NSGV PT-1000 PORTABLE WELDING STATION I, O & M MANUAL

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2 APPLICATION OF DUST CONTROL EQUIPMENT: CAUTION - Warning Improper operation of dust control system may contribute to conditions in the work area or facility that could result in severe personal injury and product or property damage. Make certain that any dust or fume collection equipment is properly selected for the intended use. - Special care must be exercised in the installation, operation, and use of all dust collection equipment where combustible and/or explosive materials such as buffing lint, paper, wood, aluminum, or magnesium dust or weld fume present. These materials may present a fire and/or explosion hazard. The PT-1000 does not contain fire or explosion prevention equipment. - Under no circumstance should anyone, including the operator, allow any burning objects or lit cigarettes to enter the hood or ducting of any dust control system. - Avoid mixing combustible materials with sparks, such as those generated from the grinding of ferrous metals, due to the potential fire hazard created by sparks being pulled into dust collection equipment. - To ensure proper operation of this NSGV equipment, read and follow the instructions contained in this manual. Under no circumstances should the unit be modified. To ensure optimum collector performance, always use NSGV replacement filters and parts. INTRODUCTION The PT-1000 Portable Collector collects dust, smoke, and welding fumes before they reach the breathing zone. A halogen lamp lights the work area. When the light is positioned to illuminate the workspace, the intake is also properly positioned. The PT-1000 operates with conventional 120 volt, 15 amp wall receptacle. The collector is mounted on wheels so that it is easy to move to different work areas. It passes through a standard doorway. The handles can be retracted out of the way during use. The Ultra-Web filter has a propriety surface coating on the filter medium. This special barrier filters submicron size fume particles and retains them on the surface. In most applications, the element can be cleaned with compressed air and used again. INSTALLATION Inspection: The PT-1000 is normally shipped by common carrier and should be checked for any damage that may have occurred during shipping. Any damage should be noted and the carrier notified immediately. Electrical Operation: The PT-1000 requires only a 120 volt single phase 15 amp circuit to operate. The 65-watt halogen light and the on-off switch operate on a 12 volt circuit. The 1 1/2 HP motor is rated at 14 amps or less at 120 volts and is also supplied with an automatic thermal overload protection. OPERATION To start the PT-1000, turn the on-off switch that is mounted in the handle of the extraction arm hood. The on-off switch also controls the 65-watt halogen work-light mounted in the hood. Fume or dust enters through the hood and then onto the filter element, where it is collected on the outside surfaces of the pleated filter element. Clean air flows up through the center of the filter cartridge into the blower, through the silencer section of the cabinet, and exits through the top clean air outlet. The hood is usually located 12 to 18 inches above the arc zone, depending upon the type of welding. With the hood in this general location, the lamp at the end of the arm should be positioned to light the work area. The air intake is now in a good position to collect fumes and smoke being generated by the welding operation. The arm rotates 259º and has three flexible joints for optimal positioning of the intake hood. Friction devices are located in each flexible joint to hold the hood where it is needed. 1

3 OPERATION cont. The PT-1000 can easily be rolled to where it is needed by pulling out on the two handles until the stop on each side is engaged. The handles are retracted into the cabinet by pressing down on the release button while sliding the handle back into the cabinet. Push & Hold Down to Retract Handle MAINTENANCE Filter Element Removal 1. Loosen the two door latches that secure the front access panel access by turning them counter-clockwise and open. 2. Grasp the filter element with two hands, twist it, and pull straight toward the collector opening to remove it from the cabinet. 3. Place the filter element in a large plastic bag to retain particulate and dispose of properly. Filter Replacement 1. Inspect the gasket material located at the top and bottom of the filter plenum for dust and/or damage. Clean with a damp cloth or replace before installing the new filter. 2. Insert the new or cleaned filter, rotating it slightly while sliding it into place. Push the filter back until it is centered against the stops inside the cabinet filter plenum. 3. Inspect the front access panel gasket and repair or replace if necessary to insure an airtight seal. 4. Close the front access panel on the cabinet and turn the two door latches clockwise. NOTE: - Do not use solvents to clean the filter seal gaskets inside the collector. - If the front access panel is damaged, leakage may result. Replace the gasket if necessary. - Do not operate the collector without the door closed or electrical overload will occur. - Do not operate the collector without the filter element or electrical overload will occur. 2

