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EN Operation instructions page 2 Original Instructions Ref 2021-05 250 400www.fumefree.net 2 Contents 1. The Falcon 250 & 400 Extractors Welding Torch 3 2. Safety 4 3. Technical specification 5 4. Unpack and Assemble before use 5 5. Installation and connection 5 6. Use of the equipment 7 7. Troubleshoot 8 8. Maintenance 9 9. Replace and Repair 10 10. De-installation 14 11. Shipment, storage and disposal 15www.fumefree.net 3 1. The Falcon 250 & 400 Extractors Welding Torch The Falcon 250 & 400 Extractors is a patented MIG welding torch with integrated extraction at the noz- zle of the welding torch. Therefore the extraction is close to the weld pool, so the fumes coming from the welding process are extracted immediately. As a result the welder is exposed up to 90% less welding fumes. Because of the conic shape of the nozzle, the protective gas exits at a high speed and is not sucked away by the extraction. The quality of the welding process remains the same as with a welding torch without integrated extraction. The welding torch is delivered ‘ready to use’. It only has to be connected to a welding machine and extraction unit. The Falcon 250 & 400 Extractors welding torch is available in a gas- and water-cooled version. The welding torches in this manual have been build in compliance with: • EN 60974-7 Arc Welding Equipment Part 7: Torches • 2014/35/EU Low Voltage Directive • 2014/30/EU Electromagnetic Compatibility The welding torch is only to be used by experienced personnel. It is not allowed for untrained persons to install, handle or maintain our welding torches. Welding torches must be checked regularly in order to guaranty optimum life time expectancy. The user is fully responsible for possible defects arising out of misuse, inadequate maintenance, damage, poor repair, or modifications by other parties than the original manufacturer, or his authorised dealers. The welding torch is a component of a complete welding system. The torch will generate an electric arc when connected with the appropriate welding machine. Ensure that you read the welding machine’s instructions thoroughly before using our welding torches. The manufacturer reserves the right, whenever necessary and without prior notice, to amend these instructions as a result of clerical or printing errors, incorrect information, or the addition of improvements.www.fumefree.net 4 2. Safety WARNING READ THESE SAFETY INSTRUCTIONS CAREFULLY. Failure to observe these safety instructions can lead to serious injury and/or damage to the product. Only operators with relevant knowledge of arc welding should use this product. • The vibration of the welding torch is less than 2.5m/s². No special precautions are required related to vibrations. • Arc welding can injure eyes, burn skin and cause hearing damage. Therefore: - Use welding shield with filter complying with respectively the EN 175 and EN 379 standards. - Wear proper protective clothing and ear protection. - Make sure others are protected (e.g. curtains) from arc rays and flashing. • Remove all combustible materials – including liquid and gaseous fuels, cloth, sawdust, wood, paints and solvents - from the work area or completely cover the materials with a protective non-flamma- ble covering. Fire extinguishing equipment should be ready at hand for instant use. Pay attention to spatter/dross created during welding; sparks can cause fire several hours after welding has finished! • Work pieces must be completely cleaned so that no substances on the material, such as chlorinated solvents, can produce flammable or toxic vapours. • Do not weld containers that have held combustibles. • Always check cables before operating the machine. Defective cables may cause injury and/or fire. • Do not make temporary repairs. Repairs should be made by qualified personnel. • Do not pull cable assembly across sharp edges or expose to welding spatter or hot surface. • To prevent electric shock, isolate yourself by using proper protective clothing and insulating mats. DO NOT wear wet clothing! • Do not exceed power rating. Overload can lead to torch damage, destruction and/or injuries. • Turn off primary power before working on torch parts and/or replacing consumables. • Do not breathe fumes or gases from welding. Welding fumes are harmful; lead, cadmium, copper, zinc, mercury, stainless steel, galvanised steel and beryllium in particular. Therefore, use ventilation or an extraction system to ensure that Maximum