Miller MW225 User manual

189482A
OM-189482
March 1998
-I.
Processes
MIG
(GMAW) Welding
Flux Cored
~OLSfi
(FCAW) Welding
Description
Arc
Welding
Power Source
And Wire Feeder
MW225
.
OWNERS
I
MANUAL
SECTION 1
SAFETY PRECAUTIONS
-
READ BEFORE USING
-
som
Symbol Usage
1-1
Means
AA
A
Watch
Out!
There
are
procedure! The possible
adjoining symbols.
shown in the
Marks
possible
hazards
are
group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary
actions to avoid the hazards.
This
special safety message.
a
Arc
1-2
The
Warning!
hazards with this
I~ Means Note~
A
_nd_5/97
not
safety related.
Welding Hazards
symbols
shown below
to call attention to and
are
used
throughout
this manual
identify possible
hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only
summary of the more complete safety information
found in the Safety Standards listed in Section 1-4. Read and
If earth
with a
grounding of the workpiece
separate cable
do not
use
is
required, ground it directly
clamp or work cable.
work
Do not touch electrode if you are in contact with the work,
another electrode from a different machine.
ground,
or
a
follow all
A
A
Only qualified persons
repair this unit.
Use
only well-maintained equipment. Repair or replace damaged
at once. Maintain unit according to manual.
parts
Safety Standards.
should
install, operate, maintain,
and
During operation, keep everybody, especially children, away.
safety
Wear
a
Keep
all
Clamp
Insulate work
ELECTRIC SHOCK
can
kill
and
as near
Do not touch live electrical
hole-free
dry,
single
Do not
and
a
Use AC
If AC
output ONLY if required for
output
required,
the
use remote
welding
output
or
if
Disconnect
present
on
Properly
Owners
input power or stop engine before installing or
equipment. Lockout/tagout input power according
CFR 1910.147 (see Safety Standards).
this
to OSHA 29
install and
this
ground
equipment according
to its
Manual and national, state, and local codes.
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.
When
making input connections,
conductor first
attach
proper
grounding
double-check connections.
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare winng can kill.
-
Turn off all
equipment
Do not
use
worn,
Do not
drape
when not in
I
electrode
or
work cable to any
fl
fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or
remove welding fumes and gases.
If ventilation is poor,
Read
Material
the
manufacturers
your
body.
or
poorly spliced
cables.
use an
use
exhaust at the
arc
to
approved air-supplied respirator.
Safety
Data
Sheets
(MSDSs)
instructions for metals, consumables,
and
the
coatings,
cleaners, and degreasers.
only if it is well ventilated, or while
air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
Work in
a
wearing
an
confined space
Do not weld in locations
operations.
form highly
near
degreasing, cleaning,
The heat and rays of the arc
toxic and irritating gases.
Do not weld
on
can
or
spraying
react with vapors to
coated metals, such as galvanized, lead, or
unless the coating is removed from the
plated steel,
weld area, the
over
one
Welding produces
-I
-
cadmium
use.
damaged, undersized,
cables
than
FUMES AND GASES canEbŁ hazardous.:
Keep your
process.
control if
unit.
servicing
more
inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
body protection.
AC output in damp areas, if movement is confined,
danger of falling.
is
workpiece
practical.
Turn Off
ground using dry insulating mats
prevent any physical contact with the
use
there is
as
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
from work and
to
the weld
parts.
insulating gloves
yourself
or covers big enough
work or ground.
place.
weld output terminal.
-
Insulate
in
metal-to-metal contact to
clamp when not connected to workpiece to prevent
object.
Do not connect
electrical parts can cause fatal
shocks or severe burns. The electrode and work
circuit is electrically 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 welding wire are electrically live. Incorrectly
installed or improperly grounded equipment is a hazard.
Wear
good
above floor level.
securely
contact with any metal
live
Touching
working
covers
work cable with
worktable
or
harness if
panels
area
is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
OM-189 482
Page
1
ARC RAYS
burn eyes and skin
can
BUILDUP OF GAS
Shutoff
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
can
injure
shielding gas supply
when not in
Always ventilate confined spaces
approved air-supplied respirator.
a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
kill
or
use.
or
use
Wear
Wear
HOT PARTS
can cause severe
helmet.
Do not touch hot
protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
Allow
Use
Wear
burns
with side shields under your
approved safety glasses
bare handed.
parts
before
cooling period
working
on
gun
or
torch.
protective clothing made from durable, flame-resistant
(leather and wool) and foot protection.
material
MAGNETIC FIELDS
WELDING
can cause
Welding
on
drums,
pipes,
closed
fire or explosion
containers, such
Pacemaker
Protect
tanks,
as
yourself
Do not weld where
flying sparks
flying sparks
can
NOISE
Noise from
strike flammable material.
fire, and keep
that
aware
can cause
fire
Do not weld
welding
on
on
a
fire
on a
ceiling, floor, bulkhead,
closed containers such
Connect work cable to the work
unknown
Do not
prevent welding
paths
use
as
and
causing
as
tip
processes
or
equipment
Wear
approved
ear
protection
if noise level is
high.
CYLINDERS
partition
or
tanks, drums,
can
explode
if
damaged
Shielding
gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the welding
process, be sure to treat them carefully.
pipes,
(see
welding area as
traveling long, possibly
electric shock and fire hazards.
welder to thaw frozen
when not in
or
to AWS F4.1
or
Protect
cut off
welding
wire at
compressed gas cylinders from excessive heat,
slag, open flames, sparks, and arcs.
mechanical shocks,
Install
pipes.
cylinders in an upright position by securing to
or cylinder rack to prevent falling or tipping.
protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Remove any combustibles, such as a butane
from your person before doing any welding.
lighter
or
matches,
a
stationary
support
Keep cylinders away from any welding
use.
Wear oil-free
Never
drape
Never allow
Never weld
a
a
welding
welding
on a
torch
over a
or
other electrical circuits.
gas cylinder.
electrode to touch any
pressurized cylinder
cylinder.
explosion
will result.
Use only correct shielding gas cylinders, regulators, hoses,
fittings designed for the specific application; maintain them
FLYING METAL
can
injure
associated
eyes.
brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side
shields even under your welding helmet.
Page
2
wire
and
and
parts in good condition.
Turn face away from valve outlet when
Welding, chipping,
OM-189 482
can
close to the
current from
Remove stick electrode from holder
contact
some
the hidden side.
they are properly prepared according
Safety Standards).
to
damage hearing.
extinguisher nearby.
unless
practical
spot
damage hearing.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Be
can
or
and hot metal.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Watch for
keep away.
going near arc welding, gouging,
welding operations.
can cause
and others from
wearers
affect pacemakers~
Wearers should consult their doctor before
them to blow up. Sparks
can fly off from the welding arc. The flying sparks,
hot workpiece, and hot equipment can cause fires
and burns. Accidental contact of electrode to metal objects can
cause sparks, explosion, overheating, or fire. Check and be sure the
area is safe before doing any welding.
or
can
opening cylinder
valve.
