Lincoln Electric Prism SUSPEND 4000 User manual

Prism SUSPEND 4000
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IM10628-A | Issue Date Mar- 22
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
13249, 13250, 13251,
13252
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Date Purchased
Code: (ex: 10859)
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Operator’s Manual
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®

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 - 10/08/2021

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 usedfor welding or
cutting, produces fumes or gases which contain
chemicals known to the State ofCalifornia 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. 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.
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
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
causes localized Electric and Magnetic Fields (EMF).
and welding machines
welders having a pacemaker should consult their physician
before welding.
which are now not known.
2.d. All welders should use the following procedures in order to
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 - 10/08/2021
1.c. Do not add the fuel near an open ame welding
with hot engine parts and igniting. Do not spill fuel when lling
2.a. Electric current owing through any conductor
Welding current creates EMF elds around welding cables
2.b. EMF elds may interfere with some pacemakers, and
2.c. Exposure to EMF elds in welding may have other health effects
minimize exposure to EMF elds from the welding circuit:
1.i. Using a generator indoors CAN KILL YOU IN
MINUTES.
1.j. Generator exhaust contains carbon monoxide. This is a poison
you cannot see or smell.
1.k. NEVER use inside a home or garage,
EVEN IF doors and windows are open.
1.l. Only use OUTSIDE and far away from
windows, doors and vents.
1.m. Avoid other generator hazards. READ
MANUAL BEFORE USE.

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 - 10/08/2021

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 - 10/08/2021

2
SAFETY
PRISM® SUSPEND 4000
As a rule of thumb, for many mild steel electrode, if the air is
visibly clear and you are comfortable, then the ventilation is
generally adequate for your work. The most accurate way to
determine if the worker exposure does not exceed the applicable
exposure limit for compounds in the fumes and gases is to have
an industrial hygienist take and analyze a sample of the air you
are breathing. This is particularly important if you are welding with
stainless, hardfacing or Special Ventilation products. All Lincoln
MSDS have a maximum fume guideline number. If exposure to
total fume is kept below that number, exposure to all fume from
the electrode (not coatings or plating on the work) will be below
the TLV.
There are steps that you can take to identify hazardous
substances in your welding environment. Read the product label
and material safety data sheet for the electrode posted in the work
be reasonably expected from use of the product and to determine
if special ventilation is needed. Secondly, know what the base
metal is and determine if there is any paint, plating, or coating that
could expose you to toxic fumes and/or gases. Remove it from the
metal being welded, if possible. If you start to feel uncomfortable,
dizzy or nauseous, there is a possibility that you are being
overexposed to fumes and gases, or suffering from oxygen
Notify your supervisor and co-workers so the situation can be
corrected and other workers can avoid the hazard. Be sure you
are following these safe practices, the consumable labeling and
MSDS to improve the ventilation in your area. Do not continue
welding until the situation has been corrected.
NOTE: The MSDS for all Lincoln consumables is available on Lincoln’s web-
site: www.lincolnelectric.com
Before we turn to the methods available to control welding fume
exposure, you should understand a few basic terms:
Natural Ventilation is the movement of air through the
workplace caused by natural forces. Outside, this is usually
windows and doors.
Mechanical Ventilation is the movement of air through the
workplace caused by an electrical device such as a portable
fan or permanently mounted fan in the ceiling or wall.
Source Extraction (Local Exhaust) is a mechanical device
contaminants out of the air.
The ventilation or exhaust needed for your application depends
upon many factors such as:
• Workspace volume
• Number of welders
• Welding process and current
• Consumables used (mild steel, hardfacing, stainless, etc.)
• Allowable levels (TLV, PEL, etc.)
• Material welded (including paint or plating)
Your work area has adequate ventilation when there is enough
ventilation and/or exhaust to control worker exposure to
hazardous materials in the welding fumes and gases so the
applicable limits for those materials is not exceeded. See chart of
TLV and PEL for Typical Electrode Ingredients, the OSHA PEL
(Permissible Exposure Limit), and the recommended guideline, the
ACGIH TLV (Threshold Limit Value), for many compounds found in
welding fume.
Ventilation
There are many methods which can be selected by the user to
following section provides general information which may be
helpful in evaluating what type of ventilation equipment may be
suitable for your application. When ventilation equipment is
applicable OSHA PEL and/or ACGIH TLV. According to OSHA
regulations, when welding and cutting (mild steels), natural
provided that:
1. The room or welding area contains at least 10,000 cubic feet
(about 22' x 22' x 22') for each welder.
2. The ceiling height is not less than 16 feet.
3. Cross ventilation is not blocked by partitions, equipment, or
other structural barriers.
Spaces that do not meet these requirements should be equipped
with mechanical ventilating equipment that exhausts at least 2000
CFM of air for each welder, except where local exhaust hoods or
booths, or air-line respirators are used.
Important Safety Note:
When welding with electrodes which require special
ventilation such as stainless or hardfacing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings which
produce hazardous fumes, keep exposure as low as
possible and below exposure limit values (PEL and TLV)
for materials in the fume using local exhaust or
emosnirosecapsdennocnI.noitalitnevlacinahcem
circumstances, for example outdoors, a respirator may
be required if exposure cannot be controlled to the PEL
or TLV. (See MSDS and chart of TLV and PEL for Typical
Electrode Ingredients.) Additional precautions are also
required when welding on galvanized steel.
Ambient Extraction is a mechanical device used to capture
and lter welding fume suspended in workplace air.

