Parweld XTS-904 User manual

OPERATOR MANUAL
ISSUE 1
XTS-904
XTS-905

Welcome
Thank you and congratulations on choosing Parweld. This Owner’s Manual is designed
to help you get the most out of your Parweld product. Please take time to read the Safety
precautions. They will help you protect yourself against potential hazards in the workplace. With
proper maintenance this equipment should provide years of reliable service. The entire product
range carries the CE mark, and is constructed in accordance with European directives and the
product specic standards where they apply. All our systems conform to ISO9001: 2000 and are
independently audited by NQA.
Further Information
Parweld is the UK’s leading manufactuer of MIG, TIG and Plasma torches and consumables.
For more information about Parweld’s complete range visit: www.parweld.com

CONTENTS
Contents
Page
1.0 Safety Precautions 4
2.0 Product Description 5
3.0 Technical Specications 5
4.0 Description of Controls 6
5.0 Installation 6
5.1 Unpacking the Machine 6
5.2 Location 6
5.3 Input and grounding connection 7
5.4 Output Connections 7
5.5 Coolant ling 7
6.0 Flow switch 7
7.0 Operation 8
8.0 Fault Finding 8
9.0 Parts and Accessories 9
9.1 Accessories 9
9.2 Spare parts 9
10.0 EC declaration of conformity 10
10.1 Rohs declaration of conformity 10
10.2 WEEE Statement 11
10.3 Statement of warranty 11

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1.0 Safety Precautions
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or severe burns.
The electrode and work circuit is electrically live whenever the output
is on. The input power circuit and machine internal circuits are also
live when power is on.
Do not touch live electrical parts.
Wear dry, sound, insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
ground.
Additional safety precautions are required when any of the following
electrically hazardous conditions are present: in damp locations
or while wearing wet clothing; on metal structures such as oors,
gratings, or sca󰀨olds; when in cramped positions such as sitting,
kneeling, or lying; or when there is a high risk of unavoidable or
accidental contact with the work piece or ground.
Disconnect input power before installing or servicing this equipment.
Lockout/tagout input power according to Safety Standards.
Properly install and ground this equipment according to national and
local standards.
Always verify the supply ground - check and ensure that input power
cable ground wire is properly connected to ground terminal in the
receptacle outlet.
When making input connections, attach proper grounding conductor
rst - double-check connections.
Frequently inspect input power cable for damage or bare wiring -
replace cable immediately if damaged - bare wiring can kill.
Turn o󰀨 all equipment when not in use.
Do not use worn, damaged, under sized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the work piece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground, or
another electrode from a di󰀨erent machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Wear a safety harness if working above oor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to work piece or
worktable as near the weld as practical.
Insulate work clamp when not connected to work piece to prevent
contact with any metal object.
FUMES AND GASES can be hazardous.
Breathing these fumes and gases can be hazardous to your health.
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
If ventilation is poor, wear an approved respirator.
Read and understand the Material Safety Data Sheets (MSDS’s) and
the manufacturer’s instructions for metals, consumable, coatings,
cleaners, and de-greasers.
Work in a conned space only if it is well ventilated, or while wearing
an air-supplied respirator. Always have a trained watch person
nearby. Welding fumes and gases can displace air and lower the
oxygen level causing injury or death. Be sure the breathing air is
safe.
Do not weld in locations near de-greasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapours to
form highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or cadmium
plated steel, unless the coating is removed from the weld area, the
area is well ventilated, and while wearing an air-supplied respirator.
The coatings and any metals containing these elements can give o󰀨
toxic fumes if welded.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense, visible and
invisible (ultraviolet and infrared) rays that can burn eyes and skin.
Sparks y o󰀨 from the weld.
Wear an approved welding helmet tted with a proper shade of lter
lense to protect your face and eyes when welding or watching
Wear approved safety glasses with side shields under your helmet.
Use protective screens or barriers to protect others from ash, glare
and sparks; warn others not to watch the arc.
Wear protective clothing made from durable, ame resistant material
(leather, heavy cotton, or wool) and foot protection. Welding on
closed containers, such as tanks, drums, or pipes, can cause them
to blow up. Sparks can y o󰀨 from the welding arc. The ying sparks,
hot work piece, and hot equipment can cause res and burns.
Accidental contact of electrode to metal objects can cause sparks,
explosion, overheating, or re. Check and be sure the area is safe
before doing any welding.
WELDING can cause re or explosion.
Remove all ammables within 10m of the welding arc. If this is not
possible, tightly cover them with approved covers.
Do not weld where ying sparks can strike ammable material.
Protect yourself and others from ying sparks and hot metal.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Watch for re, and keep a re extinguisher nearby. Be aware that
welding on a ceiling, oor, bulkhead, or partition can cause re on
SAFETY

