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Miller AUTO ARC 140, KF996056 Owner's manual

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AUTO
ARCJ
February
1996
Form:
OM-151
0160
Effective
With
Serial
No.
KF996056
OWNERS
MANUAL
U
Read
and
follow
these
instructions
and
all
Give
this
manual
to
the
operator.
safety
blocks
carefully.
Have
only
trained
and
qualified
persons
install,
operate,
or
service
this
unit.
Call
your
distributor
if
you
do
not
understand
the
directions.
ri~ij
U
For
help,
call
your
distributor
or:
MILLER
Electric
Mfg.
Co.,
P.O.
Box
1079,
Appleton,
WI
54912
414-734-9821
Auto
Arcfi
140
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_am
7/93
ST-149
628-B
PRINTED
IN
USA
LIMITED
WARRANTY
Effective
February
7,
1996
(Equipment
with
a
serial
number
preface
of
KD
or
newer)
This
limited
warranty
supersedes
all
previous
manufacturers
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY
Subject
to
the
terms
snd
conditions
below,
warranta
to
its
original
retail
purchaser
that
new
equipment
sotd
aher
the
effective
date
ot
this
lim
ited
warranty
is
tree
ot
detects
in
material
and
workmanship
at
the
time
it
is
shipped
from
factory
THIS
WARRANTY
IS
EXPRESSLY
tN
LIEU
OF
ALL
OTHER
WAR
RANTIES,
EXPRESS
OR
IMPLIED,
INCLUDING
THE
WARRANTIES
OF
MER
CHANTABILITY
AND
FITNESS.
Within
the
warranty
periods
listed
below,
manutacturer
wilt
repairor
replace
any
war
ranted
parts
or
components
that
tail
due
to
such
detects
in
material
or
workmanship.
Manufacturer
must
be
notified
in
writing
within
thirty
(30)
days
of
such
detect
or
tail
ure,
at
which
time
manutacturer
will
provide
instructions
on
the
warranty
claim
pro
cedures
to
be
tollowed.
Manutacturer
shall
honor
warranty
claims
on
warranted
equipment
listed
below
in
the
event
of
auch
a
failure
within
the
warranty
time
periods.
All
warranty
time
periods
atari
on
the
date
that
the
equipment
was
delivered
to
the
original
retail
purchaser,
or
one
year
affer
the
equipment
is
sent
to
a
North
American
distributor
or
eighteen
months
aher
the
equipment
is
aent
to
an
International
diatributor.
1.
5YearaParta3YearaLabor
Original
main
power
rectitiera
Invertera
(input
and
output
rectitiera
only)
2.
3
Years
Parts
and
Labor
Tranatormer/Rectitier
Power
Sources
Plasma
Arc
Cuaing
Power
Sourcea
*
Semi-Automatic
and
Automatic
Wire
Feeders
Inverter
Power
Supplies
Intellitig
Robots
(1
year
labor)
3.
2
Years
Parts
and
Labor
Engine
Driven
Welding
Generators
(NOTE;
Engines
are
warranted
separately
by
the
engine
manufacturer.)
-
Air
Compressors
4.
1
Year
Parts
and
Labor
Motor
Driven
Guns
Process
Controllers
IHPS
Power
Sources
Water
Coolant
Systems
HF
Units
Grida
Spot
Welders
Load
Ba~ka
SDX
Transformers
-
Running
Gear/Trailers
Plaama
Cuffing
Torches
(eacept
APT,
ZIPCUT
&
PLAZCUT
Models)
Tecumaeh
Engines
*
Deutz
Engines
(outside
North
America)
-
Field
Options
(NOTE;
Field
options
are
covered
under
the
limited
warranty
for
the
re
maining
warranty
period
of
the
product
they
are
installed
in,
or
for
a
mini
mum
ot
one
year
whichever
ia
greater.)
6
Montha
Baneries
6.
90
Days
Parts
and
Labor
MIG
Guna/TIG
Torches
APT,
ZIPCUT
&
PLAZCUT
Model
Plasma
Cutting
Torches
Remote
Controls
Accessory
Kits
Replacement
Parts
Umited
Warranty
shall
not
apply
to;
1.
Items
tumished
by
manufacturer,
but
manutactured
by
others,
such
as
engines
or
trade
accessories.
These
items
are
covered
by
the
manufacturers
warranty,
if
any.
2.
Consumable
components;
auch
as
contact
tips,
cuffing
nozzles,
contactora
and
relays
or
parts
that
tail
due
to
normal
wear.
3.
Equipment
that
has
been
modified
by
any
party
other
than
manufacturer,
or
equipment
that
has
been
improperly
installed,
improperiy
operated
or
misused
based
upon
industry
standards,
or
equipment
which
haa
not
had
reaaonable
and
necessary
maintenance,
or
equipment
which
has
been
uaed
for
operation
outside
of
the
apecificationa
for
the
equipment.