3
SAFETY
PRISM® SUSPEND 4000
BIBLIOGRAPHY AND SUGGESTED READING
ANSI Z87.1, Practice for Occupational and Educational Eye and
Face Protection, American National Standards Institute, 11 West
42nd Street, New York, NY 10036.
Arc Welding and Your Health: A Handbook of Health Information
for Welding. Published by The American Industrial Hygiene
Association, 2700 Prosperity Avenue, Suite 250, Fairfax, VA
22031-4319.
NFPA Standard 51B, Cutting and Welding Processes, National Fire
Protection Association, 1 Batterymarch Park, P.O. Box 9146,
Quincy, MA 02269-9959.
OSHA General Industry Standard 29 CFR 1910 Subpart Q. OSHA
Hazard Communication Standard 29 CFR 1910.1200. Available
from the Occupational Safety and Health Administration at
The following publications are published by The American Welding
Society, P.O. Box 351040, Miami, Florida 33135. AWS publi-
cations may be purchased from the American Welding society at
http://www.aws.org or by contacting the AWS at 800-443-9353.
ANSI, Standard Z49.1, Safety in Welding, Cutting and Allied
Processes. Z49.1 is now available for download at no charge at
http://www.lincolnelectric.com/community/safety/ or at the AWS
website http://www.aws.org.
AWS F1.1, Method for Sampling Airborne Particulates Generated
by Welding and Allied Processes.
AWS F1.2, Laboratory Method for Measuring Fume Generation
Rates and Total Fume Emission of Welding and Allied Processes.
AWS F1.3, Evaluating Contaminants in the Welding Environment: A
Strategic Sampling Guide.
AWS F1.5, Methods for Sampling and Analyzing Gases from
Welding and Allied Processes.
AWS F3.2, Ventilation Guide for Welding Fume Control
AWS F4.1, Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers and Piping That Have Held
Hazardous Substances.
AWS SHF, Safety and Health Facts Sheets. Available free of charge
from the AWS website at http://www.aws.org.
Supplemental Information:
(*) Not listed. Nuisance value maximum is 10 milligrams per cubic
meter. PEL value for iron oxide is 10 milligrams per cubic meter.
TLV value for iron oxide is 5 milligrams per cubic meter.
(**) As respirable dust.
(*****) Subject to the reporting requirements of Sections 311, 312,
and 313 of the Emergency Planning and Community Right-
to-Know Act of 1986 and of 40CFR 370 and 372.
(b) The PEL for chromium (VI) is .005 milligrams per cubic meter as
an 8 hour time weighted average. The TLV for water-soluble
chromium (VI) is 0.05 milligrams per cubic meter. The TLV for
insoluble chromium (VI) is 0.01 milligrams per cubic meter.
(c) Values are for manganese fume. STEL (Short Term Exposure
Limit) is 3.0 milligrams per cubic meter. OSHA PEL is a ceiling
value.
(****) The TLV for soluble barium compounds is 0.5 mg/m3.
TLV and PEL values are as of October 2013. Always check Safety
Data Sheet (SDS) with product or on the Lincoln Electric website at
http://www.lincolnelectric.com
LISTED BELOW ARE SOME TYPICAL INGREDIENTS IN WELDING ELECTRODES AND
THEIR TLV (ACGIH) GUIDELINES AND PEL (OSHA) EXPOSURE LIMITS
INGREDIENTS CAS No. TLV mg/m3PEL mg/m3
Aluminum and/or aluminum alloys (as AI)***** 7429-90-5 1.0 15
Aluminum oxide and/or Bauxite***** 1344-28-1 0.1 5**
Barium compounds (as Ba)***** 513-77-9 0.5 0.5
Chromium and chromium alloys or compounds (as Cr)***** 7440-47-3 0.5(b) 0.5(b)
Hexavalent Chromium (Cr VI) 18540-29-9 0.05(b) .005(b)
Copper Fume 7440-50-8 0.2 0.1
Cobalt Compounds 7440-48-4 0.02 0.1
Fluorides (as F) 7789-75-5 2.5 2.5
Iron 7439-89-6 10* 10*
Limestone and/or calcium carbonate 1317-65-3 10* 15
Lithium compounds (as Li) 554-13-2 15 10*
Magnesite 1309-48-4 10 15
Magnesium and/or magnesium alloys and compounds (as Mg) 7439-95-4 10* 10*
Manganese and/or manganese alloys and compounds (as Mn)***** 7439-96-5 0.02 5.0(c)
Mineral silicates 1332-58-7 5** 5**
Molybdenum alloys (as Mo) 7439-98-7 10 10
Nickel***** 7440-02-0 0.1 1
Silicates and other binders 1344-09-8 10* 10*
Silicon and/or silicon alloys and compounds (as Si) 7440-21-3 10* 10*
Strontium compounds (as Sr) 1633-05-2 10* 10*
Zirconium alloys and compounds (as Zr) 12004-83-0 5 5

