AUTO ARC KJ185200 Owner's manual

OM-187321

187321C

August

1998

Processes

~

MIG

(GMAW)

Welding

Flux

Cored

(FCAW)

Welding

Arc

Welding

Power

Source

And

Wire

Feeder



~

:.

Auto

Arc

190

.

OWNERS

MANUAL

AUTO

ARCJ

BescriiIlion

For

Technical

Support,

Contact:

Milweld

Inc.,

National

Distributor

P.O.

Box

338,

Hortonville,

WI

54944-0338

Tel

920-779-0924

Fax

920-779-0924

.

I

a

TABLE

OF

CONTENTS

The

following

term

is

used

interchangeably

throughout

this

manual:

MIG=GMAW

OM-187

321-C

SECTION

1

-

SAFETY

PRECAUTIONS

READ

BEFORE

USING

1

1-1.

Symbol

Usage

1

1-2.

Arc

Welding

Hazards

1

1-3.

Additional

Symbols

for

Installation,

Operation,

and

Maintenance

3

1-4.

Principal

Safety

Standards

3

1-5.

EMF

Information

4

SECTION

1

-

CONSIGNES

DE

SECURITE

-

LIRE

AVANT

UTILISATION

5

1-1.

Signification

des

sym

boles

5

1-2.

Dangers

relatifs

au

soudage

a

Iarc

5

1-3.

Dangers

supplØmentaires

en

relation

avec

Iinstallation,

le

fonctionnement

et

Ia

maintenance

7

1-4.

Principales

normes

de

sØcuritØ

8

1-5.

Information

sur

les

champs

ØlectromagnØtiques

8

SECTION

2

-

INSTALLATION

9

2-1.

Specifications

9

2-2.

Volt-Ampere

Curves

9

2-3.

Duty

Cycle

And

Overheating

10

2-4.

Installing

Work

Clamp

10

2-5.

Installing

Gas

Supply

11

2-6.

Installing

Welding

Gun

12

2-7.

Setting

Gun

Polarity

12

2-8.

Installing

Wire

Spool

And

Adjusting

Hub

Tension

13

2-9.

Changing

Input

Voltage

13

2-10.

Electrical

Service

Guide

14

2-11.

Selecting

A

Location

And

Connecting

Input

Power

14

2-12.

Threading

Welding

Wire

15

2-13.

Weld

Parameter

16

2-14.

Aluminum

Weld

Parameter

For

Use

With

Optional

Spoolmate

185

17

SECTION

3

-

OPERATION

18

3-1.

Front

Panel

Controls

18

SECTION

4

-

MAINTENANCE

&

TROUBLESHOOTING

19

4-1.

Routine

Maintenance

19

4-2.

Circuit

Breakers

CB1

And

CB2

19

4-3.

Changing

Drive

Roll,

Inlet

Wire

Guide

19

4-4.

Cleaning

Or

Replacing

Gun

Uner

20

4-5.

Replacing

Gun

Contact

Tip

21

4-6.

Troubleshooting

21

SECTION

5

-

ELECTRICAL

DIAGRAFiit

22

SECTION

6

-

MIG

WELDING

(GMAW)

GUIDELINE&

23

6-1.

Typical

MIG

Process

Connections

23

6-2.

Typical

MIG

Process

Control

Settings

24

6-3.

Holding

And

Positioning

Welding

Gun

25

6-4.

Conditions

That

Affect

Weld Bead

Shape

26

6-5.

Gun

Movement

During

Welding

27

6-6.

Poor

Weld

Bead

Characteristics

27

6-7.

Good

Weld

Bead

Characteristics

27

6-8.

Troubleshooting

-

Excessive

Spatte

28

6-9.

Troubleshooting

-

Porosity

28

6-10.

Troubleshooting

-

Excessive

Penetration

29

6-11.

Troubleshooting

-

Lack

Of

Penetration

29

6-12.

Troubleshooting

-

Incomplete

Fusion

29

6-13.

Troubleshooting

-

Burn-Through

30

6-14.

Troubleshooting

-

Waviness

Of

Bead

30

6-15.

Troubleshooting

-

Distortion

30

6-16.

Common

MIG

Shielding

Gases

31

SECTION

7

-

PARTS

LIST

WARRANTY

S

SECTION

1

-

SAFETY

PRECAUTIONS

-

READ

BEFORE

USING

som

_nd_5/97

1-1.

Symbol

Usage

4A

Means

Warning!

Watch

Out!

There

are

possible

hazards

with

this

procedure!

The

possible

hazards

are

shown

in

the

adjoining

symbols.

A

Marks

a

special

safety

message.

~T

Means

Note~

not

safety

related.

1-2.

Arc

Welding

Hazards

A

The

symbols

shown

below

are

used

throughout

this

manual

to

call

attention

to

and

identify

possible

hazards.

When

you

seethe

symbol,

watch

out,

and

followthe

to

avoid

the

hazard.

The

safety

information

given

below

is

only

a

summary

of

the

more

complete

safety

information

found

in

the

Safety

Standards

listed

in

Section

1

-4.

Read

and

follow

all

Safety

Standards.

A

Only

qualified

persons

should

install,

operate,

maintain,

and

repair

this

unit.

A

During

operation,

keep

everybody,

especially

children,

away.

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.



Do

not

touch

live

electrical

parts.



Wear

dry,

hole-free

insulating

gloves

and

body

protection.



Insulate

yourself

from

work

and

ground

using

dry

insulating

mats

or

covers

big

enough

to

prevent

any

physical

contact

with

the

work

or

ground.



Do

not

use

AC

output

in

damp

areas,

if

movement

is

confined,

or

if

there

is

a

danger

of

falling.



Use

AC

output

ONLY

if

required

for

the

welding

process.



If

AC

output

is

required,

use

remote

output

control

if

present

on

unit.



Disconnect

input

power

or

stop

engine

before

installing

or

servicing

this

equipment.

Lockout/tagout

input

power

according

to

OSHA

29

CFR

191

0.147

(see

Safety

Standards).



Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual

and

national,

state,

and

local

codes.



Always

verify

the

supply

ground

-

check

and

be

sure

that

input

power

cord

ground

wire

is

properly

connected

to

ground

terminal

in

disconnect

box

or

that

cord

plug

is

connected

to

a

properly

grounded

receptacle

outlet.



When

maldng

input

connections,

attach

proper

grounding

conductor

first

-

double-check

connections.



Frequently

inspect

input

power

cord

for

damage

or

bare

wiring

-

replace

cord

immediately

if

damaged

-

bare

wiring

can

kill.



Turn

off

all

equipment

when

not

in

use.

Do

not

use

worn,

damaged,

undersized,

or

poorly

spliced

cables.

Do

not

drape

cables

over

your

body.

This

group

of

symbols

means

Warning!

Watch

Out!

possible

ELECTRIC

SHOCK,

MOVING

PARTS,

and

HOT

PARTS

hazards.

Consult

symbols

and

below

for

necessary

actions

to

avoid

the

hazards.



