Miller KG171523 Owner's manual

AUTO

ARCS

June

1996

Form:

OM-151

015C

Effective

With

Serial

No.

KG171

523

OWNERS

MANUAL





Read

and

follow

these

instructions

and

all

safety

blocks

carefully.



Have

only

trained

and

qualified

persons

install,

operate,

or

service

this

unit.



Call

your

distributor

if

you

do

not

understand

the

directions.

U

Give

this

manual

to

the

operator.

6i~

1I~fl



For

help,

call

your

distributor,

MILLER

Electric

Mfg.

Co.,

P.O.

Box

Appleton,

WI

54912

414-734-9821

or:

1079,

Auto

Arcﬁ

120



CV/DC

Welding

Power

Source/Wire

Feeder



For

GMAW

And

FCAW

Welding



90

Amperes,

18

Volts

At

20%

Duty

Cycle



Usable

Range

Of

30

To

130

Amperes



Uses

115

Volts

AC,

Single-Phase

Input

Power



Overheating,

Short

Circuit,

And

Motor

Overload

Protection



Includes

Gun,

Welding

Wire,

Gas

Valve,

And

Instructional

Video

auto_arv

7/93



ST-149

330

PRINTED

IN

USA

I

tax

I

J

LIMITED

WARRANTY

Effective

February

7,

1996

(Equipment

with

a

serial

number

preface

of

lCD

or

newer)

This

limited

werrenty

supersedes

elI

werrenties

end

is

exclusive

with

no

other

guerentees

or

werrenties

expressed

or

implied.

LIMITED

WARRANTY



Subject

to

the

terms

end

conditions

below,

werrentx

to

its

originel

reteil

purcheser

thet

new

equipment

sold

eher

the

effective

dete

of

this

lim

ited

wenenty

is

free

of

defects

in

metedel

end

wortmenship

et

the

time

it

is

shipped

from

tectory.

THIS

WARRANTY

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTHER

WAR

RANTIES,

EXPRESS

OR

IMPLIED,

INCLUDING

THE

WARRANTIES

OF

MER

CHANTABILITY

AND

FIThESS.

Within

the

werrenty

periods

listed

below,

menufecturerwill

mpeiror

replece

eny

wer

rented

pens

orcomponents

thet

feit

due

to

such

defects

in

meteriel

orworkmenehip.

Menufecturer

must

be

notified

in

writing

within

thirty

(30)

deye

of

such

defect

or

feil

urn,

et

which

time

menufecturer

will

provide

instructions

on

the

werrenty

cleim

pro

cedures

to

be

followed.

Menufecturer

shell

honor

werrenty

cleime

on

werrsnted

equipment

listed

below

in

the

event

of

such

e

feilure

within

the

werrentytime

periods.

Alt

werrenty

time

periods

stert

on

the

dete

thet

the

equipment

wee

delivered

to

the

originel

reteil

purcheser,

or

one

yeer

efter

the

equipment

ie

sent

to

e

North

Americen

distributor

or

eighteen

months

efter

the

equipment

ix

sent

to

en

Intemetionel

distributor.

1.

SYeers

Perte3Veers

Lebor

*

Odginel

mein

power

rectifiers

*

Inverters

(input

end

output

rectifiers

ontly)

2.

3

Veers



Pens

end

Labor



Trsnsfornier/Rectifier

Power

Sources



Plesme

Arc

Cutting

Power

Sources

*

Semi-Autometic

end

Autometic

Wire

Feeders



Invener

Power

Supplies

*

Intellitig

*

Robots

(1

yeer

lebor)

3.

2

Veers



Pens

end

Labor



Engine

Driven

Welding

Generstors

(NOTE:

Engines

ere

werrsnted

seperstely

by

the

engine

menufecturer.)

*

Air

Compressors

4.

1

Veer

Pens

end

Labor

*

Motor

Driven

Guns

*

Process

Controllers



IHPS

Power

Sources

*

Weter

Coolent

Systems

*

HF

Unite

*

Grids

*

Spot

Welders

*

Loed Benks

*

SDX

Trsnsforniers

*

Running

Geer/Treilers

*

Plesme

Cutting

Torches

(except

APT,

ZIPCUT

&

PLAZCUT

Models)

*

Tecumseh

Engines

*

Deutz

Engines

(outside

North

Americe)



Pield

Options

(NOTE:

Field

options

em

covered

under

the

limited

werrenty

for

the

rs

meining

werrsnty

period

of

the

product

they

ere

inetelled

in,

orfor

e

mini

mum

of

one

yeer



whichever

is

greeter.)

5.

6

Months



BeBeries

6.

90

Deys



Pens

end

Labor

a]



MIG

Guns/tiG

Torches

*

APT,

ZIPCUT

&

PLAZCUT

Model

Plesme

Cutting

Torches



Remote

Controls

*

Accessory

Kits

*

Reptecement

Pens

Umited

Werrsnty

shell

not

epply

to:

1.

Itemsfumished

by

menufectumr,

but

menufectured

by

others,

such

es

engines

ortrsde

ecceesories.

These

items

em

covered

bythe

menufecturerswerrenty,

if

eny.

2.

Consumeble

components;

such

ee

contect

tips,

cutting

nozzles,

contectors

end

releys

or

pens

thet

feil

due

to

normel

weer.

3.

Equipment

thet

hex

been

modified

by

eny

petty

other

then

menufecturer,

or

equipment

thet

hex

been

improperiy

instelled,

improperiy

opereted

or

misused

besed

upon

industry

st~nderde,

or

equipment

which

hee

not

hed

mesoneble

end

necessery

meintenence,

orequipment

which

hex

been

used

for

operetion

outside

of

the

epecificetione

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

e

werrenty

cleim

covered

by

this

werrenty,

the exclusive

remedies

shell

be,

et

menufectumrs

option:

(1)

mpei~

or(2)

replecement;

or,

where

euthorized

in

writing

by

menufecturer

in

eppropriete

cesee,

(3)

the

reesoneble

cost

of

repeir

or

replecement

et

en

euthorized

service

stetion;

or

(4)

peyment

of

or

credit

for

the

put

chese

price

(less

ressoneble

deprecietion

besed

upon

ectuel

use)

upon

retum

of

the

goods

et

customers

risk

end

expense.

Menufecturers

option

of

repeir

or

replece

ment

will

be

FOB.,

Fectory

et

Appleton.

Wisconsin,

or

FOB.

et

en

euthorized

ser

vice

fecility

es

determined

by

menufecturer.

Therefore

no

compensetion

or

reim

bursement

for

trensponetion

costs

of

eny

kind

will

be

ellowed.

TO THE

EXTENT

PERMITTED

BY

LAW,

THE

REMEDIES

PROVIDED

HEREIN

ARETHE

SOLE

AND

EXCLUSIVE

REMEDIES.