MANUFACTURERS
PRODUCTS
ARE
tNTENDED
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
eaclusive
remedies
shall
be,
at
manufacturers
option;
(I)
repair;
or
(2)
replacement;
or,
where
authorized
in
writing
by
manufacturer
in
appropriate
cases,
(3)
the
reaaonabte
coat
of
repair
or
replacement
at
an
authorized
service
station;
or
(4)
payment
of
or
credit
for
the
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
customers
risk
and
expense.
Manufacturers
option
of
repair
or
replace
ment
will
be
FOB.,
Factory
at
Appleton,
Wisconsin,
or
FOB.
at
an
authorized
ser
vice
facility
as
determined
by
manufacturer.
Therefore
no
compensation
or
reim
bursement
for
transportation
coats
of
any
kind
will
be
allowed.
TO
THE
EXTENT
PERMITTED
BY
LAW,
THE
REMEDIES
PROVIOED
HEREIN
ARE
THE
SOLE
AND
EXCLUSIVE
REMEDIES.
IN
NO
EVENT
SHALL
MANUFAC
TURER
BE
LIABLE
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
REPRESENTATION
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,
special
or
consequential
damages,
so
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
1mm
state
to
state.
In
Canada,
legislation
in
some
provincea
provides
for
certain
additional
warranties
or
remedies
other
than
as
stated
herein,
and
to
the
extent
that
they
may
not
be
waived,
the
limitationa
and
exclusions
act
out
above
may
not
apply.
This
Limited
Warranty
providaa
specific
legal
rights.
and
other
rights
may
be
available,
but
may
vary
from
province
to
province.
I
r......
I
RECEIVING-HANDLING
Before
Unpacking
equipment,
check
carton
for
any
damage
that
may
have
occurred
during
shipment.
File
any
claims
for
loss
or
damage
with
the
delivering
carrier.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
distributor
and/or
equipment
manufacturers
Transportation
Department.
When
requesting
information
about
this
equipment,
always
provide
Model
Designation
and
Serial
or
Style
Number.
Use
the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Number
of
your
unit.
The
information
is
located
on
the
rating
label
or
nameplate.
Model
__________
Serial
or
Style
No.
Date
of
Purchase
brand_acct
3/96
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
electncafly
live
whenever
the
output
is
on.
The
Input
power
circuit
and
machine
Internal
circuits
are
also
live
when
power
is
on.
In
semiautomatic
or
automatic
wire
welding,
the
wire,
wire
reel,
drive
roll
housing,
and
all
metal
parts
touching
the
weldlnp
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
CFR
1910.147
(see
Safety
Standards).
5.
Properly
install
and
ground
this
equipment
according
to
Its
Owners
Manual and
national,
state,
and
local
codes.
6.
Always
verify
the
supply
ground
check
and
be
sure
that
Input
power
cord
ground
wire
is
properly
connected
to
ground
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.
Turn
off
all
equipment
when
not
In
use.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
11.
Do
not
drape
cables
over
your
body.
12.
If
earth
grounding
of
the
workpiece
is
required,
ground
It
directly
with
a
separate
cable
do
not
use
work
damp
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~maintalned
equipment.
Repair
or
replace
damaged
parts
at
once.
Maintain
unIt
according
to
manual.
Wear
a
safety
hamess
If
working
above
floor
level.
Keep
all
panels
and
covers
securely
In
place.
Clamp
work
cable
with
good
metal-to-metal
contact
to
workplece
or
worktable
as
near
the
weld
as
practical.
4A
WARNING
ARC
WELDING
can
be
hazardous.
PROTECT
YOURSELF
AND
OTHERS
FROM
POSSIBLE
SERIOUS
INJURY
OR
DEATH.
KEEP
CHILDREN
AWAY.
PACEMAKER
WEARERS
KEEP
AWAY
UNTIL
CONSULTING
YOUR
DOCTOR.
Inwelding,
as
in
most
jobs,
exposure
to
certain
hazards
occurs.
Welding
is
sate
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
9.
10.
15.
16.
17.
ARC
RAYS
can
burn
eyes
and
skin;
ARC
RAYS
NOISE
can
damaae
hearing;
FLYING
2.
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
to
/~
SLAG
OR
SPARKS
can
Injure
eyes.
protectyourface
and
eyeswhen
welding
orwatching
(see
ANSI
Arc
rays
from
the
welding
process
produce
Intense
Z49.1
and
Z87.1
listed
In
Satety
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,
fIame~resistant
1.
Use
approved
ear
plugs
or
ear
muffs
If
noise
level
is
high.
material
(wool
and
leather)
and
foot
protection.
P
u
I
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.
I
6.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
1.
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
fumes.