Keep protective cap in place over valve except when cylinder is in
use or
connected for
use.
Read and follow instructions
associated
Standards.
equipment,
compressed gas cylinders,
publication P-i listed in Safety
on
and CGA
Additional
1-3
Symbols
for Installation,
and Maintenance
Operation,
fIRE OR EXPLOSIONhazard.
Do not install
unit on, over,
place
or
MOVING PARTS
Do not install unit
is
properly sized, rated,
and
near
be
building wiring
power
supply system
to handle this unit.
protected
FALLING UNIT
flammables.
sure
injury
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
or near
combustible surfaces.
Do not overload
can cause
can cause
injury
ELF. RADIATION
lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
can
causeinteiference.
Use
Use
High-frequency (HF.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
equipment of adequate capacity to lift and
unit.
support
If
only qualified persons familiar with
equipment perform this installation.
Have
lift forks to
move unit, be sure forks are
using
long enough to extend beyond opposite side of
electronic
unit.
The
is
user
promptly
responsible
for
having a qualified electrician
problem resulting from the
correct any interference
installation.
OVERUSE
Allow
can cause
cooling period;
Reduce current
starting
STATIC
Put
or
follow rated
reduce
or
to weld
Do not block
OVERHEATING
on
S
before
again.
grounded
boards
or
wrist
by
at once.
the FCC about interference,
Have the installation
regularly
stop using
the
checked and maintained.
Keep high-frequency source doors and panels tightly shut,
keep spark gaps at correct setting, and use grounding and
shielding to minimize the possibility of interference.
filter airflow to unit.
(ESD~ can damage
handling
duty cycle.
duty cycle
If notified
equipment
PC boards.
BEFORE
strap
parts.
ARC. WELDING
Use proper
static-proof bags and
store, move, or ship PC boards.
can cause
interference;
boxes to
Electromagnetic energy can interfere with
electronic
equipment such as
computers and computer-driven equipment
sensitive
I.
MOVING PARTS
can cause
such
injury~
Be
Keep away from moving parts.
Keep away from pinch points
robots.
as
all equipment in the welding
electromagnetically compatible.
such
as
To reduce
drive
possible,
rolls.
sure
WELDING WIRE:caæ
causeinjury.
::
possible interference, keep weld cables as short as
together, and down low, such as on the floor.
Be
welding operation
equipment.
sure
according
Do not press gun
trigger
until instructed to do
is
close
Locate
tronic
area
this
welding
100 meters from any sensitive elec
machine is
installed
and
grounded
to this manual.
If interference still occurs, the user must take extra measures
as moving the welding machine, using shielded cables,
so.
such
Do not
point gun toward any part of the body,
people, or any metal when threading
welding wire.
using
line
filters,
or
shielding
the work
area.
other
1-4.
Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten
dent of Documents, U.S. Govemment Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for
Cutting of Containers That Have Held Hazardous
American
Welding
Welding Society Standard AWS F4.1, from
Welding Society, 550 NW. LeJeune Rd, Miami, FL 33126
National Electrical
American
Code, NFPA Standard 70, from National
Batterymarch Park, Quincy, MA 02269.
Protection Association,
and
Substances,
Fire
Safe
Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-i, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard Wi 17.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1 R3.
Safe Practices For
Occupation
And Educational
Eye
And Face
Protection, ANSI Standard Z87.1,from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51 B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-189 482
Page
3
EMF Information
1-5
Considerations About Welding And The Effects Of Low
Electric And Magnetic Fields
Frequency
Welding current, as it flows through welding cables, will cause electro-.
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: The body of evidence, in the
committees judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research
may wish to minimize your exposure to
welding
To
cutting.
reduce magnetic
are
reached, you
electromagnetic
Keep cables
2.
Arrange
3.
Do not coil
4.
close
cables to
or
together by twisting
one
drape
or
taping
them.
side and away from the operator.
cables around your
Keep welding power
practical.
source
Connect work
to
and cables
body.
as
far away from opera
tor as
5.
clamp
workpiece
as
close to the weld
as
possible.
fields when
About Pacemakers:
or
procedures:
1.
fields in the
workplace,
use
the
following
Pacemaker
then
consult your doctor first. If cleared by your doctor,
the above procedures is recommended.
wearers
following
-1
OM-189 482
Page
4
SECTION 1
CONSIGNES DE SECURITE
LIRE AVANT UTILISATION
-
som
Signification
1-1
symboles
Signifie Mise en garde! Soyez vigilant! Cette procedure
prØsente des risques de danger! Ceux-ci sont identifies
par des symboles adjacents aux directives.
4A
A
des
Identifie
message de sØcuritØ
un
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant Ily a des
risques de danger relies aux CHOCS ELECTRIQUES, aux PIECES EN
particulier.
MOUVEMENTetaux PIECES CHAUDES.
et
o:r
Signifie
1-2.
A
Dangers
relatifs
Iutilisation,
vent Œtre confiØs
A
qua
danger.
soudage a I~arc
au
Les symboles prØsentØs ci-aprŁs sont utilisØs tout au long du
present manuel pour attirer votre attention et identifier les
risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnØes afin dØviter tout
danger. Les consignes de sØcuritØ prØsentØes ci-aprŁs ne font
Linstallation,
Ientretien
reparations
qualifiees.
et les
des personnes
Au cours de lutilisation, tenirtoute personne a lØcart et
ticuliŁrement les enfants.
ne
quun materiel en bon Øtat. RØparer ou remplacer sur-le
piŁces endommagØes. Entretenir Iappareil conformŁment
Nutiliser
champ
es
ace manuel.
Porter
un
UN CHOC ELECTRIQUE
simple
contact avec des
avec
Ia
jamais
toucher
gants
es
piŁces Łlectriques
et des vØtements de
plus
par
piŁce a souder ou
on
tous les
travaille
en
hauteur.
panneaux et capots.
facon a obtenir
tin
bon contact mŁtal-mŁtal
Ia table de travail, le
plus prŁs possible
de Ia
Isoler Ia
de masse quand
objet metallique.
pince
pas mis a Ia
piŁce
pour Øviter le contact
peuttuer
piŁces electriques peut
sous
quand
place
soudure.
circuits internes de lappareil sont Łgalement sous
tension a ce moment-l. En soudage semi-automatique ou automatique,
le f ii, le dØvidoir, le logement des galets dentraInement et es piŁces
mØtalliques en contact avec le fil de soudage sont sous tension. Des
matØriels mal installØs ou mal mis a Ia terre prØsentent un danger.