If

earth

grounding

of

the

workpiece

is

required,

ground

it

directly

with

a

separate

cable

-

do

not

use

work

clamp

or

work

cable.



Do

not

touch

electrode

if

you

are

in

contact

with

the

work,

ground,

or

another

electrode

from

a

different

machine.



Use

only

well-maintained

equipment.

Repair

or

replacedamaged

parts

at

once.

Maintain

unit

according

to

manual.



Wear

a

safety

harness

if

working

above

floor

level.



Keep

all

panels

and

covers

securely

in

place.



Clamp

work

cable

with

good

metal-to-metal

contact

to

workpiece

or

worktable

as

near

the

weld

as

practical.



Insulate

work

clamp

when

not

connected

to

workpiece

to

prevent

contact

with

any

metal

object.



Do

not

connect

more

than

one

electrode

or

work

cable

to

any

single

weld

output

terminal.

SIGNIFICANT

DC

VOLTAGE

exists

after

removal

of

input

power

on

inverters.



Turn

Off

inverter,

disconnect

input

power,

and

discharge

input

capacitors

according

to

instructions

in

Maintenance

Section

before

touching

any

parts.

FUMES

AND

GASES

can

be

hazardus.~

Welding

produces

fumes

and

gases.

Breathing

these

fumes

and

gases

can

be

hazardous

to

your

health.



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

instructions

for

metals,

consumables,

coatings,

cleaners,

and

degreasers.



Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

wearing

an

air-supplied

respirator.

Always

have

a

trained

watch-

person

nearby.

Welding

fumes

and

gases

can

displace

air

and

lower

the

oxygen

level

causing

injury

or

death.

Be

sure

the

breathing

air

is

safe.



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.



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.



OM-187

321

Page

1

ARC

RAYS

can

burn

eyes

and

skin

Arc

rays

from

the

welding

process

produce

intense

visible

and

invisible

(ultraviolet

and

infrared)

rays

that

can

burn

eyes

and

skin.

Sparks

fly

off

from

the

weld.



Wear

awelding

helmet

fitted

with

a

proper

shade

of

filter

to

protect

your

face

and

eyes

when

welding

or

watching

(see

ANSI

Z49.

1

and

Z87.

1

listed

in

Safety

Standards).



Wear

approved

safety

glasses

with

side

shields

under

your

helmet.



Use

protective

screens

or

barriers

to

protect

others

from

flash

and

glare;

warn

others

not

to

watch

the

arc.



Wear

protective

clothing

made

from

durable,

flame-resistant

material

(leather

and

wool)

and

foot

protection.

WELDING

can

cause

fire

or

explosion.

Welding

on

closed

containers,

such

as

tanks,

drums,

or

pipes,

can

cause

them

to

blow

up.

Sparks

can

fly

off

from

the

welding

arc.

The

flying

sparks,

hot

workpiece,

and

hot

equipment

can

cause

fires

and

burns.

Accidental

contact

of

electrode

to

metal

objects

can

cause

sparks,

explosion,

overheating,

or

fire.

Check

and

be

sure

the

area

is

safe

before

doing

any

welding.



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.

If

this

is

not

possible,

tightly

cover

them

with

approved

covers.



Be

alert

that

welding

sparks

and

hot

materials

from

welding

can

easily

go

through

small

cracks

and

openings

to

adjacent

areas.



Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.



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,

drums,

or

pipes,

unless

they

are

properly

prepared

according

to

AWS

F4.1

(see

Safety

Standards).



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.



Do

not

use

welder

to

thaw

frozen

pipes.



Remove

stick

electrode

from

holder

or

cut

off

welding

wire

at

contact

tip

when

not

in

use.



Wear

oil-free

protective

garments

such

as

leather

gloves,

heavy

shirt,

cuffless

trousers,

high

shoes,

and

a

cap.



Remove

any

combustibles,

such

as

a

butane

lighter

or

matches,

from

your

person

before

doing

any

welding.

FLYING

METAL

can

Injure

eyes.



Welding,

chipping,

wire

brushing,

and

grinding

cause

sparks

and

flying

metal.

As

welds

cool,

they

can

throw

off

slag.



Wear

approved

safety

glasses

with

side

shields

even

under

your

welding

helmet.

BUILDUP

OF

GAScan

injure

or

kill;



Shut

off

shielding

gas

supply

when

not

in

use.



Always

ventilate

confined

spaces

or

use

approved

air-supplied

respirator.

HOT

PARTS

can

cause

severe

burns.



Do

not

touch

hot

parts

bare

handed.



Allow

cooling

period

before

working

on

gun

or

torch.

MAGNETIC

FIELDS

can

affect

pacemakers.



Pacemaker

wearers

keep

away.



Wearers

should

consult

their

doctor

before

going

near

arc

welding,

gouging,

or

spot

welding

operations.

NOISE

can

damage

hearing.

Noise

from

some

processes

or

equipment

can

damage

hearing.



Wear

approved

ear

protection

if

noise

level

is

high.

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.



Protect

compressed

gas

cylinders

from

excessive

heat,

mechanical

shocks,

slag,

open

flames,

sparks,

and

arcs.



Install

cylinders

in

an

upright

position

by

securing

to

a

stationary

support

or

cylinder

rack

to

prevent

falling

or

tipping.



Keep

cylinders

away

from

any

welding

or

other

electrical

circuits.



Never

drape

a

welding

torch

over

a

gas

cylinder.



Never

allow

a

welding

electrode

to

touch

any

cylinder.



Never

weld

on

a

pressurized

cylinder

-

explosion

will

result.



Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

in

good

condition.



Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.



Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

in

use

or

connected

for

use.



Read

and

follow

instructions

on

compressed

gas

cylinders,

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

Standards.

.

CI

OM-187

321

Page

2

1-3.

Additional

Symbols

for

Installation,

Operation,

afld

Maintenance

FIRE

OR

EXPLOSION

hazard.



Do

not

install

or

place

unit

on,

over,

or

near

combustible

surfaces.



Do

not

install

unit

near

flammables.



Do

not

overload

building

wiring

-

be

sure

power

supply

system

is

properly

sized,

rated,

and

protected

to

handle

this

unit.

FALLING

UNIT

can

cause

injury.



Use

lifting

eye

to

lift

unit

only,

NOT

running

gear,

gas

cylinders,

or

any

other

accessories.



Useequipmentofadequate

capacityto

lift

and

support

unit.



If

using

lift

forks

to

move

unit,

be

sure

forks

are

long

enough

to

extend

beyond

opposite

side

of

unit.

OVERUSE

can

cause

OVERHEATING



Allow

cooling

period;

follow

rated

duty

cycle.



Reduce

current

or

reduce

duty

cycle

before

starting

to

weld

again.



Do

not

block

or

filter

airflow

to

unit.

STATIC

(ESD)

can

damage

PC

boards.



Put

on

grounded

wrist

strap

BEFORE

handling

boards

or

parts.



Use

proper

static-proof

bags

and

boxes

to

store,

move,

or

ship

PC

boards.

MOVING

PARTS

can

cause

injury.



Keep

away

from

moving

parts.



