AUTO ARC 120 Le manuel du propriétaire

AUTO

ARC}ﬁ

April

1994

Form:

OM-151

015A

Effective

With

Serial

No.

KD461

760

OWNERS

MANUAL

U



Read

and

follow

these

instructions

and

all

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.



Give

this

manual

to

the

operator.

11111



For

help,

call

your

distributor,

MILLER

Electric

Mfg.

Co.,

P.O.

Box

Appleton,

WI

54912

414-734-9821

or:

1079,

Auto

Arcﬁ

120



CV/DC

Welding

Power

Source/Wire

Feeder



For

GMAW

And

FCAW

Welding



90

Amperes,

18

Volts

At

20%

Duty

Cycle



Usable

Range

Of

30

To 130

Amperes



Uses

115

Volts

AC,

Single-Phase

Input

Power



Overheating,

Short

Circuit,

And

Motor

Overload

Protection



Includes

Gun,

Welding

Wire,

Gas

Valve,

And

Instructional

Video

auto_arc

7/93



ST-I

49

330

PRLNTED

IN

USA

Within

the

warranty

periods

listed

below,

manufacturer

will

repair

or

replace

any

warranted

parts

or

components

that

fail

due

to

such

defects

in

material

or

workman

ship.

Manufacturer

must

be

notified

in

writing

within

thirty

(30)

days

of

such

defect

or

tailure,

at

which

time

manufacturer

will

provide

instructions

on

the

warranty

claim

procedures

to

be

followed.

Manufacturer

shall

honor

warrsnty

claims

on

warranted

equipment

listed

below

in

the

event

of

such

s

failure

within

the

wsrrsnty

time

periods.

All

warranty

time

periods

start

on

the

date

that

the

equipment

was

delivered

to

the

original

retail

purchaser.

end

are

as

follows;

3.

Equipment

that

has

bean

modified

by

any

party

other

than

manufacturer,

or

equipment

that

hss

been

Improperty

installed,

improperly

operated

or

misused

based

upon

industry

standards,

or

equipment

which

has

not

had

reasonable

and

necessary

maintenance,

or

equipment

which

has

bean

used

for

operation

outside

of

the

specifications

for

the

equipment.

MANUFACTURERS

PRODUCTS

ARE

INTENDED

FOR

PURCHASE

AND

USE

BY

COMMERCIAL/INDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPE

RIENCED

IN

THE

USE

AND

MAINTENANCE

OF

WELDING

EQUIPMENT

In

the

event

ot

a

warranty

claim

covered

by

this

warranty,

the

esctusive

remedies

shall

be,

at

manufacturers

option;

(1)

repsir;

or

(2)

replacement;

or.

where

autho

rized

in

writing

by

manufacturer

in

appropriate

cases.

(3)

the

reasonable

cost

of

re

pair

or

replacement

at

an

authorized

service

station;

or

(4)

payment

of

or

credit

for

the

purchase

price

(teas

reasonable

depreciation

based

upon

actual

use)

upon

re

turn

of

the

goods

at

customers

risk

and

espanse.

manufacturers

option

of

repaIr

or

replacement

will

be

FOB.,

Factory

at

Appleton,

Wisconsin,

or

FOB.

at

an

autho

rized

service

facility

as

determined

by

manufacturer.

Tharafore

no

compensatIon

or

reimbursement

for

transportation

coats

of

any

kind

will

be

allowed.

TO

THE

EXTENT

PERMITTED

BY

LAW,

THE REMEDIES

PROVIDED

HEREIN

ARE

THE

SOLE

AND

EXCLUSIVE

REMEDIES.

IN

NO

EVENT

SHALL

MANUFAC

TURER

BE

LIABLE

FOR

DIRECT.

INDIRECT,

SPECIAL,

INCIDENTAL

OR

CON

SEQUENTIAL

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

EQUIPMENT

FURNISHED

BY

MANUFACTURER

IS

EXCLUDED

AND

DISCLAIMED

BY

MAN

UFACTURER.

Some

states

in

the

U.S.A.

do

not

allow

limItations

of

how

tong

an

Implied

warranty

lasts,

or

the

escluaion

of

IncIdental.

Indirect,

specIal

or

coneequentlal

damages,

so

the

above

limItation

or

eacluslon

may

not

apply

10

you.

This

warranty

provIdes

ape

clfic

legal

rights,

and

other

flghls

may

be

available,

but

may

vary

from

stale

to state.

In

Canada,

legislation

In

some

provinces

provIdes

for

certaIn

edditlonat

warrantlas

or

remedies

olher

than

as

stated

herein,

and

to

the

extent

that

they

may

not

be

waived.

the

limitations

and

exclusions

set

out

above

may

not

apply.

ThIs

LimIted

Warrsnty

provIdes

specific

legal

rights,

and

other

rIghts

may

be

avaIlable,

but

may

vary

from

province

to

province.

r......

I

LIMITED

WARRANTY

Effective

January

1,

1992

(Equipment

with

a

serial

number

preface

of

ICC

or

newer)

This

limited

warranty

supersedes

all

warranties

and

is

esclusive

with

no

other

guarantees

or

warranties

espressed

or

implied.

LIMITED

WARRANTY



Subject

to

the

terms

and

conditions

below,

warrants

to

its



Remote

Controls

original

retail

purchaser

that

new

equipment

sold

after

the

effective

date

of

this

tIm-



Accessory

Kits

itad

warranty

is

free

of

defects

in

malarial

and

workmanship

at

the

time

Ills

shipped



Re

tacement

Parts

from

factory.

THIS

WARRANTY

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTHER

WAR-

p

RANTIES,

EXPRESS

OR

IMPLIED,

INCLUDING

THE

WARRANTIES

OF

MER-

Limited

Warranty

shalt

not

apply

to;

CHANTABILITY

AND

FITNESS.

1.

Items

furnished

by

manufacturer,

but

manufactured

by

others,

such

as

en

gines

or

trade

accessories.

These

items

are

covered

by

the

manufacturers

warranty,

if

any.

2.

Consumable

components;

such

as

contact

tips,

cutting

nozzles.

contectore

and

relays

or

parts

that

fail

due

to

normal

wear.

J

.1

5

Years

Parts



3

Years

Labor



Original

main

power

rectifiers

2.