IN

NO

EVENTSHALL

MANUFAC

TURER

BE

LIABLE

FOR

DIRECT,

INDIRECT,

SPECIAL

INCIDENTAL

OR

CON

SEQUENtiAL

DAMAGES

(INCLUDING

LOSS

OF

PROFIT),

WHETHER

BASED

ON

CONTRACT,

TORT

OR

ANY

OTHER

LEGAL

THEORY.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WAR

RANTY,

GUARANTY

OR

REPRESENTATION

ASTO

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

OP

CONTRACT

TORT

OR

ANY

OTHER

LEGAL

THEORY

WHICH,

BUT

FOR

THIS

PROVISION,

MIGHT

ARISE

BY

IMPLICATION,

OPERAtiON

OF

LAW,

CUSTOM

OF

TRADE

OR COURSE

OF

DEALING,

IN

CLUDING

ANY

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OR

FITNESS

FOR

PARTICULAR

PURPOSE,

WITh

RESPECT

TO

ANY

AND

ALL

EQUIPMENT

FURNISHED

BY

MANUFACTURER

IS

EXCLUDED

AND

DISCLAIMED

BY

MAN

UFACTURER.

Some

stetee

in

the

U.S.A.

do

not

ellow

limitetions

of

how

long

en

implied

werrsnty

lests,

or

the

exclusion

of

incidentel,

indirect,

epeciel

or

coneequentiel

demeges,

so

the

ebove

limitetion

or

exclusion

mey

not

epply

to

you.

This

werrsnty

provides

spe

cific

legel

rights,

end

other

rights

mey

be

eveileble,

but

mey

very

from

stete

to

etete.

In

Cenede,

Iegieletion

in

some

provinces

provides

for

cenein

edditionel

werrenties

or

remedies

other

then

es

eteted

herein,

end

to

the

extent

thet

they

mey

not

be

weived,

the

limitetions

end

exclusions

set

out

ebove

mey

not

epply.

This

Limited

Werrenty

provides

specific

legel

rights,

end

other

rights

mey

be

eveileble,

but

mey

very

from

province

to

province.

r_.

I

RECEIVING-HANDLING

Before

unpacking

equipment,

check

carton

for

any

damage

that

may

have

occurred

during

shipment.

Fi)e

any

Claims

for

loss

or

damage

with the

delivering

carrier.

Assistance

for

filing

or

settling

claims

may

be

obtained

from

distributor

and/or

equipment

manufacturers

Transportation

Department.

When

requesting

information

about

this

equipment,

always

provide

Model

Designation

and

Serial

or

Style

Number.

Use

the

following

spaces

to

record

Model

Designation

and

Serial

or

Style

Number

of

your

unit.

The

information

is

located

on

the

rating

label

or

nameplate.

Model

_________

Serial

or

Style

No.

Date

of

Purchase

.

brend_wer

3/96

ARC

WELDING

SAFETY

PRECAUTIONS

£~

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.

-

ARC

RAYS

can

burn

eyes

and

skin;

ARC

RAYS

.



NOISE

can

damage

hearing;

FLYING

SLAG

OR

SPARKS

can

injure

eyes.

Arc

rays

from

the

welding

process

produce

intense

visible

and

invisible

(ultraviolet

and

infrared)

rays

that

can

burn

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

Chipping,

gnnding,

and

welds

cooling

throw

off

pieces

of

metal

or

slag.

2.

3.

4.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

to

protectyourfaceandeyeswhenweldingorwatching(seeANSl

Z49.1

and

Z87.1

listed

in

Safety

Standards).

Wear

approved

safety

glasses

with

side

shields.

Use

protective

screens

or

barriers

to

protect

others

from

flash

and

glare;

warn

others

not

to

watch

the

arc.

NOISE

5.

Wear

protective

clothing

made

from

durable,

flame-resistant

1.

Use

approved

ear

plugs

or

ear

muffs

if

noise

level

is

high.

material

(wool

and

leather)

and

foot

protection.

I

FUMES

AND

GASES

can

be

hazardous

5.

Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

to

your

health.

I

Welding

produces

fumes

and

gases.

Breathing

-

these

fumes

and

gases

can

be

hazardous

to

your



I

health.

6.

wearing

an

air-supplied

respirator.

Always

have

a

trained

watchperson

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

1.

Keep

your

head

out

of

the

fumes.

Do

not

breathe

the

fumes.

operations.

The

heat

and

rays

of

the

arc

can

react

with

vapors

to

2.

If

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

form

highly

toxic

and

irritating

gases.

remove

welding

fumes

and

gases.

7.

Do

not

weld

on

coated

metals,

such

as

galvanized,

lead,

or

3.

If

ventilation

is

poor,

use

an

approved

air-supplied

respirator.

cadmium

plated

steel,

unless

the

coating

is

removed

from

the

4.

Read

the

Material

Safety

Data

Sheets

(MSDS5)

and

the

weld

area,

the

area

is

well

ventilated,

and

if

necessary,

while

manufacturers

instruction

for

metals,

consumables,

coatings,

wearing

an

air-supplied

respirator.

The

coatings

and

any

metals

cleaners,

and

degreasers.

containing

these

elements

can

give

off

toxic

fumes

if

welded.

CYLINDERS

can

explode

if

damaged.

4.

Never

drape

a

welding

torch

over

a

gas

cylinder.

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.

5.

6.

7.

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.

1.

Protect

compressed

gas

cylinders

from

excessive

heat,

8.

Tum

face

away

from

valve

outlet

when

opening

cylinder

valve.

mechanical

shocks,

slag,

open

flames,

sparks,

and

arcs.

9.

Keepprotectivecapinplaceovervalveexceptwhencylinderis

2.

lnstallcylindersinanuprightpositionbysecuringtoastationary

in

use

orconnected

for

use.

support

or

cylinder

rack

to

prevent

falling

or

tipping.

10.

Read

and

follow

instructions

on

compressed

gas

cylinders,

3.

Keep

cylinders

away

from

any

welding

or

other

electrical

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

circuits.

Standards.

ELECTRIC

SHOCK

can

kill.

Touching

live

electrical

parts

can

cause

fatal

shocks

or

severe

bums.

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

or,.

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.

2.

3.

Do

not

touch

live

electrical

parts.

terminal

in

disconnect

box

or

that

cord

plug

is

connected

to

a

properly

grounded

receptacle

outlet.

7.

When

making

input

connections,

attach

proper

grounding

conductor

first



double-check

connections.

8.

Frequently

inspect

input

power

cord

for

damage

or

bare

wiring



replace

cord

immediately

if

damaged



bare

wiring

can

kill.

11.

12.

9.

Turn

oft

all

equipment

when

not

in

use.

10.

Do

not

use

worn,

damaged,

undersized,

or

poorly

spliced

cables.

Do

not

drape

cables

over

your

body.

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.

4.

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).

5.

Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual

and

national,

state,

and

local

codes.

6.

Always

verify

the

supply

ground



check

and

be

sure

that

input

power

cord

ground

wire

is

properly

connected

to

ground

If

earth

grounding

of

the

workpiece

is

required,

ground

it

directly

with

a

separate

cable



do

not

use

work

clamp

or

work

cable.

13.

Do

not

touch

electrode

if

you

are

in

contact

with

the

work,

ground,

or

another

electrode

from

a

different

machine.

14.

Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

Maintain

unit

according

to

manual.

Wear

a

safety

harness

if

working

above

floor

level.

15.

16.

17.

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.

srl.1.1

2.194

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.

1.

Protect

yourself

and

others

from

flying

sparks

and

hot

metal.

2.

Do

not

weld

where

flying

sparks

can

strike

flammable

material.

3.