Porter des
en
Fixer le cable de retour de
doi.
provoquer une electrocution ou des blessures graves.
LØlectrode et le circuit de soudage sont sous tension
des que lappareil est sur ON. Le circuit dentrØe et les
Ne
harnais de sØcuritŁ
Maintenir solidement
avec tout
Un
Reportez-vous aux symboles
prendre pour
directives ci-dessous afin de connaItre les mesures a
Øviter tout
nest pas relatif a Ia sØcuritØ.
NOTA
aux
que rØsumer linformation contenue dans les normes de sØcuritØ
ØnumØrØes a Ia section 1-5. Veuillez lire et respecter toutes ces
normes de sØcuritØ.
A
_nd_Fre 4/97
Ily
DU COURANT CONTINU IMPORTANT dans les
a
convertisseurs
aprŁs
Ia
suppression
de Ialimenta
Ølectrique.
tion
ArrØter les convertisseurs, dØbrancher le courant
Łlectrique, et dØ
charger les condensateurs dalimentation selon les instructions
indiquŁes dans Ia partie entretien avant de toucher les piŁces.
tension.
protection
secs ne
comportant
pas de trous.
Sisoler de Ia
piŁce et de a terre au moyen de tapis ou dautres
moyens isolants suffisamment grands pour empŒcher le contact phy
sique Øventuel avec Ia piŁce ou Ia terre.
Ne pas
se
servir de
source
electrique
humides, dans les endroits confines
courant electrique dans es
l o~i on risque de tomber.
LES. FUMEES ET~ LES
Œtredangereux;
zones
Le soudage gØnØre des fumØes et des gaz. Leur
inhalation peut Œtre dangereux pour votre sante.
ou
Se servir dune source Ølectnque courant
procØdØ de soudage le demande.
electrique
UNIQUEMENT si le
Eloigner
Si lutilisation dune source electrique courant Ølectrique savŁre nØces
saire, se servir de Ia fonction de tØlØcommande Si lappareil en est ØquipØ.
Couper Ialimentation ou arrØter le moteur avant de procŁder a instal
lation, a Ia reparation ou a lentretien de lappareil. DŁverrouiller
lalimentation selon Ia norme OSHA 29 CFR 191 0.147 (voir normes
de sŁcuritØ).
GAZ peuvent
votre
tŒte des fumØes. Ne pas respirer
les fumŁes.
IintØrieur, ventiler Ia
zone et/ou utiliser un echappement au ni
pour IØvacuation des fumŁes et des gaz de soudage.
Si Ia ventilation est insuffisante, utiliser tin respirateur a alimenta
tion dair homologuØ.
A
veau
de larc
Installeret mettre ala terre correctement cet appareil conformØment a
manuel dutilisation
et aux codes nationaux, provinciaux et
Ure les specifications de sØcurftŁ des matŁriaux (MSDSs) et les ins
tructions du fabricant concernant es mØtaux, les consommables,
les revŁtements, les nettoyants et les degraisseurs.
municipaux.
Toujours verifier
Travailler dans
son
Ia terre du cordon dalimentation
Verifier et sassu
rer que le fil de terre du cordon dalimentation
est bien raccordØ a Ia
borne de terre du sectionneur ou que Ia fiche du cordon est raccordŁe
a une prise correctement mise a Ia terre.
En effectuant les raccordements dentrŁe fixer dabord le conducteur
de mise a Ia terre appropne et contre-vØrifler les connexions.
Verifier
espace fermØ seulement sil est bien venthØ ou
a alimentation dair. Demander toujours Ø
formØ de se tenir a proximitØ. Des fumŁes et
un surveillant dment
des gaz de soudage peuvent dØplacer lair et abaisser le niveau
doxygŁne provoquant des blessures ou des accidents mortels.
Sassurer que lair de respiration ne presente aucun danger.
en
portant
un
un
respirateur
Ne pas souder dans des endroits situØs a proximitØ doperations de
de nettoyage ou de pulvØrisation. La chaleur et les
rayons de larc peuvent rØagir en presence de vapeurs et former
frequemment le cordon dalimentation pour voir siI nest pas
endommage ou dØnudŁ remplacer le cordon immØdiatement sil est
endommage un cable dØnudØ petit provoquer une electrocution.
dØgraissage,
Mettre
Ne pas souder des mØtaux munis dun revŒtement, tels que lacier
gafvanisØ, plaque en p10mb ou au cadmium a moms que le revØte
ment nait ØtØ enlevØ dans Ia zone de soudure que Iendroit soit
bien ventilØ, et Si nØcessaire, en portant un respirateur a alimenta
lappareil
hors tension
Ne pas utiliser des
sante ou mal
quand on ne lutilise pas.
cables uses, endommagØs, de grosseur
insuffi
ØpissØs.
Ne pas enrouler les cables autour du corps.
piŁce soudØe doit Łtre mise a laterre, le faire directement avec un
cable distinct
ne pas utiliser le connecteur de piŁce ou le cable de
Si Ia
des gaz hautement
tion dair.
ments
toxiques
et irritants.
Les revŒtements et tous les mŁtaux renfermant ces ØlØ
en cas de Soudage.
peuvent degager des fumØes toxiques
retour.
Ne pas toucher IØlectrode
terre ou tine electrode
quand on est en contact avec Ia piŁce, Ia
provenant dune autre machine.
OM-189 4.82
Page
5
I,
LES RAVONS DE LARC peuvent pro
voquer des brlures dans tes yeux et
sur Ia peau
LESACCUMULATIONS:DE GAZrIs
quent de provoquer des blessures ou
mŒme Ia molt
de
arc du procØdØ de soudage
rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer
des brUlures dans les yeux et sur Ia peau. Des Øtincelles sont projetees
Veiller
pendant le soudage.
rateur dadduction
Le
Fermer lalimentation
des
non
toujours a
soudage muni dun Øcran de filtre approprie pour
protØger votre visage et vos yeux pendant le soudage ou pour regar
der (voir ANSI Z49.1 et Z87. 1 ØnumØrØ dans es normes de sØcuritØ).
Porter des protections
dair
approuvØs pour
~1
au
feu
(cuir
protection constituØ dans une matiŁre dura
ou lame) et une protection des pieds.
LE SOUDAGE peut provoquer
incendie ou une explosion
Le
PrØvoir
dutiliser
personnes de Ia
des
de
peut dØclencher
un
Ne pas effectuer le
Brancher le cable sur Ia piŁce le plus pres possible de Ia zone de sou
pour Øviter Ia transport du courant sur une longue distance par
des chemins inconnus Øventuels en provoquant des risques dØlec
trocution et dincendie.
poste de soudage pour degeler des conduites ge
lees.
utilisation, enlever Ia baguette dŁlectrode
du porte
couper le fil a Ia pointe de contact.