Keep

away

from

pinch

points

such

as

drive

rolls.

WELDING

WiRE

can

cause

injury.



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.

1-4.

Principal

Safety

Standards

Safety

in

Welding

and

Culling,

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,

American

Welding

Society

Standard

AWS

F4.1,

from

American

Welding

Society,

550

NW.

LeJeune

Rd,

Miami,

FL

33126

National

Electrical

Code,

NFPA

Standard

70,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

MOVING

PARTS

can

cause

Injury.



Keep

away

from

moving

parts

such

as

fans.



Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

H.F.

RADIATION

can

cause

interference.



High-frequency

(H.F.)

can

interfere

with

radio

navigation,

safety

services,

computers,

and

communications

equipment.



Have

only

qualified

persons

familiar

with

electronic

equipment

perform

this

installation.



The

user

is

responsible

for

having

a

qualified

electrician

promptly

correct

any

interference

problem

resulting

from

the

installation.



If

notified

by

the

FCC

about

interference,

stop

using

the

equipment

at

once.

Have

the

installation

regularly

checked

and

maintained.

Keep

high-frequency

source

doors

and

panels

tightly

shut,

keep

spark

gaps

at

correct

setting,

and

use

grounding

and

shielding

to

minimize

the

possibility

of

interference.

ARC

WELDING

can

cause

interference.



Electromagnetic

energy

can

interfere

with

sensitive

electronic

equipment

such

as

computers

and

computer-driven

equipment

such

as

robots.



Be

sure

all

equipment

in

the

welding

area

is

electromagnetically

compatible.



To

reduce

possible

interference,

keep

weld

cables

as

short

as

possible,

close

together,

and

down

low,

such

as on

the

floor.



Locate

welding

operation

100

meters

from

any

sensitive

elec

tronic

equipment.



Be

sure

this

welding

machine

is

installed

and

grounded

according

to

this

manual.



If

interference

still

occurs,

the

user

must

take

extra

measures

such

as

moving

the

welding

machine,

using

shielded

cables,

using

line

filters,

or

shielding

the

work

area.

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

P-i,

from

Compressed

Gas

Association,

1235

Jefferson

Davis

Highway,

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

Boulevard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

Protection,

ANSI

Standard

Z87.

1,

from

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

Culling

And

Welding

Processes,

NFPA

Standard

51

B,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.



.

OM-187

321

Page

3

1-5

EMF

Information

Considerations

About

Welding

And The

Effects

Of

Low

Frequency

Electric

And

Magnetic

Fields

Welding

current,

as

it

flows

through

welding

cables,

will

cause

electro

magnetic

fields.

There

has

been

and

still

is

some

concern

about

such

fields.

However,

after

examining

more

than

500

studies

spanning

17

years

of

research,

a

special

blue

ribbon

committee

of

the

National

Research

Council

concluded

that:

The

body

of

evidence,

in

the

committees

judgment,

has

not

demonstrated

that

exposure

to

power-

frequency

electric

and

magnetic

fields

is

a

human-health

hazard.

However,

studies

are

still

going

forth

and

evidence

continues

to

be

examined.

Until

the

final

conclusions

of

the

research

are

reached,

you

may

wish

to

minimize

your

exposure

to

electromagnetic

fields

when

welding

or

cutting.

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

your

body.

4.

Keep

welding

power

source

and

cables

as

far

away

from

opera

tor

as

practical.

5.

Connect

work

clamp

to

workpiece

as

close

to

the

weld

as

possible.

About

Pacemakers:

Pacemaker

wearers

consult

your

doctor

first.

If

cleared

by

your

doctor,

then

following

the

above

procedures

is

recommended.

OM-187

321

Page

4

SECTION

1

-

CONSIGNES

DE

SECURITE

-

LIRE

AVANT

UTILISATION

som

_nd_Fre

4/97

1-1

Signification

des

symboles

a

Signifie

Mise

en

garde!

Soyez

vigilant!

Cette

procedure

prØserite

des

risques

de

danger!

Ceux-ci

sont

identifies

par

des

symboles

adjacents

aux

directives.

A

Identifie

un

message

de

sØcuritØ

particulier.

UT

Signifie

NOTA

nest

pas

relatif

Ia

sØcuuitØ.

1-2.

Dangers

relatifs

au

soudage

a

Iarc

A

Les

symboles

presentØs

ci-aprŁs

soft

utilisØs

tout

au

long

du

present

manuel

pour

attirer

votre

attention

et

identifier

les

risques

de

danger.

Lorsque

vous

voyez

un

symbole,

soyez

vigilant

et

suivez

les

directives

mentionnØes

atm

dØviter

tout

danger.

Les

consignes

de

sØcuritØ

prØsentØes

ci-aprŁs

ne

font

que

rØsumer

lintormation

contenue

dana

les

normes

de

sØcuritØ

ØnumØrØes

a

Ia

section

1-5.

Veuillez

lire

et

respecter

toutes

ces

normes

de

sØcuritØ.

4

Linstallation,

Iutilisation,

lentretien

et

les

reparations

ne

doi

vent

Œtre

conflØs

qu

des

personnes

qualitiØes.

A

Au

cours

de

lutilisation,

tenirtoute

personne

lØcartet

plus

par

ticuliŁrement

les

enfants.

UN

CHOC

ELEcTRIQUE

peut

tuer.

Un

simple

contact

avec

des

piŁces

electriques

peut

provoquer

une

electrocution

ou

des

blessures

graves.

LŁlectrode

et

le

circuit

de

soudage

sont

sous

tension

des

que

apparel!

est

sur

ON.

Le

circuit

dentrØe

et

es

circuits

internes

de

Iappareil

sont

egalement

sous

tension

a

ce

moment-l.

En

soudage

semi-automatique

ou

automatique,

le

fil,

le

dØvidoir,

le

logement

des

galets

dentrainement

et

es

piŁces

metalliques

en

contact

avec

le

fil

de

soudage

sont

sous

tension.

Des

matØriels

mal

installØs

ou

mal

mis

a

Ia

terre

prØseritent

un

danger.



We

jamais

toucher

lea

piŁces

Łlectriques

sous

tension.



Porter

des

gants

et

des

vŒtements

de

protection

secs

ne

comportant

pas

de

trous.



Sisoler

de

Ia

piŁce

et

de

Ia

terre

au

moyen

de

tapis

ou

dautres

moyens

isolants

suffisamment

grands

pour

empŒcher

le

contact

phy

sique

Łventuel

avec

Ia

piŁce

ou

a

terre.



Ne

pas

se

servir

de

source

electrique

courant

electrique

dans

les

zones

humides,

dans

les

endroits

confines

ou

l

o

on

risque

de

tomber.



Se

servir

dune

source

electrique

courant

electrique

UNIQUEMENT

si

le

procØde

de

soudage

le

demande.



Si

lutilisation

dune

source

electrique

courant

Ølectrique

savØre

nØces

saire,

Se

servir

de

Ia

fonction

de

tØlØcommande

si

lappareil

en

eSt

ØquipØ.