3

Years



Parts

end

Labor

*

Transformer/Rectifier

Power

Sources



Plasma

Arc

Cutting

Power

Sources



Semi-Automatic

and

Automatic

Wire

Feeders

*

Robots

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

*

Water

Coolant

Systems



HF

Unite



Grids



Spot

Welders



Load

Banks



SOX

Transformers

*

Running

Gear/Trailers



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

tore

mini

mum

of

one

year



whichever

is

greater.)

5.

6

Months



Batteries

6.

90

Days



Parts

and

Labor



MIG

Guns/TIG

Torches



Plasma

Cutting

Torches

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

andfor

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_scot

5(93

ERRATA

SHEET

March

1,

1995

FORM:

OM-151

015A

Use

above

FORM

number

when

ordering

extra

manuals.

After

this

manual

was

printed,

refinements

in

equipment

design

occurred.

This

sheet

lists

exceptions

to

data

appearing

later

in

this

manual.

CHANGES

TO

SECTION

8

PARTS

LIST

Change

Parts

List

as

follows:

C

~

**

PNaOrt

Re~j~ed

Description

Quantity

23-14

...

120

675

....

Deleted

..

Eff

w/KF828022

23-45

...

019

663

....

Deleted

..

Eff

w/KF828022

**First

digit

represents

page

no



digits

following

dash

represent

item

no.

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

ARC

WELDING

SAFETY

PRECAUTIONS

FLYING

SPARKS

AND

HOT

METAL

can

cause

injury.

Chipping

and

grinding

cause

flying

metal,

As

welds

cool,

they

can

throw

off

slag.

5.

Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual

and

national,

state,

and

local

codes.

6.

When

making

input

connections,

attach

proper

grounding

conductor

first.

7.

Turn

off

all

equipment

when

not

in

use.

8.

Do

not

use

worn,

damaged,

undersized,

or

poorly

spliced

cables.

9.

Do

not

wrap

cables

around

your

body.

10.

Ground

the

workpiece

to

a

good

electrical

(earth)

ground.

11.

Do

not

touch

electrode

if

in

contact

with

the

work

or

ground.

12.

Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

13.

Wear

a

safety

harness

if

working

above

floor

level.

14.

Keep

all

panels

and

covers

securely

in

place.

1.

Wear

approved

face

shield

or

safety

goggles.

Side

shields

recommended.

2.

Wear

proper

body

protection

to

protect

skin.

a

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.

In

welding,

as

in

most

jobs,

exposure

to

certain

hazards

occurs.

Welding

is

safe

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

QUALIFIED

PEOPLE.

ELECTRIC

SHOCK

can

kill.

Touching

live

electrical

parts

can

cause

fatal

shocks

or

severe

burns.

The

electrode

and

work

circuit

is

electrically

live

whenever

the

output

is

on.

The

input

power

circuit

and

machine

internal

circuits

are

also

live

when

power

is

on.

In

semiautomatic

or

automatic

wire

welding,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

touching

the

welding

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.

4.

Disconnect

input

power

or

stop

engine

before

installing

or

servicing

this

equipment.

ARC

RAYS

can

burn

eyes

and

skin;

ARC

RAYS

~

NOISE

can

damage

hearing.

2.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

(see

ANSI

249.1

listed

in

Safety

Standards)

to

protect

your

face

and

Arc

rays

from

the

welding

process

produce

intense

eyes

when

welding

or

watching.

heat

and

strong

ultraviolet

rays

that

can

burn

eyes

3.

Wear

approved

safety

glasses.

Side

shields

recommended.

and

skin.

Noise

from

some

processes

can

damage

hearing.

4.

Use

protective

screens

or

barriers

to

protect

others

from

flash

and

glare;

warn

others

not

to

watch

the

arc.

NOISE

5.

Wear

protective

clothing

made

from

durable,

flame-resiŒtant

1.

Use

approved

ear

plugs

or

ear

muffs

if

noise

level

is

high.

material

(wool

and

leather)

and

foot

protection.

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.

Shielding

gases

used

for

~

~Q

Weldingproducesfumesandgases.Breathingthese

welding

can

displace

air

causing

injury

or

death.

Be

sure

the

fumes

and

gases

can

be

hazardous

to

your

health,

breathing

air

is

safe.

6.

Do

not

weld

in

locations

near

degreasing,

cleaning,

or

spraying

operations.

The

heat

and

rays

of

the

arc

can

react

with

vapors

to

1.

Keep

your

head

out

of

the

fumes.

Do

not

breathe

the

fumes.

form

highly

toxic

and

irritating

gases.

2.

If

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

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

(MSDS5)

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

and

cleaners,

containing

these

elements

can

give

off

toxic

fumes

if

welded.

WELDING

can

cause

fire

or

explosion.

5.

Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.

Sparks

and

spatter

fly

off

from

the

welding

arc.

The

flying

sparks

and

hot

metal,

weld

spatter,

hot

workpiece,

and

hot

equipment

can

cause

fires

and

burns.

Accidental

contact

of

electrode

orwelding

wire

6.

7.

Be

aware

that

welding

on

a

ceiling,

floor,

bulkhead,

or

partition

can

cause

fire

on

the

hidden

side.

Do

not

weld

on

closed

containers

such

as

tanks

or

drums.

to

metal

objects

can

cause

sparks,

overheating,

or

fire.

8.

Connect

work

cable

to

the

work

as

close

to

the

welding

area

as

practical

to

prevent

welding

current

from

traveling

long,

possibly

1.

Protect

yourself

and

others

from

flying

sparks

and

hot

metal.

2.

Do

not

weld

where

flying

sparks

can

strike

flammable

material.

9.

unknown

paths

and

causing

electric

shock

and

fire

hazards.

Do

not

use

welder

to

thaw

frozen

pipes.

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,

10.

Remove

stick

electrode

from

holder

or

cut

off

welding

wire

at

contact

tip

when

not

in

use.

4.

Be

alert

that

welding

sparks

and

hot

materials

from

welding

can

11.

Wear

oil-free

protective

garments

such

as

leather

gloves,

heavy

easily

go

through

small

cracks

and

openings

to

adjacent

areas,

shirt,

cuffless

trousers,

high

shoes,

and

a

cap.

Sri

9/92

CYLINDERS

can

explode

if

damaged.

Shielding

gas

cylinders

contain

gas

under

high

pressure.

if

damaged,

a

cylinder

can

explode.

Since

gas

cylinders

are

normally

part

of

the

welding

process,

be

sure

to

treat

them

carefully.

1.

Protect

compressed

gas

cylinders

from

excessive

heat,

mechanical

shocks,

and

arcs.

