Lincoln Electric DOWNFLEX 200 Instruction Manual
Lincoln Electric DOWNFLEX 200 Instruction Manual

Lincoln Electric DOWNFLEX 200 Instruction Manual

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DOWNFLEX 200/400
For use with machines having Code Numbers:
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 READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 888.935.3878 FAX: 216.383.8823 WEB SITE: www.lincolnelectric.com
K2751-2, K2751-3, K2751-4,
CK 2751-2, CK 2751-3, CK 2751-4,
CK 2751-25, CK 2751-35
INSTRUCTION MANUAL
• World's Leader in Welding and Cutting Products •
Copyright © Lincoln Global Inc.
IM10013
1RYHPEHU, 2011

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  • Page 1 IM10013 DOWNFLEX 200/400 1RYHPEHU, 2011 K2751-2, K2751-3, K2751-4, For use with machines having Code Numbers: CK 2751-2, CK 2751-3, CK 2751-4, CK 2751-25, CK 2751-35 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However,...
  • Page 2 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.
  • Page 3 5.e. Read and understand the manufacturerʼs instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employerʼs safety practices. MSDS forms are available from your welding distributor or from the manufacturer. 5.f. Also see item 1.b. DOWNFLEX 200/400...
  • Page 4 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. Refer to http://www.lincolnelectric.com/safety for additional safety information. DOWNFLEX 200/400...
  • Page 5 3. Avant de faires des travaux à lʼinterieur de poste, la debranch- er à lʼinterrupteur à la boite de fusibles. 4. Garder tous les couvercles et dispositifs de sûreté à leur place. DOWNFLEX 200/400...
  • Page 6 We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.
  • Page 7: Table Of Contents

    Connection To The Input Power ..................A-10 Direction Of Rotation ......................A-11 Operation.........................Section B General Description......................B-1 Operation..........................B-1 Safety Precautions .......................B-1 Filter Replacement .......................B-3 Downflex 200-M (Only) ......................B-5 Downflex 400-MS (Only) ......................B-6 Downflex 400-MS/A (Only)....................B-7 Accessories .....................Section C Options / Accessories....................C-1 Maintenance........................Section D Safety Precautions .......................D-1 Maintenance.........................D-1...
  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS - DOWNFLEX 200/400 DIMENSIONS L x W x H Downdraft Table 54.3 x 39.4 x 36.2 in. (1380 x 1005 x 920 mm) Downdraft Table incl. Backdraft Kit and Side Panels 54.3 x 39.4 x 60.8 in. (1380 x 1005 x 1543 mm) HEIGHT ADJUSTMENT 36 - 38 in.
  • Page 9: General Description

    A. Backdraft kit B. Side panels (left + right) C. Work grid (two-piece) D. Control panel E. Left door (controls/fan) F. Power outlet G. Right door (filter compartment) H. Compressed air tank (DownFlex 400-MS and DownFlex 400-MS/A only) DOWNFLEX 200/400...
  • Page 10 2. Place the narrowing plates (C). See Figure A.5. 3. Place the backdraft panel (A). See Figure A.5. 4. Fasten the narrowing plates and the backdraft panel using the 8 bolts (B). See Figure A.5. The supplied cover strip is not used. DOWNFLEX 200/400...
  • Page 11 4. Fasten the frames using the 2 bolts (B). See Figure A.6. NOTE: It is necessary to install the bolts to ground the work grids. 5. Place the bars (C). See Figure A.6. NOTE: The supplied standard work grid and the ground bracket are not used. DOWNFLEX 200/400...
  • Page 12: Installation Of Remaining Options

