Miller KD438829 Owner's manual

AUTO

ARCJ

April

Effec

1995

tive

With

Form:

Serial

No.

OM-151

016A

KD438829

OWNERS~~

MAN

UAL

Auto

Arcﬁ

140



Read

and

follow

these

instructions

and

all

safety

blocks

carefully.

Have

only

trained

and

qualified

persons

install,

operate,

or

service

this

unit.



Give

this

manual

to

the

operator.

U

For

help,

call

your

distributor

tw

~-.J~



Call

your

distributor

if

you

do

not

understand

the

directions.

j~J



or:

MILLER

Electric

Mfg.

Co.,

P.O.

Box

1079,

Appleton,

WI

54912

414-734-9821



CV/DC

Welding

Power

Source/Wire

Feeder



For

OMAW

And

FCAW

Welding



120

Amperes,

21

Volts

At

30%

Duty

Cycle



Uses

230

Volts

AC,

Single-Phase

Input

Power



Feeds

.023

Thru

.035

Wire



Overheating,

Short-Circuit,

And

Motor

Overload

Protection



Includes

Gas

Valve

auto_arc

7193

ST-I

49

628-B

PRINTED

IN

USA

I]

Lu

LIMITED

WARRANTY

Effective

January

1,

1995

(Equipment

with

a

serial

number

preface

of

lCD

or

newer)

1.

Items

furnished

by

manufacturer,

but

manufactured

by

others,

such

as

engines

ortrade

accessories.

These

Items

are

covered

by

the

manufacturers

warranty,

if

any.

Consumable

components;

such

as

contact

tips.

cutting

nozzles,

Contactors

and

relays

or

parts

that

fail

due

to

normal

wear.

Equipment

that

has been

modified

by

any

party

other

than

manufacturer,

or

equipment

that

has

been

improperly

instated,

improperly

operated

or

misused

based

upon

Industry

standards,

or

equlpmenl

which

has

not

had

reasonable

and

necessary

maintenance,

or

equipment

which

has

been

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

of

a

warranty

claim

covered

by

this

warranty,

the

exclusive

remedies

shall

be.

at

manutacturere

option:

(1)

repair~

or(2)

replacement;

or,

where

authorized

in

writing

by

manufacturer

in

appropriate

cases,

(3)

the

reasonable

cost

of

repair

or

replacement

stan

authorized

service

station;

or

(4)

payment

of

or

credit

for

the

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

retum

of

the

goods

at

customers

risk

and

expense,

manufacturers

option

of

repair

or

replace

ment

will

be

FOB.,

Factory

at

Appleton,

Wisconsin,

or

F.O.B.

Stan

authorized

ser

vice

facility

as

determined

by

manufacturer.

Therefore

no

compensation

or

reim

bursement

for

transportation

costs

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

UABLE

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.

MIGHTARISE

BY

IMPLICATION.

OPERATION

OF

LAW,

CUSTOM

OF

TRADE

OR

COURSE

OF

DEALING.

IN

CLUDING

ANY

IMPUED

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

stales

In

the

U.S.A.

do

not

allow

limitations

of

how

long

an

implied

warranty

lasts,

or

the

exclusion

of

incidental,

indirect,

special

or

consequential

damages.

so

the

above

limitation

or

exclusion

may

not

apply

to

you.

This

warranty

prpvides

spa-

cit

Ic

legal

rights,

and

other

rights

may

be

available,

but

may

vary

from

state

to

stale.

In

Canada,

legislation

in

some

provinces

provides

for

certain

additional

warranties

or

remedies

other

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

Umtted

,/s~

Warranty

provides

specific

legal

rights,

and

other

rights

may

be

available,

but

may

J~.Xvarv

from

orovince

to

orovlnce.

This

limited

warranty

supersedes

all

warranties

and

is

exclusive

with

no

other

guarantees

or

warranties

expressed

or

implied.

LIMITED

WARRANTY



Subject

to

the

terms

and

conditions

betow,

warrants

to

its

*

Remote

Controls

original

retail

purchaser

that

new

equipment

sold

after

the

effective

date

of

this

lim-

Accessory

Kits

lied

warranty

is

tree

of

defects

in

material

and

workmanship

at

the

time

his

shipped

from

lactory.

THIS

WARRANTY

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTHER

WAR-

ep

acement

arts

RANTIES.

EXPRESS

OR

IMPLIED,

INCLUDING

THE

WARRANTIES

OF

MER

CHANTABILITY

AND

FITNESS.

Limited

Warranty

shall

not

apply

to.

Within

the

warranty

periods

iisted

below,

manufacturerwill

repair

or

replace

any

war

ranted

parts

or

components

that

tail

due

to

such

detects

in

material

or

workmanship.

Manufacturer

must

be

notified

in

writing

within

thirty

(30)

days

of

such

defect

or

fail

ure,

at

which

time

manufacturer

will

provide

Instructions

on

the

warranty

claim

pro

cedures

to

be

followed.

2.

Manufacturer

shall

honor

warranty

Claims

Ofl

warranted

equipment

listed

below

in

the

event

of

sucfl

a

failure

within

the

warranty

lime

periods.

All

warranty

time

periods

start

on

the

date

that

the

equipment

was

delivered

to

the

original

retaii

purchaser,

or

one

year

after

the

equipment

is

sent

to

a

North

American

distributor

or

eighteen

months

after

the

equipment

Is

sent

to

an

International

distributor.

1.

5

Years

Parts

-

3

Years

Labor

*

Original

main

power

rectifiers

2.