Porter des vŒtements de protection dØpourvus dhuile tels que des
gants en cuir, une chemise en matØriau lourd, des pantalons sans re
vers, des chaussures hautes et un couvre chef.
ou
Avant de souder, retirer toute substance combustible de
telles quun allumeur au butane ou des allumettes.
vos
poches
NTES
de
projeter
en
risquent
OM-189 482
Page
6
Des bouteilles de gaz protecteur contiennent du gaz
haute pression. Si une bouteille est endomma
sous
I
I
gØe,ellepeutexploser. Dufaitquelesbouteillesdegaz
procØdØ de soudage, les
precaution.
font normalement partie du
manipuler
avec
Proteger
les bouteilles de gaz comprimØ dune chaleur excessive,
des chocs mecaniques, du laitier, des flammes ouvertes, des Łtin
celles at des arcs.
Placer les bouteilles debout en les fixant dans un support station
naire ou dans un porte-bouteilles pour les empŒcher de tomber ou
de se renverser.
Tenir les bouteilles
cuits
Ne
jamais placer
avec
Øcrans latØraux
ou un
une
Une electrode de
une
ŁloignØes des
circuits de
soudage
ou autres
cir
Ølectriques.
torche de
soudage
ne
soudage sur une
jamais entrer
doit
bouteille a gaz.
en
contact avec
bouteille.
jamais
souder
une
bouteille
pressurisØe
risque dexplosion.
Maintenir le chapeau de protection sur Ia soupape, sauf
dutilisation ou de branchement de a bouteille.
Øcran facial.
en cas
Lire et suivre las instructions concernant las bouteilles de gaz corn
les Øquipements associØs at les publications P-i CGA Ønu
prime,
mØrØes dans las
du laitier.
Porter des lunettes de sØcuritØ
las oreilles si
las maintenir ainsi qua les ØlØments associØs en bon Øtat.
Ne pas tenir Ia tŒte en face de Ia sortie en ouvrant Ia soupape de Ia
bouteille.
soudage, lØcaillement,
de refroidissement des soudures, elles
protections approuves pour
Si des BOUTEILLES sont endomma
Ne
Ia passage de Ia piŁce
fil de fer, et le meulage gØnØrent
desØtincelles etdes particules metalliquesvolan
pŁriode
affecter
Utiliser seulement des bouteilles de gaz protecteur, rØgulateurs,
tuyaux et raccords convenabtes pour cette application spectfique;
peuventblesser Ies~yeux.
Le
equipements peut
gØes, elles pourroflt exploser.
ctŁ.
dage
a Ia brosse
ou
le niveau sondre est trop ØlevØ.
sur
DES PARTICULES VOL
de gougeage
louIe.
separation
ou
sØcuritŁ).
non
restez a distance.
peut affecter IouIe.
Le bruit des processus et des
Porter des
des conteneurs fermØs tels que des
reservoirs, tambours, ou conduites, a moms quils naient ØtŁ prepa
rØs correctement conformØment a AWS F4.1 (voir les normes de
Ne pas utiliser le
cardiaque,
peuvent tomber
plafond, plancher, paroi
incendie de lautre
soudage
cardiaques.
operations de soudage a larc,
soudage par points.
LE BRUIT
sur un
MAGNETIQUESpeuvent
et de
Surveiller tout dØclenchement dincendie ettenir un extincteur a proxi
mite.
tes. Pendant Ia
avant
des
protections homologues.
soudage effectuŁ
le
Les porteurs dun stimulateur cardiaque doivent
dabord consulter leur mØdecin avant de sapprocher
Des Øtincelles et des matØriaux chauds du soudage peuvent facile
ment passer dans dautres zones en traversant de petites fissures et
des ouvertures.
~
pŁriode de refroidissement
pistolet ou Ia torche.
une
Porteurs de stimulateur
les substances inflammables a une distance de 10,7
de larc de soudage. En cas dimpossibilitŁ les recouvrir soigneuse
de
mains
affecter les stimutateurs
DØplacertoutes
cas
parties chaudes a
LES CHAMPS
projection dØtincelles
Ne pas souder dans un endroit l o~i des Łtincelles
sur des substances inflammables.
avec
:,
Un
soudage
Se proteger et dautres
metal chaud.
En
respi
nues
~I
electrode
servir dun
homologue.
Ne pas toucher des
effectuØ sur des conteneurs fermØs tels
que des reservoirs, tambours ou des conduites peut
Øclatement. Des Øtincelles peuvent Œtre
leur
provoguer
projetees de larc de soudure. La projection dØtincel
les, des piŁces chaudes et des Łquipements chauds peut provoquer des
incendies et des brUlures. Le contact accidentel de lØlectrode avec des
objets mØtalliques peut provoquer des Łtincelles, une explosion, un
surchauffement ou un incendie. Avant de commencer le soudage,
verifier et sassurer que lendroit ne prØsente pas de danger.
Le
ou se
DES PIECES CHAUDES peuvent pro
les oreilles ci le niveau sondre est
arc.
Porter des vØtements de
ment
de
en cas
voquerdesbrlures graves~ :~
ble, resistant
m
du gaz protecteur
utilisation.
bien aØrer les espaces confines
Utiliser des Øcrans ou des barriŁres pour protØger des tiers de lØclair
et de lŁblouissement; demander aux autres personnes de ne pas re
m.
-
casque de
un
trop ØlevØ.
garder
;
rayonnement
genŁre
Porter
:
normes
de sØcuritØ.
.
1-3.
Dangers supplØmentaires
relation
en
et Ia maintenance
:~
avec
iinstailation, le fonctionnement
:
ORGANES MOBILES
provoquer desblessures.
Risque, PINCENDIE OU..
I
DEXPLOSION.
Ne pas
DES
:
.
sur, au-dessus
de surfaces infllammables.
placer lappareil
proximitØ
.
.:
ou
a
Rester a lØcart
ventilateur.
Ne pas
tation est correctement dimensionnØ et
lappareil en service.
protØgØ
des organes mobiles
Maintenir fermØs et fixement
lappareil a proximitØ de produ its inflammables
surcharger installation Ølectrique sassurer que lalimen
Ne pas installer
panneaux,
peuvent
en
et
recouvrements
comme
le
place les portes,
dispositifs de
protection.
avant de mettre
LE RAVONNEMENT HAUTE FRE
QUENCE (H.F.) risque de provoquer
.
LA CHUTE DE LAPPAREIL
blesser.
Utiliser lanneau
des lnterterences.
peut
H
.
