Miller AUTO ARC 140 Owner's manual

AUTO

ARC}~

June

1995

Form:

OM-151

016B

Effective

With

Serial

No.

KF909888

OWNERS

MANUAL

Auto

Arcﬁ

140



Read

and

follow

these

instructions

safety

blocks

carefully.

Have

only

trained

and

qualified

install,

operate,

or

service

this

unit.

and

all

persons



Give

this

manual

to

the

operator.

U

For

help,

call

your

distributor



Call

your

distributor

if

you

do

not

understand

the

directions.

I~



or:

MILLER

Electric

Mfg.

Co.,

P.O.

Box

1079,

Appleton,

WI

54912

414-734-9821



CV/DC

Welding

Power

Source/Wire

Feeder



For

GMAW

And

FCAW

Welding



120

Amperes,

21

Volts

At

30%

Duty

Cycle



Uses

230

Volts

AC,

Single-Phase

Input

Power



Feeds

.023

Thru

.035

Wire



Overheating,

Short-Circuit,

And

Motor

Overload

Protection



Includes

Gas

Valve

auto_arc

7/93



ST-149

626-B

PRINTED

IN

USA



LIMITED

WARRANTY

Effective

January

1,

1995

(Equipment

with

a

serial

number

preface

of

KD

or

newer)

This

limited

wsrranty

supersedes

eli

warranties

end

is

exclusive

with

no

other

guarantees

or

warranties

expressed

or

implied.

LIMITED

WARRANTY



Subject

to

the

terms

snd

conditions

below,

warrants

to

its

original

retail

purchaser

that

new

equipment

sold

sfter

the

effective

dste

of

this

lim

ited

warrsnty

is

free

of

defects

In

msterial

and

workmanship

at

the

time

it

is

shipped

from

factory.

THIS

WARRANTY

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTHER

WAR

RANTIES,

EXPRESS

OR

IMPLIED,

INCLUDING

THE

WARRANTIES

OF

MER

CHANTABILITY

AND

FITNESS.

Within

the

warranty

periods

listed

below,

manufacturerwill

reriairor

replace

any

war

ranted

parts

orcomponenta

that

fail

due

to

auch

delects

in

malerial

orworkmanahip.

Manufacturer

must

be

notified

in

writing

within

thirty

(30)

days

of

auch

delect

or

fail

ure,

at

which

lime

manufacturer

will

provide

instructions

on

the

warranty

claim

pro

cedures

to

be

lollowed.

Manufacturer

ahail

honor

warranty

claims

on

warranted

equipment

listed

below

in

the

event

of

such

a

failure

within

the

warranty

time

pefloda.

All

warranty

time

perioda

start

on

the

date

that

the

equipment

was

delivered

to

Ihe

original

retail

purchaser,

or

one

year

aher

the

equipment

is

sent

to

a

North

Amprican

distributor

or

eighteen

months

after

the

equipment

is

aent

to

an

lntemalionai

distributor.

1.

5YearsParts3YearsLabor

Original

main

power

rectifiers

2.

3

Years



Parts

and

Labor



Transtormer/Rectifier

Power

Sources



Plasma

Arc

Cutting

Power

Sources



Semi-Automatic

and

Automatic

Wire

Feeders

Robots

3.

2

Years



Parts

and

Labor



Engine

Driven

Welding

Generators

(NOTE:

Engines

are

warranted

separately

by

the

engine

manufacturer.)

*

Air

Compressors

4.

1

YearParts

and

Labor



Motor

Driven

Guns



Process

Controllers



IHPS

Power

Sources



Waler

Coolant

Systems



HF

Units



Grids



Spot

Welders



Lced

Banks



SDX

Transformers



Running

Gear/Trailers



Plasma

Cutting

Torches

(except

APt

ZIPCUT

&

PLAZCUT

Models)



Tecumaeh

Engines



Deutz

Engines

(outside

North

Americe)



Field

Options

(NOTE:

Field

options

are

covered

under

the

limited

warranty

br

there

maining

warranty

period

of

the

product

they

are

installed

in.

or

br

a

mini

mum

of

one

year



whichever

is

greater.)

6

Months



Batteries

g~

Days



Parts

and

Labor



MIG

Guns/TIG

Torches



APT,

ZIPCUT

&

PLAXCUT

Model

Plasma

Cutting

Torchea

ii

_________



Remote

Controls



Accessory

Kits



Replacement

Parts

Umited

Warranty

shall

not

apply

to:

1.

Items

fumiahed

by

manufacturer,

but

manufactured

by

others.

such

as

engines

or

trade

accessories.

These

items

are

covered

by

the

manufacturers

warranty.

if

any.

2.

Consumable

components:

auch

as

contact

tips,

cuning

nozzles,

contactors

and

relays

or

parts

that

fail

due

to

normal

wear.

3.

Equipment

that

has

been

modified

by

any

party

other

than

manufacturer,

or

equipment

that

has

been

improperly

installed,

improperly

operated

or

misused

based

upon

induslry

atandarda,

or

equipment

which

has

not

had

reaaonabte

and

necessary

maintenance,

or

equipment

which

has

been

used

for

operation

outside

of

the

apecilications

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

EOUIPMENT

in

the

event

of

a

warranty

claim

covered

by

this

warranty,

the

excluaive

remedies

ahatl

be,

at

manufacturers

option:

(t)

repair:

or

(2)

replacement;

or,

where

authorized

in

writing

by

manufacturer

in

appropriala

cases,

(3)

the

reasonable

cost

of

repair

or

replacement

at

an

aulhorizad

aeMce

station;

or

(4)

payment

ol

or

credit

br

the

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

uae)

upon

retum

of

the

goods

at

customers

risk

and

expanse.

manufacturers

option

of

repair

or

replace

ment

will

be

EO.B..

Factory

at

Appleton,

Wisconsin,

or

FOB.

at

an

authorized

ser

vice

facility

as

determined

by

manufacturer.

Therefore

no

compensation

or

reim

buraamanl

for

transportation

costa

of

any

kind

will

be

allowed.

TO

THE

EXTENT

PERMITrED

BY

LAW,

THE

REMEDIES

PROVIDED

HEREIN

ARE THE SOLE

AND

EXCLUSIVE

REMEDIES.

IN

NO

EVENT

SHALL

MANUFAC

TURER

BE

UABLE

FOR

DIRECT,

INDIRECT,

SPECIAL,

INCIDENTAL

OR

CON

SEOUENTIAL

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

REPRESENTATtON

AS

TO

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

OF

CONTRACT

TORT

OR

ANY

OTHER

LEGAL

THEORY

WHICH,

BUT

FOR

THIS

PROVISION,

MIGHT

ARISE

BY

IMPLICATION,

OPERATION

OF

LAW,

CUSTOM

OF

TRADE

OR

COURSE

OF

DEALING,

IN

CLUDING

ANY

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OR

FiTNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

TO

ANY

AND

ALL

EOUIPMENT

FURNISHED

BY

MANUFACTURER

IS

EXCLUDED

AND

DISCLAIMED

BY

MAN

UFACTURER.

Some

states

in

the

U.S.A.

do

not

allow

limitations

of

how

long

an

implied

warranty

lasts,

or

the

exclusion

of

incidental,

indirect,

apacial

or

consequential

damagas,

ao

the

above

limitation

or

exclusion

may

not

apply

to

you.

This

warranty

provides

ape

cific

legal

rights,

and

other

rights

may

be

available,

but

may

vary

from

state

to

state.