Remove

all

flammables

within

35

ft

(10.7

m)

of

the

welding

arc.

If

this

is

not

possible,

tightly

cover

them

with

approved

covers.

4.

Be

alert

that

welding

sparks

and

hot

materials

from

welding

can

easily

go

through

small

cracks

and

openings

to

adjacent

areas.

5.

Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.

6.

Be

aware

that

welding

on

a

ceiling,

floor,

bulkhead,

or

partition

can

cause

fire

on

the

hidden

side.

7.

Do

not

weld

on

closed

containers

such

as

tanks,

drums,

or

pipes,

unless

they

are

properly

prepared

according

to

AWS

F4.1

(see

Safety

Standards).

8.

Connect

work

cable

to

the

work

as

close

to

the

welding

area

as

practical

to

prevent

welding

current

from

traveling

long,

possibly

unknown

paths

and

causing

electric

shock

and

fire

hazards.

9.

Do

not

use

welder

to

thaw

frozen

pipes.

10.

Remove

stick

electrode

from

holder

or

cutoff

welding

wire

at

contact

tip

when

not

in

use.

11.

Wear

oil-free

protective

garments

such

as

leather

gloves,

heavy

shirt,

cuttless

trousers,

high

shoes,

and

a

cap.

12.

Remove

any

combustibles,

such

as a

butane

lighter

or

matches,

from

your

person

before

doing

any

welding.

ENGINES

can

be

hazardous.

ENGINE

EXHAUST

GASES

can

kill.

1.

Use

equipment

outside

in

open,

well-ventilated

areas.

Engines

produce

harmful

exhaust

gases.

2.

If

used

in

a

closed

area,

away

from

any

building

al

vent

engine

exhaust

outside

and

r

intakes.

SPARKS

can

cause

BATTERY

GASES

1.

Always

wear

a

face

shield

when

working

on

a

battery.

TO

EXPLODE;

BAT1ERY

ACID

can

2.

Stop

engine

before

disconnecting

or

connecting

battery

burn

eyes

and

skin,

cables.

3.

Do

not

allow

tools

to

cause

sparks

when

working

on

a

battery.

Batteries

contain

acid

and

generate

explosive

4.

Do

not

use

welder

to

charge

batteries

or

jump

start

vehicles.

lases.

5.

Observe

correct

polarity

(+

and

)

on

batteries.

STEAM

AND

PRESSURIZED

HOT

1.

It

the

engine

is

warm

and

checking

is

needed,

follow

steps

2

COOLANT

can

burn

face,

eyes,

and

3.

skin.

2.

Wear

safety

glasses

and

gloves

and

put

a

rag

over

cap.

It

is

best

to

check

coolant

level

when

engine

is

cold

3.

Tum

cap

slightly

and

let

pressure

escape

slowly

before

to

avoid

scalding.

completely

removing

cap.

PRINCIPAL

SAFETY

STANDARDS

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.i,

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

ForOccupation

And

Educational

Eye

And

Face

Protec

tion,

ANSI

Standard

Z87.i,

from

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

Cutting

And

Welding

Processes,

NFPA

Standard

51

B,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

4~

WARNING

ENGINE

FUEL

can

cause

fire

or

explosion.

Engine

fuel

is

highly

flammable.

3.

4.

Do

not

overfill

tan

Do

riot

spill

fuel.

engine.

k



allow

room

fo

If

fuel

is

spilled,

r

fuel

t

clean

o

expand.

up

before

starting

1.

Stop

engine

and

let

it

cool

off

before

checking

or

adding

fuel.

2.

Do

not

add

fuel

while

smoking

or

if

unit

is

near

any

sparks

or

open

flames.

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.

StoD

enaine

before

installing

or

connecting

unit.

2.

3.

Have

only

qualified

people

remove

guards

or

covers

for

maintenance

and

troubleshooting

as

necessary.

4.

To

prevent

accidental

starting

during

servicing,

disconnect

negative

()

battery

cable

from

battery.

5.

Keep

hands,

hair,

loose

clothing,

and

tools

away

from

moving

parts.

6.

Reinstall

panels

or

guards

and

close

doors

when

servicing

is

finished

and

before

starting

engine.

srl.1.1

2/94

CONSIGNES

DE

SECURITE

POUR

LE

SOUDAGE

A

LARC

UN

CHOC

ELEcTRIQUE

peut

tuer.

Un

simple

contact

avec

des

piŁces

Olectriques

peut

provoquer

une

electrocution

ou

des

blessures

graves.

LØlectrode

et

le

circuit

do

soudage

sont

sous

tension

des

que

lappareil

est

sur

ON.

Le

circuit

dentrØe

et

los

circuits

intomes

de

Iappareil

sont

egalement

sous

tension

a

ce

moment-l.

En

soudage

somi-automatique

ou

automatiquo,

le

fil,

le

dØvidoir,

to

logement

des

galets

dentraInementet

los

piŁces

metalliquos

en

contact

avec

to

f

ii

do

soudago

sont

sous

tension.

Des

matØnels

mal

installØs

ou

mal

mis

a

Ia

terre

prOsentent

un

danger.

1.

Ne

jamais

toucher

los

piŁces

electriques

sous

tension.

2.

Porter

des

gants

et

des

vØtements

do

protection

secs

ne

comportant

pas

de

trous.

3.

Sisoler

de

Ia

piŁce

et

de

Ia

terre

au

moyen

do

tapis

ou

dautres

moyons

isolants

sutfisamment

grands

pour

empOcher

to

contact

physique

Łvontuel

avec

Ia

piŁce

ou

Ia

terre.

4.

Couper

lalimentation

ou

arrOter

le

moteur

avant

do

proceder

a

linstallation,

a

reparation

ou

a

Ientretien

do

Iappareil.

DØverrouiller

Ialimentation

selon

Ia

norme

OSHA

29

CFR

1910.147

(voir

normes

de

sOcuntØ).

5.

Installer

et

mettre

a

Ia

terre

correctement

cot

appareil

conformØment

a

son

manuel

dutilisation

et

au

codes

nationaux,

provinciaux

et

municipaux.

6.

Toujours

verifier

a

terre

du cordon

dalimentation



Verifier

et

sassurer

aue

le

fil

de

terre

du

cordon

dalimontation

est

bien

raccordØ

ala

borne

do

terre

du

sectionneur

ou

quo

Ia

fiche

du

cordon

ost

raccordØe

a

une

priso

corroctemont

mise

a

Ia

terre.

7.

En

effectuant

les

raccordemontsdentrØefixerdabordleconductour

de

mise

a

Ia

terre

appropriØ

et

contro-vØrifior

los

connexions.

8.

Verifierfrequemment

0

cordon

dalimentation

pourvoir

sil

nest

pas

ondommage

ou

dØnudØ



romplacer

10

cordon

immOdiatement

sil

est

endommage



un

cable

dØnudØ

peut

provoquer

une

electrocution.

9.

Mettre

Iappareil

hors

tension

quand

on

no

Iutilise

pas.

10.

Ne

pas

utiliser

des

cables

uses,

endommagOs,

de

grosseur

insuffisante

ou

mal

ØpissØs.

11.

Ne

pas

enrouler

los

cables

autourdu

corps.

12.