TABLE OF CONTENTS
PRISM® SUSPEND 4000
INSTALLATION .............................................................................................................................................SECTION A
TECHNICAL SPECIFICATIONS .....................................................................................................................................A-1
GENERAL DESCRIPTION.............................................................................................................................................A-2
THE INTENDED PURPOSE...........................................................................................................................................A-2
TRANSPORT AND ERECTION......................................................................................................................................A-2
SELECT SUITABLE LOCATION.....................................................................................................................................A-2
ENVIRONMENTAL AREA .............................................................................................................................................A-2
INSTALLATION OF PRISM® SUSPEND 4000....................................................................................................... .... . .. .A-4
ELECTRICAL CONNECTIONS.....................................................................................................................................A-14
OPERATION ................................................................................................................................................SECTION B
USERS ............................................................................................................................................................B-1
INTENDED USE ..........................................................................................................................................................B-1
MODIFICATIONS ........................................................................................................................................................B-1
RESTRICTIONS ..........................................................................................................................................................B-1
CONTROL ............................................................................................................................................................B-2
SOFTWARE FUNCTIONS (FAN, FILTER CLEANING, ALARMS, AUTO SCHEDULE).............................. ...............................B-3
PLC NAVIGATION .....................................................................................................................................................B-4
SET POINTS .................................................................... ......... ................................................................................B-4
ADJUSTING PARAMETERS .........................................................................................................................................B-4
ACCESSORIES ..............................................................................................................................................SECTION C
REPLACEMENT FILTER OPTIONS................................................................................................................................C-1
MAINTENANCE .............................................................................................................................................SECTION D
MALFUNCTIONS AND EMERGENCIES EFFECTING THE FILTER UNIT ............................................................................D-1
ESCAPE OF NOXIOUS SUBSTANCES OR RADIATION ...................................................................................................D-1
PERIODIC MAINTENANCE...........................................................................................................................................D-2
MAINTENANCE SCHEDULE.........................................................................................................................................D-2
REPLACING FILTER CARTRIDGES OR EMPTYING DUSTBINS .......................................................................................D-3
REPLACING FILTER CARTRIDGES...............................................................................................................................D-4
TROUBLESHOOTING .....................................................................................................................................SECTION E
DIAGRAMS .................................................................................................................................................SECTION F
PARTS LIST ...............................................................................................................PARTS.LINCOLNELECTRIC.COM
CONTENT/DETAILS MAY BE CHANGED OR UPDATED WITHOUT NOTICE. FOR MOST CURRENT INSTRUCTION MANUALS, GO
TO PARTS.LINCOLNELECTRIC.COM.
SYSTEM LAYOUTS ........................................................................................................................................... .. ..... ...A-3