In

Canada,

legislation

in

some

provinces

provides

for

certain

additional

warranties

or

remedies

other

than

as

ststad

herein,

and

to

the

extant

thaI

they

may

not

be

waived,

the

limitations

and

exclusions

sat

out

above

may

not

apply.

This

Umitad

Warranty

provides

specific

legal

rights,

and

other

rights

may

be

available,

but

may

<~>var~

from

province

to

province.

Sc

I

5.

6.

rU

RECEIVING-HANDLING

Before

unpacking

eqUipment,

check

carton

(or

any

damage

that

may

have

occurred

during

shipment.

File

any

claims

for

loss

or

damage

with

the

delivering

carrier.

Assistance

for

filing

or

settling

claims

may

be

obtained

from

distributor

and/or

equipment

manufacturers

Transportation

Department.

When

requesting

information

about

this

equipment,

always

provide

Model

Designation

and

Serial

or

Style

Number.

Use

the

following

spaces

to

record

Model

Designation

and

Serial

or

Style

Number

of

your

unit.

The

information

is

located

on

the

rating

label

or

nameplate.

Model

__________

Serial

or

Style

No.

Date

of

Purchase

brand..acct

4/g5

ARC

WELDING

SAFETY

PRECAUTIONS

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

Jive

when

power

is

on.

In

semiaulomatic

or

automatic

wire

welding,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

touchin9

the

weldin9

wire

are

electrically

live.

Incorrectly

installed

or

improperly

grounded

equipment

is

a

hazard.

1.

Do

not

touch

live

electrical

parts.

2.

Wear

dry,

hole-free

insulating

gloves

and

body

protection.

3.

Insulate

yourself

from

work

and

ground

using

dry

insulating

mats

or

covers

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

CPA

1910.147

(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

cower

cord

around

wire

is

orocerlv

connected

to

around

d

ARC

WELDING

can

be

hazardous.

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.

9.

Turn

off

all

equipment

when

not

in

use.

10.

Do

not

use

worn,

damaged,

undersized,

or

poorly

spliced

cables.

Do

not

drape

cables

over

your

body.

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.

15.

Wear

a

safety

harness

if

working

above

floor

level.

16.

Keep

all

panels

and

covers

securely

in

place.

17.

Clamp

work

cable

with

good

metal-to-metal

contact

to

workciece

or

worktable

as

near

the

weld

as

oractical.

a

WARNING

PROTECT

YOURSELF

AND

OTHERS

FROM

POSSIBLE

SERIOUS

INJURY

OR

DEATH.

KEEP

CHILDREN

AWAY.

PACEMAKER

WEARERS

KEEP

AWAY

UNTIL

CONSULTING

YOUR

DOCTOR.

Inwelding,

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.

11.

12.

ARC

RAYS

can

burn

eyes

and

skin;

ARC

RAYS

NOISE

can

damacie

hearing;

FLYING

2.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

to

/~

SLAG

OR

SPARKS

can

Injure

eyes.

protectyourfaceandeyeswhenweldingorwatchlng(seeANSl

Arc

rays

from

the

welding

process

produce

intense

Z49.1

and

Z87.1

listed

in

Safety

Standards).

visible

and

invisible

(ultraviolet

and

Infrared)

rays

that

3.

Wear

approved

safety

glasses

with

side

shields.

can

bum

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

Chipping,

grinding,

and

welds

4.

Use

protective

screens

or

barriers

to

protect

others

from

flash

cooling

throw

off

pieces

of

metal

or

slag.

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.

FUMES

AND

GASES

can

be

hazardous

5.

Work

In

a

confined

space

only

If

It

Is

well

ventilated,

or

while

to

your

health.

wearing

an

air-supplied

respirator.

Always

have

a

trained

Welding

produces

fumes

and

gases.

Breathing

these

watchperson

nearby.

Welding

fumes

and

gases

can

displace

air

fumes

and

gases

can

be hazardous

to

your

health.

and

lower

the

oxygen

level

causing

injury

or

death.

Be

sure

the

breathing

air

is

safe.

.~

6.

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

(MSDSs)

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.

I

CYLINDERS

can

explode

If

damaged.

4.

Never

drape

a

welding

torch

over a

gas

cylinder.

I

Shielding

cas

cylinders

contain

gas

under

high

5.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

11e~~1

pressure.

Irdamaged,

a

cylinder

can

explode.

Since

6.

Never

weld

on

a

pressurized

cylinder



explosion

will

result.

I

gas

cylinders

are

normally

part

of

the

welding

7.

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

Ill

~

process,

be

sure

to

treat

them

carefully.

fittings

designed

for

the

specific

application;

maintain

them and

associated

parts

in

good

condition.

1.

Protect

compressed

gas

cylinders

from

excessive

heat.

8.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

mechanical

shocks,

slag,

open

flames,

sparks,

and

arcs.

9.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

2. Install

cylinders

in

an

upright

position

by

securing

to

a

stationary

in

use

or

connected

for

use.

support

or

cylinder

rack

to

prevent

falling

or

tipping.

io.

Read

and

follow

instructions

on

compressed

gas

cylinders,

3.

Keep

cylinders

away

from

any

welding

or

other

electrical

associatedequipment,andCGApublicationP-1

listed

in

Safety

circuits.

Standards.

Srl1.1

2~94

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

fromt

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

toAWS

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

cut

off

welding

wire

at

contact

tip

when

not

in

use.

11.

Wearoil-free

protective

garments

such

as

leather

gloves,

heavy

shirt,

cuffless

trousers,

high

shoes,

and

a

cap.

12.

Remove

any

combustibles,

such

as

a

butane

lighteror

matches,

from

your

person

before

doing

any

welding.

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.

Stop

engine

before

installing

or

connecting

unit

SPARKS

can

cause

BATTERY

GASES

TO

EXPLODE;

BATTERY

ACID

can

burn

eyes

and

skin.

Batteries

contain

acid

and

generate

explosive

gases.

STEAM

AND

PRESSURIZED

HOT

COOLANT

can

burn

face,

eyes,

and

skin.

It

is

best

to

check

coolant

level

when

engine

is

cold

to

avoid

scalding.

ENGINES

can

be

hazardous.

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.

Always

wear

a

face

shield

when

working

on a

battery.

Stop

engine

before

disconnecting

or

connecting

battery

cables.

3.

Do

not

allow

tools

to

cause

sparks

when

working

on

a

battery.

4.

Do

not

use

welder

to

charge

batteries

or

jump

start

vehicles.

5.

Observe

correct

polarity

(

and

-

on

batteries

1.

If

the

engine

is

warm

and

checking

is

needed,

follow

steps

2

and

3.

2.

Wear

safety

glasses

and

gloves

and

put

a

rag

over

cap.

3.

Turn

cap

slightly

and

let

pressure

escape

slowly

before

completely

removing

cap.

PRINCIPAL

SAFETY

STANDARDS

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.i,

from

American

Welding

Society,

550

NW.

LeJeune

Ad,

Miami

FL

33126

Safety

and

Health

Standards,

OSHA

29

CFR

1910,

from

Superinten

dent

of

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

Recommended

Safe

Practices

for

the

Preparation

for

Welding

and

Cutting

of

Containers

That

Have

Held

Hazardous

Substances,

Ameri

can

Welding

Society

Standard

AWS

F4.i,from

American

Welding

So

ciety,

550

N.W.

LeJeune

Ad, Miami,

FL

33126

National

Electrical

Code,

NFPA

Standard

70,

from

National

Fire

Pro

tection

Association,

Batterymarch

Park.