    To mount the HEPA kit, proceed as follows. 1. Unscrew and remove the outlet panel from the downdraft table. Keep he 4 screws See Figure A.8, top image. 2. Apply the draft strip to the downdraft table (A). See Figure A.8. DOWNFLEX 200/400...
  • Page 13 1. If necessary: unscrew the outlet panel of the down- draft table or the outlet panel of the HEPA kit. Keep the 4 bolts. E (x4) 2. Apply the draft strip to the downdraft table (A) or HEPA kit (B). See Figure A.9. DOWNFLEX 200/400...
  • Page 14 FIGURE A.10 – WORKING LIGHT panel using the 3 tie-wraps (B). See Figure A.12. 4. Connect the cable. See Figure A.11, item A. FIGURE A.12 – MOVEMENT SENSOR A (x6) A (x2) B (x3) B (x3) FIGURE A.11 – CONNECTIONS DOWNFLEX 200/400...
  • Page 15 POSITIONING BRACKET The downdraft table can be positioned using: • A fork-lift truck (preferred way); or • A pallet jack (downdraft table has to be tilted); or • Cargo lashings lifted by a fork-lift truck. See Figure A.14. DOWNFLEX 200/400...
  • Page 16: Electrical Connection

    Default setting of the motor is 480V. Depending on the local input power voltage, the setting could be changed 50 mm to 208/240V. This concerns both the motor and the transformer. WARNING Make sure the downdraft table is disconnected from input power. ------------------------------------------------------------------------ DOWNFLEX 200/400...
  • Page 17: Connection To The Input Power

    4. Close and lock all doors. Canada Electrical Diagram 208-240V 480V 600V Figure # Figure # Figure # DownFlex 200-M Figure F.1 Figure F.2 Figure F.3 DownFlex 400-MS Figure F.4 Figure F.5 Figure F.6 DownFlex 400-MS/A Figure F.7 Figure F.8 Figure F.9 DOWNFLEX 200/400...
  • Page 18: Direction Of Rotation

    Check the direction of rotation of the fan. 1. Turn on the main switch. 2. Push the ON button to switch on the fan. 3. Push the OFF button to switch off the fan. 4. Wait 20 seconds. 5. Open the left door. DOWNFLEX 200/400...
  • Page 19: Operation

    DOWNFLEX 200-M sure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local The main filter cartridges of the DownFlex 200-M are disposable. A Magnehelic gauge on the control panel exhaust or mechanical ventilation. In confined...
  • Page 20 • Make sure that the workshop in the vicinity of the product, contains sufficient approved fire extin- guishers. • Maintenance should only be performed by autho- rized, qualified and trained persons (skilled) using appropriate work practices. • Always wear face mask and gloves during filter exchange / cleaning. DOWNFLEX 200/400...
  • Page 21: Downflex 400-Ms Only

    11. Replace new filter cartridges in unit. 12. Close the door and turn on main switch. 13. Reset PLC (DownFlex 400-MS/A model only)by pushing the ON/OFF button and hold for 20 sec- onds until the buzzer emits a continuous sound. DOWNFLEX 200/400...
  • Page 22 5. Clean filter housing, using a HEPA industrial vacu- um cleaner and wet wiping techniques. 6. Replace new HEPA filter cartridge. 7. Close the door. 8. Dispose of materials in accordance with federal, state and/or local regulations. DOWNFLEX 200/400...
  • Page 23 OPERATION DOWNFLEX 200-M (Only) FILTER REPLACEMENT 1. During use, regularly check the Magnehelic gauge CONTROL PANEL (B). When the pressure reaches 0.25 psi (1700 Pa), the filter cartridges need to be replaced. See The control panel is equipped with the following con- Figure B.2.
  • Page 24 4. Refer to Filter Replacement for the filter replace- See Figure B.3. ment procedure. 3. Start welding/grinding. 4. After finishing welding/grinding, push the ON/OFF button (C) to switch off the fan. See Figure B.3. 5. Turn switch (A) off to remove the main input power. DOWNFLEX 200/400...
  • Page 25: Downflex 400-Ms/A (Only