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
form
highly
toxic
and
IrritatIng
gases.
remove
welding
fumes
and
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
3.
If
ventilation
is
poor,
use
an
approved
air-supplied
respirator.
cadmium
plated
steel,
unless
the
coating
is
removed
from
the
4.
Read
the
Material
Safety
Data
Sheets
(MSDSS)
and
the
weld
area,
the
area
is
well
ventilated,
and
If
necessary,
while
manufacturers
instruction
for
metals,
consumables,
coatings,
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
cleaners,
and
degreasers.
containing
these
elements
can
give
oft
toxic
fumes
if
welded.
CYLINDERS
can
explode
If
damaged.
4.
Never
drape
a
welding
torch
over
a
gas
cylinder.
Shielding
~as
cylinders
contain
gas
under
high
5.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
pressure.
It
damaged,
a
cylinder
can
explode.
Since
6.
Never
weld
one
pressurized
cylinder
explosion
will
result.
~.
gas
cylinders
are
normally
part
of
the
welding
7.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
i
U
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.
10.
Read
and
foliow
Instructions
on
compressed
gas
cylinders,
3.
Keep
cylinders
away
from
any
welding
or
other
electrical
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
circuits.
Standards.
I
srl.1.1
2194
WELDING
can
cause
fire
or
explosion.
Welding
on
closed
containers,
such
as
tanks,
drums,
or
pipes,
can
cause
them
to
blow
up.
Sparks
can
fly
off
from~
the
welding
arc.
The
flying
sparks,
hot
workpiece,
and
hot
equipment
can
cause
fires
and
bums.
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.
£~
WARNING
ENGINE
EXHAUST
GASES
can
kill.
Engines
produce
harmful
exhaust
gases.
ENGINE
FUEL
can
cause
fire
or
explosion.
Engine
fuel
is
highly
flammable.
1.
Stop
engine
and
let
ft
cool
off
before
checking
or
adding
fuel.
2.
Do
not
add
fuel
while
smoking
or
if
unit
is
near
any
sparks
or
MOVING
PARTS
can
cause
injury.
Moving
parts,
such
as
fans,
rotors,
and
belts
can
I
cut
fingers
and
hands
and
catch
loose
clothing.
1.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
2.
-
Stop
eng
ne
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.
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
Satety
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.
Wear
oil-f
ree
protective
garments
such
as
leather
gloves,
heavy
shirt,
cuff
less
trousers,
high
shoes,
and
a
cap.
12.
Remove
anycombustibles.
such
as
a
butane
lighteror
matches,
from
your
person
before
doing
any
welding.
ENGINES
can
be
hazardous.
1.
Use
equipment
outside
in
open,
well-ventilated
areas.
2.
If
used
in
a
closed
area,
vent
engine
exhaust
outside
and
away
from
any
building
air
intakes.
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.
It
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
Z49.1,
from
American
Welding
Society,
550
N.W.
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
Haza
rdous
Substances,
Ameri
can
Welding
Society
Standard
AWS
F4.1
,from
American
Welding
So
ciety,
550
NW.
LeJeune
Ad,
Miami,
FL
33126
National
Electrical
Code,
NFPA
Standard
70,
from
National
Fire
Pro
tection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-1,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
Aexdale
Bou
levard,
Rexdale,
Ontario,
Canada
M9W
1
A3.
Safe
Practices
For
Occupation
And
EducationalEye
And
Face
Protec
tion,
ANSI
Standard
Z87.i,
from
American
National
Standards
InstItute,
1430
Broadway,
New
York,
NY
10018.
Cutting
And
Welding
Processes,
NFPA
Standard
SiB,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
4
3.
Do
not
overfill
tank
allow
room
for
fuel
to
expand.
4.
Do
not
spill
fuel.
If
fuel
is
spilled,
clean
up
before
starting
engine.
1.
2.
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.
silIl
2/94
CONSIGNES
DE
SECURITE
POUR
LE
SOUDAGE
A
LARC
UN
CHOC
ELECTRIQUE
peut
tuer.
Un
simple
contact
avec
des
piŁces
Ølectnques
pout
provoquer
une
Olectrocution
ou
des
blessures
graves.
LØlectrode
et
Ie
circuit
de
soudago
sont
sous
tension
des
quo
Iappareil
est
surON.
Le
circuit
dentrOe
et
les
circuits
intemes
de
lappareil
sont
Ogalement
sous
tension
a
ce
moment-l.
En
soudage
semi-automatique
ou
automatique,
le
fil,
le
dØvidoir,
to
logement
des
galets
dentrainement
et
les
piŁces
metalliques
en
contact
avec
to
fd
do
soudage
sont
sous
tension.
Des
matØriels
mal
installOs
ou
mel
mis
a
Ia
terre
prOsentent
un
danger.
1.