3

Years

Partsan~Labr

*

Translormer/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

*

IHPS

Power

Sources



Water

Coolant

Systems

HF

Units



Grids

Spot

Welders



Load

Banks



SDX

Transformers



Running

Gear/Trailers



Plasma

Cutting

Torches

(except

APT,

ZIPCUT

&

PLAZCUT

Models)



Tecumseh

Engines



Deutz

Engines

(outside

North

America)



Field

Options

(NOTE:

Field

options

are

covered

under

the

limited

warranty

for

the

re

Inaining

warranty

period

of

the

product

they

are

installed

in,

or

for

a

mini

mum

of

one

year



whichever

is

greater.)

5.

6

Months



Batteries

8.

90

Days



Parts

and

Labor

MIG

Guns/TIG

Torches

-

APT.

ZIPCLJT

&

PLAXCUT

Model

Plasma

Cuttino

Torches

0

U

4

~

RECEIVING-HANDLING

Before

unpacking

equipment,

check

carton

for

any

damage

that

may

have

occurred

during

shipment.

File

any

claims

for

loss

or

damage

with

the

delivering

carrier.

Assistance

for

filing

or

settling

claims

may

be

obtained

from

distributor

and/or

equipment

manufacturers

Transportation

Department.

When

requesting

information

about

this

equipment,

always

provide

Model

Designation

and

Serial

or

Style

Number.

Use

the

following

spaces

to

record

Model

Designation

and

Serial

or

Style

Number

of

your

unit.

The

information

is

located

on

the

tating

label

or

nameplate.

Model

_________

Serial

or

Style

No.

Date

of

Purchase

brand_acct

4/95

ARC

WELDING

SAFETY

PRECAUTIONS

ARC

RAYS

can

burn

eyes

and

skin;

NOISE

can

damage

hearing.

Arc

rays

from

the

welding

process

produce

intense

heat

and

strong

ultraviolet

rays

that

can

burn

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

Keep

your

head

out

of

the

fumes.

Do

not

breathe

the

fumes.

If

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

remove

welding

fumes

and

gases.

If

ventilation

is

poor,

use

an

approved

air-supplied

respirator.

Read

the

Material

Safety

Data

Sheets

(MSDS5)

and

the

manufacturers

instruction

for

metals,

consumables,

coatings,

and

cleaners.

WELDING

can

cause

fire

or

explosion.

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

to

metal

objects

can

cause

sparks,

overheating,

or

fire.

Protect

yourself

and

others

from

flying

sparks

and

hot

metal.

Do

not

weld

where

flying

sparks

can

strike

flammable

material.

Remove

all

flammables

within

35

ft

(10.7

m)

of

the

welding

arc.

U

this

is

not

possible,

tightly

cover

them

with

approved

covers.

Be

alert

that

welding

sparks

and

hot

materials

from

welding

can

through

small

cracks

and

openings

to

adjacent

areas.

ARC

RAYS

2.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

(see

ANSI

Z49.

1

listed

in

Safety

Standards)

to

protect

your

face

and

eyes

when

welding

or

watching.

3.

Wear

approved

safety

glasses.

Side

shields

recommended.

4.

Use

protective

screens

or

barriers

to

protect

others

from

flash

and

glare;

warn

others

not

to

watch

the

arc.

4

5.

Wear

protective

clothing

made

from

durable,

flame-resistant

material

(wool

and

leather)

and

foot

protection.

5.

Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

wearing

an

air-supplied

respirator.

Shielding

gases

used

for

welding

can

displace

air

causing

injury

or

death.

Be

sure

the

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

form

highly

toxic

and

irritating

gases.

7.

Do

not

weld

on

coated

metals,

such

as

galvanized,

lead,

or

cadmium

plated

steel,

unless

the

coating

is

removed

from

the

weld

area,

the

area

is

well

ventilated,

and

if

necessary,

while

wearing

an

air-supplied

respirator.

The

coatings

and

any

metals

containing

these

elements

can

give

off

toxic

fumes

if

welded.

5.

Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.

6.

Be

aware

that

welding

on

a

ceiling,

floor,

bulkhead,

or

partition

can

cause

fire

on

the

hidden

side.

7.

Do

not

weld

on

closed

containers

such

as

tanks

or

drums.

8.

Connect

work

cable

to

the

work

as

close

to

the

welding

area

as

practical

to

prevent

welding

current

from

traveling

long,

possibly

unknown

paths

and

causing

electric

shock

and

fire

hazards.

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.

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.

Use

approved

ear

plugs

or

ear

muffs

if

noise

level

is

high.

FUMES

AND

GASES

can

be

hazardous

to

your

health.

Welding

produces

fumes

and

gases.

Breathing

these

fumes

and

gases

can

be

hazardous

to

your

health.

1.

2.

3.

4.

1.

2.

3.

4.

9.

Do

not

use

welder

to

thaw

frozen

pipes.

-

10.

Remove

stick

electrode

from

holder

or

cut

off

welding

wire

at

contact

tip

when

not

in

use.

11.

Wear

oil-free

protective

garments

such

as

leather

gloves,

heavy

shirt,

cuffless

trousers,

high

shoes,

and

a

cap.

FLYING

SPARKS

AND

HOT

METAL

can

1.

Wear

approved

face

shield

or

safety

goggles.

Side

shields

cause

injury,

recommended.

Chipping

and

grinding

cause

flying

metal.

As

welds

2.

Wear

proper

body

protection

to

protect

skin.

cool,

they

can

throw

off

slag.

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.