TECHNICAL SPECIFICATIONS
GENERAL
TYPE OF CLEANING Pulse jet
DUTY CYCLE 100%
COMPRESSED AIR PRESSURE
AND QUALITY
72 - 87 psi (5 - 6 bar)
clean, dry and oil free
PRISM® SUSPEND 4000 AIR CONSUMPTION
6 BAR / 87 PSI
Recommended
Compressed Air Consumption (cfm)
Off Time (Sec)
5
10
15
20
25
30
35
40
45
50
55
60
FILTER CLASS (ACCORDING TO ASHRAE 52.2)
KP4519-1 MERV 11
KP4519-2 MERV 16 NANO
KP4519-3 MERV 16 PTFE
AMBIENT CONDITIONS
MINIMUM TEMPERATURE -4°F (-20°C)
MAXIMUM TEMPERATURE 113°F (45°C)
MAXIMUM RELATIVE HUMIDITY 75%
PRISM® SUSPEND 4000: AD2477-1 & AD2477-3
INPUT VOLTAGE NOMINAL
+/- 10%
380-480V/3~/50-60Hz (FAN)
115-230V/1~/50-60Hz (CONTROLS)
MAXIMUM CURRENT (NOMINAL)
9A max (FAN)
2A max (CONTROLS)
MOTOR POWER (NOMINAL) 7.6 HP
INSULATION CLASS FAN MOTOR F
PROTECTION CLASS FAN MOTOR IP55
FAN SUPPLY FUSE Class J OR CC 15A/600V
ALARM LEVEL 1500Pa (factory default)
PRISM® SUSPEND 4000: AD2477-2 & AD2477-4
INPUT VOLTAGE NOMINAL
+/- 10% 200-240V/3~/50-60Hz (FAN)
115-230V/1~/50-60Hz (CONTROLS)
MAXIMUM CURRENT (NOMINAL)
19.5A max (FAN)
2A max (CONTROLS)
MOTOR POWER (NOMINAL) 8.6 HP
INSULATION CLASS FAN MOTOR F
PROTECTION CLASS FAN MOTOR IP55
FAN SUPPLY FUSE Class J OR CC 30A/600V
ALARM LEVEL 1500Pa (factory default)
A-1
TECHNICAL SPECIFICATIONS
PRISM® SUSPEND 4000
74.4 (20 sec per cycle)
37.2 (40 sec per cycle)
24.8 (60 sec per cycle)
18.6 (80 sec per cycle)
14.9 (100 sec per cycle)
12.4 (120 sec per cycle)
10.6 (140 sec per cycle)
9.3 (160 sec per cycle)
8.3 (180 sec per cycle)
7.4 (200 sec per cycle)
6.7 (220 sec per cycle)
6.2 (240 sec per cycle)
On Time (msec) 200
1 valve cleans 2 lters per pulse
(4 PULSES per CLEAN CYCLE)
KP4519-4 MERV 11 OIL
RESISTANT
KP4519-5 MERV 16 NANO
OIL RESISTANT
1. Compressed air to be clean,dry, oil free, and have a dew point of
-40°F (-40°C)
2. Boldface values are factory defaults
3. Off Time Default (pause time between pulses): 20 sec
4. On Time Default: 200ms
5. Compressed air pressure of 5 bar (72 psi) reduces consumption
by 20% (approx.)
6. Filter cleaning functions detailed in section B
7. Compressed air consumption is not continuous. It is only
required for length of cleaning cycle listed in parenthesis