Si

Ia

piŁce

soudOe

doit

Otre

mise

a

Ia

terre,

le

faire

directement

avec

un

cable

distinct



no

pas

utiliser

le

connecteur

do

piŁce

ou

le

cable

de

retour.

13.

Ne

pas

toucher

IŁloctrode

quand

on

est

en

contact

avec

Ia

piŁce,

Ia

terre

ou

une

electrode

provenant

dune

autre

machine.

14.

Nutiliser

quun

materiel

en

bon

Øtat.

Reparer

ou

remplacer

sur-le-champ

es

piŁces

endommagØes.

Entretenir

lappareil

conforrnØmont

ace

manuel.

15.

Porter

un

harnais

do

sØcuntØ

quand

on

travaille

on

hauteur.

16.

Maintenir

solidement

en

place

tous

los

panneaux

et

capots.

17.

Fixer

10

cable

do

retourde

taon

obtenirun

bon

contact

mØtal-mØtal

avec

Ia

piŁce

a

souderou

latable

dotravail,

le

plus

prŁs

possible

de

Ia

soudure.

BRUIT

LE

RAVONNEMENT

DE

LARC

peut

brUler

les

yeux

et

Ia

peau.

Le

BRUIT

peut

endommager

IouIe;

les

PROJECTIONS

DE

LAITIER

OU

LES

ETINCELLES

peuvent

blesser

les

yeux.

Larc

de

soudage

produit

des

rayons

visiblos

et

invisibles

intensos

(ultraviolets

et

infrarouges)

qui

peuvent

brOler

los

yeux

et

Ia

peau.

Le

bruit

produit

par

certains

procØdes

peut

endommagor

louIe.

Des

projections

do

metal

ou

do

laitier

sont

produitos

par

10

piquage,

to

moulage

ou

to

refroidissement

des

soudures.

1.

Utiliser

des

bouche-oreilles

ou

dos

serre-tOte

antibruit

approuvØs

Si

do

bruit

est

ŁlevØ.

LES

VAPEURS

ET

LES

FUMEES

peuvent

Œtre

dangereuses

pour

Ia

sante.

Le

soudage

produit

des

vapeurs

et

des

fumØes

quil

est

dangereux

de

respirer.

s-s

1.

Garder

Ia

tŒte

a

IextØneur

des

vapeurs

et

des

fumees

et

ne

pas

les

respirer.

2.

A

lintØrieur,

vontiler

le

poste

de

travail

ou

utiliser

Un

dispositif

place

au

nivoau

do

Iarc

pour

Øvacuer

les

vapeurs

et

fumØes

do

soudago.

3.

Si

Ia

ventilation

est

mauvaise,

utiliser

Un

apparoil

rospiratoire

a

adduction

dair

pur

approuve.

4.

Consulter

les

fiches

signaletiques

et

les

consignes

du

fabricant

relatives

au

mØtaux,

produits

dapport,

rovOtements,

nottoyants

et

dŁcjraissants.

RAYONNEMENT

DE

LARC

2.

Porter

un

masque

a

serre-tOte

muni

dun

verro

filtrant

do

nuance

appropnØe

pour

proteger

le

visage

et

los

yeux

quand

on

soudo

ou

observe

Ia

travail

do

soudage

(voir

los

normes

ANSI

Z49.i

et

Z87.1

donnOes

sous

Ia

rubnque

Principales

normes

do

securitØ).

Porter

dos

lunettos

do

sØcufltØ

approuvØes

avec

Øcrans

latOraux.

Utilisor

des

paravonts

ou

des

barnOres

de

protection

pour

protØgor

los

personnes

a

proximitØ

contra

los

coups

darc

et

lØblouissement;

avertir

los

autres

personnes

de

ne

pas

regardor

Iarc.

5.

Porterdes

vŒtemonts

do

protection

en

tissu

ignifuge

durable

(lame

et

cuir)

ot

des

chaussures

do

sØcuntØ.

5.

No

travailler

dans

un

espaco

confine

quo

siI

est

bien

ventilØ,

ou en

portantun

appareilrespiratoireaadductiondairpur.

Demandor

un

observateur

ayant

recu

Ia

borne

formation

do

toujours

so

tenir

a

proximite.

Los

vapeurs

et

fumØes

do

soudago

peuvent

dØplacer

lair

et

abaisser

le

niveau

doxygOno

et

causordes

blessuros

graves

voire

mortelles.

Sassurer

quo

lair

ost

propre

a

Ia

respiration.

6.

No

pas

soudor

a

proximitØ

doperations

do

degraissago,

do

nettoyage

ou

do

pulvensation.

La

chaleur

et

los

rayons

do

larc

pouvent

rØagir

avec

los

vapours

pour

former

des

gaz

hautement

toxiquos

et

irritants.

7.

Ne

pas

souder

sur

dos

mOtaux

rovOtus

comme

lacier

galvanisØ,

au

p10mb

ou

cadmiØ

a

moms

que

Ia

piŁce

nait

ØtO

ontiŁrement

dØcapØe,

quo

le

poste

do

travail

soit

bien

vontilO.

Sil

y

a

lieu,

porter

un

appareil

respiratoire

a

adduction

dair

pur.

Los

rovOtements

ot

los

mOtaux

qui

contiennent

do

tots

ØlØments

peuvent

degagordes

vapeurs

toxiques

lors

du

soudaae.

LES

BOUTEILLES

peuvent

exploser

si

elles

sont

endommagees.

Los

bouteilles

contonant

des

gaz

do

protection

sont

a

haute

pression.

Une

bouteille

ondommagee

pout

oxploser.

Etant

dome

que

los

bouteilles

de

gaz

font

normalement

partie

du

materiel

de

soudage,

les

traitor

avec

le

plus

grand

soin.

1.

Proteger

les

bouteilles

do

gaz

comprime

contro

Ia

chaleur

intense,

les

chocs,

le

laitier,

les

flammes

nuos,

les

Øtincollos

et

larc.

2.

Placer

los

boutoilles

ala

vorticalo

en

los

fixant

a

un

support

fixe

ou

a

un

chariot

pour

Øviter

quelles

ne

tomberit

ou

ne

basculent.

3.

Tenir

los

bouteilles

a

IØcart

du

poste

de

soudage

ou

dautres

circuits

electriques.

4.

No

jarnais

poser

un

chalumeau

soudeur

sur

une

boutoille

do

gaz.

5.

Ne

jamais

laissor

une

electrode

do

soudage

toucher

une

bouteille.

6.

No

jamais

souder

sur

une

boutoille

sous

pression

:

ello

explosorait.

7.

Nutilisor

quo

dos

boutoillos

do

gaz

do

protection,

dos

dOtendours,

des

tuyaux

souples

et

des

raccords

appropriØs

conus

pour

lapplication

particuliŁre;

consorvor

ces

matØriels

et

lours

piŁces

en

bon

Otat.

8.

Eloigner

le

visage

do

Ia

sortie

du

robinot

do

Ia

boutoillo

quand

on

louvre.

9.

Replacer

le

chapoau

sur

Ia

bouteille

aprŁs

utilisation.

10.

Lire

ot

suivre

les

consignes

relatives

aux

bouteilles

do

gazcomprimO,

au

materiel

connexe

ainsi

quo

Ia

publication

P-i

do

Ia

CGA

donnØe

sous

Ia

rubrique

Pnncipales

normes

de

sOcuritØ.

a

MISE

EN

GARDE

LE

SOUDAGE

A

LARC

peut

Øtre

dangereux.