Ne
jamais
toucher
les
piŁces
Ølectriques
sous
tension.
2.
Porter
des
gants
et
des
vØtements
do
protection
secs
no
comportant
pas
do
trous.
3.
Sisoler
de
Ia
piŁce
et
de
Ia
terre
au
moyen
do
tapis
ou
dautres
moyens
isolants
suffisamment
grands
pour
empOcher
to
contact
physique
Øventuel
avec
Ia
piŁce
ou
Ia
terre.
4.
Couper
lalimentation
ou
arrØter
le
moteur
avant
do
procØder
a
linstallation,
a
Ia
reparation
ou
a
lentretien
do
Iappareil.
DØverrouiller
lalimentation
selon
Ia
norme
OSHA
29
CFR
1910.147
(voir
normes
do
sØcuntO).
5.
Installer
et
mettre
a
Ia
terre
correctement
cot
appareil
confomiØment
a
son
manuel
dutilisation
et
au
codes
nationaux,
provinclaux
et
municipaux.
6.
Toujours
verifier
Ia
terre
du
cordon
dalimentation
Verifier
et
sassurer
cue
Is
fit
de
terre
du
cordon
dalimentation
est
bion
LE
SOUDAGE
A
LARC
peut
Œtre
dangereux.
raccordØ
ala
borne
do
terre
du
sectionneur
ou
quo
Ia
fiche
du
cordon
est
raccordØe
a
une
prise
correctement
mise
a
Ia
terre.
7.
En
off
ectuant
los
raccordomonts
dontrØe
fixer
dabord
Jo
conducteur
do
mise a
Ia
terre
appropnØ
01
contro-vØnfuer
los
connexions.
8.
Verifier
frØquemment
le
cordon
dalimentation
pour
volr
sil
nest
pas
endommage
ou
dØnudØ
remplacor
le
cordon
immØdiatemont
slI
est
endommage
un
cAble
dØnudØ
pout
provoquer
uno
lectrocution.
9.
Mettre
lappareil
hors
tension
quand
on no
lutilise
pas.
10.
No
pas
utiliser
des
cAbles
uses,
endommages,
do
grosseur
insuffisante
ou
mal
episses.
11.
Ne
pas
enrouler
los
cAbles
autour
du
corps.
12.
Si
Ia
piŁce
soudŁo
doit
Øtre
mise
ala
terre.
le
faire
directement
avec
un
cAble
distinct
no
pas
utiliser
le
connectour
do
piŁce
ou
to
cAble
do
retour.
13.
Ne
pas
toucher
lØlectrode
quand
on
ost
en
contact
avoc
Ia
piŁce,
(a
terre
ou
une
electrode
provenant
dune
autre
machine.
14.
Nutiliser
quun
materiel
on
bon
etat.
Reparer
ou
remplacer
sur-le-champ
les
piŁces
endommagees.
Entrotenir
Iappareit
conformØment
a
ce
manuel.
15.
Porter
un
hamais
do
sØcuritØ
quand
on
travallle
en
hauteur.
16.
Maintenir
solidement
en
place
tousles
pannoaux
01
capots.
17.
Fixer
10
cAble
de
retourde
faon
a
obtenir
un
ban
contact
mØtal-mØtat
avec
Ia
piŁce
soudorou
Ia
table
do
travail,
le
plus
pros
possible
do
Ia
BRUIT
LE
RAYONNEMENT
DE
LARC
peut
brOler
les
yeux
et
Ia
peau.
Le
BRUIT
peut
endommager
louTe;
les
PROJECTIONS
DE
LAITIER
OU
LES
ETINCELLES
peuvent
blesser
les
yeux.
Larc
de
soudage
produit
des
rayons
visibles
et
invisibles
intenses
(ultraviolots
et
infrarouges)
qui
peuvent
brOler
Iesyeux
et
Ia
peau.
Le
bruit
produit
par
certains
procØdØs
pout
endommager
loule.
Des
projections
do
metal
ou
do
laitier
sont
produites
par
le
piquage,
10
meulage
ou
le
refroidissement
des
soudures.
1.
Utiliser
des
bouche-oreilles
ou
des
serre-tŒte
antibruit
approuves
si
to
niveau
do
bruit
est
OIevØ.
LES
VAPEURS
El
LES
FUMEES
peuvent
etre
dangereuses
pour
Ia
sante.
Le
soudago
produit
des
vapeurs
et
des
fumOes
quiI
est
dangereux
do
respirer.
1.
Garder
Ia
tŒte
a
IextOneur
des
vapeurs
ot
des
fumØes
et
no
pas
les
respiror.
2.
A
lintØneur,
ventiler
le
poste
de
travail
ou
utiliser
un
dispositif
place
au
niveau
do
larc
pour
Øvacuer
los
vapeurs
et
fumOes
de
soudage.
3.
