Miller KF996056 Le manuel du propriétaire

AUTO

ARCJ

February

1996

Form:

OM-151

0160

Effective

With

Serial

No.

KF996056

OWNERS

MANUAL

U

Read

and

follow

these

instructions

and

all



Give

this

manual

to

the

operator.



safety

blocks

carefully.

Have

only

trained

and

qualified

persons

install,

operate,

or

service

this

unit.

Call

your

distributor

if

you

do

not

understand

the

directions.



ri~ij

U

For

help,

call

your

distributor



or:

MILLER

Electric

Mfg.

Co.,

P.O.

Box

1079,

Appleton,

WI

54912

414-734-9821

Auto

Arcﬁ

140



CV/DC

Welding

Power

Source/Wire

Feeder



For

GMAW

And

FCAW

Welding



120

Amperes,

21

Volts

At

30%

Duty

Cycle



Uses

230

Volts

AC,

Single-Phase

Input

Power



Feeds

.023

Thru

.035

Wire



Overheating,

Short-Circuit,

And

Motor

Overload

Protection



Includes

Gas

Valve

auto_am

7/93



ST-149

628-B

PRINTED

IN

USA

LIMITED

WARRANTY

Effective

February

7,

1996

(Equipment

with

a

serial

number

preface

of

KD

or

newer)

This

limited

warranty

supersedes

all

warranties

and

is

exclusive

with

no

other

guarantees

or

warranties

expressed

or

implied.

LIMITED

WARRANTY



Subject

to

the

terms

snd

conditions

below,

warranta

to

its

original

retail

purchaser

that

new

equipment

sotd

aher

the

effective

date

ot

this

lim

ited

warranty

is

tree

ot

detects

in

material

and

workmanship

at

the

time

it

is

shipped

from

factory

THIS

WARRANTY

IS

EXPRESSLY

tN

LIEU

OF

ALL

OTHER

WAR

RANTIES,

EXPRESS

OR

IMPLIED,

INCLUDING

THE

WARRANTIES

OF

MER

CHANTABILITY

AND

FITNESS.

Within

the

warranty

periods

listed

below,

manutacturer

wilt

repairor

replace

any

war

ranted

parts

or

components

that

tail

due

to

such

detects

in

material

or

workmanship.

Manufacturer

must

be

notified

in

writing

within

thirty

(30)

days

of

such

detect

or

tail

ure,

at

which

time

manutacturer

will

provide

instructions

on

the

warranty

claim

pro

cedures

to

be

tollowed.

Manutacturer

shall

honor

warranty

claims

on

warranted

equipment

listed

below

in

the

event

of

auch

a

failure

within

the

warranty

time

periods.

All

warranty

time

periods

atari

on

the

date

that

the

equipment

was

delivered

to

the

original

retail

purchaser,

or

one

year

affer

the

equipment

is

sent

to

a

North

American

distributor

or

eighteen

months

aher

the

equipment

is

aent

to

an

International

diatributor.

1.

5YearaParta3YearaLabor



Original

main

power

rectitiera



Invertera

(input

and

output

rectitiera

only)

2.

3

Years



Parts

and

Labor



Tranatormer/Rectitier

Power

Sources



Plasma

Arc

Cuaing

Power

Sourcea

*

Semi-Automatic

and

Automatic

Wire

Feeders



Inverter

Power

Supplies



Intellitig



Robots

(1

year

labor)

3.

2

Years



Parts

and

Labor



Engine

Driven

Welding

Generators

(NOTE;

Engines

are

warranted

separately

by

the

engine

manufacturer.)

-

Air

Compressors

4.

1

Year



Parts

and

Labor



Motor

Driven

Guns

Process

Controllers



IHPS

Power

Sources



Water

Coolant

Systems

HF

Units



Grida



Spot

Welders



Load

Ba~ka



SDX

Transformers

-

Running

Gear/Trailers



Plaama

Cuffing

Torches

(eacept

APT,

ZIPCUT

&

PLAZCUT

Models)



Tecumaeh

Engines

*

Deutz

Engines

(outside

North

America)

-

Field

Options

(NOTE;

Field

options

are

covered

under

the

limited

warranty

for

the

re

maining

warranty

period

of

the

product

they

are

installed

in,

or

for

a

mini

mum

ot

one

year



whichever

ia

greater.)

6

Montha



Baneries

6.

90

Days



Parts

and

Labor

MIG

Guna/TIG

Torches



APT,

ZIPCUT

&

PLAZCUT

Model

Plasma

Cutting

Torches



Remote

Controls



Accessory

Kits



Replacement

Parts

Umited

Warranty

shall

not

apply

to;

1.

Items

tumished

by

manufacturer,

but

manutactured

by

others,

such

as

engines

or

trade

accessories.

These

items

are

covered

by

the

manufacturers

warranty,

if

any.

2.

Consumable

components;

auch

as

contact

tips,

cuffing

nozzles,

contactora

and

relays

or

parts

that

tail

due

to

normal

wear.

3.

Equipment

that

has

been

modified

by

any

party

other

than

manufacturer,

or

equipment

that

has

been

improperly

installed,

improperiy

operated

or

misused

based

upon

industry

standards,

or

equipment

which

haa

not

had

reaaonable

and

necessary

maintenance,

or

equipment

which

has

been

uaed

for

operation

outside

of

the

apecificationa

for

the

equipment.

MANUFACTURERS

PRODUCTS

ARE

tNTENDED

FOR

PURCHASE

AND

USE

BY

COMMERCIAL/INDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPE

RIENCED

IN

THE

USE

AND

MAINTENANCE

OF

WELDING

EOUIPMENT.

In

the

event

of

a

warranty

claim

covered

by

this

warranty,

the

eaclusive

remedies

shall

be,

at

manufacturers

option;

(I)

repair;

or

(2)

replacement;

or,

where

authorized

in

writing

by

manufacturer

in

appropriate

cases,

(3)

the

reaaonabte

coat

of

repair

or

replacement

at

an

authorized

service

station;

or

(4)

payment

of

or

credit

for

the

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

return

of

the

goods

at

customers

risk

and

expense.

Manufacturers

option

of

repair

or

replace

ment

will

be

FOB.,

Factory

at

Appleton,

Wisconsin,

or

FOB.

at

an

authorized

ser

vice

facility

as

determined

by

manufacturer.

Therefore

no

compensation

or

reim

bursement

for

transportation

coats

of

any

kind

will

be

allowed.

TO

THE

EXTENT

PERMITTED

BY

LAW,

THE

REMEDIES

PROVIOED

HEREIN

ARE

THE

SOLE

AND

EXCLUSIVE

REMEDIES.

IN

NO

EVENT

SHALL

MANUFAC

TURER

BE

LIABLE

FOR

DIRECT,

INDIRECT,

SPECIAL,

INCIDENTAL

OR

CON

SEOUENTIAL

DAMAGES

(INCLUDING

LOSS

OF

PROFIT),

WHETHER

BASED

ON

CONTRACT,

TORT

OR

ANY

OTHER

LEGAL

THEORY.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WAR

RANTY,

GUARANTY

OR

REPRESENTATION

AS

TO

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

OF

CONTRACT

TORT

OR

ANY

OTHER

LEGAL

THEORY

WHICH,

BUT

FOR

THIS

PROVISION,

MIGHT

ARISE

BY

IMPLICATION,

OPERATION

OF

LAW,

CUSTOM

OF

TRADE

OR

COURSE

OF

DEALING.

IN

CLUDING

ANY

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OR

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

TO

ANY

AND

ALL

EOUIPMENT

FURNISHED

BY

MANUFACTURER

IS

EXCLUDED

AND

DISCLAIMED

BY

MAN

UFACTURER.

Some

states

in

the

U.S.A.

do

not

allow

limitations

of

how

long

an

implied

warranty

lasts,

or

the

exclusion

of

incidental,

indirect,

special

or

consequential

damages,

so

the

above

limitation

or

exclusion

may

not

apply

to

you.

This

warranty

provides

ape

cific

legal

rights,

and

other

rights

may

be

available,

but

may

vary

1mm

state

to

state.

In

Canada,

legislation

in

some

provincea

provides

for

certain

additional

warranties

or

remedies

other

than

as

stated

herein,

and

to

the

extent

that

they

may

not

be

waived,

the

limitationa

and

exclusions

act

out

above

may

not

apply.

This

Limited

Warranty

providaa

specific

legal

rights.

and

other

rights

may

be

available,

but

may

vary

from

province

to

province.

I

r......

I

RECEIVING-HANDLING

Before

Unpacking

equipment,

check

carton

for

any

damage

that

may

have

occurred

during

shipment.

File

any

claims

for

loss

or

damage

with

the

delivering

carrier.