Couper

Ialimentation

ou

arrŒterle

moteuravantde

procØderlinstal

lation,

a

Ia

reparation

ou

a

Ientretien

de

lappareil.

DØverrouiller

lalimentation

selon

Ia

norme

OSHA

29

CFR

1910.147

(voir

normes

de

sŁcuritØ).



Installer

et

mettre

ala

terre

correctement

cetappareil

conformØment

a

son

manuel

dutilisation

et

aux

codes

nationaux,

provinciaux

et

municipaux.



Toujours

verifier

Ia

terre

du

cordon

dalimentation

-

Verifier

et

sassu

rer

que

Ie

fil

de

terre

du

cordon

dalimentation

est

bien

raccordØ

ala

borne

de

terre

du

sectionneur

ou

que

Ia

fiche

du

cordon

est

raccordØe

a

une

prise

correctement

mise

a

Ia

terre.



En

effectuant

les

raccordements

dentrŁe

fixer

dabord

le

conducteur

de

mise

a

Ia

terre

appropriŁ

et

contre-vŁrifier

es

connexions.



Verifier

frŁquemment

le

cordon

dalimentation

pour

voir

siI

nest

pas

endommagŁ

ou

dØnudØ

-

remplacer

le

cordon

immØdiatement

si!

est

endommagØ

-

un

cable

dŁnudŁ

peut

provoquer

une

electrocution.



Mettre

lappareil

hors

tension

quand

on ne

Iutilise

pas.



Ne

pas

utiliser

des

cables

uses,

endommagØs,

de

grosseur

insuffi

sante

ou

ma!

Øpisses.



Ne

paz

enrouler

Ies

cables

autour

du

corps.



Si

Ia

piŁce

soudØe

dolt

Œtre

mise

laterre,

lefaire

directement

avec

un

cable

distinct

-

ne

pas

utiliser

le

connecteur

de

piŁce

ou

Ie

cable

de

retour.



Ne

pas

toucher

IØlectrode

quand

on

est

en

contact

avec

Ia

piŁce,

Ia

terre

ou

une

electrode

provenant

dune

autre

machine.

Ce

groupe

de

symboles

signifie

Mise

en

garde!

Soyez

vigilant~

II

y

a

des

risques

de

danger

relies

aux

CHOCS

ELECTRIQUES,

aux

PIECES

EN

MOUVEMENTetaux

PIECES

CHAUDES.

Reportez-vous

auxsymboles

etauxdirectivesci-dessous

afin

de

connaltre

es

mesures

a

prendre

pour

Øviter

tout

danger.



Nutiliser

quun

materiel

en

bon

etat.

RØparer

ou

remplacer

sur-le

champ

es

piŁces

endommagŁes.

Entretenir

lappareilconformŁment

a

ce

manuel.



Porter

un

harnais

de

sØcuritØ

quand

on

travaille

en

hauteur.



Maintenir

solidement

en

place

tous

lea

panneaux

et

capots.



Fixer

le

cable

de

retour

de

facon

a

obtenir

un

bon

contact

mŁtal-mŁtal

avec

Ia

piŁce

a

souderou

Ia

table

detravail,

le

plus

prŁs

possible

de

Ia

soudure.



Isoler

Ia

pince

de

masse

quand

pas

mis

a

Ia

piŁce

pour

Øviter

le

contact

avec

tout

Objet

metallique.

Iiy

a

DU

COU

RANT

CONTINU

IMPORTANT

dans

les

convertisseurs

aprŁs

Ia

suppression

de

ialimenta

tion

Øiectrique.



ArrŒter

Ies

convertisseurs,

dØbrancher

le

courant

electrique,

et

dŁ

charger

les

condensateurs

dalimentation

selon

les

instructions

indiquŁes

dana

Ia

partie

entretien

avant

de

toucher

les

piŁces.

LES

FIJMEES

ET~

LES

GAZ

peUverit

I

Œtredangereux

Le

soudage

genŁre

des

fumØes

et

des

gaz.

Leur

inhalation

peut

Łtre

dangereux

pour

votre

sante.



Eloigner

votre

tŒte

des

fumØes.

Ne

pas

respirer

les

fumØes.



A

IintŁrieur,

ventiler

Ia

zone

et/ou

utiliser

un

Łchappement

au

ni

veau

de

Iarc

pour

IØvacuation

des

fumŁes

et

des

gaz

de

soudage.



Si

Ia

ventilation

eat

insuffisante,

utiliser

un

respirateur

a

alimenta

tion

dair

homologuŁ.



Ure

lea

specifications

de

sŁcuritØ

des

matØriaux

(MSDS5)

et

les

ins

tructions

du

fabricant

concernant

lea

mØtaux,

lea

consommables,

les

revŒtementa,

lea

nettoyants

et

les

dØgraisseurs.



Travailler

dana

un

espace

fermØ

seulement

sil

est

bien

ventilØ

ou

en

portant

un

respirateur

a

alimentation

dair.

Demander

toujoura

~

un

surveillant

dfiment

formŁ

de

se

tenir

a

proximitØ.

Des

fumŁes

et

des

gaz

de

soudage

peuvent

dØplacer

lair

et

abaisser

le

niveau

doxygØne

provoquant

des

blessures

ou

des

accidents

mortels.

Sassurer

que

Iair

de

respiration

ne

prØsente

aucun

danger.



Ne

paa

souder

dana

des

endroits

situØs

~

proximitØ

dopŁrations

de

dŁgraisaage,

de

nettoyage

ou

de

pulvØrisation.

La

chaleur

et

lea

rayons

de

larc

peuvent

reagir

en

presence

de

vapeura

et

former

des

gaz

hautement

toxiques

et

irritants.



Ne

paz

souder

des

mØtaux

munis

dun

revŒtement,

tels

que

lacier

galvanise,

plaque

en

p10mb

ou

au

cadmium

a

moms

que

le

revŒte

ment

nait

ØtŁ

enlevØ

dans

Ia

zone

de

soudure,

que

Iendroit

soit

bien

ventilŁ,

et

Si

nØcessaire,

en

portant

un

respirateur

a

alimenta

tion

dair.

Les

revŒtements

et

tous

Ies

mØtaux

renfermant

ces

ŁlŁ

ments

peuvent

dŁgager

des

fumŁes

toxiques

en

cas

de

soudage.

OM-187

321

Page

5

LES

RAVONS

DE.

LARc

peuvent

pro

voquer

des

brlUres

dans

les.yeux

et

sur

Ia

peau

Le

rayonnement

de

arc

du

procØdØ

de

soudage

gŁnŁre

des

rayons

visibles

et

invisibles

intenses

(ultraviolets

et

infrarouges)

susceptibles

de

provoquer

des

brlures

dans

les

yeux

et

sur

Ia

peau.

Des

Øtincelles

soft

projetØes

pendant

le

soudage.



Porter

un

casque

de

soudage

muni

dun

Łcran

de

filtre

appropriØ

pour

protØger

votre

visage

et

vos

yeux

pendant

le

soudage

ou

pour

regar

der

(voir

ANSI

Z49.