2.

Install

and

secure

cylinders

in

an

upright

position

by

chaining

them

to

a

stationary

support

or

equipment

cylinder

rack

to

prevent

falling

or

tipping.

3.

Keep

cylinders

away

from

any

welding

or

other

electrical

circuits.

4.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

5.

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

in

good

condition.

6.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

7.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

in

use

or

connected

for

use.

8.

Read

and

follow

instructions

on

compressed

gas

cylinders.

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

Standards.

ENGINE

EXHAUST

GASES

can

kill.

1.

Use

equipment

outside

in

open,

well-ventilated

areas.

2.

If

used

in

a

closed

area,

vent

en9ine

exhaust

outside

and

Engines

produce

harmful

exhaust

gases.

away

from

any

building

air

intakes.

SPARKS

can

cause

BATTERY

GASES

TO

EXPLODE;

BATTERY

ACID

can

burn

eyes

and

skin.

1.

Stop

engine

before

checking

or

adding

fuel.

2.

Do

not

add

fuel

while

smoking

or

if

unit

is

near

any

sparks

or

open

flames.

3.

Allow

engine

to

cool

before

fueling.

If

possible,

check

and

add

fuel

to

cold

engine

before

beginning

job.

4.

Do

not

overfill

tank



allow

room

for

fuel

to

expand.

5.

Do

not

spill

fuel.

If

fuel

is

spilled,

clean

up

before

starting

enqine.

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.

PRINCIPAL

SAFETY

STANDARDS

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.1,

from

American

Welding

Society,

550

NW.

LeJeune

Rd.

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

Hazardous

Substances,

Ameri

can

Welding

Society

Standard

AWS

F4.i,from

American

Welding

So

ciety,

550

N.W.

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-i



from

Compressed

Gas

Association,

1235

Jefferson

Davis

High.

way,

Suite

501,

Arlington,

VA

22202.

Code

for

Safety

in

Welding

and

Cutting,

GSA

Standard

Wi

17.2,

from

Canadian

Standards

Association,

Standards

Sales,

178 Rexdale

Bou

levard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

Safe

Practices

For

OccupationAnd

EducationalEyeAr7d

Face

Protec

tion,

ANSI

Standard

Z87.1,

from

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

Cutting

And

Welding

Processes,

NFPA

Standard

51

B,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Ouincy,

MA

02269.

a

WARNING

ENGINES

can

be

hazardous.

ENGINE

FUEL

can

cause

fire

or

explosion.

Engine

fuel

is

highly

flammable.

MOVING

PARTS

can

cause

injury.

Moving

parts,

such

as

fans,

rotors,

and

belts

can

cut

fingers

and

hands

and

catch

loose

clothing.

1.

Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

2.

Stop

engine

before

installing

or

connecting

unit.

Batteries

contain

acid

and

generate

explosive

gases.

1.

Always

wear

a

face

shield

when

working

on

a

battery.

2.

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.

STEAM

AND

PRESSURIZED

HOT

1.

Do

not

remove

radiator

cap

when

engine

is

hot.

Allow

engine

COOLANT

can

burn

face,

eyes,

and

to

cool.

skin.

2.

Wear

gloves

and

put

a

rag

over

cap

area

when

removing

cap.

The

coolant

in

the

radiator

can

be

very

hot

and

under

pressure.

3.

Allow

pressure

to

escape

before

completely

removing

cap.

srI

9/92

PRECAUTIONS

DE

SECURITE

EN

SOUDAGE

A

LARC

DESSAI.

LELECTROCUTION

peut

Œtre

mortelle.

~

Une

decharge

Ølectrique

peut

vous

tuer

ou

vous

brOler

gravement.

LØlectrode

et

le

circuit

de

soudage

sont

sous

tension

au

demarrage.

Le

circuit

dentrØe

et

les

circuits

internes

des

matØriels

sont

aussi

sous

__________

tension

des

Ia

mise

en

marche.

En

soudage

automatique

ou

semi-automatique

avec

fil,

ce

dernier,

le

support

de

roquette,

le

logement

des

galets

dentrainement

et

toutes

les

piŁces

mØtalliques

en

contact

avec

le

fil

de

soudage

sont

sous

tension.

Des

matØnels

mal

installØs

ou

mal

mis

a

Ia

terre

sont

dangereux.

1.

Ne

touchez

pas

a

des

piŁces

sous

tension.

2.

Portez

des

gants

et

des

vŒtements

isolants,

secs

et

non

trouØs.

3.

Isolez-vous

de

Ia

tote

a

souder

et

de

Ia

mise

ala

terre

au

moyen

de

petits

tapis

isolants

ou

autres.

4.

DŁconnectez

Ia

prise

dentrØe

des

matŁriels

ou

arrŒtez

leur

moteur

avant

de

les

installer

ou

den

faire

lentretien.

Le

RAYONNEMENT

DE

LARC

peut

brUler

es

yeux

et

Ia

peau;

le

BRUIT

peut

endommager

louIe.

____________

Larc

de

soudage

produit

une

chaleur

et

des

rayons

ultraviolets

intenses,

susceptibles

de

brler

es

yeux

et

Ia

peau.

Le

bruit

cause

par

certains

procØdØs

peut

endommager

louIe.

1.

Portez

un

casque

de

soudeur

avec

Øcran

filtrant

de

teinte

appropnØe

(consultez

Ia

norme

ANSI

Z49

indiquee

ci-aprŁs),

pour

vous

protØger

le

visage

et

les

yeux

lorsque

vous

soudez

ou

~

I

Les

VAPEURS

ET

LES

FUMEES

sont

~

dangereuses

pour

Ia

sante.

!

Le

soudage

dØgage

des

vapeurs

et

des

fumØes

quil

9..



est

dangereux

de

respirer.

1.

Ecartez

le

visage

pour

Øviter

de

respirer

les

fumØes.

2.

A

lintØrieur,

assurez-vous

que

laire

de

soudage

est

bien

ventilØe

ou

que

los

fumØes

et

les

vapeurs

sont

aspirØes

a

larc.

3.

Si

Ia

ventilation

est

mauvaise,

portez

un

respirateur

a

adduction

dair

approuve.

4.

Lisez

es

fiches

signalØtiques

et

les

consignes

du

fabricant

relatives

aux

mØtaux,

aux

produits

consummables,

aux

revŒtements

et

aux

produits

nettoyants.

Le

SOUDAGE

peut

causer

un

incendie

ou

une

explosion.