Admissible Concentration of harmful substances (MAC) level is not exceeded. • Use proper gas for the welding process (argon or helium) and pressure reducing regulator. • Keep cylinders in an upright position. When not in use, keep cylinder valves closed. Keep cylinders awa y from heat, sparks or flame. • Follow the pressurised gas manufacturer’s operating instructions for mounting the regulator to the gas cylinder.www.fumefree.net 5 3. Technical specification Falcon 250 Falcon 400 Cooling AIRAIR Power rating - Mixed gas - CO2 250A 280A 400A 450A Duty cycle 100%100% Contact tipØ 0.8- 1.2mm Ø 0.8- 2.4mm Extraction flow rate between 55 and 60m³/h between 55 and 60m³/h Gas flow rate 15-16 l/min 16-18 l/min 4. Unpack and Assemble before use The delivered welding torch is ready to use with a contact tip of 1,0mm for Falcon and 1.2mm for Falcon 400. To use a contact tip with other diameter, see chapter 9. The welding torch package should contain: • Welding torch assembly • Gas flow meter • Nozzle cleaning brush • Multitool. 5. Installation and connection Step 1: mount torch on welding machine 1a 1a. Air cooled - Plug in (A) the welding connection and fasten (B)www.fumefree.net 6 Step 2: Place Y-piece in desired position 1 2 4 5 6 1. Untighten connection ring 2. Remove suction-hose connection 3. Place Y-piece into desired position 4. Rotate suction-hose connection into most convenient position 5. Push suction-hose connection into Y-piece 6. Tighten connection ring. Step 3: Place External suction hose 1 2 1. Place external suction hose into Y-piece 2. When using special 8XE adapter; rotate adapter into lock position. www.fumefree.net 7 6. Use of the equipment Start-up 1. Switch on the extraction unit 2. Extraction flow rate must be between 55 and 60m³/h at nozzle 3. Switch on the welding machine 4. Check the protective gas flow with the special gas flow meter delivered with the torch Gas flow rate must be 16-18 l/min at nozzle. For MINI torch 15-16 l/min. Use The torch can be used like any other MIG welding torch. The functionality depends on the settings of the welding machine. Important! Don’t use Anti Spatspray or Paste, only Ceramic spray (ask your dealer for more details). Shutdown 1. Switch off the welding machine 2. Switch off the extraction unit, only if not used for other equipment.www.fumefree.net 8 7. Troubleshoot SymptomPossible causes No arc• Power to work piece or swan neck interrupted. • Defect power source or control unit. • Control signal is interrupted (cable). • Switch protection in the power source is not activated. Arcing to the work piece• Nozzle is contaminated. Poor or no smoke extraction• Extraction unit is not switched on. • Extraction flow is less than 55m3/h. • Filter of the extraction unit is contaminated. • Torch is externally damaged. Swan neck overheats• Insufficient cooling water flow (when water cooled). • Cooling water lines are blocked (when water cooled). • Duty cycle exceeds the value allowed for the torch. • Contact tip or tip adapter not properly fastened. • Torch is externally damaged. Welding wire fuses with the contact tip • Welding wire transport starts to late. • Welding wire is jammed inside the cable package due to con- tamination or bending. • Welding wire speed is too low. • Distance between the contact tip and the work piece is too big. • Contact tip overheats. Contact tip overheats• Insufficient cooling water flow (when water cooled). • Cooling water lines are blocked (when water cooled). • Duty cycle exceeds the value allowed for the torch. • Contact tip or tip adapter not properly fastened. • Torch is externally damaged. Irregular welding wire feed• Pressure of the welding wire supply rolls is too low. • Defect in the welding wire feed hose. • Wrong liner is installed. • Defect control unit. • Excessive wear of the welding wire supply rolls. • Wrong welding wire supply rolls installed. Porosity• Nozzle opening or contact tip is contaminated. • Insufficient gas shielding (gas flow). • Air flow disturbs the gas shielding. • Liner nut not tightened correctly. • Wrong liner is installed.www.fumefree.net 9 8. Maintenance WARNING ALWAYS SWITCH OFF THE WELDING MACHINE AND EXTRACTION UNIT BEFORE YOU REMOVE PARTS OF THE TORCH. Daily Regularly check if the protective gas and extraction openings are clean. If necessary remove the nozzle and clean the opening with the brush. Weekly Clean liner 1. When necessary, remove welding wire from the assembly 2. Use a compressed air cleaning gun to clean inside liner. Next >