1

et

Z87.1

ØnumØrØ

dans

es

normes

de

sØcuritØ).



Porter

des

protections

approuvØs

pour

es

oreilles

Si

le

niveau

sondre

est

trop

OlevØ.



Utiliser

des

Øcrans

ou

des

barriŁres

pour

proteger

des

tiers

de

lØclair

et

de

lØblouissement;

demander

aux

autres

personnes

de

ne

pas

re

garder

arc.



Porter

des

vŁtements

de

protection

constituØ

dans

une

matiŁre

dura

ble,

resistant

au

feu

(cuir

ou

lame)

et

une

protection

des

pieds.

m

~I

LE

SOUDAGE

peut

provoquer

tin

~

incendie

ou

une

explosion.

~

Le

souda~e

effectuØ

sur

des

conteneurs

fermØs

tels

que

des

reservoirs,

tambours

ou

des

conduites

peut

provoquerleurØclatement.

DesØtincelles

peuventØtre

projetØes

de

larc

de

soudure.

La

projection

dØtincel

les,

des

piŁces

chaudes

et

des

Øquipements

chauds

peut

provoquerdes

incendies

et

des

brlures.

Le

contact

accidentel

de

electrode

avec

des

objets

mØtalliques

peut

provoquer

des

Øtincelles,

une

explosion,

un

surchauffement

ou

un

incendie.

Avant

de

commencer

le

soudage,

verifier

et

sassurer

que

lendroit

ne

prØsente

pas

de

danger.



Se

proteger

et

dautres

personnes

de

a

projection

dØtincelles

et

de

metal

chaud.



Ne

pas

souder

dans

un

endroit

l

o

des

Øtincelles

peuvent

tomber

sur

des

substances

inflammables.



DØplacer

toutes

les

substances

inflammables

a

une

distance

del

0,7

m

de

Iarcde

soudage.

En

cas

dimpossibilitØ

les

recouvrirsoigneuse

ment

avec

des

protections

homologues.



Des

Øtincelles

et

des

matØriaux

chauds

du

soudage

peuvent

facile

ment

passer

dans

dautres

zones

en

traversant

de

petites

fissures

et

des

ouvertures.



SurveillertoutdØclenchementdincendieettenirun

extincteurproxi

mite.



Le

soudage

effectuØ

sur

un

plafond,

plancher,

paroi

ou

separation

peut

dØclencher

un

incendie

de

lautre

ctØ.



Ne

pas

effectuer

le

soudage

sur

des

conteneurs

fermØs

tels

que

des

reservoirs,

tambours,

ou

conduites,

a

moms

quils

naient

ØtØ

prØpa

rØs

correctement

conformØment

a

AWS

F4.l

(voir

les

normes

de

sØcuritØ).



Brancher

le

cable

sur

Ia

piŁce

le

plus

pres

possible

de

Ia

zone

de

sou

dage

pour

Øviter

le

transport

du

courant

sur

une

longue

distance

par

des

chemins

inconnus

Łventuels

en

provoquant

des

risques

dØlec

trocution

et

dincendie.



Ne

pas

utiliser

le

poste

de

soudage

pour

dØgeler

des

conduites

ge

lees.



En

cas

de

non

utilisation,

enlever

Ia

baguette

dØlectrode

du

porte-

electrode

ou

couper

le

fil

a

pointe

de

contact.



Porter

des

vŒtements

de

protection

dØpourvus

dhuile

tels

que

des

gants

en

cuir,

une

chemise

en

matØriau

lourd,

des

pantalons

sans

re

vers,

des

chaussures

hautes

et

un

couvre

chef.



Avant

de

souder,

retirer

toute

substance

combustible

de

vos

poches

telles

quun

allumeur

au

butane

ou

des

allumettes.



Le

soudage,

lØcaillement,

le

passage

de

Ia

piŁce

a

Ia

brosse

en

fil

de

fer,

et

le

meulage

generent

desŁtincellesetdesparticules

mØtalliquesvolan

tes.

Pendant

Ia

pØriode

de

refroidissement

des

soudures,

elles

risquent

de

projeter

du

laitier.



Porter

des

lunettes

de

sØcuritØ

avec

Øcrans

latØraux

ou

un

Øcran

facial.

~

LES

ACCUMULATIONS

:.DE

GAZ

IiS~

quent

dØ

provoquØr

des

blessures

u

mŒme

Ia

mort.

.

:

I

(

t





Fermer

Ialimentation

du

gaz

protecteur

en

cas

de

non

utilisation.



Veiller

toujours

a

bien

aØrer

es

espaces

confines

ou

se

servir

dun

respi

rateur

dadduction

dair

homologuØ.

DES

PI¨CES

CHAUDES

peuvent

prQ~

voquer

des

brCslures

graves.



Ne

pas

toucher

des

parties

chaudes

a

mains

nues



PrØvoir

une

pØriode

de

refroidissement

avant

dutiliser

le

pistolet

ou

Ia

torche.

I

LES

CHAMPS

MAGNETIQUES

peuvent

affecter

les

stimulateurs

cardiaques.



Porteursdestimulateurcardiaque,

restezdistance.

I

a



Les

porteurs

dun

stimulateur

cardiaque

doivent

dabord

consulter

leur

mØdecin

avant

de

sapprocher

des

operations

de

soudage

a

larc,

de

gougeage

ou

de

soudage

par

points.

LE

BRUIT

peut

affecter

IouIe.

Le

bruit

des

processus

et

des

Øquipements

peut

affecter

louie.



Porter

des

protections

approuves

pour

es

oreilles

si

le

niveau

sondre

est

trop

ØlevØ.

Si

des

BOUTEILLES

sont

endomma

gØes,

elles

pourront

exploser.

Des

bouteilles

de

gaz

protecteur

contiennent

du

gaz

sous

haute

pression.

Si

une

bouteille

est

endomma

_____________

gee,

elle

peut

exploser.

Du

faitque

les

bouteilles

degaz

font

normalement

partie

du

procØdØ

de

soudage,

les

manipuler

avec

precaution.



Proteger

les

bouteilles

de

gaz

comprime

dune

chaleur

excessive,

des

chocs

mecaniques,

du

laitier,

des

flammes

ouvertes,

des

Øtin

celles

et

des

arcs.



Placer

les

bouteilles

debout

en

les

fixant

dans

un

support

station

naire

ou

dans

un

porte-bouteilles

pour

les

empŒcher

de

tomber

ou

de

se

renverser.



Tenir

es

bouteilles

ØloignØes

des

circuits

de

soudage

ou

autres

cir

cuits

Ølectriques.



Ne

jamais

placer

une

torche

de

soudage

sur

une

bouteille

a

gaz.



Une

electrode

de

soudage

ne

doit

jamais

entrer

en

contact

avec

une

bouteille.



Ne

jamais

souder

une

bouteille

pressurisee

-

risque

dexplosion.



Utiliser

seulement

des

bouteilles

de

gaz

protecteur,

regulateurs,

tuyaux

et

raccords

convenables

pour

cette

application

spØcifique;

les

maintenir

ainsi

que

les

ØlØments

associØs

en

bon

Øtat.