Larc

produit

des

Øtincelles

et

des

projections.

Avec

Ia

chaleur

intense

dØgagØe

par

Ia

tle

et

les

matØriels,

elles

peuvent

causer

un

incendie

et

des

brlures.

Le

contact

accidentel

de

lŁlectrode

avec

un

objet

mØtallique

peut

provoquer

des

Øtincelles,

un

Øchauffement

ou

un

incendie.

1.

Protegez-vous,

ainsi

que

les

autres,

contre

los

Øtincelles

et

tes

projections.

2.

Ne

soudez

pas

dans

un

endroit

o

des

Øtincelles

peuvent

atteindre

des

matŁriaux

inflammables.

3.

Enlevez

toutes

les

matiŁres

inflammables

dans

un

rayon

de

10,7

metres

autourde

larc,

ou

couvrez-les

soigneusement

avec

des

bÆches

approuvees.

4.

MØfiez-vous

des

Øtincelles

et

des

Øclats

brlartts,

susceptibles

de

pØnØtrer

dans

des

aires

adjacentes

par

de

petites

ouvertures

ou

fissures.

LE

SOUDAGE

A

LARC

est

dangereux.

5.

Veillez

a

installer

ces

matØriels

eta

es

mettre

ala

terre

solon

le

manuel

dutilisation

et

es

codes

nationaux,

provinciaux

et

locaux

applicables.

6.

ArrŒtez

tous

los

matØriels

aprŁs

utilisation.

7.

Nutilisez

pas

de

cables

uses,

endommagØs,

mal

ØpissØs

ou

de

calibre

trop

petits.

8.

Nenroulez

pas

de

cables

autour

de

votre

corps.

9.

Mettez

ala

terre

Ia

tle

a

souder

au

moyen

dune

bonne

prise

de

terre.

10.

Ne

touchez

pas

a

lØlectrode

si

vous

Œtes

en

contact

avec

le

circuit

de

soudage

(terre).

11.

Nutilisez

que

des

matØriels

en

bon

Øtat.

RŁparez

ou

remplacez

sur-le-champ

les

piŁces

endommagees.

12.

Portez

un

harnais

de

sØcuritO

si

vous

travaillez

en

hauteur.

13.

Fermez

solidement

tous

les

panneaux

et

les

capots.

que

vous

observez

execution

dune

soudure.

2.

Portez

des

lunettes

de

sØcuritØ

approuvØes.

Des

Øcrans

latØraux

sont

recommandØes.

3.

Entourez

laire

de

soudage

de

rideaux

ou

de

cloisons

de

protection

contre

les

coups

darc

ou

lØblouissement;

avertissez

les

observateurs

de

ne

pas

regarder

larc.

4.

Portez

des vŒtements

en

tissus

ignifuge

durable

(lame

et

cuir)

et

des

chaussures

de

sØcuritØ.

5.

Portez

un

casque

antibruit

ou

des

bouchons

doreille

approuvØs

Si

le

niveau

de

bruit

est

ØlevØ.

5.

Ne

travaillez

dans

un

espace

confine

que

sil

est

bien

ventilØ;

sinon,

portez

un

respirateura

adduction

dair.

Les

gaz

protecleurs

de

soudage

peuvent

dŁplacer

loxygene

de

lair

et

causer

des

blessures

ou

Ia

mort.

Assurez-vous

que

lair

est

propre

a

Ia

respiration.

6.

Ne

soudez

pas

a

proximitØ

dopØrations

de

dØgraissage,

de

nettoyage

ou

de

pulvŁrisation.

La

chaleur

et

les

rayons

de

larc

peuvent

reagir

avec

des

vapeurs

et

former

des

gaz

hautement

toxiques

et

irritants.

7.

Ne

soudez

pas

de

tles

galvanisees

ou

plaquees

en

p10mb

ou

en

cadmium

sans

Ies

avoir

grattØes

a

fond,

car

ces

mØtaux,

et

tout

revŒtement

qui

en

contient,

peuvent

alors

dØgager

des

fumØes

toxiques.

Assurez-vous

dune

bonne

ventilation

et

portez

un

respirateur

a

adduction

dair

si

cest

nØcessaire.

5.

MŁfiez-vous

des

incendies

et

gardez

un

extincteur

a

portØe

do

Ia

main.

6.

Noubliez

pas

quune

soudure

sur

un

plafond,

un

plancher,

une

cloison

ou

une

paroi

peut

en

enflammer

lautre

ctØ.

7.

Ne

soudez

pas

un

recipient

fermØ,

comme

un

reservoir

ou un

tonneau.

8.

Connectez

le

cable

de

soudage

le

plus

prŁs

possible

do

Ia

tle

de

soudage

pour

empecher

le

courant

do

suivre

un

parcours

long

et

inconnu,

et

prØvenir

ainsi

les

risques

dØlectrocution

et

dincendie.

9.

Ne

faites

pas

dŁgeler

des

tuyaux

avec

un

chalumeau.

10.

Videz

votre

carquois

porte-electrodes

ou

coupez

le

fil

au

tube

contact

aprŁs

le

soudage.

11.

Portez

des

vŒtements

protecteurs

non

huileux,

tels

des

gants

en

cuir,

une

chemise

Øpaisse,

un

pantalon

sans

revers,

des

chaussures

montantes

et

un

casque.

MISE

EN

GARDE

PROTEGEZ-VOUS,

AINSI

QUE

LES

AUTRES,

CONTRE

LES

BLESSURES

GRAVES

POSSIBLES

OU

LA

MORT.

NE

LAISSEZ

PAS

LES

ENFANTS

SAPPROCHER,

NI

LES

PORTEURS

DE

STIMULATEUR

CARDIAQUE

(A

MOINS

QUILS

NAIENT

CONSULTE

UN

MEDECIN).

Le

soudage,

comme

Ia

plupart

des

activitŁs

industrielles,

expose

a

certains

risques.

Le

soudage

nest

pas

dangereux

Iorsquon

prend

des

precautions.

Les

consignes

de

sØcuritØ

suivantes

ne

font

que

rØsumer

linformation

contenue

dans

les

normes

ØnumØrØes

ci-aprŁs.

Lisez

et

respectez

toutes

ces

normes.

SEULES

DES

PERSONNES

QUALIFIEES

DOIVENT

FAIRE

DES

TRAVAUX

DINSTALLATION,

DE

REPARATION,

DENTRETIEN

ET

Les

BOUTEILLES

endommagees

peuvent

exploser.