INSTALLATION
GENERAL DESCRIPTION
fan/ltration unit designed to hang from the roof or mount to a
wall. When multiple units are strategically located in a workspace,
they function in a push/pull manner to lter out suspended weld
fume from the air.
The fan pulls air with particulate through the lters. When
pressure over the lter reaches a preset point, the internal self
cleaning mechanism cleans the lter cartridges with compressed
air shots, resulting in particulate dropping into a dustbin below
the unit.
THE INTENDED PURPOSE
Extraction of fumes that are released in the course of using
welding equipment for cutting and joining non-alloy and alloy
steels, including highalloy chromium/nickel steels with a nickel
and chromium content of ≥30%
TRANSPORT AND ERECTION
Instruct all persons whose presence is not
required to stay out of the hazard area
Do not stand under or next to the load when it is being
lifted up or set down
Transport the unit or erection components on the pallets
provided, and secure them against falling over or
slipping.
Transport them with a suitable pallet truck or forklift
truck
The PRISM® SUSPEND 4000 must be secured to the
roof or wall in a manner approved by a structural
engineer licensed in the governing jurisdiction.
• The installer is responsible for following
federal, state and local safety codes and
regulations.
• Before drilling, verify locations of existing
gas, water or electrical conduits.
Excluded Uses!
•Welding fumes containing oil
•Aluminum dust
•Burning or incandescent materials
•Cigarettes
•Aggressive media
•Water and moisture
•Explosive gases and/or dust mixtures
•Dusts with toxic characteristics other than welding
fumes
•The installation of this product is exclusively reserved
to authorized, well-trained and qualified electrical and
mechanical contractors.
•Inspect the product and check it for damage. Verify the
functioning of the safety features.
•Electrical connection to be executed in accordance
with local requirements. Ensure compliance with the
EMC regulatory arrangements.
•Check the working environment. Do not allow
unauthorized persons to enter the working
environment.
•Protect the product against water and humidity.
•Use common sense. Stay alert and keep your attention
to your work. Do not use the product when you are
•Ensure the workspace is well-illuminated.
•Never install the product over entrances and exits
which must be used for emergency services.
•Make sure that the workshop, in the vicinity of the
•The PRISM® SUSPEND 4000 must be secured to the
roof or wall in a manner approved by a structural
engineer licensed in the governing jurisdiction.
•Air containing particles such as chromium, nickel,
beryllium, cadmium, lead etc., which is a health hazard,
should never be recycled. This air must always be
brought outside the working area.
SELECT SUITABLE LOCATION
• Do not place equipment near radiant heat sources.
Do not place in a conned space. Allow a minimum of 4 feet
of clearance around sides and front of machine at all times for
proper operation and maintenance requirements.
ENVIRONMENTAL AREA
Keep the machine inside and dry at all times.
ATTENTION
WARNING
ATTENTION
A-2
INSTALLATION
PRISM® SUSPEND 4000
The Prism® Suspend 4000 is an ambient zero footprint