Ne

pas

tenir

Ia

tŒte

en

face

de

Ia

sortie

en

ouvrant

Ia

soupape

de

Ia

bouteille.



Mamntenir

le

chapeau

de

protection

sur

Ia

soupape,

sauf

en

cas

dutilisation

ou

de

branchement

de

Ia

bouteille.



Lire

et

suivre

les

instructions

concernant

les

bouteilles

de

gaz

com

prime,

les

equipements

associØs

et

tes

publications

P-i

CGA

Ønu

mØrØes

dans

les

normes

de

sØcuritØ.

I

I

DES

PARTICULES

VOLANTES

_____

peuventblesserles

yeux.

OM-187

321

Page

6



Ne

pas

placer

lappareil

sur,

au-dessus

ou

a

proximitØ

de

surfaces

infllammables.



Ne

pas

installer

lappareil

a

proximitØ

de

produits

inflammables



Ne

pas

surcharger

linstallation

Ølectrique

-

sassurerque

lalimen

tation

est

correctement

dimensionnØ

et

protØgØ

avant

de

mettre

lappareil

en

service.

LA

CHUTE

DE

LAPPAREIL

peut

blesser.



Utiliser

lanneau

de

levage

uniquement

pour

sou

lever

lappareil,

NON

PAS

les

chariot,

les

bouteil

les

de

gaz

ou

tout

autre

accessoire.



Utiliser

un

engin

dune

capacitØ

appropriØe

pour

soulever

lappareil.



En

utilisant

des

fourches

de

levage

pour

dØplacer

unite,

sassurer

que

les

fourches

sont

suffisamment

longues

pour

dØpasser

du

ctØ

oppose

de

lappareil.

LEMPLOI

EXCESSIFpeut

SURCHAUFFER

LEQUIPEMENt



PrØvoir

une

pØriode

de

refroidissement,

respec

ter

le

cycle

opØratoire

nominal.



RØduire

le

courant

ou

le

cycle

opØratoire

avantde

recommancer

le

soudage.



Ne

pas

obstruer

les

passages

dair

du

poste.

LES

CHARGES

ELECTROSTAnQUES

peuvent

endommager

tes

circuitsim-.

primes.



Etablir

Ia

connexion

avec

Ia

barrette

de

terre

avant

de

manipuler

des

caries

ou

des

pieces.



Utiliser

des

pochettes

et

des

boltes

antistatiques

pour

stocker,

dØplacer

ou

expØdier

des

caries

de

circuits

imprimes.

DES

ORGANES

I

MOBILES

peuvent.

provoquer

desblessures.



Ne

pas

sapprocher

des

organes

mobiles.



Ne

pas

sapprocher

des

points

de

coincement

tels

que

des

rouleaux

de

commande.

LES

FILSDE

SOUDAGEpeuvent

pro

voquer

des

blessures.



Ne

pas

appuyer

sur

Ia

gachette

avant

den

avoir

reu

linstruction.



Ne

pas

diriger

le

pistolet

vers

soi,

dautres

per

sonnes

ou

toute

piece

mØcanique

en

engageant

le

fil

de

soudage.

DES

ORGANES

MOBILES

peuvent

provoquer

des

blessures.:



Rester

a

lecart

des

organes

mobiles

comme

le

ventilateur.



Maintenirfermesetfixementenplaceles

portes,

panneaux,

recouvrements

et

dispositifs

de

protection.

LE

RAYONNEMENT

HAUTE

FRE

QUENCE

(ELF.)

risque

de

prov~quer

des

interferences.



Lerayonnementhautefrequence

peutprovoquer

des

interferences

avec

les

Øquipements

de

ra

dio-navigationetdecommunication,

lesservices

de

sØcuritØ

et

les

ordinateurs.



Demander

seulement

a

des

personnes

qualifiØes

familiarisØes

avec

des

Øquipements

Ølectroniques

de

faire

fonctionner

linstalla

tion.



Lutilisateur

est

tenu

de

faire

corriger

rapidement

par

un

Ølectricien

qualifiØ

les

interferences

resultant

de

linstallation.



Si

le

FCC

signale

des

interferences,

arrØter

immØdiatement

lappa

reil.



Effectuer

rØguliØrement

le

contrle

et

lentretien

de

linstallation.



Maintenir

soigneusement

fermØs

les

portes

et

les

panneaux

des

sources

de

hautefrØquence,

maintenir

les

Øclateurs

Ø

une

distance

correcte

et

utiliser

une

terre

et

un

blindage

pour

rØduire

les

inter

fØrences

Øventuelles.

LE

SOUDAGE

A

LARC

risque

de

provoquer

des

interferences.



LØnergie

ØlectromagnØtique

risque

de

provoquer

des

interferences

pour

lØquipement

Ølectronique

sensible

tel

que

les

ordinateurs

et

lØquipement

commandØ

par

ordinateur

tel

que

les

robots.



Veiller

ace

que

tout

lØquipement

de

Ia

zone

de

soudage

soit

com

patible

ØlectromagnØtiquement.



Pour

rØduire

Ia

possibilitØ

dinterfØrence,

maintenir

les

cables

de

soudage

aussi

courts

que

possible,

les

grouper,

et

les

poser

aussi

bas

que

possible

(ex.

par

terre).



Veiller

a

souder

a

une

distance

de

100

metres

de

tout

Øquipement

Ølectronique

sensible.



Veiller

a

ce

que

ce

poste

de

soudage

soit

pose

et

mis

Ø

Ia

terre

conformØment

Ø

ce

mode

demploi.



En

cas

dinterfØrences

aprØs

avoir

pris

les

mesures

prØcØdentes,

il

incombe

a

lutilisateur

de

prendre

des

mesures

supplØmentaires

telles

que

le

dØplacement

du

poste,

lutilisation

de

cables

blindØs,

lutilisation

de

filtres

de

ligne

ou

Ia

pose

de

protecteurs

dans

Ia

zone

de

travail.

LES

CHAMPS

MAGNETIQUES

peuveni

affecter

les

stimulateurs

cardiaques.



Porteurs

de

stimulateur

cardiaque,

restez

a

dis

tance.



Les

porteurs

dun

stimulateur

cardiaque

doivent

dabord

consulter

leur

medecin

avant

de

sappro

cher

des

operations

de

soudage

a

larc,

de

gou

geage

ou

de

soudage

par

points.

1

-3.

Dangers

supplØmentaires

en

relation

avec

Iinstallation,

le

fonctionnement

etlamÆintenance

RiØque

b~INCENDIE

OU

DEXPLOSION.

OM-187

321

Page

7

Safetyand

Health

Sandards,

OSHA

29

CFR

1910,

du

Superintendent

of

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

Recommended

Safe

Practice

for

the

Preparation

for

Welding

and

Cut

ting

of

Containers

That

Have

Held

Hazardous

Substances,

norme

AWS

F4.1

,

de

lAmerican

Welding

Society,

550

N.W.