Si
Ia
ventilation
051
mauvaise,
utiliser
un
appareil
respiratoire
a
adduction
dair
pur
approuvO.
4.
Consulter
los
fiches
signalØtiques
et
les
consignes
du
fabricant
relatives
au
mØtaux,
produits
dapport.
revOtements,
nettoyants
et
dØgraissants.
2.
Porter
un
masque
a
serre-tOte
muni
dun
verre
filtrant
do
nuance
appropnØe
pour
protØger
10
visage
et
los
yeux
quand
on
soude
ou
observe
Ia
travail
de
soudage
(voir
los
normos
ANSI
Z49.1
et
287.1
donnOos
sous
Ia
rubrique
Pflncipales
normes
de
socuntØ).
3.
Porter
des
lunettes
do
sØcuiitØ
approuvØes
avec
Øcrans
latØraux.
4.
Utiliser
des
paravents
ou
des
barnŁres
do
protection
pour
protØger
los
personnes
a
proximitØ
contre
los
coups
darc
et
lØblouissement;
avertir
los
autres
personnes
do
no
pas
regardor
larc.
5.
Porter
des
vOtements
do
protection
on
tissu
Ignifuge
durable
(lame
et
cuir)
et
des
chaussuros
do
sØcuntO.
5.
Ne
travailler
dans
un
espace
confine
quo
sil
est
bien
ventitØ,
ou
en
portant
un
appareil
rospiratoire
~
adduction
dair
pur.
Demander
Ł
un
obsorvateur
ayant
reu
Ia
bonno
formation
do
toujours
se
tenir
a
proximite.
Les
vapeurs
01
fumØes
do
soudage
peuvent
dØplacer
lair
01
abaissor
to
niveau
doxygOne
et
causer
des
blessuros
graves
voire
mortelles.
Sassuror
quo
lair
est
propro
a
Ia
respiration.
6.
Ne
pas
soudor
a
proximite
doperations
do
dOgmissage,
do
nettoyage
ou
do
pulverisation.
La
chaleur
et
los
rayons
do
tars
peuvent
rØagir
avec
los
vapeurs
pour
former
dos
gaz
hautement
toxiques
ot
irritants.
7.
Ne
pas
soudor
sur
des
mØtaux
revOtus
comme
lacier
galvanise,
au
plombou
cadmiØ
a
moms
quo
Ia
piŁce
naitØtØ
entiŁremontdecapOe,
quo
le
paste
do
travail
soit
bien
ventilØ.
Sil
y
a
lieu,
porter
un
apparell
respiratoire
a
adduction
dairpur.
Los
revOtements
ot
los
mOtaux
gui
contionnont
de
tols
elements
peuvent
degagor
des
vapours
toxiques
lore
du
soudaqe.
LES
BOUTEILLES
peuvent
exploser
sI
elles
sont
endommagØes.
Les
bouteillos
contenant
des
gaz
de
protection
sont
a
haute
pression.
Une
bouteillo
endommagee
pout
exploser.
Etant
donnØ
quo
les
bouteilles
do
gaz
font
normalemont
partie
du
matØnel
do
soudage,
los
trailer
avec
le
plus
grand
soin.
1.
ProtØger
los
bouteilles
do
gaz
compnmØ
contre
Ia
chaleur
intense,
los
chocs,
le
lailier.
los
flammes
nues,
los
Øtincelles
01
tars.
2.
Placer
los
bouteilles
ala
vorticale
en
les
fixant
a
un
support
fixe
ou
a
un
chariot
pour
Øviter
quelles
no
tombent
ou
no
basculent.
3.
Tenirles
bouteillos
a
lŁcart
du
poste
de
soudage
ou
dautres
circuits
dlectnques.
4.
No
jamais
poser
un
chalumoau
soudeur
sur
une
bouteillo
do
gaz.
5.
Ne
jamais
laisser
uno
electrode
do
soudage
toucher
une
bouteille.
6.
Ne
jamais
souder
sur
uno
boutoillo
sous
pressman
:
0110
oxploseralt.
7.
Nutiliser
quo
dos
bouteillos
do
gaz
do
protection,
des
dOtondeurs,
des
tuyaux
souples
of
dos
raccords
appropnØs
concus
pour
--lapplication
particuliOro;
conserver
ces
matØriels
et
lours
piŁces
en
bon
Øtat.
8.
Elaignor
10
visage
de
Ia
Sortie
du
robmnet
do
Ia
boutoille
quand
on
louvre.
9.
Replacer
lo
chapoau
sur
Ia
boutoille
apres
utilisatlon.
10.