GENERAL PRISM® SUSPEND 4000 SYSTEM LAYOUTS
Each Prism Suspend 4000 unit is designed to filter 40,000 ft3of workspace at a rate of 6 air changes per hour.
In many applications, multiple units can be strategically located to push and pull air across a workspace to
efficiently clean the ambient air. The units are designed to be hung from roof structures or walls and do not
require floor space.
Since each workspace is unique, Lincoln Electric works with each customer to determine the most effective
layout for their application. Considerations include:
•Workspace dimensions
•Obstructions such as cranes and other equipment
•Building construction capabilities to hang or wall mount the units
•Fume generating locations within the workspace
Layout possibilities include but are not limited to the following:
INSTALLATION
PRISM® SUSPEND 4000
A-3

INSTALLATION
PRISM® SUSPEND 4000
INSTALLATION OF PRISM® SUSPEND 4000
TOOLS NEEDED
• 5/16" Nutdriver
• 3/8" Nutdriver
• 1/2" Nutdriver
• 9/16" Nutdriver
• 9/16" Box Wrench
• Appropriate Hoist and Rigging
• Liquid Sealant
• Strip Foam Gasket
• Miscellaneous Hand Tools
• Ladder/Lift
• Drill or Impact
• 1/4" Drill Bit
Step 1 – Unpack the Unit
Using supplied door key, unlock/open door. Remove control
panel, dust bin and other components from inside unit.
FIGURE A.1
Step 2 – Connect Fan Motor Cable
FIGURE A.2
FIGURE A.3
Filter Boxes
4. Use supplied loop
clamps to secure
power cable to
unit and
protect
it from
sharp
edges.
1. Determine power cable
length that will reach from
fan motor (at pre-determined
installation location) to power
disconnect.
Place pallet near intended installation location and unpack in
preparation for assembly.
Hopper
2. Route power into fan motor
through this cord grip.
3. Connect cable per fan
motor instructions.
Step 3 – Hoist the Unit for Hopper Assembly and
Installation
LIFT METHOD 1
1. Use OSHA approved
2.
lifting sling or chains
rated to 1250 lbs when
used with corner lifting
brackets (similar to
shown).
Lift with fork truck or
crane.
1. Open door as shown.
2. Using fork truck, lift
unit under tube sheet
between lter
clamping rails.
CAUTION: ENSURE
UNIT’S DOOR DOES
NOT GET PINCHED
BY FORK TRUCK’S
MAST & LOAD
BACKREST.
VERIFY
FORKS
ARE
INSERTED
TO WITHIN
2” OF
UNIT’S
REAR
PANEL
BEFORE
LIFTING
UNIT.
LIFT METHOD 2
A-4

INSTALLATION
PRISM® SUSPEND 4000
Step 4 – Prepare the Hopper for Assembly
FIGURE A.4
1. Apply strip foam gasket (supplied in dust
bin carton) completely around top of
hopper ange as shown. Apply strip foam
gasket on both sides of bolt holes and
overlap in corners.
2. Apply a bead of liquid sealant
(supplied in dust bin carton)
between foam strips.
Step 5 – Assemble the Hopper
FIGURE A.5
1. Using one of the two recommended methods, lift
unit high enough for hopper installation as shown.
NOTICE: INSTALL
FASTENERS ALONG
FRONT AND REAR
FLANGES ONLY
DURING THIS STEP.
2. Orient hopper under unit
as shown with corner
0.235 holes on door side
of unit, then thread 3/8”
ange bolts from under
hopper into interior rivet
nuts (1 in each corner).
NOTE: If hopper is rotated
90° from described
position, interior 1/4-20
nuts will be required for
the four corner 1/4-20
bolts.
3. Install ¼” ˜ange bolts
from under hopper into
holes in bottom of unit
(7 per side).
.235 hole on door side
.281 hole
A-5