Assistance

for

filing

or

settling

claims

may

be

obtained

from

distributor

and/or

equipment

manufacturers

Transportation

Department.

When

requesting

information

about

this

equipment,

always

provide

Model

Designation

and

Serial

or

Style

Number.

Use

the

following

spaces

to

record

Model

Designation

and

Serial

or

Style

Number

of

your

unit.

The

information

is

located

on

the

rating

label

or

nameplate.

Model

__________

Serial

or

Style

No.

Date

of

Purchase

brand_acct

3/96

ARC

WELDING

SAFETY

PRECAUTIONS

ELECTRIC

SHOCK

can

kill.

Touching

live

electrical

parts

can

cause

fatal

shocks

or

severe

bums.

The

electrode

and

work

circuit

is

electncafly

live

whenever

the

output

is

on.

The

Input

power

circuit

and

machine

Internal

circuits

are

also

live

when

power

is

on.

In

semiautomatic

or

automatic

wire

welding,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

touching

the

weldlnp

wire

are

electrically

live.

Incorrectly

installed

or

improperly

grounded

equipment

is

a

hazard.

1.

Do

not

touch

live

electrical

parts.

2.

Wear

dry,

hole-free

insulating

gloves

and

body

protection.

3.

Insulate

yourself

from

work

and

ground

using

dry

Insulating

mats

or

covers

big

enough

to

prevent

any

physical

contact

with

the

work

or

ground.

4.

Disconnect

input

power

or

stop

engine

before

installing

or

servicing

this

equipment.

Lockout/tagout

input

power

according

to

OSHA

29

CFR

1910.147

(see

Safety

Standards).

5.

Properly

install

and

ground

this

equipment

according

to

Its

Owners

Manual and

national,

state,

and

local

codes.

6.

Always

verify

the

supply

ground



check

and

be

sure

that

Input

power

cord

ground

wire

is

properly

connected

to

ground

termInal

In

disconnect

box

or

that

cord

plug

Is

connected

to

a

properly

grounded

receptacle

outlet.

7.

When

making

Input

connections,

attach

proper

grounding

conductor

first



double~check

connections.

8.

Frequently

inspect

input

power

cord

for

damage

or

bare

wiring



replace

cord

Immediately

if

damaged



bare

wiring

can

kill.

Turn

off

all

equipment

when

not

In

use.

Do

not

use

worn,

damaged,

undersized,

or

poorly

spliced

cables.

11.

Do

not

drape

cables

over

your

body.

12.

If

earth

grounding

of

the

workpiece

is

required,

ground

It

directly

with

a

separate

cable



do

not

use

work

damp

or

work

cable.

13.

Do

not

touch

electrode

If

you

are

In

contact

with

the

work,

ground,

or

another

electrode

from

a

different

machine.

14.

Use

only

well~maintalned

equipment.

Repair

or

replace

damaged

parts

at

once.

Maintain

unIt

according

to

manual.

Wear

a

safety

hamess

If

working

above

floor

level.

Keep

all

panels

and

covers

securely

In

place.

Clamp

work

cable

with

good

metal-to-metal

contact

to

workplece

or

worktable

as

near

the

weld

as

practical.

4A

WARNING

ARC

WELDING

can

be

hazardous.

PROTECT

YOURSELF

AND

OTHERS

FROM

POSSIBLE

SERIOUS

INJURY

OR

DEATH.

KEEP

CHILDREN

AWAY.

PACEMAKER

WEARERS

KEEP

AWAY

UNTIL

CONSULTING

YOUR

DOCTOR.

Inwelding,

as

in

most

jobs,

exposure

to

certain

hazards

occurs.

Welding

is

sate

when

precautions

are

taken.

The

safety

information

given

below

is

only

a

summary

of

the

more

complete

safety

information

that

will

be

found

in

the

Safety

Standards

listed

on

the

Read

and

follow

all

Safety

Standards.

HAVE

ALL

INSTALLATION,

OPERATION,

MAINTENANCE,

AND

REPAIR

WORK

PERFORMED

ONLY

BY

9.

10.

15.

16.

17.

ARC

RAYS

can

burn

eyes

and

skin;

ARC

RAYS

NOISE

can

damaae

hearing;

FLYING

2.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

to

/~

SLAG

OR

SPARKS

can

Injure

eyes.

protectyourface

and

eyeswhen

welding

orwatching

(see

ANSI

Arc

rays

from

the

welding

process

produce

Intense

Z49.1

and

Z87.1

listed

In

Satety

Standards).

visible

and

Invisible

(ultraviolet

and

infrared)

rays

that

3.

Wear

approved

safety

glasses

with

side

shields.

can

bum

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

ChIpping,

grinding,

and

welds

4.

Use

protective

screens

or

barriers

to

protect

others

from

flash

cooling

throw

off

pieces

of

metal

or

slag.

and

glare;

warn

others

not

to

watch

the

arc.

NOISE

5.

Wear

protective

clothing

made

from

durable,

fIame~resistant

1.

Use

approved

ear

plugs

or

ear

muffs

If

noise

level

is

high.

material

(wool

and

leather)

and

foot

protection.

P

u

I

FUMES

AND

GASES

can

be

hazardous

5.

Work

In

a

confined

space

only

If

It

Is

well

ventilated,

or

whIle

to

your

health.

wearing

an

air-supplied

respirator.

Always

have

a

trained

Welding

produces

fumes

and

gases.

Breathing

these

watchperson

nearby.

Welding

fumes

and

gases

can

displace

air

fumes

and

gases

can

be

hazardous

to

your

health.

and

lower

the

oxygen

level

causing

injury

or

death.

Be

sure

the

breathing

air

Is

safe.

I

6.

Do

not

weld

in

locations

near

degreasing,

cleaning,

or

spraying

1.

Keep

your

head

out

of

the

fumes.

Do

not

breathe

the

fumes.

operations.

The

heat

and

rays

of

the

arc

can

react

with

vapors

to

2.

If

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

form

highly

toxic

and

IrritatIng

gases.

remove

welding

fumes

and

gases.

7.

Do

not

weld

on

coated

metals,

such

as

galvanized,

lead,

or

3.

If

ventilation

is

poor,

use

an

approved

air-supplied

respirator.

cadmium

plated

steel,

unless

the

coating

is

removed

from

the

4.

Read

the

Material

Safety

Data

Sheets

(MSDSS)

and

the

weld

area,

the

area

is

well

ventilated,

and

If

necessary,

while

manufacturers

instruction

for

metals,

consumables,

coatings,

wearing

an

air-supplied

respirator.

The

coatings

and

any

metals

cleaners,

and

degreasers.

containing

these

elements

can

give

oft

toxic

fumes

if

welded.



CYLINDERS

can

explode

If

damaged.

4.

Never

drape

a

welding

torch

over

a

gas

cylinder.

Shielding

~as

cylinders

contain

gas

under

high

5.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

pressure.

It

damaged,

a

cylinder

can

explode.

Since

6.

Never

weld

one

pressurized

cylinder



explosion

will

result.

~.

gas

cylinders

are

normally

part

of

the

welding

7.

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

i

U

process,

be

sure

to

treat

them

carefully,

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

In

good

condition.

1.

Protect

compressed

gas

cylinders

from

excessive

heat,

8.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

mechanical

shocks,

slag,

open

flames,

sparks,

and

arcs.

9.

Keep

protective

cap

In

place

over

valve

except

when

cylinder

Is

2.

Install

cylinders

in

an

upright

position

by

securing

to

a

stationary

In

use

or

connected

for

use.

support

or

cylinder

rack

to

prevent

falling

or

tipping.

10.

Read

and

foliow

Instructions

on

compressed

gas

cylinders,

3.

Keep

cylinders

away

from

any

welding

or

other

electrical

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

circuits.

Standards.

I

srl.1.1

2194

WELDING

can

cause

fire

or

explosion.

Welding

on

closed

containers,

such

as

tanks,

drums,

or

pipes,

can

cause

them

to

blow

up.

Sparks

can

fly

off

from~

the

welding

arc.

The

flying

sparks,

hot

workpiece,

and

hot

equipment

can

cause

fires

and

bums.

Accidental

contact

of

electrode

to

metal

objects

can

cause

sparks,

explosion,

overheating,

or

fire.

Check

and

be

sure

the

area

is

safe

before

doing

any

welding.

1.

Protect

yourself

and

others

from

flying

sparks

and

hot metal.

2.

Do

not

weld

where

flying

sparks

can

strike

flammable

material.

3.

Remove

all

flammables

within

35

ft

(10.7

m)

of

the

welding

arc,

If

this

is

not

possible,

tightly

cover

them

with

approved

covers.

4.