Quincy,

MA

02269.

srl.1.1

2/94

Sale

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

For

Occupation

And

Educational

Eye

And

Face

Protec

tion,

ANSI

Standard

Z87.1,

from

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

Cutting

And

Welding

Processes,

NFPA

Standard

51

B,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

a

WARNING

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,

vent

engine

exhaust

outside

and

away

from

any

building

air

intakes.

I

r

S~

~

ENGINE

FUEL

can

cause

fire

or

explosion.

Engine

fuel

is

highly

flammable.

3.

4.

Do

not

overfill

tan

Do

not

spill

fuel.

engine.

k



allow

room

fo

It

fuel

is

spilled,

r

fuel

to

expand.

clean

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.

2.

CONSIGNES

DE

SECURITE

POUR

LE

SOUDAGE

A

LARC

UN

CHOC

ELECTRIQUE

peut

tuer.

Un

simple

contact

avoc

des

piŁces

electnques

peut

provoquer

une

electrocution

ou

des

blessures

9raves.

LØlectrode

et

le

circuit

do

soudage

sont

sous

tension

des

quo

lappareil

ost

sur

ON.

Lo

circuit

dentrŁo

of

los

circuits

intemes

de

tappareil

sont

Łgalement

sous

tension

a

ce

moment-l.

En

soudage

semi-automatiquo

ou

automatique,

to

fit,

le

dØvidoir,

le

logement

des

galets

dentrainement

et

les

piŁces

mØtalliques

on

contact

avec

Jo

fit

do

soudago

sont

sous

tension.

Des

matOriels

mal

installŁs

ou

mal

mis

a

Ia

torro

presontent

un

danger.

1.

Ne

jamais

toucher

los

piŁces

electriques

sous

tension.

2.

Porter

des

gants

01

des

vOtements

do

protection

secs

no

comportant

pas

do

trous.

3.

Sisoler

do

Ia

piŁce

01

de

Ia

terre

au

moyon

do

tapis

ou

dautres

moyens

isolants

suffisamment

grands

pour

empOcher

lo

contact

physique

Øventuel

avec

Ia

piŁce

ou

Ia

terre.

4.

Couper

talimonlation

ou

arreter

le

moteur

avant

do

procØder

a

linstallation,

a

Ia

reparation

ou

a

lontretien

do

lappareil.

DŁverrouillerlalimentation

selon

Ia

norme

OSHA

29

CFR

1910.147

(voir

normes

do

sŁcunt).

5.

Installer

et

mettro

a

Ia

terre

correctement

cot

apparoit

conformØment

a

son

manuel

dutilisation

et

au

codes

nationaux,

provinciaux

et

municipaux.

6.

Toujours

verifier

Ia

terre

du

cordon

dalimentatton



Verifier

et

sassurer

que

10

fil

do

terre

du

cordon

dalimentation

est

bien

raccordØ

a

Ia

borne

do

torre

du

sectionnour

ou

que

Ia

fiche

du

cordon

est

raccordØe

a

une

pnse

correctoment

miso

a

ta

terre.

7.

En

effectuant

los

raccordoments

dontrØe

fixer

dabord

10

conduclour

do

miso

a

Ia

terre

appropriØ

01

contre-vØrifier

los

connexions.

8.

VØrifiorfrØquemment

le

cordon

dalimentation

pour

voir

sil

nosl

pas

endommagØ

ou

dØnudØ



remplacer

10

cordon

immOdiatement

sil

ost

endommagØ



un

cable

dØnudØ

pout

provoquor

une

electrocution.

9.

Mettre

lappareil

hors

tension

quand

on ne

lutitiso

pas.

10.

Ne

pas

utiliser

dos

cables

uses,

endommagØs,

do

grosseur

insutfisanto

ou

mat

ØpissŁs.

11.

No

pas

onrouler

los

cables

autour

du

corps.

12.

Si

Ia

piŁce

soudOo

dolt

Otre

mise

ala

terre,

lo

faire

directement

avoc

un

cable

distinct



no

pas

utitiser

lo

connocteur

do

piŁce

ou

to

cŒble

do

rotour.

13.

Ne

pas

toucher

lØlectrode

quand

on

est

en

contact

avec

Ia

piŁce.

Ia

terre

ou

une

electrode

provonant

dune

autre

machine.

14.

Nutiliser

quun

matOnel

en

boo

Øtat.

RØparer

ou

remplacer

sur-le-champ

los

piŁcos

endommagØos.

Entretonir

lappareit

conformŁment

a

ce

manuel.

15.

Porter

un

hamais

do

sØcuritØ

quand

on

travaille

en

hauteur.

16.

Mairitenir

solidement

en

place

bus

los

panneaux

01

capots.

17.

Fixer

to

cable

do

retour

de

facon

a

obtenir

un

boo

contact

mŁtal-mØtal

avec

Ia

piŁce

a

souder

ou

Ia

table

de

travail,

le

plus

prŁs

possible

do

Ia

souduro.

a

MISE

EN

GARDE

LE

SOUDAGE

A

LARC

peut

Œtre

dangereux.

SE

PROTEGER

ET

PROTEGER

LES

AUTRES

CONTRE

LES

BLESSURES

GRAVES

VOIRE

MORTELLES.

TENIR

LES

ENFANTS

A

LECART.

LES

PERSONNES

OUt

PORTENT

UN

STIMULATEUR

CARDIAQUE

NE

DOt

VENT

PAS

NON

PLUS

SAPPROCIIER

DU

POSTE

DE

SOUDAGE,

A

MOINS

DAVOIR

CONSULTE

UN

MEDECIN.

Le

soudage,

comme

Ia

plupart

des

travaux,

prØsente

certains

dangers.

Par

contre,

to

soudago

pout

Łtre

offectuØ

en

toute

sØcuntØ

quand

on

prend

los

mosures

qui

simposent.

Les

consignos

do

sOcuritØ

donnØes

ci-aprŁs

no

font

quo

rØsumer

Iinformation

contenue

dans

los

normes

do

sØcufltO

ØnumØrAes

a

Ia

page

suivante.

Lire

et

respecter

toutes

cos

normes

do

sØcuntØ.

LINSTALLATION,

LUTILISATION,

LENTRETIEN

ET

LES

REPARATIONS

NE

DOIVENT

ETRE

CONFIES

QuA

DES

PERSONNES

OUALIFIEES

LE

RAYONNEMENT

DE

LARC

peut

brler

les

RAVONNEMENT

DE

LARC

yeux

et

Ia

peau.

Le

BRUIT

peut

endommager

~

IouIe;

Ies

PROJECTIONS

DE

LAITIER

OU

LES

ETINCELLES

peuvent

blesser

les

yeux.

2.

Porter

un

masque

a

sorre-tŒte

muni

dun

verro

filtrant

do

nuance

appropnØe

pour

protØger

le

visage

01

los

yeux

quand

on

soude

ou

Larc

do

soudage

produit

des

rayons

visibles

et

irivisibles

observe

Ia

travail

do

soudago

(voir

les

norrnos

ANSI

Z49.1

ot

Z87.1

-

-.

intonses

(ultraviolets

et

infrarougos)

qul

peuvent

brOlor

donnØos

sous

Ia

rubrique

Principales

normes

de

sØcuritO).

los

yeux

ella

peau.

Le

bruit

produit

par

certains

procedes

pout

endommager

louIe.

Des

projections

do

metal

ou

do

3.

Porter

dos

lunottos

do

sOcuntO

approuvØos

avec

Ocrans

latØraux.