Le rayonnement haute frequence peut provoquer
des interferences avec les Øquipements de ra
dionavigation et de communication, les services
levage uniquement
de
pour sou
lever lappareil, NON PAS les chariot, les bouteil
les de gaz ou tout autre accessoire.
capacitØ appropriØe
Utiliser un engin dune
soulever lappareil.
pour
de sØcuritØ et les ordinateurs.
Demander seulement Ø des personnes qualifiØes familiarisØes
avec des Øquipements Ølectroniques de faire fonctionner linstalla
tion.
En utilisant des fourches de levage pour dØplacer lunitØ, sassurer
que les fourches sont suffisamment longues pour dØpasser du ctØ
oppose de lappareil.
Lutilisateur est tenu de faire corriger rapidement par
les interferences resultant de linstallation.
un
Ølectricien
qualifiØ
Si le FCC
signale
des
intertØrences, arrØter immØdiatement lappa
reil.
LEMPLOI
XCESSIF petit
SURCHAUFFER LEQUIPEMENt
rØguliØrement le contrle et lentretien de linstallation.
soigneusement fermØs les portes et les panneaux des
sources de haute frØquence, maintenir les Øclateurs a une distance
correcte et utiliser une terre et et un blindage pour rØduire les inter
Effectuer
.1:
PrØvoir
une pØriode de refroidissement, respec
cycle opØratoire nominal.
RØduire le courant ou le cycle opØratoire avant de
recommancer le soudage.
Maintenir
fØrences Øventuelles.
ter le
Ne pas obstruer les passages dair
du
LE SOUDAGE
poste.
provoquer
ELECTRSTATIQUES
peuvØnt endomrnSger les circuitsim
I
pr1mØs.~:
H
LØnergie
LES CHARGES
A
:
LARC
des interfØren
~sque
de
es.
ØlectromagnØtique
risque
de
provoquer des interferences pour lØquipement
Ølectronique sensible tel que les ordinateurs et
lØquipement commandØ par ordinateur tel que
.
les robots.
Etablir
Ia barrette de terre
des cartes ou des pieces.
Ia connexion
avant de
manipuler
Utiliser des
avec
pochettes
pour stocker, dØplacer
circuits imprimes.
DES
I
et des
ou
boites
expØdier
antistatiques
des cartes de
ORGANES MOBILES peuvent
I provoquer desbiessUresL
Ne pas
sapprocher
.
.
des organes mobiles.
Ne pas sapprocher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE
peuvent pro
lØquipement de Ia zone de soudage soit com
patible electromagnØtiquement.
Pour rØduire Ia possibilitØ dinterfØrence, maintenir les cables de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
Veiller a souder a une distance de 100 metres de tout Øquipement
Ølectronique sensible.
Veiller a ce que ce poste de soudage soft pose et mis a Ia terre
conformØment a ce mode demploi.
En cas dinterfØrences aprØs avoir pris es mesures prØcØdentes, il
incombe a lutilisateur de prendre des mesures supplØmentaires
telles que le dØplacement du poste, lutilisation de cables blindØs,
lutilisation de filtres de ligne ou Ia pose de protecteurs dans Ia zone
Veiller ace que tout
de travail.
LES CHAMPS MAGNET1QUES peuventE
I
affecter les stimulateurs cardiaques.
.
voquer des blessures.
Porteurs de stimulateur
sur
Ne pas
soi, dautres per
piece mØcanique en engageant
diriger
sonnes ou
le fil de
le
toute
soudage.
Ia
avant den avoir
Ne pas appuyer
reu linstruction.
gachette
pistolet
vers
cardiaque,
restez
a dis
tance.
Les porteurs dun stimulateur cardiaque doivent
dabord consulter leur mØdecin avant de sappro
cher des operations de soudage a larc, de gou
geage ou de soudage par points.
OM-189 482
Page
7
1-4
Principales
normes
de secuntØ
Safety in Welding and Cutting, norme ANSI Z49.1, de
ding Society, 550 NW. Lejeune Rd, Miami FL 33126
American
Wel-
OSHA 29 CFR 1910, du Superintendent
Documents, U.S. Government Printing Office, Washington, D.C.
Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme
AWS F4.1, de lAmerican Welding Society, 550 N.W. Lejeune Rd, Mia
mi FL 33126
National Electrical
Code, NFPA Standard 70, de Ia National Fire Pro
Association, Batterymarch Park, Quincy, MA 02269.
1-5
DonnØes
des
of
Compressed Gases
in
Cylinders, CGA Pamphlet
de sØcuritØ en soudage, coupage etprocØdØs connexes, norCSA Wi 17.2, de lAssociation canadienne de normalisation, vente
de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W
RŁgles
me
20402.
tection
Handling
P-i, de Ia Compressed Gas Association, 1235 Jefferson Davis High
way, Suite 501, Arlington, VA 22202.
Safety and Health Sandards,
of
Safe
Information
sur
les
Cutting and Welding Processes, norme NFPA 51 B, de Ia National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
champs Ølectromagnetiques
le
soudage Ølectrique et sur les effets, pour lorganisme,
champs magnØtiques basse frequence
sur
1 R3.
Safe Practices For Occupation And Educational Eye And Face Protec
tion, norme ANSI Z87.1, de lAmerican National Standards Institute,
1430 Broadway, New York, NY 10018.
Afin de rØduire les
de
Lextrait suivant est tire des conclusions gØnØrales du document intitu
lØ Biological Effects of Power Frequency Electric & Magnetic Fields
1
Garder les cables ensembles en les torsadant
attachant avec du ruban adhØsif.
2
Mettre tous les cables du ctØ
3
Ne pas courber pas et
-
Background Paper, OTA-BP-E-53 (Washington DC: U.S. Govern
Printing Office, mai 1989), publiØ par le Office of Technology
Assessment du CongrØs amØricain : ... il existe maintenant dabon
dantes donnØes scientifiques compilØes a Ia suite dexpØriences sur
champs ØlectromagnØtiques dans
lenvironnement
travail, respecter les consignes suivantes
oppose
de
ou en
les
lopØrateur.
ment
Ia cellule
ou
dØtudes
sur
des animaux et des
humains, qui montrent
clairement que les champs ØlectromagnØtiques basse frØquence peu
vent avoir des effets sur Iorganisme
et mŒme y produire des
transformations. MŒme sil sagit de travaux de trŁs grande qualitØ, les
rØsultats sont complexes. Cette dØmarche scientifique ne nous permet pas dØtablir
tableau densemble
coherent. Pire encore, elle ne
concernant les ris
ques Øventuels, ni doffrir des conseils sur les mesures a prendre pour
rØduire sinon Øliminer les risques Øventuels. (Traduction libre)
nous
un
permet pas de tirer des conclusions finales
OM-189 482
Page
8
ne
pas entourer pas es cables autour de
vous.