SE

PROTEGER

ET

PROTEGER

LES

AUTRES

CONTRE

LES

BLESSURES

GRAVES

VOIRE

MORTELLES.

TENIR

LES

ENFANTS

A

LECART.

LES

PERSONNES

OUI

PQRTEN!

UN

STIMULATEUR

CARDIAQUE

NE

DOIVENT

PAS

NON

PLUS

SAPPROCHER

DU

POSTE

DE

SOUDAGE,

A

MOINS

DAVOIR

CONSULTE

UN

MEDECIN.

Le

soudage,

comme

Ia

plupart

des

travaux,

prOsente

certains

dangers.

Par

contre,

le

soudage

peut

Otre

effectuØ

en

toute

sØcuritØ

quand

on

prend

les

mesures

qui

simposent.

Les

consignes

de

sØcuritØ

donnØes

ci-aprŁs

no

font

que

rOsumer

linforrration

contenue

dans

los

norrnes

do

sOcuntO

ØnumØrOes

a

Ia

page

suivante.

Lire

et

respecter

toutos

ces

normes

de

sØcuntØ.

LINSTALLATION,

LUTILISATION,

LENTRETIEN

ET

LES

REPARATIONS

NE

DOIVENT

ETRE

CONFIES

QUA

DES

PERSONNES

QUALIFIEES

=~.

3.

4.

$rl.1.2

2194

LE

SOUDAGE

peut

causer

un

incendie

ou

une

explosion.

Ne

pas

souder

sur

des

recipients

fermØs

comme

des

reservoirs,

des

fOts

ou

dos

tuyaux:

us

peuvent

exploser.

Larc

do

soudage

pout

produire

des

Otincellos.

Des

Otincelles,

une

piŁce

chaude

et

un

materiel

chaud

peuvent

provoquer

des

incendies

et

des

blessures.

Le

contact

accidentel

de

lØlectrode

sur

des

objets

metalliques

pout

produire

des

Øtincelles,

lexplosion,

Ia

surchauffo

ou

un

incendie.

Sassurer

que

le

lieu

no

prOsonte

pas

do

danger

avant

deffoctuor

10

soudage.

1.

So

protegeret

protegorles

personnes

a

proximitØ

des

Otincolles

et

du

mOtal

chaud.

2.

Ne

pas

soudor

dans

un

endroit

o

les

Øtirtcelles

peuvent

atteindro

des

matØrlaux

inflammables.

3.

Enlevertoutes

les

matiŁres

inflammables

dans

un

rayon

do

moms

do

10

m

do

larc.

Si

cola

nest

pas

possible,

bien

los

recouvriron

utilisant

des

bchos

approuvees.

4.

Prendre

garde

que

les

etincelles

et

es

projections

ne

penetrent

dans

des

zones

adjacentes

en

sinfiltrant

dans

dos

petites

fissures

et

ouvertures.

5.

Prendre

garde

aux

incendies

ot

toujours

avoir

un

oxtinctour

a

proximite.

6.

So

rappeler

quo

si

Ion

soude

sur

un

plafond,

un

plancher,

une

cloison

ou

autre,

le

feu

pout

prondre

do

lautre

cte.

7.

Ne

pas

souder

sur

des

recipients

fermØs

comme

des

reservoirs,

des

fOts

ou

dos

tuyaux

a

moms

quils

no

soient

prepares

do

faon

appropneo

conformØment

ala

norrne

F4.1

de

lAWS

(voir

Ia

rubnquo

Principales

norrnes

do

securitO).

8.

Raccordor

lo

cable

de

retour

a

Ia

piŁce,

10

plus

prŁs

possible

de

Ia

zone

de

soudago,

pour

empØchor

quo

le

courant

de

soudage

ne

suive

uno

trajoctoire

longuo

ot

Øventuellemont

inconnue

et

quil

no

provoque

des

risques

dØlectrocution

et

dincendie.

9.

Ne

pas

utiliser

0

chalumoau

soudeur

pour

degeler

des

tuyaux.

10.

Enlever

lØloctrode

enrobØe

du

porte-electrode

ou

couper

le

fil

de

soudage

au

ras

du bec

contact

quand

on

no

lutilise

pas.

11.

Portordes

vØtoments

de

protection

non

huileux

comme

des

gants

en

cuir,

une

chemise

epaisso,

dos

pantalons

sans

revers,

dos

chaussuros

montantos

ot

un

casque.

12.

Ne

pas

portordes

matiŁres

combustibles

sur

soi

comme

un

briquet

a

gaz

ou

des

allumettes

quand

on

soudo.

1.

Utiliser

lo

materiel

a

lextØrieur,

dans

dos

lioux

ouvorts

ot

bion

ventulØs.

2.

Si

on

utilise

un

moteur

dans

un

local

ferme,

evacuer

los

gaz

dechappement

a

loxtØrieur

ot

loin

dos

pnses

dair

du

btimont.

2.

No

pas

fumer

en

faisant

10

plein

ou

si

lappamil

so

trouve

a

proximite

dØtincellos

ou

do

flammos

nues.

3.

Ne

pas

romplir

le

reservoir

a

ras

bord:

prevoir

de

lespace

pour

Ia

dilatation

du

combustible.

4.

No

pas

ronversor

du

carburant.

Si

on

ronverso

du

carburant,

nettoyer

les

lioux

avant

do

faire

dØmarrer

le

moteur.

3.

Seulos

des

personnos

qualifieos

doivent

dOmonter

los

protectours

ou

los

capots

pour

faire

lentrotien

ou

los

reparations

nOcessaires.

4.

Pour

ompOchor

un

demarrage

accidentel

dun

systŁme

pendant

lontretien

ou

les

reparations,

dØbrancher

le

cable

negatif

()

do

Ia

batterie.

5.

Eloignor

los

mains,

les

chevoux,

los

vŒtements

amplos

ot

los

outils

des

piŁces

en

mouvomont.

6.

Replacer

los

capots

ou

los

protecteurs

et

reformer

les

portes

une

fois

lentretien

et

los

reparations

torminØs

et

avant

do

faire

dOmarror

10

moteur.

2.

ArrOter

le

moteur

avant

do

branchor

ou

do

dØbrancher

los

cables

de

Ia

batterlo.

3.

Ne

pas

faire

dos

Øtincellos

avec

los

outils

quand

on

travaille

sur

une

batlono.

4.

Ne

pas

utilisor

Ia

source

do

courant

do

soudage

pour

charger

los

batteries

ou

pour

faire

dØmarrer

un

vØhicule.

5.

No

pas

intorvertir

Ia

polaritØ

des

batteries.

PRINCIPALES

NORMES

DE

SECURITE

Safety

in

Welding

and

Cutting,

norme

ANSI

Z49.1,

delArnorican

Welding

Society,

550

N.W.

Lojoune

Rd,

Miami

FL

33126

Safety

and

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

Cutting

of

Containers

That

Have

Held

Hazardous

Substances,

norme

AWS

F4.

1,

do

American

Welding

Society,

550

N.W.