Jaitier

sont

produites

par

lo

piquago,

lo

moulago

ou

te

rofroidissemont

dos

soudures.

4.

Utiliser

dos

paravents

ou

dos

barriŁres

do

protection

pour

proteger

les

personnes

a

proximitØ

contre

los

coups

darc

01

lŁbtouissement;

BRUIT

avertir

tes

autres

personnes

de

no

pas

regardor

larc.

1.

Utiliser

dos

boucho-oreilles

ou

des

sorro-tOte

antibruit

approuvØs

si

5.

Porter

des

vØtements

do

protection

en

tissu

ignifuge

durable

(lame

et

le

niveau

de

bruit

051

ØfevØ.

cuir)

et

des

chaussures

de

sØcuritØ.

dangereuses

pour

Ia

sante.

portantunappareilrespiratoiroadductiondairpur.

Demanderun

observateur

ayant

recu

Ia

bonno

formation

do

toujours

so

tenir

a

,~J

LES

VAPEURS

ET

LES

FUMEES

peuvent

Œtre

5.

Ne

travailler

dans

un

ospaco

confine

quo

siI

est

bion

ventilØ,

ou en

Le

soudage

produit

dos

vapeurs

et

des

fumØes

quil

esf

proximitØ.

Los

vapeurs

et

furnØes

do

soudage

peuvent

deplacer

lair

dangereux

do

respirer.

et

abaisser

le

niveau

doxygeno

et

causer

dos

blossures

graves

voiro

mortelles.

Sassurer

quo

lair

est

propre

a

Ia

respiration.

1.

Garder

Ia

tŒte

a

lextØrieur

des

vapeurs

et

des

tumØes

01

ne

pastes

6.

Ne

pas

souder

a

proximit

dopOrations

do

dØgraissage,

do

respirer.

nettoyage

ou

do

pulvonsation.

La

chaleur

et

les

rayons

do

larc

2.

A

lintØrieur,

ventiler

le

poste

do

travail

ou

utiliser

un

dispositif

place

peuvent

rØagir

avec

es

vapours

pour

former

des

gaz

hautement

au

niveau

do

larc

pour

Ovacuer

les

vapeurs

et

fumØes

de

soudage.

toxiques

01

irritants.

7.

Ne

pas

soudor

sur

des

mØtaux

revŒtus

commo

lacier

galvanise,

au

3.

Si

Ia

ventilation

est

rnauvaise,

utiliser

un

appareil

respiratoire

a

plomboucadmieamoinsquelapiecenaitetOentierementdecapee,

adduction

dair

pur

approuvØ.

que

le

posto

de

travail

soil

bion

ventitØ.

Sit

y

a

lieu,

porter

un

appareil

4.

Consutter

les

fiches

sigriatØtiques

ot

les

consignes

du

fabricant

respiratoire

a

adduction

dair

pur.

Los

revOtements

et

los

mOtaux

qui

relatives

au

mØtaux,

produits

dapport.

revØtements,

nettoyants

01

contiennent

do

lois

ØlØments

peuvent

degager

des

vapeurs

toxiques

degraissants.

lors

du

souciage.

LES

BOUTEILLES

peuvent

exploser

ci

elles

4.

Ne

jamais

posor

un

chalumeau

soudeur

sur

une

bouteille

do

gaz.

Les

bouteilles

contenant

des

gaz

do

protection

sont

a

6.

Ne

jamais

souder

sur

une

bouteille

sous

pression

:

elle

exploserait.

sont

endommagees.

5.

Ne

jamais

laisser

une

electrode

do

soudage

toucher

une

bouteille.

~.

haute

pression.

Une

bouteillo

endommagØe

peut

7.

Nutiliser

que

des

bouteites

do

gaz

de

protection,

dos

dØtendours,

exploser.

Etant

donnØ

quo

les

boutoilles

do

gaz

font

dos

tuyaux

souples

01

dos

raccords

appropries

concus

pour

normalemorit

partle

du

materiel

do

soudage,

los

traitor

lapplication

particuliere;

conserver

ces

matOriels

et

teurs

piŁces

en

avec

le

plus

grand

soin.

boo

Øtat.

1.

ProtØger

los

bouteilles

do

gaz

comprimØ

contre

Ia

chaleur

intense,

8.

Eloigner

10

visage

do

Ia

sortie

du

robinet

do

Ia

bouteille

quand

on

les

chocs,

to

laitier,

los

flammes

nues,

los

Øtincelles

et

larc.

louvre.

2.

Placer

los

bouteilles

ala

verticale

en

les

fixant

a

un

support

fixe

ou

a

9.

Replacer

le

chapeau

sur

Ia

bouteille

aprŁs

utilisation.

un

chanot

pour

Øviter

quettes

ne

tombent

ou

ne

basculent.

10.

LireetsuivrelesconsignesrelativosauxbouteillesdegazcomprimØ,

3.

Tenir

los

boutoilles

a

lØcart

du

poste

de

soudage

ou

dautros

circuits

au

materiel

connexe

ainsi

quo

Ia

publication

P-i

do

Ia

CGA

donnØe

electriques.

sous

Ia

rubrique

Principales

normes

de

sØcuritØ.

sf11.1

2/94

LE

SOUDAGE

peut

causer

un

incendie

ou

une

explosion.

Ne

pas

souder

sur

des

recipients

ferrnOs

comme

des

reservoirs,

des

fQts

ou

des

tuyaux:

us

peuvent

exploser.

Larc

do

soudage

peut

produire

des

Otincelles.

Des

tincelles,

une

piŁce

chaude

et

un

materiel

chaud

peuvent

provoquer

des

incendies

et

des

blessures.

Le

contact

accidentel

de

lŁlectrode

sur

des

objets

metauiques

peut

produire

des

Otincelles,

lexplosion,

Ia

surchauffe

ou

un

incendie.

Sassuror

que

le

lieu

ne

prØsente

pas

de

danger

avant

deffectuer

to

soudage.

1.

Se

protOgor

et

protOgerles

personnes

a

proximitO

des

Øtincelles

et

du

metal

chaud.

2.

Ne

pas

souder

dans

un

endroit

oCi

les

Otincelles

peuvent

atteindre

des

matØriaux

inflammables.

3.

Enlevertoutes

les

matiŁres

inflammables

dans

un

rayon

do

moms

de

10

m

do

larc.

Si

cola

nest

pas

possible,

bien

los

recouvnr

en

utilisant

des

bAches

approuvees.

4.

Prendre

garde

quo

los

Otincelles

et

los

projections

no

pŁnØtrent

dans

des

zones

adjacentes

en

sinfiltrant

dans

des

petites

fissures

of

ouvortures.

5.

Prondre

garde

aux

incendies

ot

toujours

avoir

Un

extincteur

a

proximitØ.

6.

Se

rappeterque

si

Ion

soude

sur

un

plafond,

un

plancher,

uno

cloison

ou

autro,

le

feu

pout

prendre

de

lautre

ctØ.

7.

Ne

pas

soudor

sur

des

recipients

fermAs

comme

des

reservoirs,

dos

tOts

ou

dos

tuyaux

a

moms

quils

no

soient

prepares

do

facon

appropriOe

conformOment

ala

norrne

F4.1

de

lAWS

(voir

Ia

rubnque

Pnncipales

normes

de

secuntØ).

8.

