ESAB Air-Cooled 350 AMP 450 AMP Water-Cooled 400 AMP 500 AMP PulseMaster™ Mig Gun User manual

Brand: ESAB

Model: Air-Cooled 350 AMP 450 AMP Water-Cooled 400 AMP 500 AMP PulseMaster™ Mig Gun

Category: Welding System

Type: User manual

SAFETY AND OPERATING

INSTRUCTIONS

PulseMaster

™

MIG GUN

English

Français

Español

AIR-COOLED

350 AMP

450 AMP

WATER-COOLED

400 AMP

500 AMP

SAFETY AND OPERATING

INSTRUCTIONS

Issue Date: March 12, 2009

Manual No: 89200000Revision: C

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Tweco

product. We are proud to have

you as our customer and will strive to provide you with the best service

and reliability in the industry. This product is backed by our extensive

warranty and worldwide service network. To locate your nearest

distributor or service agency call 800-426-1888, or visit us on the web at

www.tweco.com.

This Manual has been designed to instruct you on the correct

installation and use of your Tweco

product. Your satisfaction with

this product and its safe operation is our ultimate concern. Therefore,

please take the time to read the entire manual, especially the Safety

Precautions. They will help you to avoid potential hazards that may

exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

Tweco

is a Global Brand of Welding Products for Thermadyne

Industries Inc. We manufacture and supply to major welding industry

sectors worldwide, including: Manufacturing, Construction, Mining,

Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.

We distinguish ourselves from our competition through market-

leading, dependable products that have stood the test of time. We

pride ourselves on technical innovation, competitive prices, excellent

delivery, superior customer service and technical support, together

with excellence in sales and marketing expertise.

Above all, we are committed to develop technologically advanced

products to achieve a safer working environment within the welding

industry.

WARNING

Read and understand this entire Manual and your employer’s safety practices

before installing, operating, or servicing the equipment. While the information

contained in this Manual represents the Manufacturer’s judgement, the

Manufacturer assumes no liability for its use.

PulseMaster MIG Gun

Safety and Operating Instructions

Instruction Guide Number 89200000

Published by:

Thermadyne

Industries, Inc.

2800 Airport Rd.

Denton, TX. 76207

(940) 566-2000

www.tweco.com

U.S. Customer Care: (800) 426-1888

International Customer Care: (940) 381-1212

Reproduction of this work, in whole or in part, without written permission of the publisher is

prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss

or damage caused by any error or omission in this Manual, whether such error results from

negligence, accident, or any other cause.

Publication Date: March 12, 2009

Record the following information for Warranty purposes:

Where Purchased:

Purchase Date:

Equipment Serial #:

Table of Contents

SECTION 1: INTRODUCTION AND DESCRIPTION ...................................................1-1

1.01 How to Use this Manual ................................................................1-1

1.02 Receipt of Equipment .................................................................... 1-1

SECTION 2: SAFETY PRECAUTIONS ..................................................................... 2-2

2.01 Mesures de sécurité ...................................................................... 2-5

2.02 Precauciones de seguridad ...........................................................2-8

SECTION 3: MIG GUN SPECIFICATIONS............................................................... 3-11

3.01 Standard Wire And Gas Combinations ........................................3-11

3.02 MIG Gun Part Number Identiﬁcation ........................................... 3-12

SECTION 4: MIG GUN INSTALLATION .................................................................. 4-14

4.01 Standard Setup ...........................................................................4-14

SECTION 5: SETTINGS AND CONTROLS (SMART GUN) .......................................5-16

5.01 Settings and Controls ..................................................................5-16

5.02 Adjustment Options ....................................................................5-16

SECTION 6: MANUAL GMAW WELDING ..............................................................6-17

6.01 Types of Weld Transfer Modes .................................................... 6-17

6.02 Holding and Manipulating the Torch ...........................................6-18

SECTION 7: CONTACT TIP ...................................................................................7-20

7.01 Contact Tip Identiﬁcation and Parts List......................................7-20

7.02 Contact Tip Replacement ............................................................7-20

SECTION 8: WIRE CONDUIT .................................................................................8-21

8.01 Conduit Identiﬁcation .................................................................. 8-21

8.02 Conduit Removal .........................................................................8-22

8.03 Teﬂon Liner Options .................................................................... 8-22

8.04 Step-by-step Teﬂon Liner Installation..........................................8-23

8.05 Step-by-step Jump Liner Installation ..........................................8-24

8.06 Step-by-step Bare Teﬂon Liner Installation .................................8-26

SECTION 9: CONDUCTOR TUBES .........................................................................9-28

SECTION 10: NOZZLES ........................................................................................9-28

SECTION 11: REPLACING PCB ASSEMBLY (SMART GUN) ................................11-29

SECTION 12: TROUBLESHOOTING ..................................................................... 12-32

SECTION 13: REPLACEMENT PARTS (AIR-COOLED) .........................................13-33

SECTION 14: REPLACEMENT PARTS (WATER-COOLED) ................................... 14-34

SECTION 15: STATEMENT OF WARRANTY ........................................................ 15-35

15.01 Warranty Schedule .................................................................... 15-36

1-1

89200000

Safety and Operating inStructiOnS

SECTION 1:

INTRODUCTION AND DESCRIPTION

1.01 HOW TO USE THIS MANUAL

To ensure safe operation, read the entire manual, including the chapters on safety instructions

and warnings.

Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular

attention to the information provided under these headings. These special annotations are

easily recognized as follows:

NOTE

NOTE conveys installation, operation, or maintenance information which is

important but not hazard-related.