Lejeuno

Rd,

Miami

FL

33126

National

Electrical

Code,

NFPA

Standard

70,

do

Ia

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

P-i,

de

Ia

Compressed

Gas

Association,

1235

Jefferson

Davis

Highway,

Suite

501,

Arlington,

VA

22202.

Regles

de

sØcuritØ

en

soudage,

coupage

et

procadØs

connexes,

norme

CSA

W1i7.2,

do

lAssociation

canadienne

do

normalisation,

vente

do

norrnos,

178

Rexdalo

Boulevard,

Roxdale

(Ontario)

Canada

M9W

1R3.

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

Protection,

norme

ANSI

Z87.1,

do

lAmorican

National

Standards

Institute,

1430

Broadway,

Now

York,

NY

10018.

Cutting

and

Welding

Processes,

normo

NFPA

51

B,

do

Ia

National

Fire

Protection

Association,

Batlorymarch

Park,

Quincy,

MA

02269.

a

MISE

EN

GARDE

LES

GAZ

DECHAPPEMENT

DES

MOTEURS

peuvent

Œtre

mortels.

Les

motours

produisent

dos

gaz

dechappement

nocifs.

LES

MOTEURS

peuvent

presenter

un

danger.

LE

CARBURANT

peut

provoquer

un

incendie

r

ou

une

explosion.

Le

carburant

est

hautomont

inflammable.

1.

ArrØter

10

motour

et

le

laisser

rofroidir

avant

de

verifier

le

nivoau

do

ou

do

refaire

0

plein.

LES

PI¨CES

EN

MOUVEMENT

peuvent

causer

des

blessures.

Los

piŁces

en

mouvement

comme

les

vontilateurs,

los

rotors

ot

los

courroios

pouvont

coupor

los

doigts

et

los

mains

et

happor

los

vOtements

amples.

1.

Sassurerquo

los

portes,

los

pannoaux,

los

capots

et

los

protecteurs

sont

bien

fermØs

ot

bion

a

leur

place.

2.

ArrOtor

le

moteur

avant

de

mettre

en

place

ou

do

raccordor

un

1.

Touiours~

LES

ETINCELLES

peuventfaire

EXPLOSER

LE

GAZ

DES

BATTERIES;

LELECTROLYTE

peut

brLiler

Ia

peau

et

les

yeux.

Les

batteries

contiennent

un

produit

acide

et

degagent

dos

vapeurs

explosives.

ortor

un

Øcran

facial

quand

on

travaillo

sur

une

battorie.

LA

VAPEUR

ET

LE

LIQUIDE

DE

1.

Si

on

dolt

verifier

le

niveau

quand

le

moteur

ost

chaud,

suivre

los

~f.

REFROIDISSEMENT

BRULANT

SOUS

etares

2

et

3.

PRESSION

peuvent

brOler

~a

peau

et

les

yeux.

2.

Porter

dos

Iunettes

do

sØcuntØ

ot

des

gants

et

placer

un

chiffon

sur

lo

II

vaut

mieux

verifier

10

nivoau

du

liquide

do

rofroidissomont

quand

0

motour

est

froid

afin

dØviter

los

3.

bouchon.

Toumer

lentemont

le

bouchon

ot

laissor

Ia

pression

sOchapper

brOlures.

lentomont

avant

denlevor

complŁtoment

10

bouchon.

sri

.1.2

2/94

EMF

INFORMATION

TABLE

OF

CONTENTS

SECTION

1

-

SAFETY

INFORMATION

SECTION

2

SPECIFICATIONS

2-1.

Volt-Ampere

Curves

2-2.

Duty

Cycle

SECTION

3INSTALLATION

3-1.

Installing

Work

Clamp

3-2.

Gun

Polarity

For

Wire

Type

3-3.

Selecting

A

Location

And

Connecting

Input

Power

3-4.

Threading

Welding

Wire

3-5.

Installing

Gas

Supply

SECTION

4-

OPERATION

7

SECTION

5-

MAINTENANCE

&

TROUBLESHOOTING

5-1.

Routine

Maintenance

5-2.

Overload

Protection

5-3.

Cleaning

Or

Repairing

Drive

Assembly

5-4.

Installing

Wire

Spool

And

Adjusting

Hub

Tension

5-5.

Troubleshooting

SECTION

6

ELECTRICAL

DIAGRAM

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

Figure

8-2.

Drive

Assembly,

Wire

NOTE

~

Considerations

About

Welding

And

The

Effects

Of

Low

Frequency

Electric

And

Magnetic

Fields

The

following

is

a

quotation

from

the

General

Conclusions

Section

of

the

U.S.

Congress,

Office

of

Technology

Assessment,

Biological

Effects

of

Power

Frequency

Electric

&

Magnetic

Fields



Background

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

cellularlevel

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

1

2

3

4

5

6

10

11

12

13

15

17

20

23

OM-151

015C6/96

SECTION

1

-

SAFETY

INFORMATION



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

\

a

WARNING

2

/

a

CAUTION

______________________________

3

______________________________

=9

ELECTRIC

SHOCK

can

kiII.i~



MOVING

PARTS

can

injure.



Do

not

touch

live

electrical

parts.



Keep

away

from

moving

parts.



Disconnect

input

power

before



Keep

all

panels

and

covers

closed

/

installing

or

servicing,

when

operating.

5

1

Safety

Alert

Symbol

2

SignalWord

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

;1 ~I

I

~e

READ

SAFETY

BLOCKS

at start

of

Section

3-1

before

proceeding.

4

Safety

Instructions

To

Avoid

Hazard

NOTE

~

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.

Type

Of

Output

Rated

Weld

Output

Specifications

Description

Constant

Voltage

(CV),

Direct

Current

(DC)

90

Amperes,

18

Volts

DC,

20%

Duty

Cycle

(See

Section

2-2)

Usable

Amperage

Range

Type

Of

Input

Amperes

At

Rated

Output

KVNKW

Used

At

Rated

Output

Max.

Open-Circuit

Voltage

Control

Circuit

Voltage

At

Gun

Welding

Processes

30

To

130

A

Single-Phase

115

Volts

AC,

60

Hertz

20

Amperes

3

kVN2.7

kW

30

Volts

DC

24

Volts

DC

Shipped

From

The

Factory

Set

For

Gas

Metal

Arc

Welding

(GMAW)

(Uses

Solid

Or

Aluminum

Wire

And

External

Shielding

Gas)

Flux

Cored

Arc

Welding

(FCAW)

(Uses

Wire

With

Flux

Inside

And

Requires

No

External

Shielding

Gas)

283

To

716

iprn

(7.1

To

17.9

mpm)

5

To

800

iprn

(.13

To

20

rnpm)

.023

To

.035

in

(0.58

To

0.89

mm)

Calculated

Speed

Range

At

No

Load

Approximate

Wire

Feed

Range

Wire

Diameter

Range

Input

Power

Cord

With

Plug

Overall

Dimensions

Weight

(with

gun)

7ft(2.1

m)

Length:

17

in

(432

mm);

Width:

10

in

(254

mm);

Height:

15-1/2

in

(394

mm)

Shipping

80

lb

(36

kg);

Net

73

lb

(33

kg)

OM-151

015

Page

1

2-1.

Volt-Ampere

Curves

Figure

2-1.

Volt-Ampere

Curves

2-2.