Raccordor

le

cable

de

retour

a

Ia

piŁce,

10

plus

prŁs

possible

do

Ia

zone

do

soudage,

pour

empechor

quo

to

courant

do

soudage

no

suive

une

trajectoire

longue

et

Łventuellement

inconnue

et

quil

no

provoque

des

nsques

dØlectrocution

et

dincendie.

9.

Ne

pas

utiliser

te

chalumeau

soudeur

pour

degeler

des

tuyaux.

10.

Enlever

lŁlectrode

enrobŁe

du

porte-electrode

ou

couper

le

fil

de

soudage

au

ras

du

boc

contact

quand

on

no

lutilise

pas.

11.

Porter

des

vŒtements

do

protection

non

huileux

comme

des

gants

en

cuir,

une

chemise

Øpaisse,

des

pantalons

sans

revers,

des

chaussures

montantes

et

un

casque.

12.

Ne

pas

porter

des

matiŁres

combustibles

sur

soi

comme

un

briquet

a

gaz

ou

des

allumettes

quand

on

soude.

4/

~

LE

CARBURANT

peut

provoquer

un

Incendle

I

~

ou

une

explosion.

Le

carburant

est

hautoment

inflammable.

1.

ArrOter

Ia

moteur

of

10

laisser

ref

roidir

avant

do

verifier

le

niveau

do

carburant

ou

do

refaire

le

plein.

LES

PI¨CES

EN

MOUVEMENT

peuvent

causer

des

blessures.

Los

piŁces

en

mouvement

comme

les

ventilateurs,

los

rotors

of

los

courroies

peuvent

couper

los

doigts

of

los

mains

et

happer

los

vOtements

amples.

1.

Sassurerque

los

portes,

los

panneaux,

los

capots

of

los

protecteurs

sont

bien

fermOs

of

bien

a

leur

place.

2.

ArrOter

10

motour

avant

do

mettro

on

place

ou

do

raccorder

un

LES

ETINCELLES

peuvent,faire

EXPLOSER

LE

GAZ

DES

BATTERIES;

LELECTROLYTE

peut

brUler

Ia

peau

et

les

yeux.

Los

batteries

contiennont

un

produit

acide

et

dogagent

des

vapeurs

explosives.

ortor

un

Ocran

facial

quand

on

travaille

sur

une

battorie.

2.

No

pas

tumor

en

faisant

le

plein

ou

Si

lappareil

so

trouve

a

proximitO

dOtincelles

ou

do

flamrhes

nues.

3.

Ne

pas

remplir

10

reservoir

a

ras

bord

:

prOvoir

do

lespace

pour

Ia

dilatation

du

combustible.

4.

Ne

pas

ronverser

du

carburant.

Si

on

renverse

du

carburant,

nettoyer

los

lieux

avant

de

faire

dOmarrer

le

moteur.

3.

Soules

des

personnes

qualifiOes

doivent

dOmonter

les

protecteurs

ou

les

capots

pour

faire

lontretion

ou

los

reparations

nOcessairos.

4.

Pour

empOcher

un

demarrage

accidentet

dun

systŁme

pendant

lent

retion

ou

los

reparations,

dObrancher

10

cable

nOgatif

()

do

Ia

batteno.

5.

Eloigner

los

mains,

los

cheveux,

los

vOtements

amples

ot

los

outils

des

piŁces

en

mouvement.

6.

Replacer

los

capots

ou

los

protecteurs

et

reformer

los

portes

une

fois

lentretien

et

los

reparations

terminOs

et

avant

de

faire

dØmarrer

le

motour.

ArrOtor

Ia

moteur

avant

do

branchor

ou

do

dObranchor

los

cables

do

Ia

batterie.

No

pas

faire

des

etincelles

avec

los

outils

quand

on

travaille

sur

une

batterie.

No

pas

utiliser Ia

source

do

courant

de

soudage

pour

charger

las

batteries

ou

pour

faire

dOmarrer

un

vØhicule.

Ne

pas

intarvertir

Ia

oolaritO

des

batteries.

a

MISE

EN

GARDE

LES

MOTEURS

peuvent

presenter

un

danger.

LES

GAZ

DECHAPPEMENT

DES

MOTEURS

1.

Utuliser

le

matŁnel

a

lextŁrieur,

dans

des

lieux

ouverts

of

bien

peuvent

Œtre

mortels.

ventiles.

Les

moteurs

produisent

des

gaz

dO

chapp

ement

nocifs.

2.

Si

on

utilise

un

moteur

dans

un

local

ferme,

dechappement

a

lextOrieur

et

loin

des

pnses

dai

Øvacuer

los

gaz

r

du

bªtiment.

1.

Toujours

2.

3.

4.

5.

.

~.

~-.

J~



~

LA

VAPEUR

ET

LE

LIQUIDE

DE

REFROIDISSEMENT

BRULANT

SOUS

PRESSION

peuvent

brOler

Ia

peau

et

les

yeux.

II

vaut

mieux

verifier

10

niveau

du

liauido

do

ref

roidissament

quand

10

moteur

est

froid

afin

&Oviter

los

brOlures.

1.

2.

3.

Si

Ion

dolt

verifier

10

niveau

quand

le

moteur

est

chaud,

suivre

les

etapes

2

et

3.

PortordeslunettosdesŁcuritOetdesgantsetplacerunchiffonsurle

bouchon.

burner

lentemant

le

bouchon

of

laisser

a

prassion

sochapper

lontament

avant

denlaver

complŁtement

Ia

bouchon.

PRINCIPALES

NORMES

DE

SECURITE

Safety

in

Welding

and

Cutting,

norme

ANSI

Z49.1,de

IAmorican

Welding

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

P-i,

de

Society,

550

NW.

Lejeune

Ad,

Miami

FL

33126

Ia

Compressed

Gas

Association,

1235

Jefferson

Davis

Highway,

Suite

501.

Arlington,

VA

22202.

Safety

and

Health

Sandards,

OSHA

29

CFR

1910,

du

Supenntendent

of

Regles

de

securitØ

en

soudage,

coupage

et

procddds

connexes,

norme

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

CSA

W117.2,

do

IAssociation

canadienne

do

normalisation,

vente

do

normes,

178

Rexdale

Boulevard,

Rexdale

(Ontario)

Canada

M9W

1

R3.

Recommended

Safe

Practice

for

the

Preparation

for

Welding

and

Cutting

of

Containers

That

Have

Held

Hazardous

Substances,

norme

AWS

F4.

1.

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

Protection,

delAmorican

Welding

Society,

550

N.W.

Lejeune

Ad,

Miami

FL

33126

norme

ANSI

Z87.1,

do

tAmerican

National

Standards

Institute.

1430

Broadway,

New

York,

NY

10018.

National

Elect

rical

Code,

NFPA

Standard

70,

de

Ia

National

Fire

Protection

Cutting

and

Welding

Processes,

norme

NFPA

51

B,

do

Ia

National

Fire

Association,

Batterymarch

Park.

Quincy,

MA

02269.

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

srl.1.1

2/94

TABLE

OF

CONTENTS

SECTION

1



SAFETY

INFORMATION

1

SECTION

2

SPECIFICATIONS

1

2-1.

Volt-Ampere

Curves

2

2-2.

Duty

Cycle

2

SECTION

3INSTALLATION

2

3-1.

Installing

Work

Clamp

3

3-2.

Installing

Gas

Supply

3

3-3.

Gun

Polarity

For

Wire

Type

4

3-4.

Selecting

A

Location

And

Connecting

Input

Power

5

3-5.

Installing

Drive

Rolls

And

Welding

Gun

6

3-6.