CAUTION

CAUTION indicates a potentially hazardous situation which, if not avoided, may

result in injury.

WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, could

result in serious injury or death.

1.02 RECEIPT OF EQUIPMENT

When you receive the equipment, check it against the invoice to make sure it is complete and

inspect the equipment for possible damage due to shipping. If there is any damage, notify the

carrier immediately to ﬁle a claim. Furnish complete information concerning damage claims

or shipping errors to the location in your area, listed in the back cover of this manual. Include

a full description of the parts in error.

If you want additional or replacement copies of this manual, please contact Tweco

at the

address and phone number in your area listed on the back cover of this manual. Include the

Manual number (from page i).

Introduction and Description

2-2

Safety and Operating inStructiOnS

89200000

SECTION 2:

SAFETY PRECAUTIONS

WARNING

SERIOUS INJURY OR DEATH may result if welding and cutting equipment is not

properly installed, used, and maintained. Misuse of this equipment and other

unsafe practices can be hazardous. The operator, supervisor, and helper must read

and understand the following safety warnings and instructions before installing

or using any welding or cutting equipment, and be aware of the dangers of the

welding or cutting process. Training and proper supervision are important for a

safe work place. Keep these instructions for future use. Additional recommended

safety and operating information is referenced in each section.

WARNING

This product contains chemicals, including lead, or otherwise produces

chemicals known to the State of California to cause cancer, birth defects and

other reproductive harm. Wash hands after handling.

(California Health & Safety Code § 25249.5 et seq.)

ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH

Install and maintain equipment in accordance with the National Electrical Code

(NFPA 70) and local codes. Do not service or repair equipment with power on.

Do not operate equipment with protective insulators or covers removed. Service

or repair to equipment must be done by qualified and/or trained

personnel only.

Do not contact electrically live parts. Always wear dry welding gloves that are in good condition.

Aluminized, protective clothing can become part of the electrical path. Keep oxygen cylinders,

chains, wires, ropes, cranes, and hoists away from any part of the electrical path. All ground

connections must be checked periodically to determine if they are mechanically strong, and

electrically adequate for the required current. When engaged in AC welding/cutting under wet

conditions or where perspiration is a factor, the use of automatic controls for reducing the no

load voltage is recommended to reduce shock hazards. Accidental contact must be prevented

when using open circuit voltage exceeding 80 volts AC, or 100 volts DC by adequate insulation

or other means. When welding is to be suspended for any length of time, such as during lunch

or overnight, all electrode holders and electrodes should be removed from the electrode holder

and the power supply should be turned off to prevent accidental contact. Keep MIG Guns,

electrode holders, Tig torches, Plasma torches, and electrodes away from moisture and water.

See safety and operating references 1, 2, and 8.

Safety Precautions

2-3

89200000

Safety and Operating inStructiOnS

SMOKE, FUMES, AND GASES CAN BE DANGEROUS TO YOUR HEALTH

Ventilation must be adequate to remove smoke, fumes, and gases during operation

to protect operators and others in the area. Vapors of chlorinated solvents can

form the toxic gas “Phosgene” when exposed to ultraviolet radiation from an

electric arc. All solvents, degreasers, and potential sources of these vapors must

be removed from the operating area. Use air-supplied respirators if ventilation

is not adequate to remove all fumes and gases. Oxygen supports, and vigorously accelerates ﬁre

and should never be used for ventilation.

See safety and operating references 1, 2, 3, and 4.

ARC RAYS, HOT SLAG, AND SPARKS CAN INJURE EYES AND BURN SKIN

Welding and cutting processes produce extreme localized heat and strong

ultraviolet rays. Never attempt to weld/cut without a federally compliant welding

helmet with the proper lens. A number 12 to 14 shade ﬁlter lens provides the

best protection against arc radiation. When in a conﬁned area, prevent the

reﬂected arc rays from entering around the helmet. Approved shielding curtains

and appropriate goggles should be used to provide protection to others in the surrounding area.

Skin should be protected from arc rays, heat, and molten metal. Always wear protective gloves

and clothing. All pockets should be closed and cuffs sewn shut. Leather aprons, sleeves, leggings,

etc. should be worn for out-of-position welding and cutting, or for heavy operations using large

electrodes. Hightop work shoes provide adequate protection from foot burns. For added protection,

use leather spats. Flammable hair preparations should not be used when welding/cutting. Wear

ear plugs to protect ears from sparks. Where work permits, the operator should be enclosed in

an individual booth painted with a low reflective material such as zinc oxide.

See safety and operating references 1, 2, and 3.

WELDING SPARKS CAN CAUSE FIRES AND EXPLOSIONS

Combustibles reached by the arc, ﬂame, ﬂying sparks, hot slag, and heated

materials can cause ﬁre and explosions. Remove combustibles from the work

area and/or provide a ﬁre watch. Avoid oily or greasy clothing as a spark may

ignite them. Have a ﬁre extinguisher nearby, and know how to use it. If welding/

cutting is to be done on a metal wall, partition, ceiling, or roof, precautions must

be taken to prevent ignition of nearby combustibles on the other side. Do not

weld/cut containers that have held combustibles. All hollow spaces, cavities, and containers

should be vented prior to welding/cutting to permit the escape of air or gases. Purging with inert

gas is recommended. Never use oxygen in a welding torch. Use only inert gases or inert gas

mixes as required by the process. Use of combustible compressed gases can cause explosions

resulting in personal injury or death. Arcing against any compressed gas cylinder can cause

cylinder damage or explosion. See safety and operating references 1, 2, 5, 7, and 8.