Be

alert

that

welding

sparks

and

hot

materials

from

welding

can

easily

go

through

small

cracks

and

openings

to

adjacent

areas.

5.

Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.

£~

WARNING

ENGINE

EXHAUST

GASES

can

kill.

Engines

produce

harmful

exhaust

gases.

ENGINE

FUEL

can

cause

fire

or

explosion.

Engine

fuel

is

highly

flammable.

1.

Stop

engine

and

let

ft

cool

off

before

checking

or

adding

fuel.

2.

Do

not

add

fuel

while

smoking

or

if

unit

is

near

any

sparks

or

MOVING

PARTS

can

cause

injury.

Moving

parts,

such

as

fans,

rotors,

and

belts

can

I

cut

fingers

and

hands

and

catch

loose

clothing.

1.

Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

2.

-

Stop

eng

ne

before

installing

or

connecting

unit

SPARKS

can

cause

BATTERY

GASES

TO

EXPLODE;

BATTERY

ACID

can

burn

eyes

and

skin.

Batteries

contain

acid

and

generate

explosive

gases.

6.

Be

aware

that

welding

on

a

ceiling,

floor,

bulkhead,

or

partition

can

cause

fire

on

the

hidden

side.

7.

Do

not

weld

on

closed

containers

such

as

tanks,

drums,

or

pipes,

unless

they

are

properly

prepared

according

toAWS

F4.1

(see

Satety

Standards).

8.

Connect

work

cable

to

the

work

as

close

to

the

welding

area

as

practical

to

prevent

welding

current

from

traveling

long,

possibly

unknown

paths

and

causing

electric

shock

and

fire

hazards.

9.

Do

not

use

welder

to

thaw

frozen

pipes.

10.

Remove

stick

electrode

from

holder

or

cut

off

welding

wire

at

contact

tip

when

not

in

use.

11.

Wear

oil-f

ree

protective

garments

such

as

leather

gloves,

heavy

shirt,

cuff

less

trousers,

high

shoes,

and

a

cap.

12.

Remove

anycombustibles.

such

as

a

butane

lighteror

matches,

from

your

person

before

doing

any

welding.

ENGINES

can

be

hazardous.

1.

Use

equipment

outside

in

open,

well-ventilated

areas.

2.

If

used

in

a

closed

area,

vent

engine

exhaust

outside

and

away

from

any

building

air

intakes.

3.

Have

only

qualified

people

remove

guards

or

covers

for

maintenance

and

troubleshooting

as

necessary.

4.

To

prevent

accidental

starting

during

servicing,

disconnect

negative

()

battery

cable

from

battery.

5.

Keep

hands,

hair,

loose

clothing,

and

tools

away

from

moving

parts.

6.

Reinstall

panels

or

guards

and

close

doors

when

servicing

is

finished

and

before

starting

engine.

Always

wear

a

face

shield

when

working

on

a

battery.

Stop

engine

before

disconnecting

or

connecting

battery

cables.

3.

Do

not

allow

tools

to

cause

sparks

when

working

on

a

battery.

4.

Do

not

use

welder

to

charge

batteries

or

jump

start

vehicles.

5.

Observe

correct

polarity

(

and



on

batteries

1.

It

the

engine

is

warm

and

checking

is

needed,

follow

steps

2

and

3.

2.

Wear

safety

glasses

and

gloves

and

put

a

rag

over

cap.

3.

Turn

cap

slightly

and

let

pressure

escape

slowly

before

completely

removing

cap.

PRINCIPAL

SAFETY

STANDARDS

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.1,

from

American

Welding

Society,

550

N.W.

LeJeune

Ad,

Miami

FL

33126

Safety

and

Health

Standards,

OSHA

29

CFR

1910,

from

Superinten

dent

of

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

Recommended

Safe

Practices

for

the

Preparation

for

Welding

and

Cutting

of

Containers

That

Have

Held

Haza

rdous

Substances,

Ameri

can

Welding

Society

Standard

AWS

F4.1

,from

American

Welding

So

ciety,

550

NW.

LeJeune

Ad,

Miami,

FL

33126

National

Electrical

Code,

NFPA

Standard

70,

from

National

Fire

Pro

tection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

P-1,from

Compressed

Gas

Association,

1235

Jefferson

Davis

High

way,

Suite

501,

Arlington,

VA

22202.

Code

for

Safety

in

Welding

and

Cutting,

CSA

Standard

Wi

17.2,

from

Canadian

Standards

Association,

Standards

Sales,

178

Aexdale

Bou

levard,

Rexdale,

Ontario,

Canada

M9W

1

A3.

Safe

Practices

For

Occupation

And

EducationalEye

And

Face

Protec

tion,

ANSI

Standard

Z87.i,

from

American

National

Standards

InstItute,

1430

Broadway,

New

York,

NY

10018.

Cutting

And

Welding

Processes,

NFPA

Standard

SiB,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

4

3.

Do

not

overfill

tank



allow

room

for

fuel

to

expand.

4.

Do

not

spill

fuel.

If

fuel

is

spilled,

clean

up

before

starting

engine.

1.

2.

STEAM

AND

PRESSURIZED

HOT

COOLANT

can

burn

face,

eyes,

and

skIn.

It

is

best

to

check

coolant

level

when

engine

is

cold

to

avoid

scalding.

silIl

2/94

CONSIGNES

DE

SECURITE

POUR

LE

SOUDAGE

A

LARC

UN

CHOC

ELECTRIQUE

peut

tuer.

Un

simple

contact

avec

des

piŁces

Ølectnques

pout

provoquer

une

Olectrocution

ou

des

blessures

graves.

LØlectrode

et

Ie

circuit

de

soudago

sont

sous

tension

des

quo

Iappareil

est

surON.

Le

circuit

dentrOe

et

les

circuits

intemes

de

lappareil

sont

Ogalement

sous

tension

a

ce

moment-l.

En

soudage

semi-automatique

ou

automatique,

le

fil,

le

dØvidoir,

to

logement

des

galets

dentrainement

et

les

piŁces

metalliques

en

contact

avec

to

fd

do

soudage

sont

sous

tension.

Des

matØriels

mal

installOs

ou

mel

mis

a

Ia

terre

prOsentent

un

danger.

1.

Ne

jamais

toucher

les

piŁces

Ølectriques

sous

tension.

2.

Porter

des

gants

et

des

vØtements

do

protection

secs

no

comportant

pas

do

trous.

3.

Sisoler

de

Ia

piŁce

et

de

Ia

terre

au

moyen

do

tapis

ou

dautres

moyens

isolants

suffisamment

grands

pour

empOcher

to

contact

physique

Øventuel

avec

Ia

piŁce

ou

Ia

terre.

4.

Couper

lalimentation

ou

arrØter

le

moteur

avant

do

procØder

a

linstallation,

a

Ia

reparation

ou

a

lentretien

do

Iappareil.

DØverrouiller

lalimentation

selon

Ia

norme

OSHA

29

CFR

1910.147

(voir

normes

do

sØcuntO).

5.

Installer

et

mettre

a

Ia

terre

correctement

cot

appareil

confomiØment

a

son

manuel

dutilisation

et

au

codes

nationaux,

provinclaux

et

municipaux.

6.

Toujours

verifier

Ia

terre

du

cordon

dalimentation



Verifier

et

sassurer

cue

Is

fit

de

terre

du

cordon

dalimentation

est

bion

LE

SOUDAGE

A

LARC

peut

Œtre

dangereux.

raccordØ

ala

borne

do

terre

du

sectionneur

ou

quo

Ia

fiche

du

cordon

est

raccordØe

a

une

prise

correctement

mise

a

Ia

terre.

7.

En

off

ectuant

los

raccordomonts

dontrØe

fixer

dabord

Jo

conducteur

do

mise a

Ia

terre

appropnØ

01

contro-vØnfuer

los

connexions.

8.

Verifier

frØquemment

le

cordon

dalimentation

pour

volr

sil

nest

pas

endommage

ou

dØnudØ



remplacor

le

cordon

immØdiatemont

slI

est

endommage



un

cAble

dØnudØ

pout

provoquer

uno

lectrocution.

9.

Mettre

lappareil

hors

tension

quand

on no

lutilise

pas.

10.

No

pas

utiliser

des

cAbles

uses,

endommages,

do

grosseur

insuffisante

ou

mal

episses.

11.

Ne

pas

enrouler

los

cAbles

autour

du

corps.

12.

Si

Ia

piŁce

soudŁo

doit

Øtre

mise

ala

terre.

le

faire

directement

avec

un

cAble

distinct



no

pas

utiliser

le

connectour

do

piŁce

ou

to

cAble

do

retour.

13.