Installing

Wire

Spool

7

3-7.

Threading

Welding

Wire

7

SECTION

4-

OPERATION

9

SECTION

5

MAINTENANCE

&

TROUBLESHOOTING

12

5-1.

Routine

Maintenance

12

5-2.

Overload

Protection

12

5-3.

Cleahing

Or

Repairing

Drive

Assembly

13

5-4.

Gun

Maintenance

14

5-5.

Troubleshooting

15

SECTION

6

ELECTRICAL

DIAGRAMS

16

SECTION

7WELDING

METHODS

&

TROUBLESHOOTING

18

7-1.

Flux

Cored

Arc

Welding

(FCAW)

And

Gas

Metal

Arc

Welding

(GMAW)

18

7-2.

Welding

Troubleshooting

20

SECTION

8

PARTS

LIST

24

Figure

8-1.

Main

Assembly

24

Figure

8-2.

Baffle,

Center

w/Components

26

Figure

8-3.

Drive

Assembly,

Wire

28

Figure

8-4.

MWG-160

Gun

29

OM-151

016B6195

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

\..

~rs!A!t~

:

2

\

3

ELECTRIC

SHOCK

can

kIII.~



Do

not

touch

live

electrical

parts.



Disconnect

input

power

before

4

Installing

or

servicing.

a

CAUTION

/

5



MOVING

PARTS

can

Injure.

~

S

Keep

away

from

moving

parts.

S

Keep

all

panels

and

covers

closed

when

operating.

1

Safety

Alert

Symbol

2

Signal

Word

WARNING

means

possible

death

or

serious

injury

can

happen.

CAUTION

means

possible

minor

injury

or

equipment

damage

can

happen.

3

Statement

Of

Hazard

And

Result

6

a

WARNING

7-H

NOTE

~

4

Safety

Instructions

To

Avoid

Hazard

READ

SAFETY

BLOCKS

at

start

of

Section

3-1

before

proceeding.

Turn

Off

switch

when

using

high

frequency.

5

Hazard

Symbol

(If

Available)

6

Safety

Banner

Read

safety

blocks

for

each

sym

bol

shown.

7

NOTE

Special

instructions

for

best

oper

ation



not

safety.

Specifications

Type

Of

Output

Description

Rated

Weld

Output

Type

Of

Input

Amperes

At

Rated

Output

KVA/KW

Used

At

Rated

Output

Max.

Open-Circuit

Voltage

Control

Circuit

Voltage

At

Gun

Welding

Processes

Constant

Voltage/Direct

Current

(CV/DC)

120

Amperes,

21

Volts

DC

At

30%

Duty

Cycle

(See

Section

2-2)

Single-Phase;

230

Volts

AC;

60

Hertz

20

Amperes

4.7

kVA/3.9

kW

32

Volts

DC

24

Volts

DC

Gas

Metal

Arc

Welding

(GMAW)

(Uses

Solid

Hard

Or

Aluminum

Wire

And

External

Shielding

Gas)

Flux

Cored

Arc

Welding

(FCAW)

(Uses

Wire

With

Flux

Inside

And

Requires

No

External

Shielding

Gas)

47

To

690

pm

(1.2

To

17.5

mpm)

.023

To

.035

in

(0.58

To

0.89

mm)

Wire

Feed

Speed Range

Wire

Diameter

Range

Input

Power

Cord

With

Plug

Overall

Dimensions

Weight

5ft(1.5m)

Length:

27

in

(686

mm);

Width:

12

in

(305

mm);

HeIght:

22.1/2

in

(571

mm)

Net:

117

lb

(53

kg):

Ship:

120

lb

(54

kg)

____________

OM-151

016

Page

1

2-1.

Volt-Ampere

Curves

Figure

2-1.

Volt-Ampere

Curves

2-2.

Duty

Cycle

£~

CAUTION

EXCEEDING

DUTY

CYCLE

RATINGS

will

damage

unit.



Do

not

exceed

indicated

duty

cycles.

wam7.1

2/92

Figure

2-2.

Duty

Cycle

Chart

SECTION

3-INSTALLATION

Table

3-1.

Items

Included

With

Welding

Power

Source

Item

Quantity

Welding

Gun



Shipped

Set

To

Feed

.030

in

(0.8

mm)

Wire

1

10

ft

(3

m)

Work

Cable

And

Clamp

1

6ft(1.8m)AirHose

1

Contact

Tubes

(3



.023

in,

2



.030

in,

And

3



.035

in)

8

Monocoil

Liner

For

.023

Thru

.030

in

Wire

1

w

(~

I-

-J

0

>

Ci

0

40

30

20

10

0

The

volt-ampere

curves

show

the

minimum

and

maximum

voltage

and

amperage

output

capabilities

of

the

welding

power

source.

Curves

of

other

settings

fall

between

the

curves

shown.

Ssbl.1

10/91

/

SB-124

625

0

50

00

ISO

200 250

D.C.

AMPERES

200

Duty

cycle

is

how

long

the

unit

can

operate

within

a

ten

minute

period

without

causing

overheating

or

so

damage.

This

unit

is

rated

at

30%

duty

cycle

allowing

welding

3

minutes

out

of

every

10

minutes

at

rated

load.

If

the

welding

amperes

decrease,

90

the

duty

cycle

increases.

80

70

60

50

U.S

20

2S 30

40

50 60

70

80

90

100

DUTY

CYCLE

X

sbl.2

2/92



SB-124

624

OM-151

016

Page

2

N

OTE

LII~T

Customer

must

obtain

proper

welding

wire

and

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.

5

Work

Cable

From

Unit

6

Nut

Tools

Needed:

3/8,

7/16

in

Ref.

ST-025

190-C

Figure

3-1.

Work

Clamp

Installation

3-2.

Installing

Gas

Supply

AA

WARNING

C



YLINDERS

can

explode

if

damaged.

Keep

cylinders

away

from

welding

and

other

electrical

circuits.

Y

~

BUILDUP

OF

SHIELDING

GAS

can

harm

health

or

kill.



Shut

off

shielding

gas

supply

when

not

in

use.



Never

touch

cylinder

with

welding

electrode.

S

Always

secure

cylinder

to

running

gear,

wall,

or

other

stationary

support.

wam4.1

9/91

A.

Installing

Safety

Chain

1

Cylinder

Bracket

As

Shipped

2

S-Hook

Crimp

between

small hole

in

bracket

and

chain.

3

Chain

4

Snap

Crimp

onto

open

end

of

chain.

5

Cylinder

Bracket

For

Large

Gas

Cylinder

6

Gas

Fitting

Tools

Needed:

~

ST-160

791

Figure

3-2.

Installing

Safety

Chain

OM-151

016

Page

3

B.

Installing

Regulator/Flowmeter

Figure

3-3.

Typical

Regulator/Flowmeter

Installation

3-3.

Gun

Polarity

For

Wire

Type

I~



ELECTRIC

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

1

Polarity

Changeover

Label

2

Polarity

Jumper

Links

Always

read

and

follow

wire

man

ufacturers

recommended

polarity.

There

are

two

jumper

links

(1

set)

across

each

set

of

terminals.

Be

sure

to

move

each

set

of

links

when

changing

polarity.

Close

door.

a

WARNING

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

6

Remove

cap,

stand

to

side

of

valve,

and

open

valve

slightly.

Gas

flow

blows

dust

and

dirt

from

valve.

Close

valve.

r



OR

5

4

Argon

Gas

3

Cylinder

4

Regulator/Flowmeter

Install

so

face

is

vertical.