4
Garder le
de
5
poste de soudage
et les cables le
plus
loin
possible
vous.
Relier Ia
pince
de
masse
le
plus prŁs possible
de Ia
zone
de
soudure.
Consignes relatives
aux
stimulateurs
cardiaques
consignes mentionnØes prØcØdemment font partie de celles desti
nØes aux personnes ayant recours a un stimulateur cardiaque.
Veuillez consulter votre mØdecin pour obtenir plus de details.
Les
SECTION 2- INSTALLATION
Specifications
2-1.
In put at
Rated Load
Output, 60 Hz,
Amperes
Rated
Welding
Output
Maximum
Amperage
Range
Open-Circuit
Voltage DC
Overall
Weight
Dimensions
Single-Phase
200V
230V
KVA
KW
Length: 36 in
(915 mm)
150 A @23 Volts
DC, 60% Duty Cycle
30
185
30
33
(1.6)*
26(1 .4)*
6
(0.27)*
5(0 13)*
165 lb
Width: 18 in
(75 kg)
(457 mm)
Height: 27 in
(686 mm)
Wire
Solid Steel /
Stainless Steel
.023
(0.6
~WhiIe
2-2.
-
-
.035 in
0.9
And Diameter
Type
Calculated Wire
I
I
Flux Cored
I
I
.045 in
I
.030
(0.8
mm)
-
1.2
mm)
Aluminum
.030
(0.8
-
.035 in
0.9 mm)
Range
138795
Speed
Max Wire Feed
While
At No Load
1PM
650 1PM
(3.520.3 rn/mm)
Speed
Welding
(16.5 m/miri)
idling
Volt-Ampere
Curves
Volt-ampere
curves
show
mini
voltage and
amperage output capabilities of
unit. Curves of other settings fall
mum
and maximum
between
curves
shown.
35
C,,
0 30
>
w
CD
~
25
~::i
0
>
~
<
20
0
-J
15
10
0
50
100
150
200
LOAD CURRENT, AMPS
vacurvel 4/95
-
SB-180 824
OM-189 482
Page
9
2-3.
Duty Cycle And Overheating
Duty Cycle
is
percentage of 10
minutes that unit
load without
If
unit
can
weld at rated
overheating.
overheats,
thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
RATED OUTPUT
unit to cool. Reduce amperage or
or
duty cycle before
200
~
-
-
-
-_
-
-
-_
Co
Iii
voltage,
welding.
A
-
:-
Exceeding duty cycle
damage unit and
can
void
warranty.
~
w
0~
150
-J
Ui
~-
100
30
40
50
80
% DUTY
60%
6 Minutes
Duty Cycle
70
80
90100
CYCLE
At 150
Welding
Amperes
4 Minutes
Resting
Overheating
~
OR
Reduce
Duty Cycle
Minutes
dutyl 4/95
OM-189 482
Page
10
SB-i 81 009
2-4.
Installing Work Clamp
1
Work Cable
2
Boot
Slide boot onto work cable. Route
cable out front panel opening from
inside.
3
Negative () Output
Connect
cover
cable
to
Terminal
terminal
and
connection with boot.
5
4
Hardware
5
Work
Clamp
Route cable
and
1
2
through clamp
handle
shown.
secure as
Close door.
Tools Needed:
~ 1/2,3/4in
ST-801 566
2-5.
Installing
Gas
Supply
Obtain gas cylinder and chain to
running gear, wall, or other sta
tionary support so cylinder
cannot
fall and break off valve.
1
Cap
2
Cylinder
Valve
2
Remove cap, stand to side of
valve, and open valve slightly.
Gas flow blows dust and dirt from
valve. Close valve.
r
I
3
3
Cylinder
4
RegulatorfFlowmeter
Install
4
5
so
face is vertical.
Regulator/Flowmeter Gas
Hose Connection
Argon
Gas
6
Welding
Power Source Gas
Hose Connection
Connect customer
OR
supplied gas
regulator/flowme
hose between
ter
2
7
gas
fitting
on
hose
connection,
of
rear
welding
and
power
source.
7
.3
Flow
Adjust
Typical flow rate is 20 cth (cubic
feet per hour). Check wire man
recommended flow
ufacturers
rate.
8
CO2 Adapter (Customer
Supplied)
9
0-Ring (Customer Supplied)
CO2 Gas
with 0-ring
regulator/flowmeter
CO2 cylinder.
Install
adapter
tween
be
and
Tools Needed:
~=Z~
1-1/8,5/8iri
Ref. ST-148 265-B/ST-802 028
OM-189 482
Page
11
2-6.
Installing Welding
Gun
1
Drive
2
Gun
3
Gun End
Assembly
Securing
Knob
securing knob. Insert gun
through opening until it bot
toms
against drive assembly.
Tighten nut.
Loosen
end
4
2
3
Gun
Trigger Plug
Insert
plug
tighten
threaded collar.
into
receptacle,
and
Close door.
4
Ref. ST-8O1 936
2-7.
Setting
Gun
Polarity
1
Polarity Changeover
(Located Near
Assembly)
Always
tures
Wire Drive
To Positive
Assembly Lead
(+) Output Terminal
Work Clamp Lead To
Negative () Output Terminal
GUN POLARITY
CHANGEOVER CONNECTIONS
Reverse Lead Connections
-
For Electrode
Negative (DCEN) For Flux Cored Wires
(FCAW Process). Drive Assembly
Becomes Negative
~ 449D
Tools Needed:
~==:~
OM-189 482
Page
3/4,11/l6in
12
Label
Drive
read and follow manufac
recommended
polarity.
2-8.
Installing
Wire
Spool
And
Adjusting
Hub Tension
Tools Needed:
When
~
15/16 in
to turn
slight force is needed
spool, tension is set.
a
ST-072573-8
2-9.
Changing Input Voltage
A
Turn
nect
Unit
was
unit, and discon
Off
input power.
shipped
from
factory
set
for 230 volts.
1
Transformer Ti
2
Rear Of Power Switch Si
3
Lead Marked 230 Volt And
Fan Motor Lead
2
Disconnect 230 volt lead and fan
motor lead from rear of Si. Leave
fan motor lead connected to 230
3
volt lead.
4
Lead Marked 200 Volt
Remove cable
and
volt
tie, and slide short
sleeving off 200 volt lead,
slide sleeving over end of 230
piece
of
and
sleeving
fan
over
motor
and
leads.
secure
in
Fold
place.
Connect 200 volt lead to Si where
230 volt lead was removed.
Reinstall wrapper.