Ne

pas

toucher

lØlectrode

quand

on

ost

en

contact

avoc

Ia

piŁce,

(a

terre

ou

une

electrode

provenant

dune

autre

machine.

14.

Nutiliser

quun

materiel

on

bon

etat.

Reparer

ou

remplacer

sur-le-champ

les

piŁces

endommagees.

Entrotenir

Iappareit

conformØment

a

ce

manuel.

15.

Porter

un

hamais

do

sØcuritØ

quand

on

travallle

en

hauteur.

16.

Maintenir

solidement

en

place

tousles

pannoaux

01

capots.

17.

Fixer

10

cAble

de

retourde

faon

a

obtenir

un

ban

contact

mØtal-mØtat

avec

Ia

piŁce

soudorou

Ia

table

do

travail,

le

plus

pros

possible

do

Ia

BRUIT

LE

RAYONNEMENT

DE

LARC

peut

brOler

les

yeux

et

Ia

peau.

Le

BRUIT

peut

endommager

louTe;

les

PROJECTIONS

DE

LAITIER

OU

LES

ETINCELLES

peuvent

blesser

les

yeux.

Larc

de

soudage

produit

des

rayons

visibles

et

invisibles

intenses

(ultraviolots

et

infrarouges)

qui

peuvent

brOler

Iesyeux

et

Ia

peau.

Le

bruit

produit

par

certains

procØdØs

pout

endommager

loule.

Des

projections

do

metal

ou

do

laitier

sont

produites

par

le

piquage,

10

meulage

ou

le

refroidissement

des

soudures.

1.

Utiliser

des

bouche-oreilles

ou

des

serre-tŒte

antibruit

approuves

si

to

niveau

do

bruit

est

OIevØ.

LES

VAPEURS

El

LES

FUMEES

peuvent

etre

dangereuses

pour

Ia

sante.

Le

soudago

produit

des

vapeurs

et

des

fumOes

quiI

est

dangereux

do

respirer.

1.

Garder

Ia

tŒte

a

IextOneur

des

vapeurs

ot

des

fumØes

et

no

pas

les

respiror.

2.

A

lintØneur,

ventiler

le

poste

de

travail

ou

utiliser

un

dispositif

place

au

niveau

do

larc

pour

Øvacuer

los

vapeurs

et

fumOes

de

soudage.

3.

Si

Ia

ventilation

051

mauvaise,

utiliser

un

appareil

respiratoire

a

adduction

dair

pur

approuvO.

4.

Consulter

los

fiches

signalØtiques

et

les

consignes

du

fabricant

relatives

au

mØtaux,

produits

dapport.

revOtements,

nettoyants

et

dØgraissants.

2.

Porter

un

masque

a

serre-tOte

muni

dun

verre

filtrant

do

nuance

appropnØe

pour

protØger

10

visage

et

los

yeux

quand

on

soude

ou

observe

Ia

travail

de

soudage

(voir

los

normos

ANSI

Z49.1

et

287.1

donnOos

sous

Ia

rubrique

Pflncipales

normes

de

socuntØ).

3.

Porter

des

lunettes

do

sØcuiitØ

approuvØes

avec

Øcrans

latØraux.

4.

Utiliser

des

paravents

ou

des

barnŁres

do

protection

pour

protØger

los

personnes

a

proximitØ

contre

los

coups

darc

et

lØblouissement;

avertir

los

autres

personnes

do

no

pas

regardor

larc.

5.

Porter

des

vOtements

do

protection

on

tissu

Ignifuge

durable

(lame

et

cuir)

et

des

chaussuros

do

sØcuntO.

5.

Ne

travailler

dans

un

espace

confine

quo

sil

est

bien

ventitØ,

ou

en

portant

un

appareil

rospiratoire

~

adduction

dair

pur.

Demander

Ł

un

obsorvateur

ayant

reu

Ia

bonno

formation

do

toujours

se

tenir

a

proximite.

Les

vapeurs

01

fumØes

do

soudage

peuvent

dØplacer

lair

01

abaissor

to

niveau

doxygOne

et

causer

des

blessuros

graves

voire

mortelles.

Sassuror

quo

lair

est

propro

a

Ia

respiration.

6.

Ne

pas

soudor

a

proximite

doperations

do

dOgmissage,

do

nettoyage

ou

do

pulverisation.

La

chaleur

et

los

rayons

do

tars

peuvent

rØagir

avec

los

vapeurs

pour

former

dos

gaz

hautement

toxiques

ot

irritants.

7.

Ne

pas

soudor

sur

des

mØtaux

revOtus

comme

lacier

galvanise,

au

plombou

cadmiØ

a

moms

quo

Ia

piŁce

naitØtØ

entiŁremontdecapOe,

quo

le

paste

do

travail

soit

bien

ventilØ.

Sil

y

a

lieu,

porter

un

apparell

respiratoire

a

adduction

dairpur.

Los

revOtements

ot

los

mOtaux

gui

contionnont

de

tols

elements

peuvent

degagor

des

vapours

toxiques

lore

du

soudaqe.

LES

BOUTEILLES

peuvent

exploser

sI

elles

sont

endommagØes.

Les

bouteillos

contenant

des

gaz

de

protection

sont

a

haute

pression.

Une

bouteillo

endommagee

pout

exploser.

Etant

donnØ

quo

les

bouteilles

do

gaz

font

normalemont

partie

du

matØnel

do

soudage,

los

trailer

avec

le

plus

grand

soin.

1.

ProtØger

los

bouteilles

do

gaz

compnmØ

contre

Ia

chaleur

intense,

los

chocs,

le

lailier.

los

flammes

nues,

los

Øtincelles

01

tars.

2.

Placer

los

bouteilles

ala

vorticale

en

les

fixant

a

un

support

fixe

ou

a

un

chariot

pour

Øviter

quelles

no

tombent

ou

no

basculent.

3.

Tenirles

bouteillos

a

lŁcart

du

poste

de

soudage

ou

dautres

circuits

dlectnques.

4.

No

jamais

poser

un

chalumoau

soudeur

sur

une

bouteillo

do

gaz.

5.

Ne

jamais

laisser

uno

electrode

do

soudage

toucher

une

bouteille.

6.

Ne

jamais

souder

sur

uno

boutoillo

sous

pressman

:

0110

oxploseralt.

7.

Nutiliser

quo

dos

bouteillos

do

gaz

do

protection,

des

dOtondeurs,

des

tuyaux

souples

of

dos

raccords

appropnØs

concus

pour

--lapplication

particuliOro;

conserver

ces

matØriels

et

lours

piŁces

en

bon

Øtat.

8.

Elaignor

10

visage

de

Ia

Sortie

du

robmnet

do

Ia

boutoille

quand

on

louvre.

9.

Replacer

lo

chapoau

sur

Ia

boutoille

apres

utilisatlon.

10.

Lire

01

suivre

los

consignes

relatives

aux

bouteillos

do

gaz

compuime,

au

materiel

connexe

ainsi

que

Ia

publication

P-i

de

Ia

CGA

donnØe

sous

Ia

rubflquo

Prmncipales

normes

do

sØcuntØ.

a

MISE

EN

GARDE

SE

PROTEGER

El

PROTEGER

LES

AUTRES

CONTRE

LES

BLESSURES

GRAVES

VOIRE

MORTELLES.

TENIR

LES

ENFANTS

A

LECART.

LES

PERSONNES

QUI

PQRTENT

UN

STIMULATEUR

CARDIAQUE

NE

DOIVENT

PAS

NON

PLUS

SAPPROCHER

DU

POSTE

DE

SOUDAGE,

A

MOINS

DAVOIR

CONSULTE

UN

MEDECIN.

Le

soudage,

comme

Ia

plupart

des

travaux,

prOsente

certains

dangers.

Par

contre,

le

soudage

pout

Œtre

effectuØ

en

toute

sOcufltØ

quand

on

prend

los

mesures

qui

simposent.

Los

consignes

do

sØcuntØ

donnØes

ci-aprŁs

ne

font

que

rØsumer

linformation

contenue

dans

los

normes

de

sOcufltO

ØnumOrOes

a

Ia

page

suivante.

Lire

et

respecter

toutes

ces

norrnes

de

sØcuntO.

LINSTALLATION,

LUTILISATION,

LENTRETIEN

El

LES

REPARATIONS

NE

DOIVENT

ETRE

CONFIES

ouA

DES

PERSONNES

QUALIFIEES

RAYONNEMENTDELARC

srl.1.1

2194

LE

SOUDAGE

peut

causer

un

Incendle

ou

une

explosion.

Ne

pas

souder

sur

des

recipients

farmØs

comma

des

reservoirs,

des

tOts

ou

des

tuyaux:

us

peuvent

exploser.

Larc de

soudage

pout

produire

des

Øtincelles.