NOISE CAN DAMAGE HEARING

Noise from the air carbon-arc process can damage your hearing. Wear protective

hearing devices to ensure protection when noise levels exceed OHSA standards.

Adequate hearing protection devices must be worn by operators and surrounding

personnel to ensure personal protection against noise. See safety and operating

references 1, 2, and 6.

Safety Precautions

2-4

Safety and Operating inStructiOnS

89200000

SAFETY AND OPERATING REFERENCES

1. Code of Federal Regulations (OSHA) Section 29, Part 1910.95, 132, 133, 134, 139, 251,

252, 253, 254 and 1000. U.S. Government Printing Ofﬁce, Washington, DC 20402.

2. ANSI Z49.1 “Safety in Welding and Cutting”.

3. ANSI Z87.1 “Practice for Occupational and Educational Eye and Face Protection”.

4. ANSI Z88.2. “Standard Practice for Respiratory Protection”. American National

Standards Institute, 1430 Broadway, New York, NY 10018.

5. AWS F4.1. “Recommended Safe Practices for Welding and Cutting Containers”.

6. AWS C5.3. “Recommended Practices for Air Carbon-Arc Gouging and Cutting”.

The American Welding Society, 550 NW Lejeune Rd., P.O. Box 351040, Miami, FL

33135.

7. NFPA 51B. “Fire Prevention in Cutting and Welding Processes”.

8. NFPA-7. “National Electrical Code”. National Fire Protection Association, Battery Park,

Quincy, MA 02269.

9. CSA W117.2. “Safety in Welding, Cutting and Allied Processes”. Canadian Standards

Association, 178 Rexdale Blvd., Rexdale, Ontario, Canada M9W 1R3.

DECLARATION OF CONFORMITY

Tweco

Products, Inc. declares under our sole responsibility that the product

Hand Held Air/Gas and Water Cooled MIG Welding Torches

To which this declaration relate(s) are in conformance with the following standards:

IEC 60974-7:2005

Following the provisions of the 73/23/EEC directive.

Safety Precautions

2-5

89200000

Safety and Operating inStructiOnS

2.01 MESURES DE SÉCURITÉ

AVERTISSEMENT

DES BLESSURES GRAVES OU MORTELLES peuvent résulter d’une installation,

d’un usage ou d’un entretien inadéquat de l’équipement de soudage et de

découpage. Une mauvaise utilisation de cet équipement et d’autres pratiques

risquées peuvent être dangereuses. L’opérateur, le superviseur et l’aide doivent

lire et comprendre les avertissements et les instructions de sécurité suivantes

avant d’installer ou d’utiliser tout équipement de soudage ou de découpage et être

conscients des dangers inhérents aux processus de soudage et de découpage.

Une formation et une supervision adaptées sont importantes pour assurer un lieu

de travail sûr. Gardez ces instructions pour une utilisation future. Chaque section

comporte des informations supplémentaires de sécurité et de fonctionnement.

AVERTISSEMENT

Ce produit contient des produits chimiques, comme le plomb, ou engendre

des produits chimiques, reconnus par l’état de Californie comme pouvant

être à l’origine de cancer, de malformations fœtales ou d’autres problèmes

de reproduction. Il faut se laver les mains après toute manipulation.

(Code de Californie de la sécurité et santé, paragraphe 25249.5 et suivants)

UN CHOC ÉLECTRIQUE PEUT CAUSER DES BLESSURES OU LA MORT

L’installation et l’entretien de l’équipement doivent être conformes au Code national

de l’électricité NFPA 70 et aux codes locaux. N’effectuez pas l’entretien ou la

réparation d’équipement en marche. N’opérez pas l’équipement sans isolateurs ou

caches de protection. L’entretien ou la réparation de l’équipement doivent être

effectués uniquement par un technicien qualiﬁé ou par du personnel formé.

Ne touchez pas aux pièces électriques chargées. Portez toujours des gants de soudage au sec

et en bon état. Les vêtements de protection aluminisés peuvent devenir une partie du chemin

électrique. Éloignez les bouteilles d’oxygène, les chaînes, les câbles métalliques, les appareils

de levage, les treuils et les élévateurs de toute partie du circuit électrique. Toutes les liaisons de

terre doivent être vériﬁées périodiquement pour déterminer si elles sont solides et appropriées au

courant demandé. En cas de soudage ou de découpage en courant alternatif dans des conditions

d’humidité ou de chaleur où l’opérateur risque de transpirer, il est recommandé d’utiliser des

contrôles automatiques pour réduire la tension à vide et ainsi diminuer les risques de choc

électrique. Lorsque le procédé de soudage et de découpage exige des valeurs de tension en

circuit ouvert dans des machines à courant alternatif supérieur à 80 volts ou dans des machines

à courant continu supérieur à 100 volts, il faut prendre des mesures pour empêcher un contact

accidentel en prévoyant une isolation adéquate ou d autres moyens. Lorsqu’il faut interrompre

les activités de soudage pendant un certain temps, à l’heure du repas ou la nuit, par exemple, il

faut enlever toutes les électrodes du porte-électrode et mettre hors tension l’alimentation pour

éviter tout contact accidentel. Gardez les pistolets MIG, les porte-électrodes, les torches TIG, les

torches à plasma et les électrodes loin de l’humidité et de l’eau. Voir les références en matière

de sécurité et d’utilisation n° 1, 2 et 8.

