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AUTO
ARC}fi
April
1994
Form:
OM-151
015A
Effective
With
Serial
No.
KD461
760
OWNERS
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.
MANUFACTURERS
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
customers
risk
and
espanse.
manufacturers
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
previous
manutacturers
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
manufacturers
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
manufacturers
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
Owners
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
next
page.
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
manufacturers
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
LARC
DESSAI.
LELECTROCUTION
peut
Œtre
mortelle.
~
Une
decharge
Ølectrique
peut
vous
tuer
ou
vous
brOler
gravement.
LØlectrode
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
dentrØe
des
matŁriels
ou
arrŒtez
leur
moteur
avant
de
les
installer
ou
den
faire
lentretien.
Le
RAYONNEMENT
DE
LARC
peut
brUler
es
yeux
et
Ia
peau;
le
BRUIT
peut
endommager
louIe.
____________
Larc
de
soudage
produit
une
chaleur
et
des
rayons
ultraviolets
intenses,
susceptibles
de
brler
es
yeux
et
Ia
peau.
Le
bruit
cause
par
certains
procØdØs
peut
endommager
louIe.
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
quil
9..
est
dangereux
de
respirer.
1.
Ecartez
le
visage
pour
Øviter
de
respirer
les
fumØes.
2.
A
lintØrieur,
assurez-vous
que
laire
de
soudage
est
bien
ventilØe
ou
que
los
fumØes
et
les
vapeurs
sont
aspirØes
a
larc.
3.
Si
Ia
ventilation
est
mauvaise,
portez
un
respirateur
a
adduction
dair
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.
Larc
produit
des
Øtincelles
et
des
projections.
Avec
Ia
chaleur
intense
dØgagØe
par
Ia
tle
et
les
matØriels,
elles
peuvent
causer
un
incendie
et
des
brlures.
Le
contact
accidentel
de
lŁlectrode
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
larc,
ou
couvrez-les
soigneusement
avec
des
bÆches
approuvees.
4.
MØfiez-vous
des
Øtincelles
et
des
Øclats
brlartts,
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
dutilisation
et
es
codes
nationaux,
provinciaux
et
locaux
applicables.
6.
ArrŒtez
tous
los
matØriels
aprŁs
utilisation.
7.
Nutilisez
pas
de
cables
uses,
endommagØs,
mal
ØpissØs
ou
de
calibre
trop
petits.
8.
Nenroulez
pas
de
cables
autour
de
votre
corps.
9.
Mettez
ala
terre
Ia
tle
a
souder
au
moyen
dune
bonne
prise
de
terre.
10.
Ne
touchez
pas
a
lØlectrode
si
vous
Œtes
en
contact
avec
le
circuit
de
soudage
(terre).
11.
Nutilisez
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
laire
de
soudage
de
rideaux
ou
de
cloisons
de
protection
contre
les
coups
darc
ou
lØblouissement;
avertissez
les
observateurs
de
ne
pas
regarder
larc.
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
sil
est
bien
ventilØ;
sinon,
portez
un
respirateura
adduction
dair.
Les
gaz
protecleurs
de
soudage
peuvent
dŁplacer
loxygene
de
lair
et
causer
des
blessures
ou
Ia
mort.
Assurez-vous
que
lair
est
propre
a
Ia
respiration.
6.
Ne
soudez
pas
a
proximitØ
dopØrations
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
tles
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
dair
si
cest
nØcessaire.
5.
MŁfiez-vous
des
incendies
et
gardez
un
extincteur
a
portØe
do
Ia
main.
6.
Noubliez
pas
quune
soudure
sur
un
plafond,
un
plancher,
une
cloison
ou
une
paroi
peut
en
enflammer
lautre
ctØ.
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
tle
de
soudage
pour
empecher
le
courant
do
suivre
un
parcours
long
et
inconnu,
et
prØvenir
ainsi
les
risques
dØlectrocution
et
dincendie.
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
SAPPROCHER,
NI
LES
PORTEURS
DE
STIMULATEUR
CARDIAQUE
(A
MOINS
QUILS
NAIENT
CONSULTE
UN
MEDECIN).
Le
soudage,
comme
Ia
plupart
des
activitŁs
industrielles,
expose
a
certains
risques.
Le
soudage
nest
pas
dangereux
Iorsquon
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
DINSTALLATION,
DE
REPARATION,
DENTRETIEN
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
dŒtre
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
dinstaller
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.
Nutilisez
que
des
bouteilles
de
gaz
protecteur,
des
dØtendeurs,
des
flexibles
et
des
raccords
conus
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
louvrant.
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
lentretien
ou
le
depannage
nØcessaire.
4.
Pour
empŒcher
un
dØmarrage
accidentel
dun
systŁme
pendant
lentretien,
dØbranchez
le
cable
daccumulateur
a
Ia
borne
negative.
5.
Napprochez
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
dentretien
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
lextØrieur
dans
des
aires
ouvertes
et
PEUVENT
ETRE
MORTELS.
bien
ventilØes.
Les
moteurs
produisent
des
gaz
nocifs.
dechappement
2.
Si
vous
utilisez
des
machines
dans
un
endroit
confine,
les
fumØes
dechappement
doivent
Œtre
envoyees
a
lextØrieur,
loin
des
prises
dair
du
btiment.
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
dune
source
3.
4.
5.
dØtincelles
ou
dune
flamme
nue.
Si
cest
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
lespace
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;
LELECTROLYTE
DUN
ACCUMULATEUR
peut
brUier
Ia
peau
et
~
2.
3.
un
accumulateur.
ArrŒtez
le
moteur
avant
de
connecter
ou
de
dØconnecter
des
cables
daccumulateur.
Nutilisez
que
des
outils
anti-Øtincelles
pour
travailler
sur
un
~UX.
accumulateur.
Les
accumulateurs
contiennent
de
lelectrolyte
et
4.
NutilisezpÆsunpostedesoudagepourchargerunaccumulateur
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
laccumulateur.
La
VAPEUR
ET
LE
LIQUIDE
DE
1.
Ntez
pas
le
bouchon
de
radiateur
tant
que
le
moteur
na
pas
REFROIDISSEMENT
BRULANT
SOUS
refroidi.
PRESSION
peuvent
brler
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
lter.
Laissez
Ia
pression
sØchapper
avant
doter
complŁtement
le
bouchon.
brlant
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
015A4/94
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!~LI~1:1~Il~ie.u
Figure
1-1.
Safety
Information
SECTION
2SPECIFICATIONS
Table
2-1.
Welding
Power
Source
2
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
related
to
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
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
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
60
70
8090100
%
DUTY
CYCLE
SB-124
655-A
OM-151
015
Page2
SECTION
3INSTALLATION
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
Owners
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
manufacturers
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
ufacturers
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
4OPERATION
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
manufacturers
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
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
/