Duty

Cycle

a

CAUTION

10

15

20

25

30 40

50

60

70

8090100

Figure

2-2.

Welding

Power

Source

Duty

Cycle

Chart

25

20

Co

0

15

10

30

The

volt-ampere

curves

show

the

minimum

and

maximum

voltage

and

amperage

output

capabilities

of

the

welding

power

source.

Curves

of

other

settings

fall

be

tween

the

curves

shown.

SB-124

646-A

5

0

20

40

60

80

100

120

DC

AMPERES

E

XCEEDING

DUTY

CYCLE

RATINGS

will

damage

unit.



Do

not

exceed

indicated

duty

cycles.

wam7.1

2/92

150

Duty

cycle

is

how

long

the

unit

can

operate

within

a

ten

minute

period

125

-

without

causing

overheating

or

damage.

100

This

unit

is

rated

at

20%

duty

cycle

allowing

welding

2

minutes

out

of

every

10

minutes.

Co

75

.

w

a

~

<

~

50

-J

w

~

37.5

25







0

-





%

DUTY

CYCLE

SB-124

655-A

OM-151

Ol5Page2

SECTION

3-INSTALLATION

Table

3-1.

Items

Included

With

Welding

Power

Source

Item

Quantity

Welding

Gun



Shipped

Set

To

Feed

.023

in

(0.6

mm)

Hard

1

Wire

(See

Gun

Owners

Manual

Form

112

934)

Spool

Of

Wire

.023

in

(0.6

mm)

Hard

Wire

1

VHS

Videotape

(28

Minutes)

1

lOft

(3

m)

Work

Cable

And

Clamp

1

6ft(1.8m)AirHose

1

Contact

Tubes

(2

.030

in,

3

.023

in,

And

3

.035

in)

8

Monocoil

Liner

For

.023



.030

in

Wire

1

NOTE

~

Customer

must

supply

proper

shielding

gas

for

desired

application.

3-1.

Installing

Work

Clamp

1

Insulator

2

Bolt

3

Smaller

Hole

4

Work

Clamp

Tabs

Bend

tabs

around

work

cable.

2

5

Work

Cable

From

Unit

6

Nut

3

Tools

Needed:

3/8,7/l6in

Ref.

ST-025

190-C

Figure

3-1.

Installing

Work

Clamp

3-2.

Gun

Polarity

For

Wire

Type

a

WARNING

~STRAIGHT

I

REVERSE

~

For

Solid

For

Flux

Stool

Or

Cored

Wires

Aluminum

I

POLARITY

Process)

(GMAW)

(FCAW

Wires

DCEN

DCEP

J

GUN

POLARITY

CHANGEOVER

Tools

Needed:

3/8in

E

LECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

welding

power

source,

and

disconnect

input

power

before

inspecting

or

installing.

swaml.1

2/93

2

1

Polarity

Changeover

Label

2

Polanty

~Jumper

Links

Always

read

and

follow

welding

wire

manufacturers

recom

mended

polarity.

Close

door.

Figure

3-2.

Gun

Polarity

Jumper

Link

Position

ST-151

358

OM-151

015

Page

3

3-3.

Selecting

A

Location

And

Connecting

Input

Power

a

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Have

only

qualified

persons

install

unit.



Installation

must

meet

National

Electrical

Code

and

all

other

codes.

BLOCKED

AIRFLOW

causes

overheating

and

possible

damage

to

unit.



Do

not

block

or

filter

airflow.

Warranty

is

void

if

any

type

of

filter

is

used.

3

2

1

18

in

(457

mm)

Open

Space

At

Front

And

Sides

For

Good

Airflow

2

Rating

Label

3

Grounded

Receptacle

A

20

ampere

individual

branch

circuit

protected

by

time-delay

fuses

or

circuit

breaker

is

required.

4

Plug

From

Unit

Select

extension

cord

of

12

AWG

for

up

to

75

ft

(23

m)

or

10

AWG

for

up

to

140

ft

(46

m).

ST-149

354-A

4

Figure

3-3.

Location

And

Input

Power

Connections

OM-151

015

Page

4

3-4.

Threading

Welding

Wire

£~

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

electncal

parts.

The

welding

wire,

drive

rolls,

drive

assembly,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live

when

welding

or

feeding

wire

using

gun

trigger.

WELDING

WIRE

can

cause

puncture

wounds.



Do

not

press

gun

trigger

until

instructed

to

do

so.



Do

not

point

gun

toward

any

part

of

the

body,

other

people,

or

any

metal

when

threading

welding

wire.

HOT

SURFACES

can

burn

skin.



Allow

gun

to

cool

before

touching.

swam2.1

9191

Iswam5.1

10/91

~-6in-~

(1

50

mm)

Pull

and

hold

wire;

cut

off

end.

Remove

gun

nozzle

and

contact

tube.

Tools

Needed:

Figure

3-4.

Threading

Welding

Wire

Ref.

ST-i

51

289/

Ref.

ST-i

5i

357

/

Ref.

ST-i

56 256-A

/

S-0627-A

1

Wire

Spool

2

Welding

Wire

3

Inlet

Wire

Guide

4

Pressure

Adjustment

Knob

5

Drive

Roll

6

Outlet

Wire

Guide

7

Gun

Conduit

Cable

Lay

gun

cable

out

straight.

Hold

wire

tightly

to

keep

it

from

unraveling.

-+

Open

pressure

assembly.

Push

wire

thru

guides

into

gun;

continue

to

hold

wire.

P~ER

~

-e

-4

Close

and

tighten

pressure

assembly,

and

let

go

of

wire.

Press

gun

trigger

until

wire

comes

out

of

gun.

Reinstall

contact

tube

and

nozzle.

-~

~t~Il

Feed

wire

to

check

drive

roll

pressure.

Tighten

knob

enough

to

prevent

slipping.

Set

switch.

c4~J~J

Cut

oft

wire.

Close

and

latch

door.

OM-151

015

Page

5

3-5.

Installing

Gas

Supply

4A

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,

other

stationary

support.

Tools

Needed:

~

1-1/8,5/8

in

1~~~~

OR

L

BUILDUP

OF

SHIELDING

GAS

can

harm

health

or

kill.



Shut

off

shielding

gas

supply

when

not

in

use.

2

3

wam4.1

9/91

Obtain

gas

cylinder

and

chain

to

running

gear,

wall,

or

other

station

ary

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

Gas

Hose

Connection

Fitting

has

5/8-18

right-hand

threads.

Install

air

hose.

6

Flow

Adjust

Typical

flow

rate

is

20

cfh

(cubic

feet

per

hour).

Check

wire

man

ufacturers

recommended

flow

rate.

7

CO2

Adapter

8

0-Ring

Install

adapterwith

0-ring

between

regulator/flowmeter

and

CO2

cylinder.

ssb3.1*

12/92ST-158

697-A

Figure

3-5.

Typical

Regulator/Flowmeter

Installation

or

Argon

Gas

4

7 8

CO2

Gas

OM-151

015

Page

6

SECTION

4-

OPERATION

AA

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.

ARC

RAYS

can

burn

eyes

and

skin;

NOISE

can

damage

hearing.



Wear

welding

helmet

with

correct

shade

of

filter.



Wear

correct

eye,

ear,

and

body

protection.

