Miller AUTO ARC 140 Owner's manual
- Category
- Welding System
- Type
- Owner's manual
This manual is also suitable for
AUTO
ARC}~
June
1995
Form:
OM-151
016B
Effective
With
Serial
No.
KF909888
OWNERS
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
previous
manufacturers
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.
5YearsParts3YearsLabor
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
YearParts
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.
MANUFACTURERS
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USE
BY
COMMERCIAL/INDUSTRIAL
USERS
AND PERSONS
TRAINED
AND
EXPE
RIENCED
IN
THE USE
AND
MAINTENANCE
OF
WELDING
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
customers
risk
and
expanse.
manufacturers
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
manufacturers
Transportation
Department.
When
requesting
information
about
this
equipment,
always
provide
Model
Designation
and
Serial
or
Style
Number.
Use
the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Number
of
your
unit.
The
information
is
located
on
the
rating
label
or
nameplate.
Model
__________
Serial
or
Style
No.
Date
of
Purchase
brand..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
Owners
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
next
page.
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
manufacturers
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
LARC
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
lappareil
ost
sur
ON.
Lo
circuit
dentrŁo
of
los
circuits
intemes
de
tappareil
sont
Łgalement
sous
tension
a
ce
moment-l.
En
soudage
semi-automatiquo
ou
automatique,
to
fit,
le
dØvidoir,
le
logement
des
galets
dentrainement
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.
Sisoler
do
Ia
piŁce
01
de
Ia
terre
au
moyon
do
tapis
ou
dautres
moyens
isolants
suffisamment
grands
pour
empOcher
lo
contact
physique
Øventuel
avec
Ia
piŁce
ou
Ia
terre.
4.
Couper
talimonlation
ou
arreter
le
moteur
avant
do
procØder
a
linstallation,
a
Ia
reparation
ou
a
lontretien
do
lappareil.
DŁverrouillerlalimentation
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
dutilisation
et
au
codes
nationaux,
provinciaux
et
municipaux.
6.
Toujours
verifier
Ia
terre
du
cordon
dalimentatton
Verifier
et
sassurer
que
10
fil
do
terre
du
cordon
dalimentation
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
dontrØe
fixer
dabord
10
conduclour
do
miso
a
Ia
terre
appropriØ
01
contre-vØrifier
los
connexions.
8.
VØrifiorfrØquemment
le
cordon
dalimentation
pour
voir
sil
nosl
pas
endommagØ
ou
dØnudØ
remplacer
10
cordon
immOdiatement
sil
ost
endommagØ
un
cable
dØnudØ
pout
provoquor
une
electrocution.
9.
Mettre
lappareil
hors
tension
quand
on ne
lutitiso
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
lØlectrode
quand
on
est
en
contact
avec
Ia
piŁce.
Ia
terre
ou
une
electrode
provonant
dune
autre
machine.
14.
Nutiliser
quun
matOnel
en
boo
Øtat.
RØparer
ou
remplacer
sur-le-champ
los
piŁcos
endommagØos.
Entretonir
lappareit
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
LARC
peut
Œtre
dangereux.
SE
PROTEGER
ET
PROTEGER
LES
AUTRES
CONTRE
LES
BLESSURES
GRAVES
VOIRE
MORTELLES.
TENIR
LES
ENFANTS
A
LECART.
LES
PERSONNES
OUt
PORTENT
UN
STIMULATEUR
CARDIAQUE
NE
DOt
VENT
PAS
NON
PLUS
SAPPROCIIER
DU
POSTE
DE
SOUDAGE,
A
MOINS
DAVOIR
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
simposent.
Les
consignos
do
sOcuritØ
donnØes
ci-aprŁs
no
font
quo
rØsumer
Iinformation
contenue
dans
los
normes
do
sØcufltO
ØnumØrAes
a
Ia
page
suivante.
Lire
et
respecter
toutes
cos
normes
do
sØcuntØ.
LINSTALLATION,
LUTILISATION,
LENTRETIEN
ET
LES
REPARATIONS
NE
DOIVENT
ETRE
CONFIES
QuA
DES
PERSONNES
OUALIFIEES
LE
RAYONNEMENT
DE
LARC
peut
brler
les
RAVONNEMENT
DE
LARC
yeux
et
Ia
peau.
Le
BRUIT
peut
endommager
~
IouIe;
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
Larc
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
louIe.
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
darc
01
lŁbtouissement;
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.
portantunappareilrespiratoiroadductiondairpur.
Demanderun
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
siI
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
doxygeno
et
causer
dos
blossures
graves
voiro
mortelles.
Sassurer
quo
lair
est
propre
a
Ia
respiration.
1.
Garder
Ia
tŒte
a
lextØrieur
des
vapeurs
et
des
tumØes
01
ne
pastes
6.
Ne
pas
souder
a
proximit
dopOrations
do
dØgraissage,
do
respirer.
nettoyage
ou
do
pulvonsation.
La
chaleur
et
les
rayons
do
larc
2.