4
Tools Needed:
~=::::r 3/8,7/16
in
ST-aol 580-A
OM-189 482
Page
13
2-10. Electrical Service Guide
Input Voltage
200
230
30
26
45
40
10
10
Input Amperes At Rated Output
Max Recommended Standard Fuse Or Circuit Breaker
Rating
Mm
Input
Conductor Size In AWG/Kcmil
Max Recommended
Mm
Grounding
Input
Conductor
Selecting
OM-189 482
Page
In Feet
(Meters)
97
Conductor Size In AWG/Kcmil
Reference: 1996 National Electrical Code
2-11.
Length
14
(29)
10
(NEC).
A Location And
.
In
Amperes
128
(39)
10
S-0092-J
Connecting Input
Power
2-12.
Threading Welding
Wire
Tools Needed:
-4
Qin~
(150 mm)
Open pressure assembly.
Pull and hold
wire;
cut offend.
Push wire thru
guides
into gun;
continue to hold wire.
ON
~
Q
Close and
tighten pressure
assembly,
and let go of wire.
Remove gun nozzle and contact
POWER
OFF
Turn On.
tip.
Cut off wire. Close
and latch door.
-4
Press gun
out of gun.
trigger
until wire
comes
-4
Reinstall contact
tip
and nozzle.
II
I
dl
I II
Feed wire to check drive roll pressure.
knob enough to prevent slipping.
Tighten
Cut off wire. Close and latch door.
Ref. ST-801 9381 Ref. ST~149 326-A
OM-189 482
Page
15
2-13. Weld Parameter
Material Thickness
Wire
Wire
Type,
Shielding Gas,
Diameter
And Flow Rate
(inch)
Operator
r
3/8 in
1/4 in
3/16 in
1/8 in
(9.5
mm)
(6.4
mm)
(4.8
mm)
(3.2
mm)
12 ga
14 ga
16 ga
18 ga
20 ga
6
5
4
3
3
2
1
1
100
90
70
65
60
40
25
20
4
4
3
2
2
2
1
70
60
50
45
40
30
25
6
4
4
3
3
2
2
1
80
65
40
35
30
25
30
10
3
4
3
3
2
2
1
1
1
80
90
70
60
70
40
45
25
12
6
4
4
3
3
2
2
1
1
90
58
70
55
50
48
45
30
5
6
4
4
3
3
2
2
1
1
80
48
60
50
35
27
30
11
3
5
4
4
3
2
2
1
1
80
65
65
50
30
30
10
5
5
4
3
2
2
2
1
1
50
50
40
30
25
20
10
0
5
4
4
4
3
3
3
2
2
2
95
85
80
60
50
50
50
30
20
20
5
5
4
3
3
2
2
2
1
70
70
70
50
45
50
45
40
0
6
5
5
4
3
2
2
2
65
40
40
30
30
25
20
10
S
VoltageTap
-
22 ga
.023
Wire
Speed
-
Voltage Tap
E7OS-6
.030
CO2
20 cfh+
Wire
Speed
Voltage Tap
.035
Wire
Speed
Voltage Tap
-
.023
Wire
E70S6
75%
Speed
Voltage Tap
Argon
.030
2~02
Wire
Speed
Voltage Tap
.035
Wire
Speed
Voltage Tap
.030
Wire
E71TGS
Flux Core
Speed
Voltage Tap
.035
Wire
Speed
VoltageTap
.023
Wire
ER 308
Speed
Voltage Tap
Stainless Steel
~
Tn-MIx
030
Wire
Speed
Voltage Tap
.035
Wire
*Do not
change Voltage switch position
during welding.
fine tuned
OM-189 482
Page
16
Speed
while
welding
Wire
Speed
value in Table is
a
starting
value
only,
and Wire
Speed
control
setting
can
be
S-181 020-A
2-14. Aluminum Weld Parameter For Use With
Optional Spoolmate
185
Material Thickness
Wire
Type,
Shielding Gas,
Diameter
And Flow Rate
(inch)
Wire
Operator
Controls
VoltageTap
3/8 in (9.5 mm)
1/4 in (6.4 mm)
5
5
88
3/16 in
1/8in(3.2mm)
l4ga
4
3
2
88
73
55
45
6
6
5
4
2
95
85
68
59
34
5
4
3
2
100
90
80
70
6
6
5
4
2
100
92
85
70
60
(4.8
m
m)
.030
Wire
4043 AL
100%
Argon
Speed
Voltage Tap
.035
Wire
Speed
Voltage Tap
.030
Wire
5356 AL
100% Argon
Speed
Voltage Tap
-
.035
Wire
Speed
OM-189 482
Page
17
SECTION 3- OPERATION
3-1.
Front Panel Controls
Controls For Standard Units
1
Speed
Wire
Control
Use control to select
speed. Scale
actual wire feed
reference
2
The
a
wire feed
around control is not
speed,
but is for
only.
Voltage Switch
higher
the selected number,
can be
the thicker the material that
welded
(see Section 2-13).
Do not
switch under load.
3
Pilot
4
Power Switch
Light
20
ii
~
WIRE SPEED
_______
2
3
4
Ref ST-187 317
OM-189 482
Page
18
.
SECTION 4- MAINTENANCE & TROUBLESHOOTING
4-1.
4-2.
Routine Maintenance
Circuit Breakers CB1 And CB2
A
Turn Off unit.
1
Circuit Breaker CB1
CB1 protects the transformer from
If CB1
overload.
opens, wire
feeding stops.
2
Circuit Breaker CB2
CB2
protects
the
trigger
circuit
from overload. If CB1 opens, weld
output stops.
Press
button
to
reset
circuit
breaker. Close door.
Ref. ST-801 567
4-3.
Changing
Drive
ri ~*H
Roll, Inlet Wire Guide
1
Drive Roll
Choose correct drive roll for wire
type, and install as shown.
2
Inlet Wire Guide
Remove
guide by pressing on
or cutting off one end
near housing and pulling it out of
hole. Push new guide into hole
from rear until it snaps in place.
barbed area,
Tools Needed:
Ref. ST-801 569
OM-189 482
Page
19
4-4.
Cleaning
Or
Replacing
Gun Liner
Tools Needed:
first.
3/8 in
Head
I
3/8 in
r
Remove nozzle,
tip, and
contact
liner collet.
~in
Remove liner.
1~
To Reassemble Gun:
Gun/Feeder
ector
gun casing.
Install contact
Insert
new
tip.
liner.
Install collet onto liner and
into
gun/feeder
connector
wrench.
Cut liner off
end is
as
near
sible without
touching.
Install nozzle.
OM-189 482
Page
20
collet
so
that I
close to drive rolls
as i
Replacing
4-5.
Gun Contact
Tip
A
Turn Off unit.
1
Nozzle
2
Contact
Tip
Cut off welding wire at contact
Remove nozzle.
Remove contact
Tools Needed:
contact
tip.
tip
and install
tip.
new
Reinstall nozzle.
ST.149 326-B
4-6.