5

Gas

Hose

Connection

Fitting

has

5/8-18

right-hand

threads.

Install

supplied

air

hose.

6

Flow

Adjust

Tools

Needed:

1-1/8,

~/8

in

Typical

flow

rate

is

20

cfh

(cubic

feet

per

hour).

Check

wire

man

ufacturers

recommended

flow

rate.

7

CO2

Adapter

7

8

0-Ring

CO2

Gas

Install

adapter

with

0-ring

between

regulator/flowmeter

and

CO2

cylinder.

ssb3.1

12/92



ST-158

697-A

Tools

Needed:

~3/8in

Figure

3-4.

Gun

Polarity

Jumper

Link

Position

Ret.

ST.149

631-C

OM-151

016

Page

4

3-4.

Selecting

A

Location

And

Connecting

Input

Power

£~

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

welding

power

source,

and

disconnect

input

power

before

inspecting

or

installing.



Have

only

qualified

persons

install

unit.



Installation

must

meet

National

Electrical

Code

and

all

other

codes.

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.

Table

3-2.

Electrical

Service

Guide

Input

Voltage

220

Input

Amperes

At

Rated

Output

20

Max

Recommended

Standard

Fuse

Or

Circuit

Breaker

Rating

In

Amperes

30

Mm

Input

Conductor

Size

In

AWG/KcmH

14

Max

Recommended

Input

Conductor

Length

In

Feet

(Meters)

65(20)

Mm

Grounding

Conductor

Size

In

AWG/KcmIl

14

Reference:

1993

National

Electrical

Code

(NEC).

s-oog~j

swam3.r

2/93

5

7

6

4

1

18

in

(457

mm)

Open

Space

At

Front

And

Rear

2

Rating

Label

Supply

correct

input

power.

3

230

Volts

AC

Wall

Receptacle

4

Input

Conductors

Select

size

and

length

using

Table

3-2.

Conductor

rating

must

comply

with

national,

state,

and

local

codes.

5

Line

Disconnect

Device

Of

Proper

Rating

Obtain

and

install

switch

and

wall

receptacle.

6

Grounding

Conductor

Select

size

and

length

using

Table

3-2.

Be

sure

grounding

con

ductor

goes

to

an

earth

ground.

Install

and

connect

input

conduc

tors

and

grounding

conductor

In

conduit

or

equivalent

between

wall

receptacle

and

deenergized

line

disconnect

device.

7

Overcurrent

Protection

Select

type

and

size

using

Table

3-2.

Install

into

deenergized

line

disconnect

device

(fused

dis

connect

Switch

shown).

Connect

deenergized

supply

con

ductors

to

line

disconnect

device.

8

Input

Power

Plug

Turn

Off

unit

Power

switch,

and

connect

plug

to

wall

receptacle.

Place

line

disconnect

switch

in

On

position

before

using

welding

power

source.

ssb2.2

3/93



ST-149

630-C

3

Figure

3-5.

Location

And

Input

Power

Connections

OM-151

016

Page

5

3-5.

Installing

Drive

Rolls

And

Welding

Gun

Tools

Needed:

Figure

3-6.

Drive

Roll

And

Welding

Gun

Installation

1

Pressure

Adjustment

2

Pressure

Assembly

3

Drive

Roll

4

Washers

5

Securing

Screw

Install

drive

roll

as

shown.

6

Gun

Securing

Knob

7

Gun

End

Loosen

knob.

Insert

gun

end

through

opening

until

it

bottoms

against

drive

assembly.

Tighten

knob.

8

Gun

Trigger

Plug

Insert

plug

into

receptacle,

and

tighten

threaded

collar.

Ret.

ST-150

193-D

/

Ret.

ST-149

629-C

/

ST~155

578

OM-151

016

Page

6

3-6.

Installing

Wire

Spool.

a

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

welding

power

source,

and

disconnect

input

power

before

inspecting

or

installing.

swaml.1

2193

N

OTE

~

If

hub

tension

is

too

tight,

motor

fuse

Fl

can

open

(see

Section

5-2).

If

hub

tension

is

too

loose,

wire

unravels

and

can

become

tangled

inside

unit.

Turn

Oft

and

unplug

unit.

1

Wire

Spool

2

Gun

Contact

Tip

If

necessary,

cut

welding

wire

off

at

contact

tip,

and

retract

wire

onto

spool

and

secure.

3

Retaining

Ring

Remove

ring

and

pull

off

spool.

4

Compression

Spring

Compression

spring

is

used

with

8

in

(200

mm)

spools.

2

5

Hub

6

HubPin

Slide

spool

onto

hub

so

wire

feeds

off

bottom.

Turn

spool

until

hub

fits

hole

in

back

of

spool.

Reinstall

retaining

ring.

7

Hub

Tension

Nut

Grasp

spool

In

one

hand

and

turn

while

using

a

wrench

to

adjust

hub

tension

nut.

When

a

slight

force

Is

needed

to

turn

spool,

tension

is

set.

Tools

Needed:

Thread

welding

wire

(see

Section

3-7).

Close

door.

~

15/16

in

Ref.

ST-150

193-C/

SA-072

573-B

Figure

3-7.

Welding

Wire

Spool

Installation

3-7.

Threading

Welding

Wire

a

WARNING

CYLINDERS

can

explode

if

damaged.



Keep

cylinders

away

from

welding

and

other

electrical

circuits.



Never

touch

cylinder

with

welding

electrode.



Always

secure

cylinder

to

running

gear,

wall,

or

other

stationary

support.

ELECTRiC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.

The

welding

wire,

drive

rolls,

drive

assembly,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live

when

welding

or

feeding

wire

using

gun

trigger.

WELDING

WIRE

can

cause

puncture

wounds.



Do

not

press

gun

trigger

until

instructed

to

do

so.



Do

not

point

gun

toward

any

part

of

the

body,

other

people,

or

any

metal

when

threading

welding

wire.

HOT

SURFACES

can

burn

skin.



Allow

gun

to

cool

before

touching.

swam2.1

9/91

/8wam5.1

10/91

OM-151

016

Page

7

Hold

wire

tightlyto

keep

it

from

unraveling.

1

Wire

Spool

2

Welding

Wire

3

Inlet

Wire

Guide

4

Pressure

Adjustment

Knob

5

Drive

Roll

6

Outlet

Wire

Guide

7

Gun

Conduit

Cable

Lay

gun

cable

out

straight.

Tools

Needed:

Close

and

tighten

pressure

assembly,

and

let

go

of

wire.

Push

wire

thru

guides

into

gun;

continue

to

hold

wire.

Press

gun

trigger

until

wire

comes

out

of

gun.

Reinstall

contact

tip

and

nozzle.

-,

Feed

wire

to

check

drive

roll

pressure.

Tighten

knob

enough

to

prevent

slipping.

Cut

off

wire.

Close

and

latch

door.

p

Figure

3-8.

Threading

Welding

Wire

Ref.

ST-149

632.C

/

Ref.

ST-150

193/

Ret.

5T-159

272/

S-0627.A

1

23

5

6

Open

pressure

assembly.

4

in~

(102

mm)

Pull

and

hold

wire;

cut

off

end.

Remove

gun

nozzle

and

contact

tip.

POWER

-e

ON

QOFF

Set

switch.

OM-151

016

Page

8

SECTION

4-

OPERATION

a

WARNING

ELECTRIC

SHOCK

can

kill.



Always

wear

dry

insulating

gloves.



Insulate

yourself

from

work

and

ground.