~,

MOVING

PARTS

can

cause

injury.



Keep

away

from

pinch

points

such

as

drive

rolls.



Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

I

~

=~

~

~

MAGNETIC

FIELDS

FROM

HIGH

CUR

RENTS

can

affect

pacemaker

operation.



Pacemaker

wearers

keep

away.



Wearers

should

consult

their

doctor

before

going

near

arc

welding,

gouging,

or

spot

welding

opera

tions.

See

Safety

Precautions

at

beginning

of

manual

for

ba

sic

welding

safety

information.

swam6.2

10)91

Figure

4-1.

Safety

Equipment

Figure

4-2.

Work

Clamp

2

/

1

Insulating

Gloves

2

Safety

Glasses

With

Side

Shields

3

Welding

Helmet

Wear

dry

insulating

gloves,

safety

glasses

with

side

shields,

and

a

welding

helmet

with

a

correct

shade

of

filter

(see

ANSI

Z49.1).

sb3.1

10/91

1

Work

Cable

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.

Tools

Needed:

sb4.1

2/93

/

Ret.

5T-156

256-A

OM-151

015

Page

7

a

CAUTION

ARCING

can

damage

switch.



Do

not

change

ThicknessNoltage

switch

position

while

welding.

Arcing

inside

switch

can

damage

contacts,

causing

switch

to

fail.

wam5.1

9/91

a

WARNING

BUILDUP

OF

SHIELDING

GAS

can

harm

health

or

kill.



Shut

oft

shielding

gas

supply

when

not

in

use.

waml.1

9/91

Figure

4-4.

Shielding

Gas

1

Fine

Tuning/Wire

Speed

Control

Use

this

control

to

select

a

wire

feed

speed.

As

ThicknessNoltage

switch

setting

increases,

wire

speed

range

also

increases.

The

numbers

around

the

control

are

not

a

wire

feed

speed

and

are

for

reference

only.

2

ThicknessNoltage

Switch

Use

this

switch

to

select

an

arc

voltage.

The

higher

the

selected

number,

the

thicker

the

matenal

that

can

be

welded.

3

Power

Switch

Use

switch

to

turn

unit

On

and

Off.

Figure

4-3.

Controls

ST-150

092

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-0780

OM-151

015

Page

8

Connect

Install

&

Put

On

Turn

O\



Do

)~\

Readjust

Co~~i?~

Personal

Safety

)

)Equiprnent

&

Gas

)

Set

controisj)

Sample

Weld

)

And

Prepare

)

Equipment~J}

Equipment

j)

(lfApplicable)

)

_______________

J

ForWelding

J

Figure

4-5.

Sequence

Of

Operation

For

GMAW

And

FCAW

~\

Install&Connec~\\

Adjust

Hub

~\

Adjust

Dnve

Roli~~

T

)Equipment

Using

)

Tension

To

i

)

Pressure

To

I

1

Put

On

Personal

urn

On

J

Knu~ed

Groo~Jj

Minimum

})

Minimum

))Safety

Equipme~)

To

30

cfh

}

Straig

And

Adjust

Gas

I

)

~\

Readjust

Control~~

Do

Sample

Weld

I

And

Prepare

For

I

)

Welding~J

Figure

4-6.

Sequence

Of

Operation

For

Aluminum

Welding

OM-151

Ol5Page9

SECTION

5-

MAINTENANCE

&

TROUBLESHOOTING

£~

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

MOVING

PARTS

can

cause

injury.



Keep

away

from

moving

parts.



Keep

away

from

pinch

points

such

as

drive

rolls.

5-2.

Overload

Protection

READ

SAFETY

BLOCKS

at

start

of

Section

5

before

proceeding.

4~

CAUTION

STATIC

ELECTRICITY

can

damage

parts

on

circuit

boards.



Put

on

grounded

wrist

strap

BEFORE

handling

boards

or

parts.

fwam5.1

9/91

iance

to

be

performed

only

by

qualified

swam8.2

2/93

Turn

Off

all

power

before

maintaining.

~

3

Months

Replace

Cracked

Parts



Trigger

Cord

Gas

Hose

Gun

Cable

Figure

5-1.

Maintenance

Schedule

A.

Motor

Fuse

Fl

Turn

Off

and

unplug

unit.

Unlatch

door

and

remove

door/wrapper.

1

Circuit

Board

PCi

Located

behind

fan.

2

Fuse

Fl

(See

Parts

List

For

Rating)

Pull

fuse

from

fuse

holder

on

PCi.

To

reinstall,

push

fuse

into

fuse

holder.

Reinstall

wrapper,

and

latch

door.

ST-150

114/ST-149

327

Tools

Needed:

~

3/8

in

Figure

5-2.

Fuse

Fl

Location

OM-151

015

Page

10

B.

Overheating

Thermostat

TP1

protects

the

unit

from

damage

due

to

overheating.

If

main

transformer

Ti

gets

too

hot,

TP1

opens

and

weld

output

stops.

The

fan

keeps

running

to

cool

the

transformer.

Wait

several

minutes

before

trying

to

weld.

C.

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.

5-3.

Cleaning

Or

Repairing

Drive

Assembly

READ

SAFETY

BLOCKS

at

start

of

.7

Section

5

before

proceeding.

Turn

Off

and

unplug

unit.

1

Wire

Spool

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

beanng

as

shown.

Install

new

bearing

and

secure

with

screw.

Reinstall

am,

onto

and

secure

with

cotter

pin.

8

Setscrew

9

Smooth

Groove

For

Hard

Wire

10

Drive

Roll

Remove

drive

roll

as

shown.

Use

a

wire

brush

to

clean

drive

roll.

Push

drive

roll

onto

shaft

with

desired

groove

in.

Tum

drive

roll

so

one

setscrew

faces

flat

side

of

shaft,

and

tighten

both

setscrews.

11

Knurled

Groove

For

Flux-

Cored

Wire

12

Wire

Inlet

Guide

Remove

guide

by

pressing

on

barbed

area

or

cutting

off

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

3-4).

Close

door.

Tools

Needed:

5/64

in

Pet.

ST-i

51

357

/

ST-i

49

266-B

Figure

5-3.

Cleaning

Or

Repairing

Drive

Assembly

CM-i

51

015

Page

ii

5-4.

Installing

Wire

Spool

And

Adjusting

Hub

Tension

Figure

5-4.

Installing

Wire

And

Adjusting

Tension

a

WARNING

READ

SAFETY

BLOCKS

at

start

of

Section

5

before

proceeding.

N

OTE

~

if

hub

tension

is

too

tight,

motor

fuse

Fican

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

oft

at

contact

tube,

and

retract

wire

onto

spool

and

secure.

3

Retaining

Remove

and

pull

off

spool.

4

Flub

5

Hub

Slide

spool

onto

hub

so

wire

feeds

off

bottom.

Turn

spool

until

hub

fits

hole

in

back

of

spooi.

Push

retaining

through

hub.

6

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.

Close

and

secure

pressure

roll

assembly.

Thread

welding

wire

(see

Section

3-4).

Close

door.

6

Tools

Needed:

9/16

in

Ref.

ST-i

51

357/S-0499

OM-151

015

Page

12

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Miller KG171523, 120, AUTO ARC 120 Owner's manual

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