Les

bouteilles

contiennent

des

gaz

protecteurs

sous

haute

pression.

Des

bouteilles

endommagØes

peuvent

exploser.

Comme

les

bouteilles

font

normalement

partie

du

procØdØ

de

soudage,

traitez-les

avec

soin.

1.

Les

bouteilles

doivent

Œtre

protegees

contre

les

sources

de

chaleur

intense,

les

chocs

et

les

arcs

de

soudage.

2.

EnchaInez

verticalement

les

bouteilles

a

un

support

ou

a

un

cadre

fixe

pour

les

empŒcher

de tomber

ou

dŒtre

renversØes.

3.

Eloignez

les

bouteilles

de

tout

circuit

Ølectrique

ou

de

soudage.

MISE

EN

GARDE

Des

PIECES

EN

MOUVEMENT

peuvent

causer

des

blessures.

Des

piŁces

en

mouvement,

telles

des

ventilateurs,

des

rotors

et

des

courroies

peuvent

couper

les

doigts

et

les

mains,

ou

accrocher

des

vØtements

amples.

1.

Assurez-vous

que

les

portes,

les

panneaux,

les

capots

et

les

protecteurs

sont

bien

fermØs.

2.

Avant

dinstaller

ou

de

connecter

un

systŁme,

arrŒtez-en

le

moteur.

3.

Seules

des

personnes

qualifiees

doivent

dØmonter

des

4.

EmpŒchez

tout

contact

entre

une

bouteille

et

une

electrode.

5.

Nutilisez

que

des

bouteilles

de

gaz

protecteur,

des

dØtendeurs,

des

flexibles

et

des

raccords

conus

pour

chaque

application

specifique;

ces

matØriels

et

les

piŁces

connexes

doivent

Œtre

en

bon

Øtat.

6.

Ne

mettez

pas

le

visage

devant

le

robinet

de

bouteille

en

louvrant.

7.

Remettez

le

chapeau

de

bouteille

aprŁs

utilisation.

8.

Lisez

et

respectez

les

consignes

relatives

aux

bouteilles

de

gaz

comprimØ

et

aux

matØriels

connexes,

ainsi

que

Ia

publication

P-i

de

Ia

CGA,

ØnumØrØes

dans

les

normes

ci-dessous.

Les

MOTEURS

peuvent

Œtre

dangereux.

protecteurs

ou

des

capots

pour

faire

lentretien

ou

le

depannage

nØcessaire.

4.

Pour

empŒcher

un

dØmarrage

accidentel

dun

systŁme

pendant

lentretien,

dØbranchez

le

cable

daccumulateur

a

Ia

borne

negative.

5.

Napprochez

pas

les

mains

ou

les

cheveux

de

piŁces

en

mouvement;

elles

peuvent

aussi

accrocher

des

vŒtements

amples

et

des

outils.

6.

RØinstallez

les

capots

ou

les

protecteurs

et

fermez

les

portes

aprŁs

des

travaux

dentretien

et

avant

de

faire

dØmarrer

le

moteur.

Safety

in

Welding

~nd

Cutting

norme

ANSI

Z49.

1,

American

Welding

Society,

550,

N.W.

LeJeune

Rd.,

Miami

FL

33128.

Safety

and

Health

Standards

OSHA

29

CFR

1910,

Superintendent

of

Documents,

U.S.

Government

Printing

Office,

Washington

D.C.

20402.

Recommended

Safe

Practices

For

the

Preoaration

For

Welding

and

Cutting

of

Containers

That

Have

Held

Hazardous

Substances

AWS

F4.1,

American

Welding

Society,

550,

N.W.

LeJeune

Rd.,

Miami

FL

33128.

National

Electrical

Code

norme

70

NFPA,

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

srlf

9/91

Safe

Handling

of

Comoressed

Gases

in

Cylinders

document

P-i,

Compressed

Gas

Association,

1235

Jefferson

Davis

Highway,

Suite

501,

Arlington,

Va

22202.

Code

for

Safety

in

Welding

and

Cutting

norme

CSA

Wi

17.2,

Asso

ciation

canadienne

de

normalisation,

Standards

Sales,

176

Rexdale

Boulevard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

nnrmA

Safe

Practices

for

Occupation

and

Educational

Eye

and

Face

Protec

tion

norme

ANSI

Z87.i

,American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

Cutting

and

Welding

Processes

norme

51B

NFPA,

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

LES

ETINCELLES

ET

LES

metal.

En

refroidissant,

Ia

soudure

peut

projeter

du

laitier.

PROJECTIONS

BRULANTES

peuvent

causer

des

blessures.

Le

piquage

et

le

meulage

produisent

des

Øclats

de

1.

2.

Portez

un

Øcran

facial

ou

des

lunettes

a

coques

approuvees.

Des

Øcrans

latØraux

sont

recommandØs.

Portez

des

vOtements

de

protection

individuelle

appropriØs.

I

Les

GAZ

DECHAPPEMENT

D

ES

MOTEURS

1.

Utilisez

des

machines

a

lextØrieur

dans

des

aires

ouvertes

et

PEUVENT

ETRE

MORTELS.

bien

ventilØes.

Les

moteurs

produisent

des

gaz

nocifs.

dechappement

2.

Si

vous

utilisez

des

machines

dans

un

endroit

confine,

les

fumØes

dechappement

doivent

Œtre

envoyees

a

lextØrieur,

loin

des

prises

dair

du

btiment.

Le

CARBURANT

peut

causer

un

incendie

ou

une

explosion.

Le

carburant

est

hautement

inflammable.

1.

ArrŒtez

le

moteur

avant

de

verifier

le

niveau

de

carburant

ou

de

faire

le

plein.

Ne

faites

pas

le

plein

en

fumant

ou

proche

dune

source

3.

4.

5.

dØtincelles

ou

dune

flamme

nue.

Si

cest

possible,

laissez

le

moteur

refroidiravant

de

faire

le

plein

de

carburant

ou

den

verifier

le

niveau

au

debut

du

soudage.

Ne

faites

pas

le

plein

de

carburant

a

ras

bord

:

prØvoyez

de

lespace

pour

son

expansion.

Faites

attention

de

ne

pas

renverser

de

carburant.

Nettoyez

tout

carburant

renversØ

avant

de

faire

dØmarrer

le

moteur.