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the hidden side.
Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to local regulations
Connect work cable to the work as close to the welding area as
practical to prevent welding current from travelling along, possibly
unknown paths and causing electric shock, sparks, and re hazards.
Wear oil-free protective garments such as leather gloves, heavy
shirt, cu󰀪ess trousers, high shoes, and a cap. Remove any
combustibles, such as a butane lighter or matches, from your person
before doing any welding.
FLYING METAL can injure eyes.
Welding, chipping, wire brushing, and grinding cause sparks and
ying metal. As welds cool they can throw o󰀨 slag. Wear approved
safety glasses with side shields even under your welding helmet.
BUILD UP OF GAS can injure or kill.
Shut o󰀨 shielding gas supply when not in use. Always ventilate
conned spaces or use approved air-supplied respirator.
HOT PARTS can cause severe burns.
Do not touch hot parts with bare hands.
Allow cooling period before working on gun or torch.
To handle hot parts, use proper tools and/or wear heavy, insulated
welding gloves and clothing to prevent burns.
MAGNETIC FIELDS can a󰀨ect pacemakers.
Pacemaker wearers keep away.
Wearers should consult their doctor before going near arc welding,
gouging, or spot welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can damage hearing.
Wear approved ear protection if noise level is high.
Shielding gas cylinders contain gas under high pressure.
CYLINDERS can explode if damaged.
Protect compressed gas cylinders from excessive heat, mechanical
shocks, physical damage, slag, open ames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping. Keep cylinders
away from any welding or other electrical circuits. Never drape a
welding torch over a gas cylinder. Never allow a welding electrode to
touch any cylinder. Never weld on a pressurized cylinder - explosion
will result. Use only correct shielding gas cylinders, regulators,
hoses, and ttings designed for the specic application; maintain
them and associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Use the right equipment, correct procedures, and su󰀩cient number
of persons to lift and move cylinders.
Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
recommendations.
2.0 Product Description
This water cooling unit is designed to be integrated
with MIG and TIG welding equipment to provide cooling for water
cooled torches up to a rating of 500A. In addition the unit may be
used on small spot welding or other similar equipment up to a rating
of 60KVA .The small footprint allows the unit to be mounted on the
cylinder stand of most welding machines.
3.0 Technical
Specications
Machine Model
XTS-904 XTS-905
Weight empty (kg) 19.5 19.5
Weight full (kg) 27.5 27.5
Tank capacity (litres) 8.0 8.0
Motor rating 230V (A) 1.3 1.3
Motor power (KW) 0.3 0.3
Motor Speed (rpm) 2800 2800
Pump max. pressure (Bar) 4 4
Pump max head (m) 45 45
Pump max. flow (lpm) 8 8
Heat exchanger rating (W) 900 900
Max. water temperature (0C) 60 60
Min. water temperature (0C) 4 4
Max ambient temperature (0C) 40 40
Noise (dba) 74 74
SAFETY

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5.1 Unpacking the Machine
Carefully remove the unit from the packaging, we recommend you
retain the packaging until the unit has been fully installed and tested
incase it has been damaged in transit and has to be returned to the
re-seller.
5.2 Location
Be sure to locate the unit according to the following guidelines:
In areas, free from moisture and dust.
Ambient temperature between 0-400C.
In areas, free from oil, steam and corrosive gases.
In areas, not subjected to abnormal vibration or shock.
In areas not exposed to direct sunlight or rain.
Place at a distance of 12” (300 mm) or more from walls or similar
that could restrict natural airow for cooling.
Do not obstruct any of the cooling vents
4.0 Description of Controls
1) ON OFF Switch for switching on or o󰀨 the mains supply to the
machine. Note the output of the machine is permanently on unless
the on/o󰀨 switch is in the o󰀨 position.
2) Mains input fuse for protection of the unit in case of malfunction.
3) Water lling spout.
4) Water level indicator
5) Water return connection (Red). In
6) Water supply connection (Blue). Out
7) Mains input cable
5.0 Installation
Read entire installation section before starting installation.
SAFETY PRECAUTIONS
• ELECTRIC SHOCK can kill.
• Only qualied personnel should perform this installation.
• Only personnel that have read and understood the Operating
Manual should install and operate this equipment.
• Machine must be grounded per any national, local or other
applicable electrical regulations.
• The power switch is to be in the OFF position when installing
work cable and electrode cable and when connecting other
equipment.
1
2
4
3
CONTROLS
5
6
7
Part Rear
View
Part Rear
View