Des

Øtincelles,

une

piŁce

chaude

at

un

matØrial

chaud

peuvent

provoquer

des

incendies

at

des

blassures.

La

contact

accidental

de

lØlectrode

sur

des

objats

metalliques

pout

produire

des

Øtincalles,

lexplosion,

Ia

surchauffe

ou

un

incendie.

Sassurer

qua

Ia

lieu

ne

presenta

pas

do

danger

avant

deffectuer

to

soudage.

1.

Se

proteger

et

protOgerles

personnes

proximitØ

des

tincellesetdu

metal

chaud.

2.

Ne

pas

souder

dans

un

endroit

oCr

las

Øtincelles

peuvent

atteindre

des

matØnaux

inflammablas.

3.

Enlevartoutes

las

matiŁres

inflammables

dana

un

rayon

de

moms

do

10

m

de

Iarc.

Si

cola

nest

pas

possible,

bien

los

recouvriren

utilisant

des

bAches

approuvOes.

4.

Prendre

garde

que

los

Øtincelles

et

las

projections

ne

penetrent

dans

des

zones

adjacentes

en

smnfiltrant

dans

des

petites

fissures

at

ouvertures.

5.

Prendre

garde

aux

incendies

at

toujours

avoir

un

extincteur

a

proximitØ.

6.

Se

rappelerque

si

Ion

soude

sur

un

plafond,

un

plancher,

une

cloison

ou

autre,

to

feu

peut

prendre

do

lautro

ctØ.

7.

Ne

pas

souder

sur

des

recipients

termØs

comme

dos

reservoirs,

des

tOts

ou

des

tuyaux

a

moms

quils

no

soient

prØparOs

de

facon

appropriOe

conformØmant

ala

norma

F4.1

do

lAWS

(voir

Ia

rubrique

Pnncipales

nomies

do

secuntØ).

8.

Raccorder

le

cØble

do

retour

a

~a

piŁce,

le

plus

prØs

possible

de

Ia

zone

de

soudage,

pour

ampØcher

que

le

courant

da

soudage

no

sulva

una

trajectoira

longue

et

Øventuellement

inconnue

at

quit

no

provoque

des

nsques

dØlectrocution

et

dincendie.

9.

Ne

pas

utiliser

10

chalumeau

soudeur

pour

degeler

des

tuyaux.

10.

Enlever

lOlectrode

onrobOa

du

porte-electrode

ou

couper

le

fit

do

soudage

au

ras

du

bec

contact

quand

on

no

lutilise

pas.

11.

Porter

des

vØtements

de

protection

non

huileux

comma

des

gants

en

cuir.

une

chemise

Øpaisse,

des

pantalons

sans

rovers,

des

chaussures

montantes

at

un

casqua.

12.

Ne

pas

porter

des

matiOres

combustibles

sur

soi

comme

un

briquet

a

oaz

ou

des

atlumettes

ciuand

on

soude.

r

LES

GAZ

DECHAPPEMENT

DES

MOTEURS

1.

Utillser

to

materiel

a

lextØrieur,

dans

des

lieux

ouvarts

at

bien

peuvent

Łtre

morteis.

ventilØs.

2.

Si

on

utilise

un

moteur

dans

un

local

fermØ,

Øvacuer

las

gaz

~

Las

moteurs

produisent

des

gaz

dØchappement

nocifs.

dechappament

a

lextØneur

at

loin

des

pflses

dair

du

btimant.

LE

CARBURANT

peut

provoquer

un

Incendie

ou

une

explosion.

La

carburant

est

hautement

inflammable.

2.

3.

Ne

pas

tumor

en

faisant

le

plain

ou

51

lappareit

se

trouve

a

proximitØ

dØtincelles

ou

do

flammes

flues.

Ne

pas

remplir

to

rOservoir

a

ras

boW

:

prØvoir

do

lespace

pour

Ia

dilatation

du

combustible.

1.

ArrOter

Ia

moteur

et

Ia

talsser

retroidir

avant

do

verifier

to

niveau

do

4.

Ne

pea

renverser

du

carburant.

SI

on

renversa

du

carburant,

ou

do

refaire

le

plein.

nettoyer

los

Iieux

avant

do

faire

dØmarrer

Ia

moteur.

LES

PIECES

EN

MOUVEMENT

peuvent

causer

des

blessures.

3.

Seutes

des

personnes

qualifiØes

doivent

dOmonter

las

protecteurs

ou

las

capots

pour

faire

Ientretien

ou

las

reparations

nØcessaires.

Los

piŁces

en

mouvement

comma

tes

ventilateurs,

les

rotors

at

las

courroles

peuvent

couper

los

doigts

at

los

mains

et

happer

tea

vØtementa

amplas.

1.

Sassurerque

los

portos,

los

panneaux,

los

capots

at

los

protecteurs

sont

bian

fermØs

et

bien

a

tour

place.

4.

Pour

empOcher

un

demarraga

accidentel

dun

systŁme

pendant

lentretien

ou

lea

reparations,

dØbrancher

to

cØble

nØgatif

()

de

Ia

baftene.

Eloigner

lea

mains,

los

choveux,

los

vØtements

amples

et

los

outils

des

piŁces

en

mouvement.

Replacerlescapotsoulesprotecteursetreformerlesportosunefois

2.

ArrØter

to

moteur

avant

de

mottre

en

place

ou

do

raccorder

un

lentretien

et

los

reparations

terminØs

of

avant

de

faire

dØmarrer

Ia

moteur.

LES

ETINCELLES

peuvent

faire

EXPLOSER

LE

GAZ

DES

BATTERIES;

LELECTROLY1E

peut

brUler

Ia

peau

et

les

yeux.

2.

3.

ArrØter

to

moteur

avant

do

brancher

ou

do

dØbrancher

los

cØbles

do

Ia

battefle.

No

pea

faire

dos

Øtincettos

avec

los

outils

quand

on

travaille

sur

uno

Les

batteries

contiennent

un

produit

acido

et

dOgagent

des

vapeurs

explosives.

4.

batterie.

No

pea

utilisor

Ia

source

do

courant

do

soudage

pour

charger

los

batteries

ou

pour

faire

dØmarrer

un

vØhicule.

1

Toujours

2orter

un

Øcran

facial

quand

on

travailte

sur

une

batterie.

5.

No

pas

intervortir

Ia

polantØ

dos

batteries.

~

4

~

~,.

~.

~

LA

VAPEUR

Er

LE

LIQUIDE

DE

REFROIDISSEMENT

BRULANT

SOUS

PRESSION

peuvent

brOter

Ia

peau

et

lee

yeux.

II

vaut

mioux

verifier

le

nivoau

du

li~uide

do

refroidissement

quand

Ia

moteur

est

froid

atm

d

Øviter

les

brOlures.

1.

2.

3.

Si

lon

doit

verifier

le

niveau

quand

te

moteur

est

chaud,

suivro

los

Øtapes

2

et

3.

Porter

des

Iunottes

do

sØcufltØ

at

des

gants

et

placer

un

chiffon

surle

bouchon.

Toumer

lentement

le

bouchon

at

laisser

Ia

pression

sOchapper

lentement

avant

dentever

complŁtoment

to

bouchon.

PRINCIPALES

NORMES

DE

SECURITE

Safety

in

Welding

and

Cutting,

normo

ANSI

Z49.1

do

lAmerican

Welding

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

P-ide

Society,

550

N.W.

Lejeune

Rd

Miami

FL

33126

Ia

Compressed

Gas

Association,

1235

Jefferson

Davis

Highway,

Suite

501.

Arlington.

VA

22202.

Safety

and

Health

Sandarrls,

OSHA

29

CFR

1910,

du

Superintendent

of

RØgles

de

sOcuntd

en

soudage,

coupage

et

procedds

connexes,

norme

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

CSA

W117.2,

do

IAssociation

canadienne de

normatisation,

vente

do

normes,

178

Rexdale

Boulevard,

Rexdale

(Ontario)

Canada

M9W

1

R3.

Recommended

Safe

Practice

for

the

Preparation

for

Welding

and

Cutting

of

Containers

Thai

Have

Held

Hazardous

Substances,

norme

AWS

F4.1,

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

Protection,

do

lAmorican

Welding

Society,

550

N.W.

Lejeuno

Rd

Miami

FL

33126

norme

ANSI

Z87.1,

do

lAmencan

National

Standards

Institute,

1430

Broadway,

Now

York,

NY

10018.

National

Electncal

Code,

NFPA

Standard

70,

do

Ia

National

Fire

Protection

Cutting

and

Welding

Processes,

normo

NFPA

51

B,

do

Ia

National

Fire

Association,

Batterymarch

Park.

Qumncy,

MA

02269.