A
lintØrieur,
ventiler
le
poste
do
travail
ou
utiliser
un
dispositif
place
peuvent
rØagir
avec
es
vapours
pour
former
des
gaz
hautement
au
niveau
do
larc
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
plomboucadmieamoinsquelapiecenaitetOentierementdecapee,
adduction
dair
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
dapport.
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.
Nutiliser
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
lapplication
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
larc.
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
quettes
ne
tombent
ou
ne
basculent.
10.
LireetsuivrelesconsignesrelativosauxbouteillesdegazcomprimØ,
3.
Tenir
los
boutoilles
a
lØcart
du
poste
de
soudage
ou
dautros
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.
Larc
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
lŁlectrode
sur
des
objets
metauiques
peut
produire
des
Otincelles,
lexplosion,
Ia
surchauffe
ou
un
incendie.
Sassuror
que
le
lieu
ne
prØsente
pas
de
danger
avant
deffectuer
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
larc.
Si
cola
nest
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
sinfiltrant
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
lautre
ctØ.
7.
Ne
pas
soudor
sur
des
recipients
fermAs
comme
des
reservoirs,
dos
tOts
ou
dos
tuyaux
a
moms
quils
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
dØlectrocution
et
dincendie.
9.
Ne
pas
utiliser
te
chalumeau
soudeur
pour
degeler
des
tuyaux.
10.
Enlever
lŁlectrode
enrobŁe
du
porte-electrode
ou
couper
le
fil
de
soudage
au
ras
du
boc
contact
quand
on
no
lutilise
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.
Sassurerque
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;
LELECTROLYTE
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
lappareil
so
trouve
a
proximitO
dOtincelles
ou
do
flamrhes
nues.
3.
Ne
pas
remplir
10
reservoir
a
ras
bord
:
prOvoir
do
lespace
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
lontretion
ou
los
reparations
nOcessairos.
4.
Pour
empOcher
un
demarrage
accidentet
dun
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
DECHAPPEMENT
DES
MOTEURS
1.
Utuliser
le
matŁnel
a
lextŁrieur,
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,
dechappement
a
lextOrieur
et
loin
des
pnses
dai
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
denlaver
complŁtement
Ia
bouchon.
PRINCIPALES
NORMES
DE
SECURITE
Safety
in
Welding
and
Cutting,
norme
ANSI
Z49.1,de
IAmorican
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
IAssociation
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,
delAmorican
Welding
Society,
550
N.W.
Lejeune
Ad,
Miami
FL
33126
norme
ANSI
Z87.1,
do
tAmerican
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
3INSTALLATION
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
7WELDING
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
016B6195
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
related
to
safety.
Specifications
Type
Of
Output
Description
Rated
Weld
Output
Type
Of
Input
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
ufacturers
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
ufacturers
recommended
flow
rate.
7
CO2
Adapter
7
8
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
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
pin
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
manufacturers
instructions
for
material
used.
WELDING
can
cause
fire
or
explosion.
Do
not
weld
near
flammable
material.
Watch
for
fire;
keep
extinguisher
nearby.
Do
not
locate
unit
over
combustible
surfaces.
Do
not
weld
on
closed
containers.
Allow
work
and
equipment
to
cool
before
handling.
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
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
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
2
1
1
1
~
Wire
Speed
100%
80%
70%
60%
55%
45%
.030
Voltage
4 4
3
2
2
1 1
Wire
Speed
80%
75%
60%
60%
50%
40%
30%
.035
Voltage
4 4
3
2
1
1
1
Wire
Speed
65%
60%
50%
40%
30%
20%
15%
E7OS-6
75%
Argon
25%
CO2
20
of
h+
.023
Voltage
4
3
2
2
1
1
1
Wire
Speed
100%
90%
80%
70% 60% 50%
40%
.030
Voltage
4
3
3
2
2
1
-
1
Wire
Speed
90%
80%
70%
60% 50%
45%
30%
.035
Voltage
4
3
3
3
2
2
1
Wire
Speed
75%
70%
60%
50%
40%
33%
25%
E71T-GS
Flux
Core
.030
Voltage
3
3
2
1
1
1
Wire
Speed*
40% 65%
45%
40%
30%
20%
035
Voltage
3
3
2
1
1
1
Wire
Speed
60% 50%
40% 30%
20%
10%
ER
308
Stainless
Steel
Tn-Mix
20
cfh+
.023
Voltage
4
4 3
3
3
2
1
Wire
Speed
100%
100%
90%
85%
75%
70%
60%
.030
Voltage
4
4
3
3
2
2
Wire
Speed
75% 75%
65%
60%
55%
50%
.035
Voltage
4
4
3
Wire
Speed
60% 60%
50%
.
Aluminum
Argon
30cfh+
.030
Voltage
4 3
3
2
1
1
Wire
Speed
90%
85%
80%
90%
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
Page
12
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Miller AUTO ARC 140 Owner's manual
- Category
- Welding System
- Type
- Owner's manual
- This manual is also suitable for
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