1
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
2
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.
i
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
Copyright © 2009 Thermadyne Industries, Inc. All rights reserved.
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 #:
ii
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
2
.030" (0,8mm)
a
.035" (0,9mm)
a a a
.045" (1,1mm)
a a a
.052" (1,4mm)
a a
90% argon
10% CO
2
or
92% argon
8% CO
2
.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
2
.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
2
.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
2
.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
2
.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
2
.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
2
.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)
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
/