Des

ET1NCELLES

peuvent

FAIRE

EXPLOSER

UNACCUMULATEUR;

LELECTROLYTE

DUN

ACCUMULATEUR

peut

brUier

Ia

peau

et

~

2.

3.

un

accumulateur.

ArrŒtez

le

moteur

avant

de

connecter

ou

de

dØconnecter

des

cables

daccumulateur.

Nutilisez

que

des

outils

anti-Øtincelles

pour

travailler

sur

un

~UX.

accumulateur.

Les

accumulateurs

contiennent

de

lelectrolyte

et

4.

NutilisezpÆsunpostedesoudagepourchargerunaccumulateur

degagent

des

vapeurs

explosives.

ou

connecter

provisoirement

un

vØhicule.

1.

Portez

toujours

un

Øcran

facial

en

travaillant

sur

5.

Utilisez

Ia

polaritØ

correcte

(+

et

-)

de

laccumulateur.

La

VAPEUR

ET

LE

LIQUIDE

DE

1.

Ntez

pas

le

bouchon

de

radiateur

tant

que

le

moteur

na

pas

REFROIDISSEMENT

BRULANT

SOUS

refroidi.

PRESSION

peuvent

brler

Ia

peau

et

les

yeux.

Le

liquide

de

ref

roidissement

dun

radiateur

peut

Œtre

2.

3.

Mettez

des

gants

et

posez

un

torchon

sur

le

bouchon

pour

lter.

Laissez

Ia

pression

sØchapper

avant

doter

complŁtement

le

bouchon.

brlant

et

sous

pression.

PRINCIPALES

NORMES

DE

SECURITE

EMF

INFORMATION

NOTE

~

Considerations

About

Welding

And

The

Effects

Of

Low

Frequency

Electric

And

_____________________

Magnetic

Fields

The

toflowing

is

a

quotation

from

the

General

Conclusions

Section

To

reduce

magnetic

fields

in

the

workplace,

use

the

following

of

the

U.S.

Congress,

Office

of

Technology

Assessment,

Biological

procedures:

Effects

of

Power

Frequency

Electric

&

Magnetic

Fields



1.

Keep

cables

close

together

by

twisting

or

taping

them.

Background

Paper,

OTA-BP-E-53

(Washington,

DC:

U.S.

Government

Printing

Office,

May

1989):.

.

there

is

now

a

very

2.

Arrange

cables

to

one

side

and

away

from

the

operator.

large

volume

of

scientific

findings

based

on

experiments

at

the

3.

Do

not

coil

or

drape

cables

around

the

body.

cellular

level

and

from

studies

with

animals

and

people

which

clearly

4.

Keep

welding

power

source

and

cables

as

far

away

as

establish

that

low

frequency

magnetic

fields

can

interact

with,

and

~ractical

produce

changes

in,

biological

systems.

While

most

of

this

work

is

of

very

high

quality,

the

results

are

complex.

Current

scientific

5.

Connect

work

clamp

to

workpiece

as

close

to

the

weld

as

understanding

does

not

yet

allow

us

to

interpret

the

evidence

in

a

possible.

single

coherent

framework.

Even

more

frustrating,

it

does

not

yet

About

Pacemakers:

allow

us

to

draw

definite

conclusions

about

questions

of

possible

The

above

procedures

are

among

those

also

normally

risk

or

to

offer

clear

science-based

advice

on

strategies

to

minimize

recommended

for

pacemaker

wearers.

Consult

your

doctor

for

or

avoid

potential

risks.

complete

information.

modlo.1

4/93

TABLE

OF

CONTENTS

SECTION

1



SAFETY

INFORMATION

1

SECTION

2-

SPECIFICATIONS

2-1.

Volt-Ampere

Curves

2

2-2.

Duty

Cycle

2

SECTION

3

INSTALLATION

3-1.

Installing

Work

Clamp

3

3-2.

Gun

Polarity

For

Wire

Type

3

3-3.

Selecting

A

Location

And

Connecting

Input

Power

4

3-4.

Threading

Welding

Wire

5

3-5,

Installing

Gas

Supply

6

SECTION

4-OPERATION

7

SECTION

5

MAINTENANCE

&

TROUBLESHOOTING

5-1.

Routine

Maintenance

10

5-2.

Overload

Protection

10

5-3.

Cleaning

Or

Repairing

Drive

Assembly

11

5-4.

Installing

Wire

Spool

And

Adjusting

Hub

Tension

12

5-5.

Troubleshooting

13

SECTION

6

ELECTRICAL

DIAGRAMS

14

SECTION

7-

WELDING

METHODS

&

TROUBLESHOOTING

7-1.

Flux

Cored

Arc

Welding

(FCAW)

And

Gas

Metal

Arc

Welding

(GMAW)

16

7-2.

Welding

Troubleshooting

18

SECTION

8

PARTS

LIST

Figure

8-1.

Main

Assembly

22

Figure

8-2.

Drive

Assembly,

Wire

25

OM-151

015A4/94

SECTION

1



SAFETY

INFORMATION

modl.1

2/93



Read

all

safety

messages

throughout

this

manual.



Obey

all

safety

messages

to

avoid

injury.



Learn

the

meaning

of

WARNING

and

CAUTION.

V!~LI~1:1~Il~ie.u

Figure

1-1.

Safety

Information

SECTION

2SPECIFICATIONS

Table

2-1.

Welding

Power

Source

2

/

a_CAUTION

________

3

_

___

L

~

ELECTRIC

SHOCK

can

kill



MOVING

PARTS

can

injure.



Do

not

touch

live

electrical

parts.

!



Keep

away

from

moving

parts.



Disconnect

input

power

before

installing

or

servicing



Keep

all

panels

and

covers

closed

when

operating.

5

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

7-~i

NOTE

~

READ

SAFETY

BLOCKS

at

start

of!

______

Section

3-1

before

proceeding.

4

Safety

Instructions

To

Avoid

Hazard

Turn

Off

switch

when

using

high

frequency.

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.

Specifications

Type

Of

Output

Rated

Weld

Output

Description

Constant

Voltage

(CV),

Direct

Current

(DC)

90

Amperes,

16

Volts

DC,

20%

Duty

Cycle

(See

Section

2-2)

Usable

Amperage

Range

Type

Of

Input

Amperes

At

Rated

Output

KVNKW

Used

At

Rated

Output

Max.