Lejeune

Rd,

Mia

mi

FL

33126

National

Electrical

Code,

NFPA

Standard

70,

de

a

National

Fire

Pro

tection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

DonnØes

sur

le

soudage

Ølectrique

et

sur

les

effets,

pour

lorganisme,

des

champs

magnØtiques

basse

frequence

Lextrait

des

conclusions

gØnØrales

du

document

intitu

lØ

Biological

Effects

of

Power

Frequency

Electric

&

Magnetic

Fields

-

Background

Paper,

OTA-BP-E-53

(Washington

DC:

U.S.

Govern

ment

Printing

Office,

mai

1989),

publiØ

par

le

Office

of

Technology

Assessment

du

CongrŁs

amØricain:

...

il

existe

maintenant

dabon

dantes

donnØes

scientifiques

compilØes

a

suite

dexpØriences

sur

Ia

cellule

ou

dØtudes

sur

des

animaux

et

des

humains,

qui

montrent

clairement

que

les

champs

ØlectromagnØtiques

basse

frequence

peu

vent

avoir

des

effets

sur

lorganisme

et

mØme

y

produire

des

transformations.

MŒme

sil

sagit

de

travaux

de

trŁs

grande

qualite,

les

rØsultats

sont

complexes.

Cette

dØmarche

scientifique

ne

nous

per-

met

pas

dØtablir

un

tableau

densemble

coherent.

Pire

encore,

elle

ne

nous

permet

pas

de

tirer

des

conclusions

finales

concernant

les

ris

ques

Øventuels,

ni

doffrir

des

conseils

sur

les

mesures

a

prendre

pour

rØduire

sinon

Øliminer

les

risques

Øventuels.

(Traduction

libre)

RØgles

de

sØcuritØ

en

soudage,

coupage

et

procØdØs

connexes,

nor-

me

CSA

Wi

17.2,

de

Association

canadienne

de

normalisation,

vente

de

normes,

178

Rexdale

Boulevard,

Rexdale

(Ontario)

Canada

M9W

1R3.

Safe

Practices

ForOccupafionAnd

Educational

Eye

And

Face

Protec

tion,

norme

ANSI

Z87.1,

de

lAmerican

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

Cutting

and

Welding

Processes,

norme

NFPA

51

B,

de

Ia

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

Afin

de

rØduire

les

champs

Ølectromagnetiques

dans

lenvironnement

de

travail,

respecter

les

consignes

suivantes

1

Garder

les

cables

ensembles

en

es

torsadant

ou en

les

attachant

avec

du

ruban

adhØsif.

2

Mettre

tous

les

cables

du

ctØ

oppose

de

lopØrateur.

3

Ne

pas

courber

pas

et

ne

pas

entourer

pas

les

cables

autour

de

vous.

4

Garder

le

poste

de

soudage

et

les

cables

le

plus

loin

possible

de

vous.

5

Relier

Ia

pince

de

masse

le

plus

prŁs

possible

de

Ia

zone

de

soudure.

Consignes

relatives

aux

stimulateurs

cardiaques

Les

consignes

mentionnØes

prØcØdemment

font

partie

de

celles

desti

nØes

aux

personnes

ayant

recours

a

un

stimulateur

cardiaque.

Veuillez

consulter

votre

mØdecin

pour

obtenir

plus

de

details.

1-4

Pruncipales

normes

de

securitØ

Safety

in

Welding

and

Cutting,

norme

ANSI

Z49.

1,

de

lAmerican

Wel-

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

ding

Society,

550

N.W.

Lejeune

Rd,

Miami

FL

33126

P-i,

de

Ia

Compressed

Gas

Association,

1235

Jefferson

Davis

High

way,

Suite

501,

Arlington,

VA

22202.

1-5.

Information

sur

les

champs

ØlectrmagnØtiques

.

OM-187

321

Page

8

2-1.

Specifications

SECTION

2-

INSTALLATION

Amperes

Input

at

Rated

Welding

Output

Amperage

Range

Maximum

Open-circuit

Voltage

DC

Rated

Load

Output,

60

Hz,

Single-Phase

Weight

Overall

Dimensions

200V

230V

KVA

KW

Length:

36

in

(915

mm)

150

A

@

23

Volts

DC,

60%

Duty

Cycle

30

-

185

33

30

(1

.6)*

26

(1

.4)*

6

(0.27)*

5

(0.1

3)*

165

lb

(75

kg)

Width:

18

in

(457

mm)

Height:

27

in

(686

mm)

Wire

Type

And

Diameter

Calculated

Wire

Speed

Max

Wire

Feed

Speed

Solid

Steel

/

Flux

Cored

Aluminum

Range

At

No

Load

While

Welding

Stainless

Steel

I

.023

-

.035

in

.030

-

.045

in

.030

-

.035

in

138

-

795

1PM

(3.5

-

20.3

m/min)

650

1PM

(16.5

m/min)

(0.6

-

0.9

mm)

(0.8

-

1.2

mm)

(0.8

-

0.9

mm)

*While

idling

2-2.

Volt-Ampere

Curves

Volt-ampere

curves

show

mini

mum

and

maximum

voltage

and

amperage

output

capabilities

of

unit.

Curves

of

other

settings

fall

between

curves

shown.

100

150

200

LOAD

CURRENT,

AMPS

va~irve1

4/95

-

SB-iSO

824

Cl)

0

>

Ui

0

~

~::i

0

>

c~

<

0

-J

35

30

25

20

15

10

0

50

OM-187

321

Page

9

2-3.

Duty

Cycle

And

Overheating

6

Minutes

Welding

4

Minutes

Resting

.

Route

cable

through

clamp

handle

and

secure

as

shown.

RATED

OUTPUT-,

-___-

-~

-

Duty

Cycle

is

percentage

of

10

minutes

that

unit

can

weld

at

rated

load

without

overheating.

~.-

~.

~

~-

200

U)

LU

Ui

0~

____

___

~150

-j

LU

____

100

30

%

DUTY

CYCLE

60%

Duty

Cycle

At

150

Amperes

Overheating

~~4O15

Minutes

If

unit

overheats,

thermostat(s)

opens,

output

stops,

and

cooling

fan

runs.

Wait

fifteen

minutes

for

______

unit

to

cool.

Reduce

amperage

or

voltage,

or

duty

cycle

before

welding.

A

Exceeding

duty

cycle

can

______

damage

unit

and

void

warranty.

40

50

80

70

8080100

A

or

V

OR

Reduce

Duty

Cycle

2-4.

Installing

Work

Clamp

1

Work

Cable

2

Boot

Slide

boot

onto

work

cable.

Route

cable

out

front

panel

opening

from

inside.

2

3

Negative

(-)

Output

Terminal

Connect

cable

to

terminal

and

cover

connection

with

boot.

4

Hardware

5

Work

Clamp

Close

door.

Tools

Needed:

~

1/2,3/4in

OM-187321

Page

10

2-5.