INSTALLATION
PRISM® SUSPEND 4000
Step 6a – HANGING MOUNT ONLY - Install the
Suspension Brackets and Threaded Rods
FIGURE A.6a
4. Determine required lengths of ½-
13 threaded rod (10ft lengths
supplied with unit) required for your
installation and cut to length.
CAUTION: INSTALLATIONS REQUIRING
THREADED ROD OVER 10FT NOT
SUPPLIED AND MUST BE SPECIFIED
BY LICENSED STRUCTURAL ENGINEER.
1. Continue to lift unit at height similar
to used in the hopper installation step.
7. Install ½-13 ange nut on both
sides of upper tabs as shown.
3. Install ¼” ange bolts
through holes in bracket
and hopper into holes in
bottom of unit (5 per side).
2. Align lower support
brackets along each
side of unit, then thread
3/8” ange bolts through
the brackets and hopper
into interior rivet nuts
(1 in each corner).
6. Install ½-13 ange nuts
on both sides of lower
brackets as shown.
and lower holes in each corner of
unit.
NOTICE: THREAD TWO NUTS ON
TO CENTER OF EACH ROD WITH
NUT FLANGES TOWARDS ROD
ENDS PRIOR TO ALIGNING
THROUGH HOLES
5. Align threaded rods through upper
A-6

INSTALLATION
PRISM® SUSPEND 4000
4. Remove three center 3/8” ange
bolts from top rear panel, then
install upper bracket by reinstalling
the bolts just removed.
Step 6b – WALL MOUNT ONLY - Install the Wall Mount Brackets
FIGURE A.6b
1. Continue to lift unit at height
similar to used in the hopper
installation step.
3. Install ¼” ange bolts
through holes in bracket
and hopper into holes in
bottom of unit (5 per side).
2. Align lower support
brackets along each
side of unit, then thread
3/8” ange bolts through
the brackets and hopper
into interior rivet nuts
(1 in each corner).
A-7

INSTALLATION
PRISM® SUSPEND 4000
Step 7a – (HANGING MOUNT ONLY) - Hanging Mount To Typical Buildings
FIGURE A.7a
PRISM® SUSPEND 4000 can be hung from many roof
structures. Typical roof structures include:
1. Steel Bar Joist
2. Steel Wide Flange Beam
3. Steel Channel Beam
4. Light Gage Roof Purlin
WARNING!
• Existing building structure types and framing
considerations vary greatly from building to building,
therefore each installation of this unit (including but not
limited to the building structure, brackets, hardware and any
other structural supports) shall be approved by a structural
engineer licensed in the governing jurisdiction. Subsequent
building alterations or addition of other nearby high vibration
equipment may require follow up analysis by the licensed
structural engineer. Unapproved installations can result in
falling equipment leading to severe personnel injury or
death.
• High seismic locations may require special reinforcement
and additional lateral support. Follow governing local
building codes for inspection requirements following any
significant event. Significant events include but are not
limited to seismic and other impacts to the unit or structural
mounts.
• Do not store other material on top of or hang anything
from unit.
• Do not allow personnel under unit during service and
maintenance procedures
NOTICE!
• Do not locate other heat generating equipment nearby
that could raise the ambient temperature around the unit
above the max rating stated in the Technical Specifications
section.
• For unit to meet designed operation efficiency, do not
allow other equipment to obstruct the free flow of air to the
side intakes and from the front fan exhaust.
• Refer to the maintenance section for recommended
procedures to ensure unit functionality and safety
throughout the life of the product. For most unit
maintenance procedures, ensure access to front and sides
of unit using OSHA approved access equipment.
WARNING!
Do not use corner brackets for
primary mounting support of
this unit. They are only
intended for hoisting unit during
installation and for secondary or
redundant support.
WARNING!
Do not operate without the side
intake pre-filters installed in
their housings. For maximum
protection, prevent sparks from
reaching within 3 feet of unit's
side intakes.
A-8