ENGINES

can

be

hazardous.

1.

Use

equipment

outside

in

open,

well-ventilated

areas.

2.

If

used

in

a

closed

area,

vent

engine

exhaust

outside

and

away

from

any

building

air

intakes.

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

pn(,inp

PRINCIPAL

SAFETY

STANDARDS

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.1,

from

American

Welding

Society,

550

N.W.

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.

1,

from

American

Welding

So

ciety,

550

N.W.

LeJeune

Rd. 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,

CSA

Standard

Wi

17.2,

from

Canadian

Standards

Association,

Standards

Sales,

178

Rexdale

Bou

levard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

Safe

Practices

ForOccupationAndEducationalEyeAndFace

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,

Quincy,

MA

02269.

a

WARNING

ENGINE

EXHAUST

GASES

can

kill.

Engines

produce

harmful

exhaust

gases.

ENGINE

FUEL

can

cause

fire

or

explosion.

Engine

fuel

is

highly

flammable.

1.

MOVING

PARTS

can

cause

injury.

Moving

parts,

such

as

fans,

rotors,

and

belts

can

cut

fingers

and

hands

and

catch

loose

clothing,

Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

3.

4.

5.

6.

Have

only

qualified

people

remove

guards

or

covers

for

maintenance

and

troubleshooting

as

necessary.

To

prevent

accidental

starting

during

servicing,

disconnect

negative

()

battery

cable

from

battery.

Keep

hands,

hair,

loose

clothing,

and

tools

away

from

moving

parts.

Reinstall

panels

or

guards

and

close

doors

when

servicing

is

2.

Stop

eng

ne

before

installing

or

connecting

unit,

finished

and

before

starting

engine.

SPARKS

can

cause

BATTERY

GASES

1.

Always

wear

a

face

shield

when

working

on

a

battery.

TO

EXPLODE;

BATTERY

ACID

can

burn

eyes

and

skin,

2.

Stop

engine

before

disconnecting

or

connecting

battery

cables.

Batteries

contain

acid

and

generate

explosive

3.

4.

Do

not

allow

tools

to

cause

sparks

when

working

on

a

battery.

Do

not

use

welder

to

charge

batteries

or

jump

start

vehicles.

ases.

5.

Observe

correct

polarity

(+

and

)

on

batteries.

~.

~

2

~-.

STEAM

AND

COOLANT

can

skin.

The

coolant

in

the

r

under

pressure.

PRESSURIZED

burn

face,

eyes,

adiator

can

be

very

h

HOT

and

ot

and

1.

2.

3.

Do

not

remove

radiator

cap

when

engine

is

hot.

Allow

engine

to

cool.

Wear

gloves

and

put

a

rag

over

cap

area

when

removing

cap.

Allow

pressure

to

escape

before

completely

removing

cap.

sri

9/92

Page is loading ...

EMF

INFORMATION

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

3-2.

Installing

Gas

Supply

3-3.

Gun

Polarity

For

Wire

Type

3-4.

Selecting

A

Location

And

Connecting

Input

Power

3-5.

Installing

Wire

Spool

3-6.

Threading

Welding

Wire

SECTION

4OPERATION

8

SECTION

5-

MAINTENANCE

&

TROUBLESHOOTING

5-1.

Routine

Maintenance

5-2.

Overload

Protection

5-3.

Cleaning

Or

Repairing

Drive

Assembly

5-4.

Troubleshooting

SECTION

6

ELECTRICAL

DIAGRAMS

14

SECTION

7

WELDING

METHODS

&

TROUBLESHOOTING

7-1.

Flux

Cored

Arc

Welding

(FCAW)

And

Gas

Metal

Arc

Welding

(GMAW)

7-2.

Welding

Troubleshooting

SECTION

8-

PARTS

LIST

Figure

8-1.

Main

Assembly

22

Figure

8-2.

Baffle,

Center

w/Components

24

Figure

8-3.

Drive

Assembly,

Wire

26

OM-151

016A4/95

NOTE

D~

Considerations

About

Welding

And

The

Effects

Of

Low

Frequency

Electric

And

Magnetic

Fields

The

following

isa

quotation

from

the

General

Conclusions

Section

of

the

U.S.

Congress,

Office

of

Technology

Assessment,

Biological

Effects

of

Power

Frequency

Electric

&

Magnetic

Fields



Backg

round

Paper,

OTA-BP-E-53

(Washington,

DC:

U.S.

Govemment

Printing

Office,

May

1989):.

.

there

is

now

a

very

large

volume

of

scientific

findings

based

on

experiments

at

the

cellular

level

and

from

studies

with

animals

and

people

which

clearly

establish

that

low

frequency

magnetic

fields

can

interact

with,

and

produce

changes

in,

biological

systems.

While

most

of

this

work

is

of

very

high

quality,

the

results

are

complex.

Current

scientific

understanding

does

not

yet

allow

us

to

interpret

the

evidence

in

a

single

coherent

framework.

Even

more

frustrating,

it

does

not

yet

allow

us

to

draw

definite

conclusions

about

questions

of

possible

risk

or

to

offer

clear

science-based

advice

on

strategies

to

minimize

or

avoid

potential

risks.

To

reduce

magnetic

fields

in

the

workplace,

use

the

following

procedures:

1.

Keep

cables

close

together

by

twisting

or

taping

them.

2.

Arrange

cables

to

one

side

and

away

from

the

operator.

3.

Do

not

coil

or

drape

cables

around

the

body.

4.

Keep

welding

power

source

and

cables

as

far

away

as

practical.