Mesures de sécurité

2-6

Safety and Operating inStructiOnS

89200000

LA FUMÉE, LES ÉMANATIONS ET LES GAZ PEUVENT ÊTRE DANGEREUX POUR VOTRE SANTÉ

La ventilation doit être sufﬁsante pour enlever la fumée, les émanations et les

gaz pendant le fonctionnement de la torche aﬁn protéger les opérateurs et les

autres personnes présentes dans la zone. Les vapeurs de solvants chlorés

peuvent former un gaz toxique appelé « Phosgène » si elles sont exposées au

rayonnement ultraviolet d un arc électrique. Il faut enlever de la zone de travail

tous les solvants, décapants et sources potentielles de ces vapeurs. Servez-vous d’appareils

respiratoires à adduction d’air si la ventilation n’est pas sufﬁsante pour enlever toutes les

émanations et gaz. L’oxygène alimente les incendies et en accélère la propagation il ne faut

jamais l’utiliser à des ﬁns de ventilation. Voir les références en matière de sécurité et

d’utilisation n° 1, 2, 3 et 4.

L LES RAYONS DE L’ARC, LES SCORIES ET LES ÉTINCELLES CHAUDS PEUVENT BLESSER

LES YEUX ET BRÛLER LA PEAU

Les procédés de soudage et de découpage produisent une chaleur extrême

localisée et de puissants rayons ultraviolets. N’essayez jamais de souder ou de

couper sans casque soudage conforme aux normes du gouvernement fédéral et

muni d’une lentille appropriée. Des lentilles à ﬁltre de numéro 12 à 14 fournissent

la meilleure protection contre le rayonnement de l’arc. Dans un endroit conﬁné,

il faut éviter que les rayons reﬂétés de l’arc n’entrent autour du casque. Il faut utiliser des rideaux

de protection approuvés et des lunettes de protection appropriées pour protéger les autres personnes

se trouvant aux abords. Il faut aussi protéger la peau nue des rayons de l’arc, de la chaleur et du

métal fondu. Portez toujours des gants et des vêtements de protection. Toutes les poches doivent

être fermées et les manchettes, cousues. Il faut porter un tablier, des manches, des guêtres, etc.

en cuir pour effectuer de soudage ou de découpage et dans le cas des activités intensives nécessitant

de grandes électrodes. Les chaussures de sécurité montantes fournissent une protection sufﬁsante

contre les brûlures aux pieds. Pour obtenir une plus grande protection, portez des guêtres en cuir.

Il ne faut pas utiliser de produits capillaires inﬂammables avant d’effectuer des activités de soudage

ou de découpage. Portez des bouchons d’oreilles pour vous protéger les oreilles des étincelles.

Lorsqu’il est possible de le faire dans la zone de travail, l’opérateur doit s’isoler dans une cabine

individuelle recouverte d’un revêtement à faible réﬂectivité, comme l’oxyde de zinc. Voir les

références en matière de sécurité et d’utilisation n° 1, 2 et 3.

LES ÉTINCELLES DE SOUDAGE PEUVENT CAUSER DES INCENDIES ET DES EXPLOSIONS

Les combustibles atteints par l’arc, les ﬂammes, les vols d’étincelles, les scories

chaudes et les matériaux chauffés peuvent causer des incendies et des explosions.

Enlevez les combustibles de la zone de travail ou mettez en place du personnel

de surveillance. Évitez les vêtements huileux ou graisseux, car une étincelle peut

y mettre le feu. Ayez un extincteur à proximité et sachez comment l’utiliser. Si

l’activité de soudage ou de découpage doit être fait contre un mur, une cloison,

un plafond ou un toit, il faut prendre des précautions pour d’enﬂammer des combustibles qui se

trouveraient à proximité, de l’autre côté. Ne soudez pas et ne coupez pas de conteneurs ayant

contenu des combustibles. Il faut aérer tous les espaces creux, les cavités et les conteneurs avant

de les soumettre au soudage ou au découpage aﬁn d’évacuer tout l’air ou le gaz qui peut s’y

trouver. Il est recommandé d’effectuer une purge avec du gaz inerte. N’utilisez jamais d’oxygène

dans une tête de soudage. N’utilisez que des gaz inertes ou des mélanges de gaz inertes,

conformément aux exigences du procédé. L’utilisation de gaz combustibles comprimés peut

causer des explosions entraînant des blessures ou la mort. Le fait d’utiliser l’arc sur une bouteille

de gaz comprimé peut endommager la bouteille ou causer une explosion. Voir les références

en matière de sécurité et d’utilisation n° 1, 2, 5, 7 et 8.

Mesures de sécurité

2-7

89200000

Safety and Operating inStructiOnS

LE BRUIT PEUT ENDOMMAGER L’OUÏE

Le bruit du procédé de l’arc avec électrode en carbone et jet d’air peut endommager

l’ouïe. Portez un dispositif de protection de l’ouïe pour vous protéger lorsque le

niveau de bruit dépasse les normes de l’OSHA. Les opérateurs et le personnel aux

abords doivent porter un dispositif de protection de l’ouïe approprié pour les protéger

efﬁcacement contre le bruit. Voir les références en matière de sécurité et

d’utilisation n° 1, 2 et 6.

RÉFÉRENCES EN MATIÈRE DE SÉCURITÉ ET D’UTILISATION

1. Code of Federal Regulations (OSHA), section 29, partie 1910.95, 132, 133, 134,

139, 251, 252, 253, 254 et 1000. U.S. Government Printing Ofﬁce, Washington, DC

20402.

2. ANSI Z49.1 « Safety in Welding and Cutting ».

3. ANSI Z87.1 « Practice for Occupational and Educational Eye and Face Protection ».

4. ANSI Z88.2. « Standard Practice for Respiratory Protection ». American National

Standards Institute, 1430 Broadway, New York, NY 10018.