INSTALLATION
PRISM® SUSPEND 4000
Step 7b – (WALL MOUNT ONLY) - Hanging Mount To Typical Buildings
FIGURE A.7b
WARNING!
Do not use corner brackets for
primary mounting support of
this unit. They are only
intended for hoisting unit during
installation and for secondary or
redundant support.
WARNING!
Do not operate without the side
intake pre-filters installed in their
housings. For maximum
protection, prevent sparks from
reaching within 3 feet of unit's side
intakes.
PRISM® SUSPEND 4000 can be mounted to many existing
masonry and concrete walls.
WARNING!
• Existing building structure types and framing
considerations vary greatly from building to building,
therefore each installation of this unit (including but not
limited to the building structure, brackets, hardware and any
other structural supports) shall be approved by a structural
engineer licensed in the governing jurisdiction. Subsequent
building alterations or addition of other nearby high vibration
equipment may require follow up analysis by the licensed
structural engineer. Unapproved installations can result in
falling equipment leading to severe personnel injury or death.
• High seismic locations may require special reinforcement
and additional lateral support. Follow governing local
building codes for inspection requirements following any
significant event. Significant events include but are not
limited to seismic and other impacts to the unit or structural
mounts.
• Do not store other material on top of or hang anything from
unit.
• Do not allow personnel under unit during service and
maintenance procedures
NOTICE!
• Do not locate other heat generating equipment nearby that
could raise the ambient temperature around the unit above
the max rating stated in the Technical Specifications section.
• For unit to meet designed operation efficiency, do not
allow other equipment to obstruct the free flow of air to the
side intakes and from the front fan exhaust.
• Refer to the maintenance section for recommended
procedures to ensure unit functionality and safety
throughout the life of the product. For most unit
maintenance procedures, ensure access to front and sides
of unit using OSHA approved access equipment.
A-9

INSTALLATION
PRISM® SUSPEND 4000
Step 8 – Duct To Dust Bin Assembly
FIGURE A.8
PRISM® SUSPEND 4000 supplied with 6” ductwork of
sufcient length for most installations where the dust bin
rests on the oor. The dust bin can also be placed on a
shelf above the oor.
1. Determine desired dust bin location on oor or on a
shelf.
2. Assemble duct as shown which aligns dust bin with
rear of unit.
3.With dust bin in desired location, shorten 5ft straight
duct so exible hose allows for easy removal of dust
bin lid.
4.Seal all duct connections with liquid duct sealant or
duct tape.
5.Support duct at wall or other support structure.
6.Secure exible hose to reducer and dust bin lid with
supplied screw clamps.
2 ft. Straight
6” to 8” Reducer
Coupler
45° Elbow
5 ft. Straight
Flexible Hose
Dust Bin
A-10

INSTALLATION
PRISM® SUSPEND 4000
Step 9 – Compressed Air Connection
FIGURE A.9
1. Mount the compressed air regulator in an appropriate
location within reach of the tubing connected to the
unit’s rear compressed air fitting. Connect the 12mm
tubing to the regulator’s outlet fitting and the 1/4"
tubing to the regulator's sensor fitting.
2. Connect compressed air source to regulator’s inlet
fitting (ISO 6150 B PROFILE-1/4”). Adjust regulator
pressure between 5- 6 bar (73 - 87psi). For best
filter cleaning performance, set regulator to 6 bar
(87psi).
Inlet Fitting
(ISO 6150 B
Prole - 1/4”)
Sensor Fitting
(1/4" tube)
Unit’s Compressed
Air Fitting
Outlet Fitting
(12mm tube)
A-11

INSTALLATION
PRISM® SUSPEND 4000
Step 10 - Install Filters (See section D for filter
replacement instructions)
Before opening door, unit must be off and the power
switch on the side of the control panel turned to the off
position.
a. Unlock door latches
FIGURE A.10a
FIGURE A.10b
FIGURE A.10c
FIGURE A.10d
Step 11 - lock door
To prevent accidental door opening during unit operation, lock
door latches using the supplied hex tool (or standard 5/16" hex
wrench.
FIGURE A.11
WARNING
1. Unclasp
handles for
installation.
Unit ships with
door latches
locked. Unlock
latches using the
supplied hex tool
(or standard 5/16"
hex wrench), then
open door.
into unit as
shown,
making sure
they are
pushed
against rear
of unit.
1. Reclasp lter
handles to lift
lters to their
sealed
position.
2. Close and
latch door.
A-12