5.

Connect

work

clamp

to

workpiece

as

close

to

the

weld

as

possible.

About

Pacemakers:

The

above

procedures

are

among

those

also

normally

recommended

for

pacemaker

wearers.

Consult

your

doctor

for

complete

information.

modlo.1

4/93

3

4

5

6

11

12

13

16

18

Page is loading ...

SECTION

1



SAFETY

IN

FORMATION



Read

all

safety

messages

throughout

this

manual.



Obey

all

safety

messages

to

avoid

injury.



Learn

the

meaning

of

WARNING

and

CAUTION.

Figure

1-1.

Safety

Information

SECTION

2

SPECIFICATIONS

Table

2-1.

Welding

Power

Source

modl.1

2/93

1

2

WY

~~AI~

2

\~

3

ELECTRIC

SHOCK

can

kiII.i



Do

not

touch

live

electrical

parts.

~fl



Disconnect

input

power

before

~

installing

or

servicing.

JJ

/

a

CAUTION

5

MOVING

PARTS

can

injure.

~

I~$lh~~,

S

Keep

away

Iron,

moving

parts.

I



Keep

all

panels

and

covers

closed

I

when

operating.

I

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

~

READ

SAFETY

BLOCKS

at

start

of

______

Section

3-1

before

proceeding.

7H

NOTE

~

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

Type

Of

Input

Constant

Voltage/Direct

Current

(CV/DC)

Description

Input

Amperes

At

Rated

Output

KVA/KW

Used

At

Rated

Output

Max.

Open-Circuit

Voltage

Control

Circuit

Voltage

At

Gun

Welding

Processes

120

Amperes,

21

Volts

DC

At

30%

Duty

Cycle

(See

Section

2-2)

Single-Phase;

230

Volts

AC;

60

Hertz

20

Amperes

4.7

kVAJ3.9

kW

32

Volts

DC

24

Volts

DC

Wire

Feed

Speed

Range

Wire

Diameter

Range

Gas

Metal

Arc

Welding

(GMAW)

(Uses

Solid

Hard

Or

Aluminum

Wire

And

External

Shielding

Gas)

Flux

Cored

Arc

Welding

(FCAW)

(Uses

Wire

With

Flux

Inside

And

Requires

No

External

Shielding

Gas)

Input

Power

Cord

With

Plug

Overall

Dimensions

Weight

47

To

690

ipm

(1.2

To

17.5

mpm)

.023

To

.035

in

(0.58

To

0.89

mm)

5ft(1.5m)

Length:

27

in

(686

mm);

Width:

12

in

(305

mm),

Height:

22-1/2

in

(571

mm)

Net:

117

lb

(53

kg);

Ship:

120

lb

(54

kg)

OM-151

016

Page

1

2-1.

Volt-Ampere

Curves

a

CAUTION

EXCEEDING

DUTY

CYCLE

RATINGS

will

damage

unit.



Do

not

exceed

indicated

duty

cycles.

warn7.1

2/92

200

I~0

U,

Ui

~

80

70

60

DUTY

CYCLE

~

sbl.22192SB-124624

Figure

2-2.

Duty

Cycle

Chart

SECTION

3INSTALLATION

Table

3-1.

Items

Included

With

Welding

Power

Source

Item

Quantity

Welding

Gun



Shipped

Set

To

Feed

.030

in

(0

.8

mm)

Wire

1

(See

Gun

Owners

Manual

Form

112

934)

10

ft

(3

m)

Work

Cable

And

Clamp

1

6ft(1.8m)AirHose

j

Contact

Tubes

(3

.023

in,

2

.030

in,

And

3



.035

in)

8

Monocoil

Liner

For

.023

Thru

.030

in

Wire

1

Ui

0

-)

C

>

C

40

30

20

IC

0

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.

sSbl.1

10/91

/SB-124

625

SO

00

50

200

250

D.C.

AMPERES

Figure

2-1.

Volt-Ampere

Curves

2-2.

Duty

Cycle

Duty

cycle

is

how

long

the

unit

can

operate

within

a

ten

minute

period

without

causing

overheating

or

damage.

This

unit

is

rated

at

30%

duty

cycle

allowing

welding

3

minutes

out

of

every

10

minutes

at

rated

load.

If

the

welding

amperes

decrease,

the

duty

cycle

increases.

1.5

20

25

30 40

50

60

70

80

90

00

OM-151

016

Page

2

NOTE

~

]

Customer

must

obtain

proper

welding

wire

and

application.

shielding

gas

for

desired

3-1.

Installing

Work

Clamp

1

Insulator

2

Bolt

3

Smaller

Hole

4

Work

Clamp

Tabs

Bend

tabs

around

work

cable.

5

Work

Cable

From

Unit

6

Nut

Tools

Needed:

3/8,7116in

Ref.

ST-025

190.C

Figure

3-1.

Work

Clamp

Installation

3-2.

Installing

Gas

Supply

a

WARNING

.-.

:~

C



YLINDERS

can

explode

if

damaged.

~

BUILDUP

OF

SHIELDING

GAS

can

harm

Keep

cylinders

away

from

welding

and

other

~

health

or

kill.

electrical

circuits.



Shut

off

shielding

gas

Supply

when

not

in

use.



Never

touch

cylinder

with

welding

electrode.

Always

secure

cylinder

to

running

gear,

wall,

or

other

stationary_support.

wam4.1

9/91

A.

Installing

Safety

Chain

1

Cylinder

Bracket

As

Shipped

2

S-Hook

2

.