5. AWS F4.1. « Recommended Safe Practices for Welding and Cutting Containers ».

6. AWS C5.3. « Recommended Practices for Air Carbon-Arc Gouging and Cutting ».

The American Welding Society, 550 NW Lejeune Rd., P.O. Box 351040, Miami, FL

33135.

7. NFPA 51B. « Fire Prevention in Cutting and Welding Processes ».

8. NFPA-7. « National Electrical Code » (code national de l’électricité). National Fire

Protection Association, Battery Park, Quincy, MA 02269.

9. CSA W117.2. « Règles de sécurité en soudage, coupage et procédés connexes ».

Association canadienne de normalisation, 178 boul. Rexdale, Rexdale, Ontario, Canada

M9W 1R3.

DECLARATION OF CONFORMITY

Tweco

Products, Inc. declares under our sole responsibility that the product

Hand Held Air/Gas and Water Cooled MIG Welding Torches

To which this declaration relate(s) are in conformance with the following standards:

IEC 60974-7:2005

Following the provisions of the 73/23/EEC directive.

Mesures de sécurité

2-8

Safety and Operating inStructiOnS

89200000

Precauciones de seguridad

2.02 PRECAUCIONES DE SEGURIDAD

ADVERTENCIA

Se pueden sufrir LESIONES GRAVES O LA MUERTE si el equipo de soldadura

y corte no se instala, utiliza y mantiene debidamente. El uso inadecuado

de este equipo y otras prácticas no seguras pueden ser peligrosos. El operador,

supervisor y ayudante deben leer y comprender las siguientes advertencias e

instrucciones de seguridad antes de instalar o usar cualquier equipo de soldadura

o corte y deberán estar atentos a los peligros del proceso de soldadura y corte. El

entrenamiento y supervisión adecuados son importantes para un lugar de trabajo

seguro. Guarde estas instrucciones para uso futuro. En cada sección se incluyen

otras recomendaciones sobre seguridad y operación.

ADVERTENCIA

Este producto contiene sustancias químicas, dentro de las que se incluye el

plomo, o de otro modo produce sustancias químicas que el Estado de California

sabe que provocan cáncer, defectos congénitos y/u otros daños reproductores.

Lávese las manos después de haber estado en contacto con estas

sustancias.

(Código sobre Salud y Seguridad de California, Sec. 25249.5 y siguientes)

LAS DESCARGAS ELÉCTRICAS PUEDEN CAUSAR HERIDAS O LA MUERTE

Instale y mantenga el equipo de acuerdo al Código Nacional Eléctrico (NFPA 70)

y las normas locales. No realice mantenimiento o reparaciones con el equipo

prendido. No opere equipos sin los aisladores de protección o sin tapas. Los

servicios o reparación de los equipos solamente deben ser ejecutados por personal

caliﬁcado o entrenado..

No toque componentes eléctricos mientras están eléctricamente vivos. Siempre use guantes

de soldar secos y en buen estado. La ropa de protección aluminizada puede ser conductora

de la electricidad. Mantenga los tubos de oxígeno, cadenas, cuerdas de alambre, guinchos,

grúas y elevadores fuera del alcance de cualquier parte del circuito eléctrico. Se deben veriﬁcar

periódicamente todas las conexiones a tierra para determinar si están mecánicamente ﬁrmes y

eléctricamente adecuadas para la tensión requerida. Al trabajar con corriente alterna para soldar

o cortar en condiciones de humedad o en ambientes calurosos donde se transpira copiosamente,

se recomienda utilizar mandos automáticos conﬁables para reducir el voltaje y así reducir los

riesgos de descarga eléctrica. Se debe evitar cualquier tipo de contacto accidental al utilizar un

voltaje de circuito abierto que supere los 80 VCA o 100 VCC emplazando un aislamiento u otros

medios adecuados. Cuando se tenga que interrumpir la soldadura durante un importante período

de tiempo, como durante el almuerzo o la noche, todos los electrodos deben ser retirados del

portaelectrodos y se debe apagar la alimentación eléctrica de manera que no puedan producirse

contactos accidentales. Evite que las pistolas MIG, los portaelectrodos, los sopletes Tig, los

sopletes de Plasma y los electrodos se vean afectados por la humedad y el agua. Consulte las

referencias de seguridad y uso 1, 2 y 8.

2-9

89200000

Safety and Operating inStructiOnS

EL HUMO, LOS VAPORES Y LOS GASES PUEDEN SER PELIGROSOS PARA LA SALUD

La ventilación debe ser adecuada para que salga el humo, los vapores y los

gases durante la operación para proteger a los operadores y al resto del personal

en el área. Los vapores de solventes clorados pueden formar el gas tóxico

“Fosgeno” cuando quedan expuestos a los rayos ultravioletas producidos por

un arco eléctrico. Todos los solventes, desengrasantes y fuentes potenciales de

esos vapores deben ser retirados del área de trabajo. Utilice respiradores con tanque de aire si

la ventilación no resulta adecuada para eliminar todos los humos y gases. El oxígeno sostiene y

acelera vigorosamente el fuego, por lo que nunca debe ser utilizado para ventilación. Consulte

las referencias de seguridad y uso 1, 2, 3 y 4.