Open-Circuit

Voltage

Control

Circuit

Voltage

At

Gun

Welding

Processes

Calculated

Speed

Range

At

No

Load

Approximate

Wire

Feed

Range

Wire

Diameter

Range

Input

Power

Cord

With

Plug

Overall

Dimensions

30

To

130

A

Single-Phase

115

Volts

AC,

60

Hertz

20

Amperes

3

kVAJ2.7

kW

30

Volts

DC

24

Volts

DC

Shipped

From

The

Factory

Set

For

Gas

Metal

Arc

Welding

(GMAW)

(Uses

Solid

Or

Aluminum

Wire

And

External

Shielding

Gas)

Flux

Cored

Arc

Welding

(FCAW)

(Uses

Wire

With

Flux

Inside

And

Requires

No

External

Shielding

Gas)

283

To

716

ipm

(7.1

To

17.9

mpm)

5

To

800

ipm

(.13

To

20

mpm)

.023

To

.035

in

(0.58

To

0.89

mm)

7ft(2.1

m)

Length:

17

in

(432

mm);

Width:

10

in

(254

mm);

Height:

15-1/2

in

(394

mm)

Shipping

80

lb

(36

kg):

Net

73

lb

(33

kg)



Weight

(with

gun)

OM-151

015

Page

1

2-1.

Volt-Ampere

Curves

Figure

2-1.

Volt-Ampere

Curves

__a__CAUTION

___

EXCEEDING

DUTY

CYCLE

RATINGS

will

damage

unit.



Do

not

exceed

indicated

duty

cycles.

wam7.1

Figure

2-2.

Welding

Power

Source

Duty

Cycle

Chart

25

20

15

Cl)

0

>

0

10

30

The

volt-ampere

curves

show

the

minimum

and

maximum

voltage

and

amperage

output

capabilities

of

the

welding

power

source.

Curves

of

other

settings

fall

between

the

curves

shown.

SB-124

646-A

5

0

20

40

60

80

DC

AMPERES

100

120

2-2.

Duty

Cycle

Duty

cycle

is

how

long

the

unit

can

150

operate

within

a

ten

minute

period

without

causing

overheating

or

125

damage.

This

unit

is

rated

at

20%

duty

cycle

100

allowing

welding

2

minutes

out

of

every

10

minutes.

Cl)

75

lii

50

~

37.5

25

0

10

15

20

25

30

40

60

70

8090100

%

DUTY

CYCLE

SB-124

655-A

OM-151

015

Page2

SECTION

3INSTALLATION

Table

3-1.

Items

Included

With

Welding

Power

Source

Item

Quantity

Welding

Gun



Shipped

Set

To

Feed

.023

in

(0.6

mm)

Hard

1

Wire

(See

Gun

Owners

Manual

Form

112

934)

Spool

Of

Wire

.023

in

(0.6

mm)

Hard

Wire

1

VHS

Videotape

(28

Minutes)

1

lOft

(3

m)

Work

Cable

And

Clamp

1

6ft(1.8m)AirHose

1

Contact

Tubes

(2

.030

in,

3

.023

in,

And

3

.035

in)

8

Monocoil

Liner

For

.023



.030

in

Wire

I

~

NOTE

~

Customer

must

supply

proper

shielding

gas

for

desired

application.

a

WARNING

Tools

Needed:

3/8

in

3-1.

Installing

Work

Clamp

1

Insulator

2

Bolt

3

Smaller

Hole

4

Work

Clamp

Tabs

Bend

tabs

around

work

cable.

2

5

Work

Cable

From

Unit

3

Tools

Needed:

6

Nut

3/8,

7116

in

Ref.

ST-025

190-C

Figure

3-1.

Installing

Work

Clamp

3-2.

Gun

Polarity

For

Wire

Type

E

LECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

welding

power

source,

and

disconnect

input

power

before

inspecting

or

installing.

Bwaml.1

2/93

1

Polarity

Changeover

Label

2

Polarity

Jumper

Links

Always

read

and

follow

welding

wire

manufacturers

recom

2

mended

polarity.

Close

door.

Figure

3-2.

Gun

Polarity

Jumper

Link

Position

ST-151

358

OM-151

015

Page3

3-3.

Selecting

A

Location

And

Connecting

Input

Power

A

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



1-lave

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.

1

18

in

(457

mm)

Open

Space

At

Front

And

Sides

For

Good

Airflow

2

Rating

Label

3

Grounded

Receptacle

A

20

ampere

individual

branch

circuit

protected

by

time-delay

fuses

or

circuit

breaker

is

required.

4

Plug

From

Unit

Select

extension

cord

of

12

AWG

for

up

to

75

ft

(23

rn)

or

10

AWG

for

up

to

140

ft

(46

m).

3

2

4

Figure

3-3.

Location

And

Input

Power

Connections

5T-149

354-A

OM-151

015

Page4

3-4.

Threading

Welding

Wire

____

a

WARNING

__

CYLINDERS

can

explode

if

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.

sworn2.1

9/91

/Bwam5.1

10/91

Figure

3-4.

Threading

Welding

Wire

Rel.

ST-151

289/

flel.

ST-151

357

I

Ret.

ST.156

256~A

/

5.0827~A

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:

6

in~

(150

mm)

-~

Open

pressure

assembly.

Pull

and

hold

wire;

cut

offend.

Push

wire

thru

guides

into

gun;

continue

to

hold

wire.

41n

~

(102

mm)

POWER

I

L-J10N1

Close

and

tighten

pressure

assembly,

and

letgoof

wire.

Press

gun

trigger

until

wire

comes

out

of

gun.

Reinstall

contact

tube

and

nozzle.

Remove

gun

nozzle

and

contact

tube.

4~Lu~1ll

-,

Feed

wire

to

check

drive

roll

pressure.

Tighten

knob

enough

to

prevent

slipping.

Set

switch.

Cut

off

wire.

Close

and

latch

door.

p

OM.151

Ol5Page5

3-5.

Installing

Gas

Supply

a

WARNING

CYLINDERS

can

explode

if

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.

wam4.1

9/91

Obtain

gas

cylinder

and

chain

to

running

gear,

wall,

or

other

station.

ary

support

so

cylinder

cannot

tall

and

break

off

valve.

1

Cap

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

4

Regulator/Flowmeter

Install

so

face

is

vertical.

5

Gas

Hose

Connection

Fitting

has

5/8-18

.

right-hand

threads.

Install

air

hose.

6

Flow

Adjust

Typical

flow

rate

is

20

cth

(cubic

feet

per

hour).

Check

wire

man

ufacturers

recommended

flow

rate.