Do

not

touch

live

electrical

parts.



Keep

all

panels

and

covers

securely

in

place

FUMES

AND

GASES

can

be

hazardous

to

your

health.



Keep

your

head

out

of

the

fumes.



Ventilate

area,

or

use

breathing

device.



Read

Material

Safety

Data

Sheets

(MSDSs)

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.

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

I

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.

sb4.1

2/93



Ret.

ST-156

258

Figure

4-2.

Work

Clamp

a

WARNING

Figure

4-3.

ShIelding

Gas

~9%)

~~-

ARC

RAYS

can

burn

eyes

and

skin;

NOISE

can

damage

hearing.



Wear

welding

helmet

with

correct

shade

of

filter.



Wear

correct

eye,

ear,

and

body

protection.

0

MOVING

PARTS

can

cause

injury.



Keep

away

from

pinch

points

such

as

drive

rolls.



Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

.

1

~

2

~

3

~

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

10/01

Figure

4-1

-

Safety

Equipment

~=z=~

B

UILDUP

OF

SHIELDING

GAS

can

harm

health

or

kill.



Shut

off

shielding

gas

supply

when

not

in

use.

waml.1

9/91

1

Shielding

Gas

Cylinder

2

Valve

3

Gun

Trigger

3

Open

valve

on

cylinder

just

before

welding.

Gun

trigger

tums

weld

output

and

gas

flow

on

and

off.

Close

valve

on

cylinder

when

f

in

ished

welding.

8b5.1

6/92-S-0621-C

OM-151

016

Page

9

a

CAUTION

wam5.1

2/93

Use

control

to

select

a

wire

feed

speed.

As

Thickness/Voltage

switch

setting

increases,

wire

speed

range

also

increases.

The

numbers

around

the

control

are

not

a

wire

feed

speed

and

are

for

reference

only

(see

Table

4-1).

2

Thickness/Voltage

Switch

Use

switch

to

select

an

arc

voltage.

The

higher

the

selected

number,

the

thicker

the

material

that

can

be

welded

(see

Table

4-1).

3

Power

Switch

Use

switch

to

turn

unit

and

fan

On

and

Off.

ARCING

can

damage

switch.



Do

not

change

Thickness/Voltage

switch

position

while

welding.

Arcing

inside

switch

can

damage

contacts,

causing

switch

to

fail.

1

Fine

Tuning/Wire

Speed

Control

Figure

4-4.

Controls

Ref.

ST-I

50092-A

/

Ref.

ST-i

56

258

OM-151

016

Page

10

Install

&

~\

~

Put

On

Connect

1

Personal

Safety

i

Turn

On

~V\

Set

Controls

Do

~)S\

Readjust

Controls~\

_________________

________________

________________)

)

Sample

Weld

I

And

Prepare

J

Equipment

})

Equiprnej}

(If

Applicable

______________

J

For

Production

J

Equipment

&

Gas

ssb4.1

10/91

Figure

4.5.

Sequence

Of

Operation

For

Hard

And

Flux

Cored

Wires

Install

&

Connecj~

\

Adjust

Hub



~\

Adjust

Drive

Roll

~

Controls

&

Equipment

Using

1

Tension

To

1

Pressure

To

Put

On

Persona~~~um

On

~

And

Adjust

Gas

J

Knurled

Groove}J

Minirnum~y)

Minimum

)JSafety

Equipmer9)

To

30

cfh

J

_________________

Straight

)

Do

Sample

Weld)

Control~\

And

Prepare

For

________________

Welding~J

Figure

4-6.

Sequence

Of

Operation

For

Aluminum

Welding

Table

4-1.

Suggested

Welding

Settings

Wire

Type,

Shielding

Gas,

And

Flow

Rate

Wire

Diameter

(inch)

Operator

Control

SettIngs

Material_Thickness

1/4

In

(6.4

mm)

3/16

In

(4.8

mm)

1/8

In

(3.2

mm)

14

ga

16

ga

18

ga

22

ga

24

ga

E7OS-6

CO2

20

cfh+

.023

Voltage

4

3

2

1

~

Wire

Speed



100%

80%

70%

60%

55%

45%

.030

Voltage

4 4

3

2

1 1



Wire

Speed

80%

75%

60%

50%

40%

30%



.035

Voltage

4 4

3

2

1



Wire

Speed

65%

60%

50%

40%

30%

20%

15%



E7OS-6

75%

Argon

25%

CO2

20

of

h+

.023

Voltage



4

3

2

1

Wire

Speed



100%

90%

80%

70% 60% 50%

40%

.030

Voltage

4

3

2

1

-

1



Wire

Speed

90%

80%

70%

60% 50%

45%

30%



.035

Voltage

4

3

2

1



Wire

Speed

75%

70%

60%

50%

40%

33%

25%



E71T-GS

Flux

Core

.030

Voltage

3

2

1



Wire

Speed*

40% 65%

45%

40%

30%

20%



035



Voltage

3

2

1



Wire

Speed

60% 50%

40% 30%

20%

10%



ER

308

Stainless

Steel

Tn-Mix

20

cfh+

.023

Voltage

4

4 3

3

2

1



Wire

Speed

100%

90%

85%

75%

70%

60%



.030

Voltage

4

3

2



Wire

Speed

75% 75%

65%

60%

55%

50%



.035

Voltage

4

3



Wire

Speed

60% 60%

50%



.

Aluminum

Argon

30cfh+

.030

Voltage

4 3

3

2

1



Wire

Speed

90%

85%

80%

90%

85%



035



Voltage

Wire

Speed

4

85%

4

85%

3

85%

2

90%

2

90%

1

80%



 



Do

not

change

Thicknesa/Voltage

awitch

poeltion

while

welding.

Fine

Tuning/Wire

Speed

value

In

Table

4-1

Ia

a

atartlng

value

only,

and

Fine

Tuning/Wire

Speed

control

setting

can

be

fine

tuned

during

welding.

+cfh

=

cubic

ft

per

hour

OM-151

016

Page

11

SECTION

5-

MAINTENANCE

&

TROUBLESHOOTING

A~

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.

Turn

Off

welding

power

source,

and

disconnect

input

power

before

inspecting,

maintaining,

or

servicing.

HOT

PARTS

can

cause

severe

burns.



Allow

cooling

period

before

maintaining

or

servicing.

MOVING

PARTS

can

cause

injury.



Keep

away

from

moving

parts.



Keep

away

from

pinch

points

such

as

drive

rolls.

Maintenance

to

be

performed

only

by

qualified

persons.

Swam8.2

2/93

5-1.

Routine

Maintenance

5-2.

Overload

Protection

a

WARNING

READ

SAFETY

BLOCKS

at

start

of

Section

5

before

proceeding.

A.

Overheating

Thermostat

TP1

protects

the

unit

from

damage

due

to

overheating,

If

rectifier

SR2

gets

too

hot,

TP1

opens

and

weld

output

stops.

The

fan

keeps

running

to

cool

SR2.

Wait

several

minutes

before

trying

to

weld.

B.

Short

Circuit

Shutdown

If

contact

tip

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

tip

from

workpiece.

Check

contact

tip

and

replace

if

damaged.

Turn

On

unit

to

continue

operation.

Turn

Off

all

power

before

maintaining.

-~

3

Months

Replace

(

Cracked

Parts

 

Trigger

Cord

Gas

Hose

Gun

Cable

Figure

5-1.

Maintenance

Schedule

OM-151

016

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Miller AUTO ARC 140 Owner's manual

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