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

5.

6.

a

MISE

EN

GARDE

LES

MOTEURS

peuvent

presenter

un

danger.

srl.l.1

2t94

TABLE

OF

CONTENTS

SECTION

1



SAFETY

INFORMATION

1

SECTION

2

SPECIFICATIONS

1

2-1.

Volt-Ampere

Curves

2

2-2.

Duty

Cycle

2

SECTION

3INSTALLATION

2

3-1.

Installing

Work

Clamp

3

3-2.

Installing

Gas

Supply

3

3-3.

Gun

Polarity

For

Wire

Type

4

3-4.

Selecting

A

Location

And

Connecting

Input

Power

5

3-5.

Installing

Drive

Rolls

And

Welding

Gun

6

3-6.

Installing

Wire

Spool

7

3-7.

Threading

Welding

Wire

7

SECTION

4OPERATION

9

SECTION

5

MAINTENANCE

&

TROUBLESHOOTING

12

5-1.

Routine

Maintenance

12

5-2.

Overload

Protection

12

5-3.

Cleaning

Or

Repairing

Drive

Assembly

13

5-4.

Gun

Maintenance

14

5-5.

Troubleshooting

15

SECTION

6-

ELECTRICAL

DIAGRAMS

16

SECTION

7-WELDING

METHODS

&

TROUBLESHOOTING

18

7-1.

Flux

Cored

Arc

Welding

(FCAW)

And

Gas

Metal

Arc

Welding

(GMAW)

18

7-2.

Welding

Troubleshooting

20

SECTION

8

PARTS

LIST

24

Figure

8-1.

Main

Assembly

24

Figure

8-2.

Baffle,

Center

w/Components

26

Figure

8-3.

Drive

Assembly,

Wire

28

Figure

8-4.

MWG-160

Gun

29

OM-151

016C2196

SECTION

1

-

SAFETY

INFORMATION

Figure

1-1.

Safety

Information

modl.1

2/93

1

Safety

Alert

Symbol

2

Signal

Word

WARNING

means

possible

death

or

serious

injury

can

happen.

CAUTION

means

possible

minor

injury

or

equipment

damage

can

happen.

3

Statement

Of

Hazard

And

Result

4

Safety

Instructions

To

Avoid

Hazard

5

Hazard

Symbol

(If

Available)

6

Safety

Banner

Read

safety

blocks

for

each

sym

bol

shown.

7

NOTE

Special

instructions

for

best

oper

ation



not

safety.

SECTION

2-

SPECIFICATIONS

Table

2-1.

Welding

Power

Source



Read

all

safety

messages

throughout

this

manual.



Obey

all

safety

messages

to

avoid

injury.



Learn

the

meaning

of

WARNING

and

CAUTION.

2 2

a

CAUTION

/

5



MOVING

PARTS

can

Injure.

~

ELECTRIC

SHOCK

can

kill

I I



Do

not

louch

live

electrical

parts.

1]

~

S

Keep

away

from

moving

pads.

I



Keep

all

panels

and

covers

closed



Disconnect

input

power

before

when

operating.

installing

or

servicing.

6

a

WARNING

READ

SAFETY

BLOCKS

at

start

of

Section

3-1

before

proceedin9.

7H

NOTE

~

Turn

Off

switch

when

using

high

frequency.

Specifications

Description

Type

Of

Output

Rated

Weld

Output

Type

Of

Input

Amperes

At

Rated

Output

KVA/KW

Used

At

Rated

Output

Max.

Open-Circuit

Voltage

Control

Circuit

Voltage

At

Gun

Welding

Processes

Wire

Feed

Speed

Range

Wire

Diameter

Range

Input

Power

Cord

With

Plug

Overall

Dimensions

Weight

Constant

Voltage/Direct

Current

(CV/DC)

120

Amperes,

21

Volts

DC

At

30%

Duty

Cycle

(See

Section

2-2)

Single-Phase;

230

Volts

AC;

60

Hertz

20

Amperes

4.7

kVA/3.9

kW

32

Volts

DC

24

Volts

DC

Gas

Metal

Arc

Welding

(GMAW)

(Uses

Solid

Hard

Or

Aluminum

Wire

And

External

Shielding

Gas)

Flux

Cored

Arc

Welding

(FCAW)

(Uses

Wire

With

Flux

Inside

And

Requires

No

External

Shielding

Gas)

47

To

690

1pm

(1.2

To

17.5

mpm)

.023

To

.035

in

(0.58

To

0.89

mm)

5ft(1.5m)

Length:

27

In

(686

mm);

Width:

12

in

(305

mm);

Height:

22-1/2

In

(571

mm)

Net:

117

lb

(53

kg);

Ship:

120

lb

(54

kg)

OM-151

016

Page

1

2-1.

Volt-Ampere

Curves

Figure

2-1.

Volt-Ampere

Curves

2-2.

Duty

Cycle

a

CAUTION

Table

3-1.

Items

Included

With

Welding

Power

Source

Item

Quantity

Welding

Gun



Shipped

Set

To

Feed

.030

in

(0:8

mm)

Wire

1

10

ft

(3

m)

Work

Cable

And

Clamp

1

6ft(1.8m)AirHose

1

Contact

Tubes

(3

.023

in,

2



.030

in,

And

3

.035

in)

8

Monocoil

Liner

For

.023

Thru

.030

in

Wire

1

40

30

20

10

Ui

I-.

-J

0

>

C-)

0

The

volt-ampere

curves

show

the

minimum

and

maximum

voltage

and

amperage

output

capabilities

of

the

welding

power

source.

Curves

of

other

sethngs

fall

between

the

curves

shown.

ssbl.1

10/91/S8-124

625

50

00

150

200

250

D.C.

AMPERES

EX



CEE

Do

no

DING

DUTY

CYCLE

RATINGS

will

damage

unit.

t

exceed

indicated

duty

cycles.

wam7.1

2/92

.

200

 



Duty

cycle

is

how

long

the

unit

can

operate

within

a

ten

minute

period

50



without

causing

overheating

or

damage.

90

This

unit

is

rated

at

30%

duty

cycle

allowing

welding

3

minutes

out

of

every

10

minutes

at

rated

load,

If

the

welding

amperes

decrease,

the

duty

cycle

increases.



 

80



.

70



60



50



~



 



I

1.5

20

25

30

40

50

60 70

80

90

100

DUTY

CYCLE

%

sbl.22/92SB-124624

Figure

2-2.

Duty

Cycle

Chart

SECTION

3-INSTALLATION

OM-151

016

Page

2

N

OTE

LI~

Customer

must

obtain

proper

welding

wire

and

s

application.

hielding

gas

for

desired

3-1.

Installing

Work

Clamp

1

Insulator

2

Bolt

3

Smaller

Hole

4

Work

Clamp

Tabs

Bend

tabs

around

work

cable.

5

Work

Cable

From

Unit

6

Nut

Tools

Needed:

3/8,7/16

in

Ref.

ST-025

190-C

Figure

3-1.

Work

Clamp

Installation

3-2.

Installing

Gas

Supply

__

a

WARNING

.

C



YLINDERS

can

explode

if

damaged.

~

Keep

cylinders

away

from

welding

and

other

~

electrical

circuits.

BUILDUP

OF

SHIELDING

GAS

can

harm

health

or

kill.



Shut

off

shielding

gas

supply

when

not

in

use.



Never

touch

cylinder

with

welding

electrode.



Always

secure

cylinder

to

running

gear,

wall,

or

other

stationary

support..

wam4.1

9/91

A.

Installing

Safety

Chain

1

Cylinder

Bracket

As

Shipped

2

S-Hook

Crimp

between

small hole

in

bracket

and

chain.

2

3

Chain

4

Snap

Crimp

onto

open

end

of

chain.

5

Cylinder

Bracket

For

Large

Gas

Cylinder

6

Gas

Fitting

.

Tools

Needed:

ST-160

791

Figure

3-2.

Installing

Safety

Chain

OM-151

016

Page

3

B.

Installing

Regulator/Flowmeter

Figure

3-3.

Typical

Regulator/Flowmeter

Installation

3-3.

Gun

Polarity

For

Wire

Type

a

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

welding

power

source,

and

disconnect

input

power

before

inspecting

or

installing.

swaml.1

2/93

Obtain

gas

cylinder

and

chain

to

running

gear,

wall,

or

other

station

ary

support

so

cylinder

cannot

fall

and

break

off

valve.

1

Cap

6

2

Cylinder

Valve

Remove

cap,

stand

to

side

of

valve,

and

open

valve

slightly.

Gas

flow

blows

dust

and

dirt

from

valve.

Close

valve.

3

Cylinder

I---



OR

4

Regulator/Flowmeter

Install

so

face

is

vertical.

