 scfh

0.01 volt/scfh

The output impedance of this signal is 100 ohms and can source 10 milliamps of

current. The analog-interface cable can also be used to supply power to the GFM.

The power requirement is (12 - 28) vdc @ 100 ma. This cable also has the

connections for the Fault Relay and Modbus® RS-485 serial port.

The following is the pin out for the GFM AUX Cable (P/N: A3W0418).

Pin No.

Function

1 (WHT)

Modbus RS-485 D+ serial port

2 (BRN)

User supplied Power Input VIN+ (12-28 VDC @100 ma)

3 (GRN)

CR-A - Will be active when gas flow is within programmed limits.

4 (YEL)

CR-B – Will be active when gas flow is within programmed limits.

5 (GRY)

User supply power common VCOM

6 (PNK)

Modbus RS485 and Vout analog common

7 (BLU)

Modbus RS-485 D- serial port

8 (RED)

Gas Flow Analog output VOUT+ (0.00 – 2.55 vdc)

2.5 Gas Flow Limits

The GFM can be used to test for High/Low gas flow limits. An internal fault relay will

be set (CLOSED) when the gas flow is within the programmed limits. The fault relay

can be interfaced to an external weld fixture controller.

2.6 Gas Flow Volume

The GFM can also be used to monitor accumulated gas flow and to provide an

indication when the volume in a gas cylinder has reached a programmed minimum

limit. The GFM will calculate the volume of gas used based on the measure flow

rate. If the user programs the minimum volume for safe operation, the GFM will

indicate when the estimate minimum volume has been reached. The GFM will set a

fault relay when the estimated volume has decreased below the programmed

minimum. Setting the starting volume “V” to 0 disables the function.

NOTE: THE LOW GAS VOLUME FAULT WILL NOT ACTIVATE THE FAULT RELAY BUT

WILL INDICATE THE FAULT CONDITION BY SETTING A MODBUS® COIL

CR15.

3.0 OPERATION

3.1 Firmware Version

The GFM is supplied with a plug-in the wall transformer, which powers the GFM and

will also charge the optional internal battery. Plug the transformer into a suitable ac

receptacle, and connect the power cable into the "POWER" jack located on the

bottom panel of the GFM. Press the power switch on the front panel "ON".The

“POWER” LED will light and the following power up message will be displayed:

******* GFM *******

P/N A5Z0055 Ver #.##

CWT, a Lincoln

Electric Brand

Where: #.## is the firmware version number

Followed by the run time display:

0 CFH

Note: CFH will be replaced with LPH in metric mode

Activate the gas solenoid for the welding torch. The GFM will now display the gas

flow rate in CFH (Cubic Feet per Hour) or LPM (Liters per Minute).

NOTE: When using the portable model, ensure no wire is fed while the cone is

attached to the gas cup.

3.2 Program Limits

To program the High/Low limits and test parameters press both “▼” and "▲" switch

simultaneously to enter the “Select Para INC/DEC”mode. The first programmable

parameter will appear on the display. To increment through the program menus

press the “▲” button. To decrement through the menus press the “▼” button. To

edit a menu option press both “▼” and "▲" switch simultaneously to enter the “Edit

Para INC/DEC” mode. To increment the parameter press the “▲” button. To

decrement the parameter press the “▼” button. To end the “Edit Para INC/DEC”

press both “▼” and "▲" switch simultaneously to exit and return to the normal display

mode. The user can edit only one parameter at a time. To edit other parameters

repeat the above sequence.

3.3 Parameters

The following is the list of the parameters and system configurations that can be

modified by the user:

•Max Limit= ### - Maximum gas flow Limits. This value is used to set the high

fault alarm and disable the output alarm. This value is also used to trigger the

Peak Flow detector. The Peak flow value is updated and the peak flow time is

incremented when the flow rate is greater then this limit. (Value range 5 – 255)

•MIN Limit= ### -Minimum gas flow rate limits. This limit in conjunction with

the test delay time is used to set the Low Fault alarm and to disable the output

alarm. When the flow is detected the Test delay timer is decremented and

when the user defined delay time is reached the Low limit is tested and the

output relay will be disabled if the flow rate is below this limit. (Value range 5 to

100)

•Test Delay= ##.# - This is the time in seconds that the GFM will wait before

testing for a Low or High limit fault following an initial detection of gas flow.

(Value range 0.5 to 10.0 seconds)

•Enable Alarms? - Allows the user to enable or disable the High Low limit

testing. Setting this option to “No” will disable the alarm relay output. Setting

this option to “Yes” will enable the alarm relay output. (Status Yes or No)

•Enable Peak? – Setting this parameter to yes will enable the Peak Flow

display. When enabled an additional “Peak= ### *.** sec” display will be

active. Where ### is the last peak flow rate measured and “*.**” is the Total

time at peak flow. The time at peak is the total time measured above the High

limit value. The Peak is the peak flow measured above the High Limit. The

peak value and time is reset at the start of the next detected gas flow period.