Installing

Gas

Supply

Obtain

gas

cylinder

and

chain

to

running

gear,

wall,

or

other

sta

tionary

support

so

cylinder

cannot

fall

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

Regulator/Flowmeter

Gas

Hose

Connection

6

Welding

Power

Source

Gas

Hose

Connection

Connect

customer

supplied

gas

hose

between

regulator/flowme

ter

gas

hose

connection,

and

fitting

on

rear

of

welding

power

source.

7

Flow

Adjust

Typical

flow

rate

is

20

cfh

(cubic

feet

per

hour).

Check

wire

man

ufacturers

recommended

flow

rate.

8

CO2

Adapter

(Customer

Supplied)

9

0-Ring

(Customer

Supplied)

Install

adapter

with

0-ring

be

tween

regulator/flowmeter

and

CO2

cylinder.

2

3

4

L

.2

Pet.

ST-148

265-B

/

ST-802

028

3

CO2

Gas

Tools

Needed:

~r

1-1/8,

5/Bin

OM-187321

Page

11

2-6.

Installing

Welding

Gun

2-7.

Setting

Gun

Polarity

______

-

Tools

Needed:

~

3/4,11/l6in

1

Polarity

Changeover

Label

(Located

Near

Drive

Assembly)

Always

read

and

follow

manufac

tures

recommended

polarity.

3

1

Drive

Assembly

2

Gun

Securing

Knob

3

Gun

End

Loosen

securing

knob.

Insert

gun

end

through

opening

until

it

bot

toms

against

drive

assembly.

Tighten

nut.

4

Gun

Trigger

Plug

Insert

plug

into

receptacle,

and

tighten

threaded

collar.

Close

door.

Ref.

ST-801

936

.

Wire

Drive

Assembly

Lead

To

Positive

(+)

Output

Terminal

Work

Clamp

Lead

To

Negative

(-)

Output

Terminal

GUN

POLARITY

CHANGEOVER

CONNECTIONS

Reverse

Lead

Connections

-

For

Electrode

Negative

(DCEN)

For

Flux

Cored

Wires

(FCAW

Process).

Drive

Assembly

Becomes

Negative

s1~.~9.o

OM-187

321

Page

12

2-8.

Installing

Wire

Spool

And

Adjusting

Hub

Tension

2-9.

Changing

Input

Voltage

A

Turn

Off

unit,

and

discon

nect

input

power.

Unit

was

shipped

from

factory

set

for

230

volts.

1

Transformer

Ti

2

Rear

Of

Power

Switch

Si

3

Lead

Marked

230

Volt

And

Fan

Motor

Lead

Disconnect

230

volt

lead

and

fan

motor

lead

from

rear

of

Si.

Leave

fan

motor

lead

connected

to

230

volt

lead.

4

Lead

Marked

200

Volt

Remove

cable

tie,

and

slide

short

piece

of

sleeving

off

200

volt

lead,

and

slide

sleeving

over

end

of

230

volt

and

fan

motor

leads.

Fold

sleeving

over

and

secure

in

place.

Connect

200

volt

lead

to

Si

where

230

volt

lead

was

removed.

Reinstall

wrapper.

4

Tools

Needed:

~

318,7/i6in

ST-801

580-A

OM-187321

Page

13

2-10.

Electrical

Service

Guide

.

Input

Voltage

200

230

Input

Amperes

At

Rated

Output

30

26

Max

Recommended

Standard

Fuse

Or

Circuit

Breaker

Rating

In

Amperes

45

40

Mm

Input

Conductor

Size

In

AWG/Kcmil

10

Max

Recommended

Input

Conductor

Length

In

Feet

(Meters)

97

(29)

128

(39)

Mm

Grounding

Conductor

Size

In

AWG/Kcmil

10

Reference:

1996

National

Electrical

Code

(NEC).

S-oog2-J

2-11.

Selecting

A

Location

And

Connecting

Input

Power

OM-187321

Page

14

2-12.

Threading

Welding

Wire

*4

~

-+

~6in~

(150

mm)

Pull

and

hold

wire;

cut

off

end.

Press

gun

trigger

until

wire

comes

out

of

gun.

ON

~

POWER

-e

Qon~

II

I I

II

Feed

wire

to

check

drive

roll

pressure.

Tighten

knob

enough

to

prevent

slipping.

Cut

off

wire.

Close

and

latch

door.

Tools

Needed:

Open

pressure

assembly.

4in~

-~

Push

wire

thru

guides

into

gun;

continue

to

hold

wire.

Close

and

tighten

pressure

assembly,

and

let

go

of

wire.

Turn

On.

Cut

off

wire.

Close

and

latch

door.

Remove

gun

nozzle

and

contact

tip.

-4

Reinstall

contact

tip

and

nozzle.

Ref.

ST-801

938

I

Ref.

ST-149

326-A

OM-187

321

Page

15

2-13.

Weld

Parameter

.

____________

.

*Do

not

change

Voltage

switch

position

while

welding

Wire

Speed

value

in

Table

is

a

starting

value

only,

and

Wire

Speed

control

setting

can

be

fine

tuned

during

welding.

S-181

020-A

Wire

Type,

Shielding

Gas,

And

Flow

Rate

Wire

Diameter

(inch)

Operator

Controls

Material

Thickness

3/8

in

(9.5

mm)

1/4

in

(6.4

mm)

3/16

in

(4.8

mm)

1/8

in

(3.2

mm)

12

ga

14

ga

16

ga

18

ga

20

ga

22

ga

E7OS-6

CO2

20

cfh+

.023

Voltage

Tap

-

6

5

4

3

2

1

- -

Wire

Speed

-

100

90

70

65

60

40

25

20

-

.030

Voltage

Tap

-

4

3

2

2 2

1

- -

Wire

Speed

-

70

60

50

45 40

30

25

-

- -

.035

Voltage

Tap

6

4

3 3

2 2

1

-

WireSpeed

80

65

40

35 30

25 30

10

-- --

E7OS-6

75%

Argon

25%

CO2

20

cfh+

.023

Voltage

Tap

-

3

4

3 3

2

1

Wire

Speed

-

80

90

70

60

70 40

45

25

12

.030

Voltage

Tap

6

4 4

3

2 2

1

-

Wire

Speed

90

58

70

55

50

48

45

30

5

-

.035

Voltage

Tap

6

4

3

2 2

1 1

- -

Wire

Speed

80

48

60

50

35

27 30

11

3

-

E71

T-GS

Flux

Core

.030

Voltage

Tap

5

4 4

3

2

1

- - - -

Wire

Speed

80

65 65

50 30

30

10

5

-

.035

Voltage

Tap

5

4

3

2 2 2

1

- -

Wire

Speed

50

40

30

25

20

10

0

-

- - -

ER

308

Stainless

Steel

Tn-Mix

20

cfh+

.023

VoltageTap

5

4 4

4

3

2

Wire

Speed

95

85 80

60 50

50

30

20

.030

Voltage

Tap

5

4

3

2

1

- -

Wire

Speed

70

50

45

50

45

40

0

-

.035

Voltage

Tap

6

5

4 3 2

2

- -

-

Wire

Speed

65

40 40

30

25

20

10

- -

-

OM-187

321

Page

16

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