4

Argon

Gas

5

Gas

Hose

Connection

Fitting

has

5/8-18

right-hand

threads.

Install

supplied

air

hose.

6

Flow

Adjust

Typical

flow

rate

is

20

cfh

(cubic

feet

per

hour).

Check

wire

man

ufacturers

recommended

flow

rate.

2

Tools

Needed:

1-1/8,5/8

in

7

8

7

CO2

Adapter

8

0-Ring

CO2

Gas

Install

adapter

with

0-ring

between

regulator/flowmeter

and

CO2

cylinder.

ssb3.1

12/92



ST-158

697-A

STRAIGHT

I

POLARITY

I

For

Flux

Cored

Wires,,~

~

(FCAW

Process)

L

REVERSE

POLARITY

For

Solid

Steel

Or

Aluminum

(

Wires

I

(GMAW~

R\_~

Process

DCEP

1

Tools

Needed:

t3/Sin

I

Polarity

Changeover

Label

2

Polarity

Jumper

Links

Always

read

and

follow

wire

man

ufacturers

recommended

polarity.

There

are

two

jumper

links

(1

set)

across

each

set

of

terminals.

Be

sure

to

move

each

set

of

links

when

changing

polarity.

Close

door.

Ael.

ST-149

631-c

Figure

3-4.

Gun

Polarity

Jumper

Link

Position

OM-151

016

Page

4

3-4.

Selecting

A

Location

And

Connecting

Input

Power

a

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

welding

power

source,

and

disconnect

input

power

before

inspecting

or

installing.



Have

only

qualified

persons

install

unit.



Installation

must

meet

National

Electrical

Code

and

all

other

codes.

BLOCKED

AIRFLOW

causes

overheating

and

possible

damage

to

unit.



Do

not

block

or

filter

airflow

Warranty

is

void

if

any

type

of

filter

is

used.

swam3.r

2193

Table

3-2.

Electrical

Service

Guide

Input

Voltage

220

Input

Amperes

At

Rated

Output

20

Max

Recommended

Standard

Fuse Or

Circuit

Breaker

RatIng

in

Amperes

30

Mm

Input

Conductor

Size

In

AWG/Kcmll

14

Max

Recommended

Input

Conductor

Length

In

Feet

(Meters)

65

(20)

Mm

Grounding

Conductor

Size

In

AWG/Kcmll

14

Reference:

1993

National

Electrical

Code

(NEC).

s-ooeaj

1

5

7

1

18

in

(457

mm)

Open

Space

At

Front

And

Rear

2

Rating

Label

Supply

correct

input

power.

3

230

Volts

AC

Wall

Receptacle

.4

Input

Conductors

Select

size

and

length

using

Table

3-2.

Conductor

rating

must

comply

with

national,

state,

and

local

codes.

5

Line

Disconnect

Device

Of

Proper

Rating

Obtain

and

install

switch

and

wall

receptacle.

6

Grounding

Conductor

Select

size

and

length

using

Table

3-2.

Be

sure

grounding

con

ductor

goes

to

an

earth

ground.

Install

and

connect

input

conduc

tors

and

grounding

conductor

in

conduit

or

equivalent

between

wall

receptacle

and

deenergized

line

disconnect

device.

7

Overcurrent

Protection

Select

type

and

size

using

Table

3-2.

Install

into

deenergized

line

disconnect

device

(fused

dis

connect

switch

shown).

Connect

deenergized

supply

con

ductors

to

line

disconnect

device.

8

input

Power

Plug

Turn

Off

unit

Power

switch,

and

connect

plug

to

wall

receptacle.

Place

line

disconnect

switch

in

On

position

before

using

welding

power

source.

ssb2.2

3/93



ST-149

630.C

3

Figure

3-5.

Location

And

Input

Power

Connections

OM-151

016

Page

5

3-5.

Installing

Drive

Rolls

And

Welding

Gun

Tools

Needed:

1

Pressure

Adlustment

2

Pressure

Assembly

3

Drive

Roll

4

Washers

5

Securing

Screw

Install

drive

roll

as

shown.

6

Gun

Securing

Knob

7

Gun

End

Loosen

knob.

Insert

gun

end

through

opening

until

it

bottoms

against

drive

assembly.

lighten

knob.

8

Gun

Trigger

Plug

Insert

plug

into

receptacle,

and

tighten

threaded

collar.

Figure

3-6.

Drive

Roll

And

Welding

Gun

Installation

Ref.

ST~15O

193-D

I

Ref.

ST-149

629-C

I

ST-155

578

2

OM-151

016

Page

6

3-6.

Installing

Wire

Spool

4~

WARNING

7

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

welding

power

source,

and

disconnect

input

power

before

inspecting

or

installing.

Figure

3-7.

Welding

Wire

Spool

Installation

3-7.

Threading

Welding

Wire

£~

WARNING

CYLINDERS

can

explode

it

damaged.



Keep

cylinders

away

from

welding

and

other

electrical

circuits.

Never

touch

cylinder

with

welding

electrode.

Always

secure

cylinder

to

running

gear,

wall,

or

other

stationary

support.

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.

The

welding

wire,

drive

rolls,

drive

assembly,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live

when

welding

or

feeding

wire

using

gun

trigger

WELDING

WIRE

can

cause

puncture

wounds.



Do

not

press

gun

trigger

until

instructed

to

do

so.



Do

not

point

gun

toward

any

part

of

the

body,

other

people,

or

any

metal

when

threading

welding

wire.

HOT

SURFACES

can

burn

skin.



Allow

gun

to

cool

before

touching.

swaml.1

2/93

NOTE

L

if

hub

tension

is

too

tight,

motor

fuse

Fl

can

open

(see

Section

5-2).

If

hub

tension

is

too

loose,

wire

unravels

and

can

become

tangled

inside

unit.

Turn

Off

and

unplug

unit.

1

Wire

Spool

2

Gun

Contact

Tip

If

necessary,

cut

welding

wire

off

at

contact

tip,

and

retract

wire

onto

spool

and

secure.

3

Retaining

Ring

Remove

ring

and

pull

off

spool.

4

Compression

Spring

Compression

spring

is

used

with

B

in

(200

mm)

spools.

2

5

Hub

6

HubPin

Slide

spool

onto

hub

so

wire

feeds

off

bottom.

Turn

spool

until

hub

fits

hole

in

back

of

spool.

Reinstall

retaining

nng.

7

Hub

Tension

Nut

Grasp

spool

In

one

hand

and

turn

while

using

a

wrench

to

adjust

hub

tension

nut.

When

a

slight

force

Is

needed

to

turn

spool,

tension

is

set.

Tools

Needed:

Thread

welding

wire

(see

Section

3.7)

Close

door.

~

15/16

in

Ref.

ST-Iso

193-C

/

5A-072

573-B

~tf

~wam2.1

9/91

/swam5.1

10/91

OM-151

016

Page

7

1

Wire

Spool

2

Welding

Wire

3

Inlet

Wire

Guide

4

Pressure

Adjustment

Knob

5

Drive

Roll

6

Outlet

Wire

Guide

7

Gun

Conduit

Cable

Lay

gun

cable

out

straight.

Tools

Needed:

I

6

in~

(150

mm)

Pull

and

hold

wire;

cut

off

end.

Push

wire

thru

guides

into

gun;

continue

to

hold

wire.

-+=~

Remove

gun

nozzle

and

contact

tip.

Press

gun

trigger

until

wire

comes

out

of

gun.

Reinstall

contact

tip

and

nozzle.

o

ii

I

II

Feed

wire

to

check

drive

roll

pressure.

Tighten

knob

enough

to

prevent

slipping.

Cut

off

wire.

Close

and

latch

door.

Figure

3-8.

Threading

Welding

Wire

Ret.

ST-149

632-C

/

Ref.

ST-ISO

193/

Ref.

ST-159

272

/

S-0627-A

Hold

wire

tight

lyfokeep

it

from

unraveling.

I1~T~

~

-*

Open

pressure

assembly.

ON

Close

and

tighten

pressure

assembly,

and

let

go

of

wire.

POWER

~e

H

QOFF

Set

switch.

-*

p

OM-151

016

Page

8

SECTION

4-

OPERATION

____

a_WARNING

ELECTRIC

SHOCK

can

kill.



Always

wear

dry

insulating

gloves.



Insulate

yourself

from

work

and

ground.



Do

not

touch

live

electrical

parts.



Keep

all

panels

and

covers

securely

in

place

FUMES

AND

GASES

can

be

hazardous

to

your

health.



Keep

your

head

out

of

the

fumes.



Ventilate

area,

or

use

breathing

device.

___________



Read

Material

Safety

Data

Sheets

(MSDS5)

and

manufacturers

instructions

for

material

used.