7

CO2

Adapter

8

0-Ring

Install

adapter

with

0-ring

between

regulator/flowmeter

and

CO2

cylinder.

Tobls

Needed:

~

1-1/8,5/Bin

Figure

3-5.

TypIcal

Regulator/Flowmeter

Installation

.

BUILDUP

OF

SHIELDING

GAS

can

harm

health

or

kill.



Shut

off

shielding

gas

supply

when

not

in

use.

.2

3

Argon

Gas



OR

4

CO2

Gas

ssb3.1

12/92



5T-158

697-A

OM-151

015

Page

6

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.

welding

helmet

with

a

correct

shade

of

filter

(see

ANSI

Z49.1).

sb3.1

10/91

Figure

4-1.

Safety

Equipment

1

Work

Cable

2

Work

Clamp

I

~

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.

sbd.1

2/93

/

Ref.

5T-156

256-A

~=4

Figure

4-2.

Work

Clamp

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.

,-..

~

MOVING

PARTS

can

cause

injury.

S

Keep

away

from

pinch

points

such

as

drive

rolls.



Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.



~

~%

._..

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.

~

~

~

OM-151

015

Page

7

a

CAUTION

ARCING

can

damage

switch.

S

Do

not

change

ThicknessNoltage

switch

position

while

welding.

Arcing

inside

switch

can

damage

contacts,

causing

switch

to

fail.

wam5.1

9191

1

Fine

Tuning/Wire

Speed

Control

ST-150

092

Figure

4-3.

Controls

a

WARNING

BUILDUP

OF

SHIELDING

GAS

can

harm

health

or

kill.

S

Shut

off

shielding

gas

supply

when

not

in

use.

waml.1

9191

2

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

off.

Close

valve

on

cylinder

when

fin

ished

welding.

sb5.1

8l92



S-0780

Use

this

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

this

switch

to

select

an

arc

voltage.

The

higher

the

selected

number,

the

thicker

the

material

that

can

be

welded

(seelable

4-1).

3

Power

Switch

Use

switch

to

turn

unit

On

and

Off.

Figure

4-4.

Shielding

Gas

OM-151

015

Page

8

Install

Put

On

~\

Turn

On

~\

~\

Do

Readjust

Contro~\

Connect

I

)

Personal

Safety

I

)Equipment

&

Gas

I

i

Set

Controls

))

Sample

Weld

)

And

Prepare

,

Equipment

))

Equipment

J)

(lfApplicable)J

_______________

J

For

Welding

}

Figure

4-5.

Sequence

Of

Operation

For

GMAW

And

FCAW

Install

&

Co~~~\\

Adjust

Hub

Adjust

Drive

RoIl~\\

T

Equipment

Using

I

Tension

To

)

I

Pressure To

)

Put

On

Personal

urn

On

J

Knurled

Groove))

Minimum

J)

Minimum

JySafe~

Equipm~)

To

30

cfh

J

Straig

And

Adjust

Gas

)

Do

Sample

Weld

And

Prepare

For

)

Contro~

__________________

Welding

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*

Metal

Thickness

1/8

in

(3.2

mm)

12

ga

14

ga

16

ga

18

ga

20

ga

22

ga

And

Thinner

E-71T-GS

Flux

Core

0.030

Voltage

Wire

Speed

4

30

3

30

3

20

1

25

1

20

1

20



0.035

Voltage

Wire

Speed

4

30

3

25

2

25

1

25

1

25

1

20



ER7OS-6,

Mild

Steel,

CO2

20

cfh+

0.023

Voltage

Wire

Speed

4

50

4

50

3

50

2

45

2

40

1

30

1

30

0.030

Voltage

Wire

Speed

4

40

4

40

3

40

3

40

2

40

1

40

1

35

ER7OS-6,

Mild

Steel,

75%

Argon

25%

CO2,

20

cfh+

0.023

Voltage

Wire

Speed

4

60

4

55

3

50

2

45

2

40

1

35

1

35

0.030

Voltage

Wire

Speed

4

50

4

50

3

50

3

50

2

45

1

45

1

40

ER

308,

Stainless

Steel,

Tn-Mix,

20

cfh+

o

023

~

Voltage

Wire

Speed

4

40

4

35

4

35

3

30

3

30

2

20



0.030

Voltage

Wire

Speed

4

30

4

30

4

30

3

25

3

20

2

15



0.035

Voltage

Wire

Speed

~

15

4

15

4

15

3

15

2

15



Aluminum,

Argon,

30

cfh

0.030

Voltage

Wire

Speed



4

85

3

80

2

75

1

70



0.035

Voltage

Wire

Speed



4

55

4

60

2

60

2

55



*Do

not

change

ThicknessNoltage

switch

position

while

welding.

Fine

TuningiWire

Speed

value

in

Table

4-1

is

a

starting

value

only,

and

Fine

Tuning/Wire

Speed

control

setting

can

be

fine

tuned

during

welding.

+cfh

=

cubic

feet

per

hour

OM-151

015

Page9

SECTION

5

MAINTENANCE

&

TROUBLESHOOTING.

a

WARNING

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.

MOVING

PARTS

can

cause

Injury.



Keep

away

from

moving

parts.



Keep

away

from

pinch

points

such

as

drive

rolls.

ance

to

be

performed

only

by

qualified

swarn8.2

2/93

A.

Motor

Fuse

Fl

Located

behind

fan.

2

Fuse

Fl

(See

Parts

List

For

Rating)

Pull

fuse

from

fuse

holder

on

PCi.

To

reinstall,

push

fuse

into

fuse

holder.

Reinstall

wrapper,

and

latch

door.

5-1.

Routine

Maintenance

Turn

Off

all

power

before

maintaining.

3

Months

Trigger

Cord

-

Gun

Cable

5-2.

Overload

Protection

Figure

5-1.

Maintenance

Schedule

a

CAUTION

READ

SAFETY

BLOCKS

at

start

of

Section

5

before

proceeding.

STATIC

ELECTRICITY

can

damage

parts

on

circuit

boards.



Put

on

grounded

wrist

strap

BEFORE

handling

boards

or

parts.

fwam5.1

9/91

Turn

Off

and

unplug

unit.

Unlatch

door

and

remove

door/wrapper.

1

Circuit

Board

PCi

Tools

Needed:

~

3/8

in

Figure

5-2.

Fuse

Fl

Location

5T-150

114/ST-149

327

OM-15i

015

Page

10

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