Crimp

between

small

hole

in

bracket

and

chain.

3

Chain

4

Snap

Crimp

onto

open

end

of

chain.

5

Cylinder

Bracket

For

Large

Gas

Cylinder

6

Gas

Fitting

Tools

Needed:

ST-160

791

3

Figure

3-2.

Installing

Safety

Chain

OM-151

016

Page

3

B.

Installing

Regulator/Flowmeter

Figure

3-3.

Typical

Regulator/Flowmeter

Installation

3-3.

Gun

Polarity

For

Wire

Type

a

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

welding

power

source,

and

disconnect

input

power

before

inspecting

or

installing.

Swami

.1

2/93

1

Polarity

Changeover

Label

2

Polarity

Jumper

Links

Always

read

and

follow

wire

man

ufacturers

recommended

polarity.

There

are

two

jumper

links

(1

set)

across

each

set

of

terminals.

Be

sure

to

move

each

set

of

links

when

changing

polarity.

Close

door.

Ret.

sT-14g631.c

1

2

6

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

supplied

air

hose.

6

Flow

Adjust

Typical

flow

rate

is

20

cth

(cubic

feet

per

hour).

Check

wire

man

ufacturers

recommended

flow

rate.

5



OR

4

Argon

Gas

Tools

Needed:

~

1-1/8,5/Sin

7

8

7

CO2

Adapter

8

0-Ring

Install

adapter

with

0-ring

between

regulator/flowmeter

and

CO2

cylinder.

CO2

Gas

ssb3.i

12/92



ST-158

697-A

/

STRAIGHT

I

REVERSE

-

(

:1::)

c<~~~~b

For

Solid

For

Flux

Steel

Or

Cored

Wires

Aluminum

I

POLARITY

Process)

)GMAW)

OCEN

DCEP

I

(FCAW

~

Wires

GUN

POLARITY

cHANGEovER

Tools

Needed:

~

3/Bin

Figure

3-4.

Gun

Polarity

Jumper

Link

Position

OM-151

016

Page

4

3-4.

S&ecting

A

Location

And

Connecting

Input

Power

a

WARNING

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.

swarn3.1

2/93

Table

3-2.

Electrical

Service

Requirements*

Input

Voltage

230

Input

Amperes

At

Rated

Output

20

Recommended

Standard

Fuse

Or

Circuit

Breaker

Rating

In

Amperes1

30

Input

Conductor

Size

In

AWG/KcmiI2

14

Max

Input

Conductor

Length

In

Feet

(Meters)3

65

(20)

Grounding

Conductor

Size

In

AWG/KcmiI4

14

*

These

values

are

calculated

from

the

1990

edition

of

the

National

Electrical

Code

(NEC).

1

Recommended

fuse

or

circuit

breaker

size

is

that

closest

to

150%

of

rated

input

amperage

of

the

welding

power

source.

Article

630-12(a)

of

NEC

allows

fuse

or

circuit

breaker

sizing

up

to

200%

of

rated

input

amperage.

2

Input

conductor

size

is

for

insulated

copper

wire

with

75C

rating

with

not

more

than

three

single

current-carrying

conductors

in

a

cable

or

raceway

(Table

310-16

of

NEC).

3

Maximum

length

is

to

prevent

more

than

a

3%

voltage

drop

between

service

entrance

and

input

terminals

of

the

welding

power

source

(Articles

210-19(a)

and

215-2(b)

of

NEC).

4

The

grounding

conductor

shall

be

colored

or

identified

as

specified

in

the

NEC.

Grounding

conductor

size

for

copper

wire

is

not

required

to

be

larger

than

input

conductor

(Article

250-95

of

NEC).

S-0092-F

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Oft

welding

power

source,

and

disconnect

input

power

before

inspecting

or

installing.



Have

only

qualified

persons

install

unit.



Installation

must

meet

National

Electrical

Code

and

all

other

codes.



5

7

4

1

18

in

(457

mm)

Open

Space

At

Front

And

Rear

2

Rating

Label

Supply

correct

input

power.

3

230

Volts

AC

Wall

Receptacle

4

Input

Conductors

Select

size

and

length

using

Table

3-2.

Conductor

rating

must

comply

with

national,

state,

and

local

codes.

5

Line

Disconnect

Device

Of

Proper

Rating

Obtain

and

install

switch

and

wall

receptacle.

6

Grounding

Conductor

Select

size

and

length

using

Table

3-2.

Be

sure

grounding

con

ductor

goes

to

an

earth

ground.

Install

and

connect

input

conduc

tors

and

grounding

conductor

in

conduit

or

equivalent

between

wall

receptacle

and

deenergized

line

disconnect

device.

7

Overcurrent

Protection

Select

type

and

size

using

Table

3-2.

Install

into

deenergized

line

disconnect

device

(fused

dis

connect

switch

shown).

Connect

deenergized

supply

con

ductors

to

line

disconnect

device.

8

Input

Power

Plug

Turn

Off

unit

Power

switch,

and

connect

plug

to

wall

receptacle.

Place

line

disconnect

switch

in

On

position

before

using

welding

power

source.

ssb2.2

3/93



ST-149

630-C

.3

Figure

3-5.

Location

And

Input

Power

Connections

OM-151

016

Page

5

3-5.

Installing

Wire

Spool

a

WARNING

ELECTRIC

SHOCK

can

kill.

~



Do

not

touch

live

electrical

parts.

I



Turn

Off

welding

power

source,

and

disconnect

input

power

before

inspecting

or

installing.