Lire
01
suivre
los
consignes
relatives
aux
bouteillos
do
gaz
compuime,
au
materiel
connexe
ainsi
que
Ia
publication
P-i
de
Ia
CGA
donnØe
sous
Ia
rubflquo
Prmncipales
normes
do
sØcuntØ.
a
MISE
EN
GARDE
SE
PROTEGER
El
PROTEGER
LES
AUTRES
CONTRE
LES
BLESSURES
GRAVES
VOIRE
MORTELLES.
TENIR
LES
ENFANTS
A
LECART.
LES
PERSONNES
QUI
PQRTENT
UN
STIMULATEUR
CARDIAQUE
NE
DOIVENT
PAS
NON
PLUS
SAPPROCHER
DU
POSTE
DE
SOUDAGE,
A
MOINS
DAVOIR
CONSULTE
UN
MEDECIN.
Le
soudage,
comme
Ia
plupart
des
travaux,
prOsente
certains
dangers.
Par
contre,
le
soudage
pout
Œtre
effectuØ
en
toute
sOcufltØ
quand
on
prend
los
mesures
qui
simposent.
Los
consignes
do
sØcuntØ
donnØes
ci-aprŁs
ne
font
que
rØsumer
linformation
contenue
dans
los
normes
de
sOcufltO
ØnumOrOes
a
Ia
page
suivante.
Lire
et
respecter
toutes
ces
norrnes
de
sØcuntO.
LINSTALLATION,
LUTILISATION,
LENTRETIEN
El
LES
REPARATIONS
NE
DOIVENT
ETRE
CONFIES
ouA
DES
PERSONNES
QUALIFIEES
RAYONNEMENTDELARC
srl.1.1
2194
TABLE
OF
CONTENTS
SECTION
1
SAFETY
INFORMATION
1
SECTION
2
SPECIFICATIONS
1
2-1.
Volt-Ampere
Curves
2
2-2.
Duty
Cycle
2
SECTION
3INSTALLATION
2
3-1.
Installing
Work
Clamp
3
3-2.
Installing
Gas
Supply
3
3-3.
Gun
Polarity
For
Wire
Type
4
3-4.
Selecting
A
Location
And
Connecting
Input
Power
5
3-5.
Installing
Drive
Rolls
And
Welding
Gun
6
3-6.
Installing
Wire
Spool
7
3-7.
Threading
Welding
Wire
7
SECTION
4OPERATION
9
SECTION
5
MAINTENANCE
&
TROUBLESHOOTING
12
5-1.
Routine
Maintenance
12
5-2.
Overload
Protection
12
5-3.
Cleaning
Or
Repairing
Drive
Assembly
13
5-4.
Gun
Maintenance
14
5-5.
Troubleshooting
15
SECTION
6-
ELECTRICAL
DIAGRAMS
16
SECTION
7-WELDING
METHODS
&
TROUBLESHOOTING
18
7-1.
Flux
Cored
Arc
Welding
(FCAW)
And
Gas
Metal
Arc
Welding
(GMAW)
18
7-2.
Welding
Troubleshooting
20
SECTION
8
PARTS
LIST
24
Figure
8-1.
Main
Assembly
24
Figure
8-2.
Baffle,
Center
w/Components
26
Figure
8-3.
Drive
Assembly,
Wire
28
Figure
8-4.
MWG-160
Gun
29
OM-151
016C2196
SECTION
1
-
SAFETY
INFORMATION
Figure
1-1.
Safety
Information
modl.1
2/93
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
4
Safety
Instructions
To
Avoid
Hazard
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.
SECTION
2-
SPECIFICATIONS
Table
2-1.
Welding
Power
Source
Read
all
safety
messages
throughout
this
manual.
Obey
all
safety
messages
to
avoid
injury.
Learn
the
meaning
of
WARNING
and
CAUTION.
2 2
a
CAUTION
/
5
MOVING
PARTS
can
Injure.
~
ELECTRIC
SHOCK
can
kill
I I
Do
not
louch
live
electrical
parts.
1]
~
S
Keep
away
from
moving
pads.
I
Keep
all
panels
and
covers
closed
Disconnect
input
power
before
when
operating.
installing
or
servicing.
6
a
WARNING
READ
SAFETY
BLOCKS
at
start
of
Section
3-1
before
proceedin9.
7H
NOTE
~
Turn
Off
switch
when
using
high
frequency.
Specifications
Description
Type
Of
Output
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
Wire
Feed
Speed
Range
Wire
Diameter
Range
Input
Power
Cord
With
Plug
Overall
Dimensions
Weight
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
1pm
(1.2
To
17.5
mpm)
.023
To
.035
in
(0.58
To
0.89
mm)
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
a
CAUTION
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
40
30
20
10
Ui
I-.
-J
0
>
C-)
0
The
volt-ampere
curves
show
the
minimum
and
maximum
voltage
and
amperage
output
capabilities
of
the
welding
power
source.
Curves
of
other
sethngs
fall
between
the
curves
shown.
ssbl.1
10/91/S8-124
625
50
00
150
200
250
D.C.