    • After finishing welding welding / grind- machine. ing, push the ON • Start welding. / OFF button (C) The fan will start to switch off the and stop auto- fan. matically. DOWNFLEX 200/400...
  • Page 26 (D) to deactivate the buzzer (E). See Figure B.4. 2. Push the ON/OFF button (C) to switch off the fan. See Figure B.4. 3. Wait 20 seconds for fan to stop rotating. 4. Refer to Filter Replacement for the filter replace- ment procedure. DOWNFLEX 200/400...
  • Page 27: Accessories

    Specially constructed work grid suitable for plasma cut- ting, including additional perforated steel spark arresters. The plasma cutting work grid is required for plasma cutting applications (max. 50 A). The addition- al perforated steel spark arresters protect the prefilters already present. DOWNFLEX 200/400...
  • Page 28 When the dust drawer underneath the main filter cartridges needs to be emp- tied, the plastic bag and the personal protection equip- ment enable dust free removal. FIGURE C.1 – OPTIONS C (x2) L (x5) DOWNFLEX 200/400...
  • Page 29: Maintenance

    Engine manual as well. ----------------------------------------------------------- DOWNFLEX 200-M MAINTENANCE The main filter cartridges of the DownFlex 200-M are disposable. The product has been designed to be reliable for extended periods of time with reasonable mainte- DOWNFLEX 400-MS nance. In order to guarantee optimal performance...
  • Page 30 Check for damage and correct installation. Replace if necessary. spark arresters (underneath plasma work grid) * Text printed in italics refers to options and accessories. DISPOSAL After life of the product, dispose it of in accordance with state or local regulations. DOWNFLEX 200/400...
  • Page 31 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 32 * Text printed in Bold refers to options and accessories. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. DOWNFLEX 200/400...
  • Page 33 * Text printed in Bold refers to options and accessories. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. DOWNFLEX 200/400...
  • Page 34 * Text printed in Bold refers to options and accessories. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. DOWNFLEX 200/400...
  • Page 35 DIAGRAMS FIGURE F.1 – 548677 DOWNFLEX 200-M (208-240V/3~/60HZ) (USA) DOWNFLEX 200/400...
  • Page 36 DIAGRAMS FIGURE F.2 – 548677 DOWNFLEX 200-M (480V/3~/60HZ) (USA) DOWNFLEX 200/400...
  • Page 37 DIAGRAMS FIGURE F.3 – 548677 DOWNFLEX 200-M (600V/3~/60HZ) (CANADA) DOWNFLEX 200/400...
  • Page 38 DIAGRAMS FIGURE F.4 – 548651 DOWNFLEX 400-MS (208-240V/3~/60HZ) (USA) DOWNFLEX 200/400...
  • Page 39 DIAGRAMS FIGURE F.5 – 548651 DOWNFLEX 400-MS (480V/3~/60HZ) (USA) DOWNFLEX 200/400...
  • Page 40 DIAGRAMS FIGURE F.6 – 548651 DOWNFLEX 400-MS (600V/3~/60HZ) (CANADA) DOWNFLEX 200/400...
  • Page 41 DIAGRAMS FIGURE F.7 – 548636 DOWNFLEX 400-MS/A (208-240V/3~/60HZ) (USA) DOWNFLEX 200/400...
  • Page 42 DIAGRAMS FIGURE F.8 – 548636 DOWNFLEX 400-MS/A (480V/3~/60HZ) (USA) DOWNFLEX 200/400...
  • Page 43 DIAGRAMS FIGURE F.9 – 548636 DOWNFLEX 400-MS/A (600V/3~/60HZ) (USA) DOWNFLEX 200/400...
  • Page 44 NOTES DOWNFLEX 200/400...
  • Page 45 NOTES DOWNFLEX 200/400...
  • Page 46 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. • • • WARNING electrode with skin or wet clothing. Insulate yourself from work and • ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el •...
  • Page 47 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or • • • Use ventilation or exhaust to guards off. WARNING • remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- •...
  • Page 48 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...

This manual is also suitable for:

Downflex 400

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