7

NOTE

if

hub

tension

is

too

tight,

motor

fuse

Fl

can

open

(see

Section

5-2).

If

hub

tension

is

too

loose,

wire

unravels

and

can

become

tangled

inside

unit.

Turn

Off

and

unplug

unit.

1

Wire

Spool

2

Gun

Contact

Tube

If

necessary,

cut

welding

wire

off

at

contact

tube,

and

retract

wire

onto

spool

and

secure.

3

Retaining

Ring

Remove

ring

and

pull

off

spool.

4

Compression

Spring

2

\

~

Compression

spring

is

used

with

8

in

(200

mm)

spools.

5

Hub

6

Slide

spool

onto

hub

so

wire

feeds

off

bottom.

Turn

spool

until

hub

fits

hole

in

back

of

spool.

Reinstall

retaining

ring.

7

Hub

Tension

Nut

Grasp

spool

in

one

hand

and

turn

while

using

a

wrench

to

adjust

hub

tension

nut.

When

a

slight

force

is

needed

to

turn

spool,

tension

is

set.

Tools

Needed:

Thread

welding

wire

(see

Section

3-6).

Close

door.

~:

15/16

in

Ret.

ST-150

193-C

/

SA-072

573.B

Figure

3-6.

Welding

Wire

Spool

Installation

3-6.

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

instruct~d

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.

Swarfll.1

2/93

!

Swarn2.l

9/91

/

swam5.1

10191

OM-151

016

Page

6

Hold

wire

tightly

to

keep

it

from

unraveling.

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:

Close

and

tighten

pressure

assembly,

and

let

go

of

wire.

Feed

wire

to

check

drive

roll

pressure.

Tighten

knob

enough

to

prevent

slipping.

~I

~ee

S

0

_____

4

in~

(102

mm)

~

Cut

off

wire.

Close

and

latch

door.

Figure

3-7.

Threading

Welding

Wire

23

5

6

Open

pressure

assembly.

Push

wire

thru

guides

into

gun;

continue

to

hold

wire.

ION

POWER

I

OO~I

Pull

and

hold

wire;

cut

offend.

Remove

gun

nozzle

and

contact

tube.

1111

II

Set

switch.

Press

gun

trigger

until

wire

comes

out

of

gun.

Reinstall

contact

tube

and

nozzle.

Ref.

ST-149

632-C/

Ref.

ST-i50

193/

Ref.

ST-i

59272!

S-0627-A

OM-151

Ol6Page7

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.

1

Work

Cable

2

Tools

Needed:

~

2

Work

Clamp

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.

sb4.l

2)93



Ret.

5T-156

258

Figure

4-2.

W

ork

Clamp

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

6/92S.0621.C

p

~



ARC

RAYS

can

burn

eyes

and

skin;

NOISE

can

damage

hearing.



Wear

welding

helmet

with

correct

shade

of

filter.



Wear

correct

eye,

ear,

and

body

protection.

0

MOVING

PARTS

can

cause

injury.



Keep

away

from

pinch

points

such

as

drive

rolls.



Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.



~

-

L.~

MAGNETIC

FIELDS

FROM

HIGH

CUR

RENTS

can

affect

pacemaker

operation.



Pacemaker

wearers

keep

away.



Wearers

should

consult

their

doctor

before

going

near

arc

welding,

gouging,

or

spot

welding

opera

tions.

See

Safety

Precautions

at

beginning

of

manual

for

ba

sic

welding

safety

information.

swam6.~

10/91

1

~

2

~

Figure

4-1.

3

~

Safety

Equipment

1

Insulating

Gloves

2

Safety

Glasses

With

Side

Shields

3

Welding

Helmet

Wear

dry

insulating

gloves,

safety

glasses

with

side

shields,

and

a

welding

helmet

with

a

correct

shade

of

filter

(see

ANSI

Z49.1).

sb3.1

10/91

BUILDUP

OF

SHIE

LDING

GAS

can

harm

health

or

kill.



Shut

off

shielding

gas

supply

when

not

in

use.

1~.J

waml.19/91

Figure

4-3.

Shielding

Gas

OM-151

016

Page

8

I

Fine

TuninglWire

Speed

Control

Use

control

to

select

a

wire

feed

speed.

As

ThicknessNoltage

switch

setting

increases,

wire

speed

range

also

increases.

The

numbers

around

the

control

are

not

a

wire

feed

speed

and

are

for

reference

only

(see

Table

4-1).

2

ThicknessNoltage

Switch

Use

switch

to

select

an

arc

voltage.

The

higher

the

selected

number,

the

thicker

the

material

that

can

be

welded

(see

Table

4-1).

3

Power

Switch

Use

switch

to

turn

unit

and

fan

On

and

Off.

a

CAUTION

ARCING

can

damage

switch.



Do

not

change

ThicknessNoltage

switch

position

while

welding.

Arcing

inside

switch

can

damage

contacts,

causing

switch

to

fail.

warn5.I

2/93

Figure

4-4.

Contros

Ret

ST-I

50

092-Al

Ret.

ST-I

58 258

OM-151

OI6Page9

lnstall&

~

Put

On~\\

Turn

On

Do

)

Control

Connect

j

)

Personal

Safety

I

)Equipment

&

Gas

I

)

Set

Controls))

Sample

Weld

For

Production

J

And

Prepare

J

Equipment

J)

Equipment

JJ

(lfApplicable~,/

________________

Ssb4.1

tO/91

Figure

4-5.