4 TROUBLESHOOTING TROUBLE POSSIBLE CAUSE REMEDY Blower wheel and motor do not start. 1. Electrical supply circuit is down. 1. Check the electrical supply circuit for proper output voltage, fuse, or circuit breaker fault. 2. Fuses have blown in the control box. 2. CAUTION: Disconnect the electrical power to the arm and open the access panel. Remove the electrical control box cover to access fuse(s) on the control panel/ With a volt ohm electrical meter, check for blown fuses in the electrical control box and disconnect. If fuses are blown, replace as needed. 3a. Transformer has failed (single phase system). 3a. Using a volt ohm meter, check the input voltage on terminals H1 and H4 (it should be 120 volts AC). Next, check output voltage on X1 and X2 terminals (it should be 12 volts AC). If there is no output voltage, replace the transformer. 3b. Transformer has failed (three phase system). 3b. Using a volt ohm meter check the input voltage on terminals H1 and H4 on the primary transformer feed-lines. Look at the voltage rating on the transformer that is rated for your input voltage. Check that the proper shorting bars or jumper wires have been installed per your voltage requirements. Next, check the fuse on the X1 terminal and if it is blown out, replace with a MDX 3 amp fuse. Then check the output voltage on X1 and X2 terminals (it should be 120 volts AC). If there is no output voltage, replace the transformer. 4. Relay 12 volt AC has failed. 4. With the arm hood switch on, check with a volt ohm meter for 12 volts AC input to the relay. Next, check for 120 volts AC input and output on the relay socket terminals. If there is no voltage output, replace the 12 volt AC relay. 5. Heater motor overload 5. With the arm hood switch on, check with a volt ohm meter for voltage protection has failed. inputs and outputs and outputs on contactor through the heater terminals. Be sure before testing, that the heater thermal protection has cooled to reset. If there is no voltage output, replace the heater overload relay. 6. Starter contactor has failed. 6. With the arm hood switch on, check with a volt ohm meter for 120 volts AC input to starter coil. No input, check the thermal overload protection. Next, check for supply voltage input and output of the contactor terminals. If 120 volt AC input to coil relay is okay on starter contactor and it still does not function, replace the starter contactor. Blower wheel and motor start, but do not keep running. 1. Supply circuit is not adequate. Check for sufficient amperage to run the arm (reference the nameplate on the motor for amperage and voltage requirements). Also check to see that there is not too much other equipment on your supply circuit. 2. Collector front access panel is open or not closed tight. 2. Check to see that the front access panel is closed securely. Turn the latches clockwise to tighten. 3

5 TROUBLESHOOTING cont. TROUBLE POSSIBLE CAUSE REMEDY Blower wheel and motor start, but do not keep 3a. Starter kicks out (too much airflow for blower and motor). 3a. Check that all the flexible ducting is installed onto the joint assemblies and that it is not torn or damaged. Replace if necessary. running (continued). 3b. Starter kicks out (wire size on 3b. Check for proper wire size on electrical supply lines. Too small of a the supply circuit is incorrect). supply wire will cause motor overload. Re-wire per local and national codes. 3c. Starter kicks out (Motor is wired incorrectly). 3c. Wiring is incorrect per motor manufacturer s wiring diagram (reference motor manufacturer s wiring diagram and correct wiring per supply voltage located on nameplate and). Insufficient airflow at 1. Motor and blower rotation are 1. Check motor rotation by looking down from the top of the motor. The hood. backward. rotation should be clockwise. Also reference the sticker on the blower housing. To correct blower rotation on single phase motors, reference the motor manufacturer s wiring diagram located on the motor. 2. Arm damper is closed. 2. Locate the damper control handle and move the handle to be in-line with the rigid ducting. This will be the wide open setting. 3. Obstruction in ducting or hood. 3. Check the hood, ducting, & flex duct for blockage. Remove any debris that is blocking airflow. 4. Flexible ducting is torn or collapsed, or the rigid ducting is 4. Check the flexible ducting and replace any damaged parts. Check the rigid ducting for cracks or collapsed section(s). broken or collapsed. 5. Fan exhaust area restricted. Check the blower exhaust area for blockage. Remove any debris that is blocking the blower area. Also remove all material that may be stored on top of the collector such as boxes and tools. 6. Filter plugged. 6. Clean or replace the filter by following the steps on Page 2. Visual discharge of dust 1. Filter cartridge is leaking. 1. Remove and inspect the filter cartridge. If the filter end caps have been or fume at collector bent or dented, or if any of the filter media appears to be damaged, replace it exhaust. by using only a genuine Ultra-Web filter. See Page 2 for replacement. 2. Filter gasket seals are 2. Remove the filter and inspect the gasket seal area for visual damage or damaged. debris on the gasket. Clean or replace the gasket. See Page 2. 4

6 REPLACEMENT PARTS LIST REERENCE NUMBER DESCRIPTION REFERENCE NUMBER DESCRIPTION 1 Filter Element Ultra-Web Wheel 2 Door 13 Tube Handle 3 Gasket, Fold Out 14 Rubber Handle 4 Foam Top (Specify 2 x 5 ) 15 Motor Wheel Assembly 1 1/2 hp 4 Foam Door (Specify 3 x 5 ) 16 Motor 1 1/2 HPVT 1/60/115 5 Door Latch, Vise Action 17 Fan Inlet Ring 6 Hinge, Lift Off 18 Fan.625 Bore 7 Gasket, Bottom (Filter) 19 Motor Mounting Plate 8 Gasket, Top (Filter) 20 Pad, Rubber 9 Panel Top 21 Knob, Plastic Push/Pull 10 Axle Shaft 22 Control Panel Assembly 1/60/ Axle Cap