LOS RAYOS DEL ARCO, LA ESCORIA CALIENTE Y LAS CHISPAS PUEDEN LASTIMAR LOS OJOS

Y QUEMAR LA PIEL

Los procesos de soldadura y corte producen calor extremadamente localizado

y fuertes rayos ultravioletas. Nunca intente soldar o cortar sin una máscara de

soldadura con lentes adecuados y que cumpla con las exigencias federales. Los

lentes con ﬁltro número 12 a 14 ofrecen la mejor protección contra la radiación

del arco. Cuando trabaje en un área conﬁnada, evite que los rayos reﬂejados del

arco entren alrededor de la máscara. Se deben usar cortinas de protección y gafas apropiadas

para proteger al personal presente en áreas cercanas. La piel también debe ser protegida de los

rayos del arco, del calor y del metal derretido. Siempre se deberán utilizar guantes y vestimenta

de protección. Todos los bolsillos deben estar cerrados y los dobladillos cosidos. Se deben usar

delantales de cuero, mangas, pantalones, etc., para la soldadura y el corte fuera de posición o

para operaciones pesadas con electrodos grandes. Las botas de trabajo de caña alta ofrecen

protección adecuada contra las quemaduras de los pies. Use protectores de cuero para brazos

y piernas para contar con protección adicional. No se deben usar productos inﬂamables para el

cabello cuando se suelde o corte. Usar orejeras para proteger las orejas de las chispas. Cuando

el área de trabajo lo permita, el operador debe trabajar dentro de una cabina individual pintada

con una terminación de baja reﬂexión, como por ejemplo: óxido de zinc. Consulte las referencias

de seguridad y uso 1, 2 y 3.

LAS CHISPAS DE SOLDADURA PUEDEN CAUSAR INCENDIO Y EXPLOSIONES

Los combustibles alcanzados por el arco, por llamas, chispas, escorias o materiales

calientes pueden ser las causas de incendios y explosiones. Retire los combustibles

del área de trabajo u organice una guardia contra incendios. Evite que las ropas

estén sucias con aceite o grasa, ya que una chispa puede encenderlas. Tenga un

extintor de incendios cerca y sepa como usarlo. Si se está soldando o cortando

en una pared, un divisorio, un cielorraso o un techo metálico, se deben tomar

precauciones para evitar la ignición de combustibles que puedan estar del otro lado. No suelde

ni corte recipientes que hayan contenido combustibles. Todos los espacios vacíos, cavidades y

recipientes deben ventilarse antes de soldar o cortar para permitir la salida de aire o gases. Se

recomienda purgarlos con gas inerte. Nunca use oxígeno en un soplete de soldar. Use solamente

gases inertes o mezclas de gases inertes conforme a lo exigido por el proceso. El uso de gases

comprimidos combustibles puede provocar explosiones y causar daños personales o la muerte.

La radiación del arco contra cualquier tubo de gas comprimido puede causarle daños al tubo o

su explosión. Consulte las referencias de seguridad y uso 1, 2, 5, 7 y 8.

Precauciones de seguridad

2-10

Safety and Operating inStructiOnS

89200000

EL RUIDO PUEDE DAÑAR LA AUDICIÓN

El ruido del proceso con arco de aire/carbón puede dañar su audición. Use dispositivos

de protección auditiva para contar con protección cuando los niveles superen las

normas de la OSHA. Los operadores y personal próximo deben usar protectores

auriculares para asegurar la protección contra el ruido. Consulte las referencias

de seguridad y uso 1, 2 y 6.

REFERENCIAS DE SEGURIDAD Y USO

1. Código de Normas Federales (OSHA), Sección 29, Partes 1910.95, 132, 133, 134, 139,

251, 252, 253, 254 y 1000. Oﬁcina de la Imprenta Gubernamental de los EE.UU.,

Washington, DC 20402.

2 ANSI Z49.1 “Safety in Welding and Cutting” (Seguridad en la soldadura y el corte).

3. ANSI Z87.1 “Practice for Occupational and Educational Eye and Face Protection” (Práctica

para la protección ocupacional y educativa de ojos y rostro).

4. ANSI Z88.2. “Standard Practice for Respiratory Protection” (Práctica estándar para

protección respiratoria). American National Standards Institute (Instituto norteamericano

de normas nacionales), 1430 Broadway, New York, NY 10018.

5. AWS F4.1. “Recommended Safe Practices for Welding and Cutting Containers” (Prácticas

seguras recomendadas para soldadura y corte de recipientes).

6. AWS C5.3. “Recommended Safe Practices for Air Carbon-Arc Gouging and Cutting”

(Prácticas seguras recomendadas para ranurado y corte con arco de aire/carbón). The

American Welding Society (Sociedad norteamericana de soldadura), 550 NW Lejeune

Rd., P.O. Box 351040, Miami, FL 33135.

7. NFPA 51B. “Fire Prevention in Cutting and Welding Processes” (Prevención de incencios

en procesos de corte y soldadura).

8. NFPA-7. “National Electrical Code” (Código eléctrico nacional). National Fire Protection

Association (Asociación nacional para la protección contra incendios), Battery Park,

Quincy, MA 02269.

9. CSA W117.2. “Safety in Welding, Cutting and Allied Processes” (Seguridad en procesos de

soldadura, corte y asociados). Canadian Standards Association (Asociación canadiense

de normas), 178 Rexdale Blvd., Rexdale, Ontario, Canadá M9W 1R3.

DECLARATION OF CONFORMITY

Tweco

Products, Inc. declares under our sole responsibility that the product

Hand Held Air/Gas and Water Cooled MIG Welding Torches

To which this declaration relate(s) are in conformance with the following standards:

IEC 60974-7:2005

Following the provisions of the 73/23/EEC directive.