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5.3 Input and grounding connection
WARNING
Before starting the installation, check that your power supply
is adequate for the voltage, amperage, phase, and frequency
specied on the Machine nameplate.
Operate the water cooler in accordance with the voltage marked on
the cabinet.
XTS905 400V 50/60 Hz, AC power supply.
XTS904 230V 50/60 Hz, AC power supply.
The input voltage must match one of the electrical input voltages
shown on the input data label on the unit nameplate.
5.4 Output Connections
The Red Connection is the hot water return connection and should
be connected to the red hose on the welding torch or if connected
through the power source to the water drain connection.
The Blue Connection is the cold water supply connection and should
be connected to the blue hose on the welding torch or if connected
through the power source to the water supply connection.
Both hose connections are Type 21 Quick connections, if the water
cooler is mounted away from the power source/torch a hook up
extension kit my be used, refer to the parts list.
5.5 Coolant lling
Remove the ller cap (3) and ll the unit with Parweld UltraCool
until the Max mark is reached in the sight glass. Secure the ller
cap before starting the unit. There is not need to prime the pump
but on rst running the pump should be allowed to run with the torch
connected for 1 minute to ensure all air has been expelled from the
system before welding is started. After initial running rell the water
tank to the Max level.
Warning
Operating the unit without the use of Parweld
UltraCool will shorten the life of the pump and torch. UltraCool
contains special additive to lubricate the pump and prevent corrosion
in all parts of the system including the torch.
Glycol based uids should not be used as they
promote corrosion due to the electrical conductivity of the uid.
OPERATION

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the usage and the operating environment.
Warning
Disconnect primary power at the source before removing the cover.
Wait at least two minutes before opening the cover to allow the
primary capacitors to discharge.
To clean the unit, remove the screws securing the outer cover,
lift o󰀨 the outer cover and use a vacuum cleaner to remove any
accumulated dirt and dust. The unit should also be wiped clean with
a damp cloth.
Weekly 6 months 2 Years
Check coolant
level *
Check hoses for
kinks *
Blowout heat
exchanger *
Drain & replace
UltraCool *
6.0 Operation
Before switching on the unit ensure the header tank is full none of
the cooling vents are obstructed and the electrical connections are
secure.
Move the on/o󰀨 switch into the on position before operating the torch
or welding plant. Allow the water cooler to run for 5 minutes to allow
the air to be vented from the system if necessary un-clip the return
hose from the torch at various points until the water ows through.
7.0 Fault Finding
Description Possible cause Remedy
Unit does not
switch on
(a) The primary supply
voltage has not been
switched on
(b) The input voltage has
not been set correctly
(c) obstruction preventing
rotation of the pump
(a) Switch on the
primary supply
voltage
(b) check the input
voltage matches
that set on the unit
(c) Have a qualied
service engineer
disconnect the
power and the
remove the service
panel to check
rotation of the pump
Torch over
heats
Low coolant ow Check coolant level
is correct, check
for kinks in the
hoses and system
blockages.
Ensure cooling
vents on the unit are
not obstructed.
Blow out the heat
exchanger.
Welding torch
stops working
Low coolant ow Check coolant level
is correct, check
for kinks in the
hoses and system
blockages.
Have a service
engineer check the
operation of the ow
switch.
8.1 ROUTINE MAINTENANCE
The only routine maintenance required for the water cooler is a
thorough cleaning and inspection, with the frequency depending on
FAULT
FINDING