WELDING

can

cause

fire

or

explosion.



Do

not

weld

near

flammable

material.



Watch

for

fire;

keep

extinguisher

nearby.



Do

not

locate

unit

over

combustible

surfaces.



Do

not

weld

on

closed

containers.



Allow

work

and

equipment

to

cool

before

handling.

Figure

4-1.

Safety

Equipment

Figure

4-2.

Work

Clamp

MAGNETIC

FIELDS

FROM

HIGH

CUR

RENTS

can

affect

pacemaker

operation.



Pacemaker

wearers

keep

away.



Wearers

should

consult

their

doctor

before

going

near

arc

welding,

gouging,

or

spot

welding

opera

tions.

See

Safety

Precautions

at

beginning

of

manual

for

ba

sic

welding

safety

information.

swam6.2~

10/91

1

Insulating

Gloves

2

Safety

Glasses

With

Side

Shields

3

Welding

Helmet

Wear

dry

insulating

gloves,

safety

glasses

with

side

shields,

and

a

welding

helmet

with

a

correct

shade

of

filter

(see

ANSI

Z49.1).

sb3.1

10/91

1

Shielding

Gas

Cylinder

2

Valve

3

Gun

Trigger

Open

valve

on

cylinder

just

before

welding.

Gun

trigger

turns

weld

output

and

gas

flow

on

and

oft.

Close

valve

on

cylinder

when

fin

ished

welding.

sb5.1

6/92-S.0621-C

~p

~

ARC

RAYS

can

burn

eyes

and

skin;

NOISE

can

damage

hearing.



Wear

welding

helmet

with

correct

shade

of

filter.



Wear

correct

eye,

ear,

and

body

protection.

,..~

~

0

MOVING

PARTS

can

cause

Injury.



Keep

away

from

pinch

points

such

as

drive

rolls.



Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

1

Work

Cable

2

Work

Clamp

2

Tools

Needed:

Connect

work

clamp

to

a

clean,

paint-free

location

on

workpiece,

as

close

to

weld

area

as

possible.

Use

wire

brush

or

sandpaper

to

clean

metal

at

weld

joint

area.

Use

chipping

hammer

to

remove

slag

after

welding.

sM.1

2/93



Ret.

ST.156

258

a

WARNING

BUILDUP

OF

SHIELDING

GAS

can

harm

health

or

kill.



Shut

off

shielding

gas

supply

when

not

in

use.

waml.1

9/91

Figure

4-3.

Shielding

Gas

OM-151

016

Page

9

wam5.1

2193

1

Fine

Tuning/Wire

Speed

Control

Use

control

to

select

a

wire

feed

speed.

As

ThicknessNoltage

switch

setting

increases,

wire

speed

range

also

increases.

The

numbers

around

the

control

are

not

a

wire

feed

speed

and

are

for

reference

only

(see

Table

4-1).

2

ThicknessNoltage

Switch

Use

switch

to

select

an

arc

voltage.

The

higher

the

selected

number,

the

thicker

the

material

that

can

be

welded

(see

Table

4-1).

3

Power

Switch

Use

switch

to

turn

unit

and

Ian

On

and

Off.

a

CAUTION

ARCING

can

damage

switch.



Do

not

change

ThicknessNoltage

switch

position

while

welding.

Arcing

inside

switch

can

damage

contacts,

causing

switch

to

fail.

Figure

4-4.

Controls

Ref.

5T-150

092-A

/

Ref.

5T-156

258

OM-151

016

Page

10

install

&

Put

On

~

Turn

On

~

~\

Do

)~S\

Readjust

Contro~~

Connect

)

Personal

Safety

)

)Eauipment

&

Gas

3

)

Set

Controls

))

Sample

Weld

And

Prepare

J

Equipm~~,/J

Equipment

JJ

(if

ApplicableL,uJ

_____________

J

For

Production}

ssb4.1

10191

Figure

4-5.

Sequence

Of

Operation

For

Hard

And

Flux

Cored

Wires

Install

&

Conneci\

~

Adjust

Hub



\

Adjust

Drive

R~ii

Put

On

Persona~\\Tum

On

Equipme~

Set

Controls

&

Equipment

Using

3

Tension

To

3

Pressure

To

J

Knu~ed

G~~JJ

Minimum

}J

Minimum

})Safety

Equipmen9)

To

30

cfh~~ght

And

Adjust

Gas

I

Keep

Gun

Cable

)

Do

Sample

Weld

And

Prepare

For

~)Read~ust

Contr~

________________

Welding

J

Figure

4-6.

Sequence

Of

Operation

For

Aluminum

Welding

Table

4-1.

Suggested

Welding

Settings

Wire

Type,

Shielding

Gas,

And

Flow

Rate

Wire

Diameter

(inch)

Operator

Control

SettIngs

Material

Thickness

1/4

In

(6.4

mm)

3/16

In

(4.8

mm)

1/8

in

(3.2

mm)

14

ga

16

ga

18

ga

22

ga

24

ga

E7OS-6

CO2

20

cfh+

.023

Voltage

4

3

2

1 1

1

Wire

Speed



100%

80% 70%

60%

55%

45%

35%

.030

Voltage

4

3

2

1 1



Wire

Speed

80%

75% 60%

60%

50%

40%

30%



.035

Voltage

4

3

2

1 1 1



Wire

Speed*

65%

60%

50%

40%

30%

20%

15%



E7OS-6

75%

Argon

25%

CO2

20

of

h+

~________________

.023

Voltage



4

3

2

1

Wire

Speed



100%

90%

80%

70% 60%

50%

40%

.030

Voltage

4

3

2

1 1



Wire

Speed

90%

80%

70%

60%

50%

45%

30%



.035

Voltage

4

3 3 3

2

1



Wire

Speed

75%

70% 60%

50%

40%

33%

25%



E71T-GS

Flux

Core

.030

Voltage

3

3 2

1

1 1



Wire

Speed*

40%

65%

45%

40% 30%

20%



035

Voltage

3

2

1



Wire

Speed*

60% 50%

40%

30%

20%

10%



ER

308

Stainless

Steel

Tri~Mix

20

cfh+

.023

Voltage

4

3 3 3 2

1



Wire

Speed

100% 100%

90%

85%

75%

70% 60%

.030

Voltage

4

3 3 2 2



Wire

Speed

75% 75% 65% 60%

55%

50%



.035

Voltage

4

3



 



Wire

Speed*

60% 60%

50%



  



.

Aluminum

Argon

30

Cf

11+

.030

Voltage

4

3 3

2

1



Wire

Speed*

90% 85%

80%

90%

85%



.035

Voltage

4

3

2

1



Wire

Speed

85%

90%

80%



*

Do

not

change

ThlckneBe/Voltage

ewitch

poaitIon

while

welding.

Fine

TunInglWire

Speed

value

in

Table

4-1

Ia

a

etarting

value

only

and

Fine

Tuning/Wire

Speed

control

setting

can

be

fine

tuned

during

welding.

+cth

=

cubic

ft

per

hour

OM-151

016

Page

11

SECTION

5-

MAINTENANCE

&

TROUBLESHOOTING

MOVING

PARTS

can

cause

injury.



Keep

away

from

moving

parts.



Keep

away

from

pinch

points

such

as

drive

rolls.

Maintenance

to

be

performed

only

by

qualified

persons.

swam8.2

2/93

5-2.

Overload

Protection

I

READ

Sectio

SAFETY

n

5

befor

BLOCKS

at

start

of

e

proceeding.

I

A.

Overheating

Thermostat

TP1

protects

the

unit

from

damage

due

to

overheating.

If

rectifier

SR2

gets

too

hot,

TP1

opens

and

weld

output

stops.

The

fan

keeps

running

to

cool

SR2.

Wait

several

minutes

before

trying

to

weld.

B.

Short

Circuit

Shutdown

If

contact

tip

is

shorted

and

sticks

to

workpiece,

the

unit

shuts

down,

but

fan

runs.

To

resume

operation,

release

gun

trigger,

turn

Off

unit,

and

remove

contact

tip

from

workpiece.

Check

contact

tip

and

replace

if

damaged.

Turn

On

unit

to

continue

operation.

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

welding

power

source,

and

disconnect

input

power

before

inspecting,

maintaining,

or

servicing.

HOT

PARTS

can

cause

severe

burns.



Allow

cooling

period

before

maintaining

or

servicing.

5-1.

Routine

Maintenance

Turn

Off

all

power

before

maintainIng.

-~

3

Months

Replace

~

Cracked

Parts

 

Trigger

Cord

Gas

Hose

Gun

Cable

Figure

5-1.

Maintenance

Schedule

OM-151

016

Page

12

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