Precauciones de seguridad

3-11

89200000

Safety and Operating inStructiOnS

SECTION 3:

MIG GUN SPECIFICATIONS

3.01 STANDARD WIRE AND GAS COMBINATIONS

Material Gas Wire

320SP 400SP 500SP

SSM P&TP SSM P&TP SSM P&TP

Mild Steel

75% argon

25% CO

.030" (0,8mm)

.035" (0,9mm)

a a a

.045" (1,1mm)

a a a

.052" (1,4mm)

a a

90% argon

10% CO

92% argon

8% CO

.030" (0,8mm)

a a a a a a

.035" (0,9mm)

a a a a a a

.045" (1,1mm)

a a a a a a

.052" (1,4mm)

a a a a

.062" (1,6mm)

a a a

Fluxcored

E71-T1

75% argon

25% CO

.045" (1,1mm)

a a a a a a

.062" (1,6mm)

a a a a a a

Fluxcored

E70C-6m

75% argon

25% CO

.045" (1,1mm)

a a a

.052" (1,4mm)

a a

.062" (1,6mm)

a a

Stainless Steel

308/309

81% argon

18% helium

1% CO

.030" (0,8mm)

a a a a a a

.035" (0,9mm)

a a a a a a

.045" (1,1mm)

a a a a a a

98% argon

2% CO

.030" (0,8mm)

a a a a a a

.035" (0,9mm)

a a a a a a

.045" (1,1mm)

a a a a a a

Stainless Steel

316

81% argon

18% helium

1% CO

.030" (0,8mm)

a a a a a a

.035" (0,9mm)

a a a a a a

.045" (1,1mm)

a a a a a a

98% argon

2% CO

.030" (0,8mm)

a a a a a a

.035" (0,9mm)

a a a a a a

.045" (1,1mm)

a a a a a a

*SSM: Synergic Smart MIG *P: Pulse MIG *TP: Twin Pulse MIG

MIG Gun Speciﬁcations

3-12

Safety and Operating inStructiOnS

89200000

Material Gas Wire

320SP 400SP 500SP

SSM P&TP SSM P&TP SSM P&TP

Aluminum

4043

Argon

.035" (0,9mm)

a a a a a a

.045" (1,1mm)

a a a a a a

.047" (1,2mm)

a a a a a a

.062" (1,6mm)

a a a a

75% argon

25% helium

.047" (1,2mm)

a a a a a a

.062" (1,6mm)

a a a a

Aluminum

5356

Argon

.035" (0,9mm)

a a a a a a

.045" (1,1mm)

a a a a a a

.047" (1,2mm)

a a a a a a

.062" (1,6mm)

a a a a a a

75% argon

25% helium

.047" (1,2mm)

a a a a a a

.062" (1,6mm)

a a a a

Aluminum

5183

Argon

.035" (0,9mm)

a a a a a a

.045" (1,1mm)

a a a a a a

.047" (1,2mm)

a a a a a a

.062" (1,6mm)

a a a a a a

75% argon

25% helium

.045" (1,1mm)

a a a a a a

.047" (1,2mm)

a a a a a a

.062" (1,6mm)

a a a a

Silicon Bronze Argon

.035" (0,9mm)

a a a a a a

.045" (1,1mm)

a a a a a a

*SSM: Synergic Smart MIG *P: Pulse MIG *TP: Twin Pulse MIG

3.02 MIG GUN PART NUMBER IDENTIFICATION

NOTE

Tweco

MIG Guns, as a general rule, have a speciﬁc nomenclature incorporated

within each part number to help determine the speciﬁcations of each MIG Gun.

Please review the following example.

Example Part Number: Abbreviation / Deﬁnition

PMAS415-3545

PulseMaster, Air-Cooled, Smart Gun

450 amp gun, 15 foot cable

.035"-.045" Wire Capacity

(0,9mm - 1,2mm)

PM PulseMaster

A Air-Cooled

W Water-Cooled

S Smart Gun

X Euro-Kwik Connection

MIG Gun Speciﬁcations

3-13

89200000

Safety and Operating inStructiOnS

Air-Cooled PulseMaster Guns

Part No. Stock No.

Rating (AMP/

Duty Cycle)

Connection Cable Length

PMA312-3545

1038-1150

350 @ 80%

Tweco

12 ft. (4M)

PMA315-3545

1038-1155

15 ft. (5M)

PMA412-3545

1041-1500

450 @ 80%

12 ft. (4M)

PMA415-3545

1041-1501

15 ft. (5M)

PMA312X-3545

1038-1151

350 @ 80%

Euro

12 ft. (4M)

PMA315X-3545

1038-1156

15 ft. (5M)

PMA412X-3545

1041-1505

450 @ 80%

12 ft. (4M)

PMA415X-3545

1041-1506

15 ft. (5M)

Air-Cooled PulseMaster Smart Guns with Advanced Digital Controls

Part No. Stock No.

Rating (AMP/

Duty Cycle)

Connection Cable Length

PMAS312-3545 1038-1152

350 @ 80%

Tweco

12 ft. (4M)

PMAS315-3545 1038-1157 15 ft. (5M)

PMAS412-3545 1041-1510

450 @ 80%

12 ft. (4M)

PMAS415-3545 1041-1511 15 ft. (5M)

PMAS312X-3545 1038-1153

350 @ 80%

Euro

12 ft. (4M)

PMAS315X-3545 1038-1158 15 ft. (5M)

PMAS412X-3545 1041-1515

450 @ 80%

12 ft. (4M)

PMAS415X-3545 1041-1516 15 ft. (5M)

Water-Cooled PulseMaster Guns

Part No. Stock No.