AMPERES
EX
CEE
Do
no
DING
DUTY
CYCLE
RATINGS
will
damage
unit.
t
exceed
indicated
duty
cycles.
wam7.1
2/92
.
200
Duty
cycle
is
how
long
the
unit
can
operate
within
a
ten
minute
period
50
without
causing
overheating
or
damage.
90
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,
the
duty
cycle
increases.
80
.
70
60
50
~
I
1.5
20
25
30
40
50
60 70
80
90
100
DUTY
CYCLE
%
sbl.22/92SB-124624
Figure
2-2.
Duty
Cycle
Chart
SECTION
3-INSTALLATION
OM-151
016
Page
2
N
OTE
LI~
Customer
must
obtain
proper
welding
wire
and
s
application.
hielding
gas
for
desired
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
__
a
WARNING
.
C
YLINDERS
can
explode
if
damaged.
~
Keep
cylinders
away
from
welding
and
other
~
electrical
circuits.
BUILDUP
OF
SHIELDING
GAS
can
harm
health
or
kill.
Shut
off
shielding
gas
supply
when
not
in
use.
Never
touch
cylinder
with
welding
electrode.
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.
2
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
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
2/93
Obtain
gas
cylinder
and
chain
to
running
gear,
wall,
or
other
station
ary
support
so
cylinder
cannot
fall
and
break
off
valve.
1
Cap
6
2
Cylinder
Valve
Remove
cap,
stand
to
side
of
valve,
and
open
valve
slightly.
Gas
flow
blows
dust
and
dirt
from
valve.
Close
valve.
3
Cylinder
I---
OR
4
Regulator/Flowmeter
Install
so
face
is
vertical.
4
Argon
Gas
5
Gas
Hose
Connection
Fitting
has
5/8-18
right-hand
threads.
Install
supplied
air
hose.
6
Flow
Adjust
Typical
flow
rate
is
20
cfh
(cubic
feet
per
hour).
Check
wire
man
ufacturers
recommended
flow
rate.
2
Tools
Needed:
1-1/8,5/8
in
7
8
7
CO2
Adapter
8
0-Ring
CO2
Gas
Install
adapter
with
0-ring
between
regulator/flowmeter
and
CO2
cylinder.
ssb3.1
12/92
ST-158
697-A
STRAIGHT
I
I
POLARITY
I
For
Flux
Cored
Wires,,~
~
~
(FCAW
Process)
L
REVERSE
POLARITY
For
Solid
Steel
Or
Aluminum
(
Wires
I
(GMAW~
R\_~
Process
DCEP
1
Tools
Needed:
t3/Sin
I
Polarity
Changeover
Label
2
Polarity
Jumper
Links
Always
read
and
follow
wire
man
ufacturers
recommended
polarity.
There
are
two
jumper
links
(1
set)
across
each
set
of
terminals.
Be
sure
to
move
each
set
of
links
when
changing
polarity.
Close
door.
Ael.
ST-149
631-c
Figure
3-4.
Gun
Polarity
Jumper
Link
Position
OM-151
016
Page
4
3-4.
Selecting
A
Location
And
Connecting
Input
Power
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.
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.
swam3.r
2193
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/Kcmll
14
Max
Recommended
Input
Conductor
Length
In
Feet
(Meters)
65
(20)
Mm
Grounding
Conductor
Size
In
AWG/Kcmll
14
Reference:
1993
National
Electrical
Code
(NEC).
s-ooeaj
1
5
7
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:
1
Pressure
Adlustment
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.
lighten
knob.
8
Gun
Trigger
Plug
Insert
plug
into
receptacle,
and
tighten
threaded
collar.
Figure
3-6.
Drive
Roll
And
Welding
Gun
Installation
Ref.
ST~15O
193-D
I
Ref.
ST-149
629-C
I
ST-155
578
2
OM-151
016
Page
6
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:
I
6
in~
(150
mm)
Pull
and
hold
wire;
cut
off
end.
Push
wire
thru
guides
into
gun;
continue
to
hold
wire.
-+=~
Remove
gun
nozzle
and
contact
tip.
Press
gun
trigger
until
wire
comes
out
of
gun.
Reinstall
contact
tip
and
nozzle.
o
ii
I
II
Feed
wire
to
check
drive
roll
pressure.
Tighten
knob
enough
to
prevent
slipping.
Cut
off
wire.
Close
and
latch
door.
Figure
3-8.
Threading
Welding
Wire
Ret.
ST-149
632-C
/
Ref.
ST-ISO
193/
Ref.
ST-159
272
/
S-0627-A
Hold
wire
tight
lyfokeep
it
from
unraveling.
I1~T~
~
-*
Open
pressure
assembly.
ON
Close
and
tighten
pressure
assembly,
and
let
go
of
wire.