Sequence

Of

Operation

For

Hard

And

Flux

Cored

Wires

Install

&

Connec~\~\

Adjust

Hub

~~\

Adjust

Drive

Roi\\

p~~51\~Vu~

On

~

I

Equipment

Using

I

Tension

To

I

J

Pressure

To

I

Put

On

And

Adjust

Gas

Keep

Gun

C

J

Knurled

Groovejj

Minimum

JJ

Minimum

}JSafety

Equipmen~}j

To

30

cfh

Straight

)

Do

Sample

Weld

And

Prepare

For

D)ReadJustContro~

__________________

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

Material_Thickness

1/4

in

(6.4

mm)

3/16

in

(4.8

mm)

1/8

in

(3.2

mm)

14

ga

16

ga

18

ga

22

ga

24

ga

E7OS-6

CO2

20

cfh+

.023

Voltage

4

3

2

1

Wire

Speed*



100%

80% 70%

60%

55%

45%

35%

.030

Voltage

4

3

2

1 1



Wire

Speed*

80%

75%

60% 60% 50%

40%

30%

.035

Voltage

4

3 2

1 1 1



Wire

Speed*

65%

60%

50%

40%

30%

20%

15%



E7OS-6

75%

Argon

25%

CO2

20

cfh+

.023

Voltage



4

3 2

2

1

Wire

Speed*



100%

90%

80%

70%

60%

50%

40%

.030

Voltage

4

3 3 2

2

1



Wire

Speed*

90%

80%

70%

60%

50%

45%

30%



.035

Voltage

4

3

2

1



Wire

Speed*

75%

70%

60% 50%

40%

33%

25%



E71T-GS

Flux

Core

.030

Voltage

3

2

1



Wire

Speed*

40%

65%

45%

40%

30% 20%



.035

Voltage

3

2

1



Wire

Speed*

60%

50%

40%

30%

20%

10%



ER

308

Stainless

Steel

Tn-Mix

20

cfh+

.023

Voltage

4

3

2

1



Wire

Speed*

100%

90%

85%

75%

70%

60%

.030

Voltage

4

3

2



Wire

Speed*

75%

65%

60% 55%

50%



.035

Voltage

4

3



Wire

Speed*

60%

50%



 

Aluminum

Argon

30

cfh+

.030

Voltage

4

3

2

1



Wire

Speed*

90%

85%

80% 90% 90%

85%

 

.035

Voltage

4

3

2

1



Wire

Speed*

85% 85%

85%

90%

80%



*

Do

not

change

ThicknessNoltage

switch

position

while

welding.

Fine

Tuning/Wire

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

ft

per

hour

OM-151

016

Page

10

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.

5-1.

Routine

Maintenance

Turn

Off

all

power

before

maintaining.

3

Months

See

Section

Replace

Unreadable

Labels

~/H~

5-2.

Overload

Protection

Figure

5-1.

Maintenance

Schedule

READ

SAFETY

BLOCKS

at

start

of

Section

5

before

proceeding.

1

Thermostat

TP1

protects

the

unit

from

damage

due

to

overheating.

If

rectifier

SR2

gets

too

hot,

TP1

oper~s

and

weld

output

stops.

The

fan

keeps

running

to

cool

SR2.

Wait

several

minutes

before

trying

to

weld.

Short

Circuit

Shutdown

If

contact

tube

is

shorted

and

sticks

to

workpiece,

the

unit

shuts

down,

but

fan

runs.

To

resume

operation,

release

gun

trigger,

turn

Off

unit,

and

remove

contact

tube

from

workpiece.

Check

contact

tube

and

replace

if

damaged.

Turn

On

unit

to

continue

operation.

MOVING

PARTS

can

cause

Injury.



Keep

away

from

moving

parts.



Keep

away

from

pinch

points

such

as

drive

rolls.

Maintenance

to

be

performed

only

by

qualified

persons.

9warn8.2

2/93

-~

3

Months

Replace

~

Cracked

Parts



Trigger

Cord

Gas

Hose

Gun

Cable

A.

Overheating

OM-151

016

Page

11

C.

Motor

Fuse

Fl

5-3.

Cleaning

Or

Repairing

Drive

Assembly

READ

SAFETY

BLOCKS

at

start

of

Section

5

before

proceeding.

Figure

5-2.

Fuse

Fl

Location

Tools

Needed:

Turn

Off

and

unplug

unit.

I

Wire

Spoof

2

Gun

Contact

Tube

Cut

welding

wire

off

at

contact

tube.

Retract

wire

onto

spool

and

secure.

3

Pressure

Roll

Arm

4

Cotter

5

6

Screw

7

Bearing

Remove

bearing

as

shown.

Install

new

bearing

and

secure

with

screw.

Reinstall

arm.

8

Securing

Screw

9

Washers

10

Drive

Roll

Remove

drive

roll

as

shown.

Use

a

wire

brush

to

clean

drive

roll.

Push

drive

roll

onto

shaft

and

secure

with

washers

and

screw.

11

Wire

Inlet

Guide

Remove

guide

by

pressing

on

barbed

area

or

cutting

oft

one

end

near

housing

and

pulling

it

out

of

hole.

Push

new

guide

into

hole

from

rear

until

it

snaps

in

place.

Thread

welding

wire

(see

Section

3-6).

Close

door.

Ret.

ST-150

193-c

I

ST-i

55

578

Figure

5-3.

Removing

Drive

Roll,

Drive

Bearing,

And

Wire

Inlet

Guide

OM-151

Ol6Pagel2

5-4.

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

servicing

gun

or

unit.