Rating (AMP/

Duty Cycle)

Connection Cable Length

PMW412-3545 1042-1500

400 @ 100%

Tweco

12 ft. (4M)

PMW415-3545 1042-1501 15 ft. (5M)

PMW512-3545 1042-1525

500 @ 100%

12 ft. (4M)

PMW515-3545 1052-1526 15 ft. (5M)

PMW412X-3545 1042-1505

400 @ 100%

Euro

12 ft. (4M)

PMW415X-3545 1042-1506 15 ft. (5M)

PMW512X-3545 1042-1530

500 @ 100%

12 ft. (4M)

PMW515X-3545 1042-1531 15 ft. (5M)

Water-Cooled PulseMaster Guns with Advanced Digital Controls

Part No. Stock No.

Rating (AMP/

Duty Cycle)

Connection Cable Length

PMWS412-3545 1042-1510

400 @ 100%

Tweco

12 ft. (4M)

PMWS415-3545 1042-1511 15 ft. (5M)

PMWS512-3545 1042-1535

500 @ 100%

12 ft. (4M)

PMWS515-3545 1042-1536 15 ft. (5M)

PMWS512X-3545 1042-1540

500 @ 100%

Euro

12 ft. (4M)

PMWS515X-3545 1042-1541 15 ft. (5M)

PMWS412X-3545 1042-1515

400 @ 100%

12 ft. (4M)

PMWS415X-3545 1042-1516 15 ft. (5M)

MIG Gun Speciﬁcations

4-14

Safety and Operating inStructiOnS

89200000

SECTION 4:

MIG GUN INSTALLATION

NOTE

Be certain that the end user (welder, operator, or helper) reads and understands

these instructions. Be certain that the welder also reads Section 2, “Safety

Precautions.”

WARNING

Electric shock can cause injury or death.

4.01 STANDARD SETUP

Figure 1: Standard MIG Gun Setup

1. Plug the gun connector plug into the

feeder. Tweco plug and Euro-Kwik.

2. Plug the 4-pin Amphenol plug, attached

to the gun, into the 4-pin socket on the

welder.

MIG Gun Installation

4-15

89200000

Safety and Operating inStructiOnS

3. After inserting a wire inlet guide or

conduit from the MIG Gun, tighten the

brass nut and O-ring seal inside feeder.

If this nut is not tightened it may cause

gas ﬂow to escape, resulting in decreased

gas ﬂow. When removing the inlet guide

or conduit, loosen this nut.

NOTE

DO NOT OVER-TIGHTEN. Ensure that the conduit/liner does not touch or rub

against drive rolls.

4. Adjust the drive roll pressure on the feeder to a minimum. If needed, drive roll pressure

may be increased in order to facilitate proper feedability. Do not tighten drive roll pressure

too much as it could deform the wire.

NOTE

The tension adjusters on both drive rolls should be set to the minimum setting

when using 3/64" (1,2mm) aluminum. For 1/16" (1,6mm) aluminum, the user

may need to tighten the rolls one or two turns of the adjusting screw.

5. Tighten the wire spool drag to ﬁnger tip tight. The spool, when pushed 1/4 turn, should

freely spin one complete rotation.

6. Adjust voltage and wire speed as recommended by the wire manufacturer. (Refer to

table in Section 6.01). Gun is now ready for operation.

NOTE

Do not weld with the gun if the cable is coiled in circles less than 3 ft. (91cm) in

diameter because this will cause wire feed problems.

NOTE

Wipe off drive rolls with a Scotch Pad between each spool of wire. Lay pad against

roller and push the inch switch button in the feeder cabinet to turn the rollers.

MIG Gun Installation

5-16

Safety and Operating inStructiOnS

89200000

SECTION 5:

SETTINGS AND CONTROLS (SMART GUN)

5.01 SETTINGS AND CONTROLS

PulseMaster Smart Guns include integrated digital controls in the gun handle. These controls

allow the user to make adjustments to either welding current or arc length via the MIG gun

handle. The digital display provides the user with a visual conﬁ rmation of the changes as

they are made.

Digital Display

Control Up + : Allows operator to make upward

(increase) adjustments.

Control Down - : Allows operator to make downward

(decrease) adjustments.

Select: Allows operator to switch between welding current,

metal thickness, and wire speed adjustment mode

to arc length adjustment mode.

NOTE

When changing between Tiptronic programs on the gun controls: pressing the

select button will make the number on the left (set) start flashing and enable

the gun to switch between sets of programs by pressing the up or down button

while the screen is blinking. If you press just the up or down buttons, the gun

will scroll between programs in that set, but will not go through other sets.

Example: 3 - 4 (3 is the set, 4 is the program).

5.02 ADJUSTMENT OPTIONS

The SELECT button allows the operator to navigate between the following settings on the

power supply:

NOTE

The operator will need to adjust the settings manually on the welder to change from

welding current to metal thickness or to wire speed. The SELECT button allows the operator

to change from "length of arc mode" to the mode set manually on the welder.

• Welding current (amperage), metal thickness, or wire speed mode.

• Arc length adjustment mode

The ﬁ rst setting to display will be the last setting used on the power supply.

Longer and Shorter arc settings are displayed as:

Longer arc length Shorter arc length

Settings and Controls (Smart Gun)

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ESAB Air-Cooled 350 AMP 450 AMP Water-Cooled 400 AMP 500 AMP PulseMaster™ Mig Gun User manual

Brand: ESAB

Model: Air-Cooled 350 AMP 450 AMP Water-Cooled 400 AMP 500 AMP PulseMaster™ Mig Gun

Category: Welding System

Type: User manual

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