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FAULT
FINDING
9.0 Parts and Accessories
9.1 Accessories
Item Stock Code Description
NI XTSUC Parweld UltraCool coolant 10l
1 XTSH1 Hook up kit 1m
XTSH3 Hook up kit 3m
9.2 Spare parts
Item Description Stock Code
1Water Pump, 230V 764816
2Fan 974236
3Heat Exchanger 709945
4Water Tank, 8L 250435
5Auxiliary Transformer 050164
620mm fuse, 3A (230V) 921332
1
1
2
4
6
Male QF to
suit water
cooler
Female QF to
suit torch
3/8 BSP
adaptors
for tig
torches
5
3

10.0 EC declaration of conformity
Hereby we declare that the machines as stated below
Type: XTS-904, XTS-905
Conform to the EC Directives: 73/23/EEC and 89/336/EEC
European standard: EN/IEC 60974-1
This is to certify that the tested sample is in conformity with all provisions of the above detailed EU directives and product standards.
10.1 Rohs Compliance Declaration
Directive 2002/95/ec of the European Parliament
Restriction of use of certain hazardous substances in electrical and electronic equipment
Type: XTS-904, XTS-905
The above listed products are certied to be compliant with the rohs directive with all homogeneous component parts being controlled to
ensure material contents as per the list below.
Cadmium 0.01% by weight
Lead 0.1% by weight
Mercury 0.1% by weight
Hexavalent chromium 0.1% by weight
Polybrominated biphenyl’s (pbbs) 0.1% by weight
Polybrominated diphenyl ethers (pbdes) 0.1% by weight
It should be noted that under specic exempted applications, where lead is used as an alloying element the following limits are applied in
accordance with the regulations.
Copper and copper alloy parts use less than 4% by weight of each homogeneous component.
Steel and steel alloy parts use less than 4% by weight of each homogeneous component.
Aluminium and aluminium alloy parts use less than 4% by weight of each homogeneous component.
Only dispose o󰀨 in authorised sites for electrical and electronic waste do not dispose of with general refuse or landll waste.
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EC DECL’

10.2 WEEE Statement
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WEEE (Waste Electrical & Electronic Equipment) 2002/96/EC
In relation to implementing the legislation, Parweld has established relevant recycling and recovery methods. We have been fully compliant
against the marking requirements since August 2005. Parweld is registered in the UK with the Environment agency as detailed below. For
WEE compliance outside the UK please contact your supplier/Importer
Parweld is registered with a compliance scheme O󰀩cial registration number is WEE/FD0255QV
When your equipment reaches the end of its service life you should return it to Parweld where it will be reconditioned or processed for
recycling.
10.3 Statement of warranty
Limited Warranty:
Parweld Ltd, hereafter, “Parweld” warrants its customers that its products will be free of defects in workmanship or material. Should any failure
to conform to this warranty appear within the time period applicable to the Parweld products as stated below, Parweld shall, upon notication
thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Parweld’s specications,
instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident,
correct such defects by suitable repair or replacement, at Parweld’s sole option, of any components or parts of the product determined by
Parweld to be defective.
Parweld makes no other warranty, express or implied. This warranty is exclusive and in lieu of all others, including, but not limited to any
warranty of merchantability or tness for any particular purpose.
Limitation of Liability:
Parweld shall not under any circumstances be liable for special, indirect or consequential damages, such as, but not limited to, lost prots and
business interruption. The remedies of the purchaser set forth herein are exclusive and the liability of Parweld with respect to any contract, or
anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any
goods covered by or furnished by Parweld whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not,
except as expressly provided herein, exceed the price of the goods upon which such liability is based. No employee, agent, or representative
of Parweld is authorized to change this warranty in any way or grant any other warranty.
Purchaser’s rights under this warranty are void if replacement parts or accessories are used which in Parweld’s sole judgement may impair the
safety or performance of any Parweld product.
Purchaser’s rights under this warranty are void if the product is sold to purchaser by non-authorized persons.
The warranty is e󰀨ective for the time stated below beginning on the date that the authorized Distributor delivers the products to the purchaser.
Notwithstanding the foregoing, in no event shall the warranty period extend more than the time stated plus one year from the date Parweld
delivered the product to the authorized distributor.
WEEE

Parweld Limited
Bewdley Business Park
Long Bank
Bewdley
Worcestershire
England
DY12 2TZ
tel. [phone]
fax. [phone]
www.parweld.com
[email protected]