POWER
~e
H
QOFF
Set
switch.
-*
p
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
(MSDS5)
and
manufacturers
instructions
for
material
used.
WELDING
can
cause
fire
or
explosion.
Do
not
weld
near
flammable
material.
Watch
for
fire;
keep
extinguisher
nearby.
Do
not
locate
unit
over
combustible
surfaces.
Do
not
weld
on
closed
containers.
Allow
work
and
equipment
to
cool
before
handling.
Figure
4-1.
Safety
Equipment
Figure
4-2.
Work
Clamp
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
1
Insulating
Gloves
2
Safety
Glasses
With
Side
Shields
3
Welding
Helmet
Wear
dry
insulating
gloves,
safety
glasses
with
side
shields,
and
a
welding
helmet
with
a
correct
shade
of
filter
(see
ANSI
Z49.1).
sb3.1
10/91
1
Shielding
Gas
Cylinder
2
Valve
3
Gun
Trigger
Open
valve
on
cylinder
just
before
welding.
Gun
trigger
turns
weld
output
and
gas
flow
on
and
oft.
Close
valve
on
cylinder
when
fin
ished
welding.
sb5.1
6/92-S.0621-C
~p
~
~
ARC
RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
Wear
welding
helmet
with
correct
shade
of
filter.
Wear
correct
eye,
ear,
and
body
protection.
,..~
~
0
MOVING
PARTS
can
cause
Injury.
Keep
away
from
pinch
points
such
as
drive
rolls.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
1
Work
Cable
2
Work
Clamp
2
Tools
Needed:
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.
sM.1
2/93
Ret.
ST.156
258
a
WARNING
BUILDUP
OF
SHIELDING
GAS
can
harm
health
or
kill.
Shut
off
shielding
gas
supply
when
not
in
use.
waml.1
9/91
Figure
4-3.
Shielding
Gas
OM-151
016
Page
9
wam5.1
2193
1
Fine
Tuning/Wire
Speed
Control
Use
control
to
select
a
wire
feed
speed.
As
ThicknessNoltage
switch
setting
increases,
wire
speed
range
also
increases.
The
numbers
around
the
control
are
not
a
wire
feed
speed
and
are
for
reference
only
(see
Table
4-1).
2
ThicknessNoltage
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
Ian
On
and
Off.
a
CAUTION
ARCING
can
damage
switch.
Do
not
change
ThicknessNoltage
switch
position
while
welding.
Arcing
inside
switch
can
damage
contacts,
causing
switch
to
fail.
Figure
4-4.
Controls
Ref.
5T-150
092-A
/
Ref.
5T-156
258
OM-151
016
Page
10
install
&
Put
On
~
~
Turn
On
~
~\
Do
)~S\
Readjust
Contro~~
Connect
)
)
Personal
Safety
)
)Eauipment
&
Gas
3
)
Set
Controls
))
Sample
Weld
And
Prepare
J
Equipm~~,/J
Equipment
JJ
(if
ApplicableL,uJ
_____________
J
For
Production}
ssb4.1
10191
Figure
4-5.
Sequence
Of
Operation
For
Hard
And
Flux
Cored
Wires
Install
&
Conneci\
~
Adjust
Hub
\
Adjust
Drive
R~ii
Put
On
Persona~\\Tum
On
Equipme~
Set
Controls
&
Equipment
Using
3
3
Tension
To
3
3
Pressure
To
J
Knu~ed
G~~JJ
Minimum
}J
Minimum
})Safety
Equipmen9)
To
30
cfh~~ght
And
Adjust
Gas
I
Keep
Gun
Cable
)
Do
Sample
Weld
And
Prepare
For
~)Read~ust
Contr~
________________
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%
35%
.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
Tri~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
30
Cf
11+
.030
Voltage
4
3 3
2
1
1
Wire
Speed*
90% 85%
80%
90%
90%
85%
.035
Voltage
4
4
3
2
2
1
Wire
Speed
85%
85%
85%
90%
90%
80%
*
Do
not
change
ThlckneBe/Voltage
ewitch
poaitIon
while
welding.
Fine
TunInglWire
Speed
value
in
Table
4-1
Ia
a
etarting
value
only
and
Fine
Tuning/Wire
Speed
control
setting
can
be
fine
tuned
during
welding.
+cth
=
cubic
ft
per
hour
OM-151
016
Page
11
SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
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
5-2.
Overload
Protection
I
READ
Sectio
SAFETY
n
5
befor
BLOCKS
at
start
of
e
proceeding.
I
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.
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Off
welding
power
source,
and
disconnect
input
power
before
inspecting,
maintaining,
or
servicing.
HOT
PARTS
can
cause
severe
burns.
Allow
cooling
period
before
maintaining
or
servicing.
5-1.
Routine
Maintenance
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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