Table

5-1.

Welding

Trouble

*See

Gun

Owners

Manual

MOVING

PARTS

can

cause

Injury.



Keep

away

from

moving

parts.



Keep

away

from

pinch

points

such

as

drive

rolls.

shooting

to

be

performed

only

by

qualified

swamg.2

10/91

Table

5-2.

Wire

DrivefGun

Trouble

Adjust

drive

roll

pressure.

Change

to

proper

groove.

Readjust

hub

tension.

Replace

contact

tube

if

blocked.

*See

Gun

Owners

Manual

Trouble

~o

weld

output;

wire

does

not

teed;

fan



_

does

not

run.

Remedy

Secure

power

cord

plug

in

receptacle.

Replace

line

disconnect

fuse

or

reset

circuit

breaker

if

open.

Secure

gun

trigger

plug

in

receptacle

or

repair

leads,

or

replace

trigger

switch.

No

weld

output;

wire

does

not

feed;

fan

H



-~

motor

continues

to

run.

j

Section

~

3-4

~

3-4

*

No

weld

output;

wire

feeds.

Thermostat

TP1

open

(overheating).

Allow

fan

to

run;

the

thermo

stat

will

close

when

the

unit

has

cooled.

Check

motor

fuse

Fl,

and

replace

if

necessary.

j---I.

-~

5-2A

-s

5-2C

Connect

work

clamp

to

get

good

metal

to

metal

contact.

Low

weld

output.

Replace

contact

tube.

Check

for

proper

connections

at

polarity

changeover

board.

Figure

4-2

-~

3.3

-~

~

]



--~_Connect

unit

to

proper

input

voltage

or

check

for

low

line

voltage._~



-~

3.4

--~

Trouble

Remedy

Section

Electrode

wire

feeding

stops

during

~



-~

Straighten

gun

cable

and/or

replace

damaged

parts.

*

welding.

]

_____________________________________________________

___________

3~6

5.3

3-5

*

~

53,*

.~

5.3

..

*

5-2C

~

*

---~

--

Clean

or

replace

wire

inlet

guide

or

liner

if

dirty

or

plugged.

--a

Replace

drive

roll

or

pressure

bearing

if

worn

or

slipping.

Secure

gun

trigger

plug

in

receptacle

or

repair

leads,

or

replace

trigger

switch.

Check

motor

fuse

Fl,

and

replace

if

necessary.

Check

and

clear

any

restrictions

at

drive

assembly

and

liner.

Have

nearest

Factory

Authorized

Service

Station/Service

Distribu

tor

check

drive

motor.

OM-151

016

Page

13

230

VOLTS

SECTION

6

ELECTRICAL

DIAGRAMS

Figure

6-1.

Circuit

Diagram

For

Welding

Power

Source

SB-I

62

243

IDENTICAL

CONNECTED

VOLTAGE(S)

200

VOLTS

220

VOLTS

T~CH

OM-151

016

Page

14

01

0 0

-

0

2

4(6

8

CR

I

I~3~5~

~A

166(CRI-6)

J

I

L

8A(RC3

2)

)

I

~

88(PLG2-14

I

4B(PLG2-2)

146(ORIVE

~T~)

DRIVE MOTOR

COIL)

286(11)

58(PLG2-

2)

5A(PC3

I)

5C(FM

24V

L

26(52

WIPER)

WHITE(POWER

CONO)

278(05)

COIL)

J~

216(5)

CC8UION)

7A(PLG2-)O

P

CR2

3A(S2

WIPER)

BLACK(POWER

Cr110

2

3

4

5 6

7

8 9

10

2

)3

4

PC

I

PC

I

IOA(Rl

-COW)



14B)CPI-5)

l9A)TI-E~)

13A)T

I-BEG)

126(R)-CW)

17A(CPI-3)

158(CP)-2(

116(R)-WIPER

66

(

CR

I-B)

7A(CR2

RIGHT)

30B(TEI-POS)

58(C52

COIL)

3IA(TE)-I~EG

68(cP)-A)

PLG2

56(05)

2)

46

(CR)

-5)

IOA(Pt.G2))

~

_~f~_

~

H

S2

J~jI~

-j

0



Li

6

Li

U

In

~

I

2

3

4

00

RC3

32(TE)

Wt11)(

Li

((A

lT~l

1I~IHl

5C(C92

COIL)

IA

S2

ON)

TE

I

32)WOPI(

cLAP.~

~

WOR)(

A\

(

31A)PLG2-)3

(1~11~T

31C)SP2

pos~a~

a14

~

)-POs)

24V.

(A)TPI

I

ZI

278(012

1)])

RIGHT

)9A(PLG2-3)

~

)3A(PLG2-4)

23(5)) 24(51)

E

~

(952-AC)

Ti

(15

B-

\\~a~c1

T)-~C.

\sN..~,~j4

c~~rJi

f)-~C.

U,

~

(0

01

~

N

POS.j

296)C)-POS)

~

e

~

3)C)TE)-(G)

AC

~

o

SR2

AC

25(SI)

0

(Ii

a

(a

CR

J

-I

/

2881012

1(1)

LEFT

~IIJ

C)

(POS)

C)

(POS)

C~)

R3~1~i~1

CI(UEG)

C)

((G)

-S

SC-162

244

W)4ITE(012

BO1!GH)

RnTrrl4)

66(011-6)

ILIUM

DLVI

I11EEN

~J

GND

POWER

CORD

(PLC

I)



Figure

6-2.

Wiring

Diagram

For

Welding

Power

Source

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