This peak display will remain on the display until the peak is set to “No”.

•Log Mode? – Setting this parameter to yes will enable the flow volume

accumulator and it will enable the “Tot Volume= ##.#” and the “Total Time=

HR:MN:SS” display. Where ##.# is the total accumulated volume and

HR:MN:SS is the total time of gas flow since the last user reset. When

disabled the volume display will be inactive and the gas flow accumulator will

be disabled.

•Metric Units? – This parameter is used to select the units of measure for the

gas flow rate. When set to “Yes” the units of measure is in Liters per Minute

(LPM). When set to no, the units of measure are standard Cubic Feet per Hour

(CFH).

•DEVICE ID= -This parameter sets the Modbus address ID number for the

GFM. This address is used to identify the Device when using the Modbus®

serial communications protocol. Each sensor connected to the Modbus®

network must have a unique ID number assigned. (Value Range 1 to 247)

•Clear Log Timer? – This Option is used to reset the accumulated gas flow

timer used when the log option is enabled. When set to “Yes” the timer will be

reset to 00:00:00.

•Reset Volume? – This option is used to reset the gas volume accumulator to

zero. The accumulator is used when the Log mode is set to yes. Setting this

option to “Yes” will clear the accumulated volume of gas to zero.

•Filter TC = ## -The parameter sets the filter time constant for the displayed

gas flow. Increasing this value will decrease the fluctuation in the gas flow

reading. This filter does not impact the peak readings or accumulated flow

parameters. (Value Range from 1 to 255).

•Argon Gas? - Allows the user to enable or disable Argon Gas conversion

factor. Setting this option to “No” will disable the Argon Gas conversion factor.

Setting this option to “Yes” will enable the Argon Gas conversion factor. (Status

Yes or No) Note: Disabling all Gas types (set to NO) will enable the Air

conversion factor.

•CO2Gas? - Allows the user to enable or disable CO2Gas conversion factor.

Setting this option to “No” will disable the CO2Gas conversion factor. Setting

this option to “Yes” will enable the CO2Gas conversion factor. (Status Yes or

No) Note: Disabling All Gas types (set to NO) will enable the Air conversion

factor.

•Helium Gas? - Allows the user to enable or disable Helium Gas conversion

factor. Setting this option to “No” will disable the Helium Gas conversion factor.

Setting this option to “Yes” will enable the Helium Gas conversion factor.

(Status Yes or No) Note: Disabling All Gas types (set to NO) will enable the

Air conversion factor.

•75/25 Argon/ CO2Gas? - Allows the user to enable or disable 75/25 Argon/

CO2Gas conversion factor. Setting this option to “No” will disable the 75/25

Argon/ CO2Gas conversion factor. Setting this option to “Yes” will enable the

75/25 Argon/ CO2Gas conversion factor. (Status Yes or No) Note: Disabling

All Gas types (set to NO) will enable the Air conversion factor.

•80/20 Argon/ CO2Gas? - Allows the user to enable or disable 80/20 Argon/

CO2Gas conversion factor. Setting this option to “No” will disable the 80/20

Argon/ CO2Gas conversion factor. Setting this option to “Yes” will enable the

80/20 Argon/ CO2Gas conversion factor. (Status Yes or No) Note: Disabling

All Gas types (set to NO) will enable the Air conversion factor.

•90/10 Argon/ CO2Gas? - Allows the user to enable or disable 90/10 Argon/

CO2Gas conversion factor. Setting this option to “No” will disable the 90/10

Argon/ CO2Gas conversion factor. Setting this option to “Yes” will enable the

90/10 Argon/ CO2Gas conversion factor. (Status Yes or No) Note: Disabling

All Gas types (set to NO) will enable the Air conversion factor.

4.0 SETTING GAS FLOW CONTROL LIMITS

4.1 Description

To use the GFM as a Sure-Flow gas switch, the user can set the “Max Limit” and

“Min Limit”.

The GFM will activate the internal fault relay as long as the gas flow remains above

the lower limit and below the upper limit. If the gas flow rate moves outside of the

control limits the fault relay will be deactivated. The "Test Delay" parameter is used

to delay the start of high limit testing. The value of this parameter will determine

when the GFM will begin testing for the upper control limit after the gas flow is

initiated. The lower limit is always being checked during the gas flow period. A high

gas flow fault will only occur after this time period has expired.

4.2 Setup