Troubleshooting
Welding
No weld
output;
Trouble
wire does not feed.
Remedy
Secure power cord
Check and
.
plug
in
receptacle (see Section 2-11).
switch if necessary.
replace power
Check circuit breakers CB1 and/or
Replace building
line fuse
Secure gun
in
plug
Connect work
Replace
Low weld
Low, high,
contact
erratic wire
speed.
Readjust
Change
front
or
to
get good
Replace
metal to metal contact.
panel settings (see
guide,
contact
check for low line
or
Section
(see
wire
feeding stops during
voltage (see Section 2-11).
3-1).
Section
4-3).
(see Section 2-12).
liner if necessary
tip, and/or
Wire Drive/Gun Trouble
Electrode
2-6).
Allowfan to run; the thermostat will close when the unit has cooled
input voltage
drive roll pressure
inlet
(see Section 2-11).
Section
(see
(see Section 4-2).
tip (see Section 4-5).
to correct size drive roll
Readjust
leads
repair
(overheating).
Connect unit to proper
output.
or
clamp
and reset if necessary
reset circuit breaker if open
receptacle
Thermostat TP1 open
(see Section 2-3).
No weld output; wire feeds.
or
CB2,
(see
Sections 2-12, and
4-4).
Remedy
Straighten
gun cable and/or
replace damaged parts (see
Section
4-4).
welding.
Adjust
drive roll pressure
Readjust
hub tension
(see
contact
tip
Clean
replace
wire inlet
Replace
drive roll if
Secure gun
plug
in
2-12).
(see Section 2-8).
Replace
or
Section
if blocked
(see Section 4-5).
guide
worn or
or
liner if
slipping (see
receptacle
or
repair
Factory
or
Section
leads
Check and clear any restrictions at drive
Have nearest
dirty
plugged (see Section 4-4).
4-3).
(see
assembly
Authorized Service
Agent
Section
2-6).
and liner
(see
Section
4-4).
check drive motor.
OM-189 482
Page
21
SECTION 5- ELECTRICAL DIAGRAM
SB- 186 065
Figure
OM-1 69 482
Page
22
5-1. Circuit
Diagram
SECTION 6- MIG WELDING
(GMAW) GUIDELINES
~
6-1.
Typical MIG Process Connections
A
Weld
can damage
parts in vehicles.
Disconnect
both
battery
current
electronic
cables before
vehicle.
as
welding on a
clamp
Place work
close
to
the
weld
as
possible.
Regulator!
Flowmeter
Wire
Feeder!
Power Source
Gun
Shielding
Gas
Workpiece
Work
Clamp
ight mig 5/967 / ST-801
OM-189 482
909
Page
23
6-2.
Typical
N OTE
MIG Process Control
Settings
These settings
L~
guidelines only. Material and wire type, joint design, fitup,
position, shielding gas, etc. affect settings. Test welds to be sure they comply to
specifications.
are
Material thickness determines
parameters.
weld~~~~
or
125 in
Convert Material
Thickness to
Amperage (A)
(.001
in
=
.125 in
1
ampere)
=
125A
4,
Amperage Range
30
-
90 A
Select Wire Size
40
145 A
50
180 A
1~
Wire
Select Wire
Speed
(Amperage)
Wire
Speed
(Approx.)
Recommendation
Size
.023 in
3.5 in per ampere
3.5
.030 in
2 in per ampere
2
.035 in
1.6 in per ampere
1.6
x
x
125 A
=
437
125A= 250
x
125 A
=
ipm
ipm
200
l25Abased
on
1/8 in
material thickness
ipm
ipm
=
inch per minute
4,
Low
voltage:
High voltage:
Set
wire stubs into work
arc
voltage midway
is unstable
between
(spatter)
Select
Voltage
high/low voltage.
Wire speed (amperage) controls weld
penetration (wire speed burn-off rate)
=
Ref. ST-801 885
OM-189 482
Page
24
6-3.
Holding
N OTE
And
fJ~I~~
Positioning Welding
Gun
Welding wire is energized when gun trigger is pressed Before lowering helmet and
pressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle,
and tip of wire is positioned correctly on seam.
.
1
Hold Gun and Control Gun
Trigger
3
2
Workpiece
3
Work
4
Electrode Extension
Clamp
(Stickout) 1/4
mm)
to
1/2 in (6 To
13
5
Cradle Gun and Rest Hand
on
(>
End View Of Work
Angle
Workpiece
S
Side View Of Gun
Angle
GROOVE WELDS
End View Of Work
Angle
Side View Of Gun
Angle
FILLET WELDS
S-0421-A
OM-189 482
Page
25
6-4.
Conditions That Affect Weld Bead
N OTE
~
Shape
Weld bead shape depends on gun angle, direction of travel, electrode extension
(stickout), travel speed, thickness of base metal, wire feed speed (weld current),
and voltage.
Push
Perpendicular
Drag
GUN ANGLES AND WELD BEAD PROFILES
y
Short
Normal
Long
ELECTRODE EXTENSIONS (STICKOUT)
Short
Normal
Long
FILLET WELD ELECTRODE EXTENSIONS
(STICKOUT)
S
Slow
Normal
S
Fast
GUN TRAVEL SPEED
S-0634
OM-189 482
Page
26
6-5.
Gun Movement
N OTE
~jE~
During Welding
single stringer bead is satisfactory for most narrow groove weld joints;
or bridging across gaps, a weave bead or
multiple stringer beads works better.
Normally,
I
a
however, for wide groove weld joints
1
Stringer
1
2
2
~
Side To Side
Seam
Weave Bead
Movement
3
Steady
Along Seam
Bead
Movement
Along
Weave Patterns
Use
weave
wide
area
to
cover
pass
of
patterns
in
one
a
the
electrode.
3
4~<((
S-0054-A
6-6.
Poor Weld Bead Characteristics
1
Large Spatter Deposits
2
3
Rough, Uneven Bead
Slight Crater During Welding
4
Bad
5
Poor Penetration
1
2
Overlap
34
I~/~
S-0053-A
6-7.
Good Weld Bead Characteristics
1
Spatter
1
Fine
2
Uniform Bead
3
Moderate Crater
During
Welding
Weld
a new
bead
or
layer
for each
1/8 in (3.2 mm) thickness in metals
being
welded.
Overlap
4
No
5
Good Penetration into Base
Metal
S-0052-B
OM-189 482
Page
27
6-8.
Troubleshooting
Excessive
Spatter
I
Excessive
scattering of molten
Spatter
cool to solid form
near
metal
particles that
weld bead.
S-0636
Possible Causes
Wire feed
Voltage
speed
too
too
Corrective Actions
Select lower wire feed
high.
Select lower
high.
Electrode extension
(stickout)
too
long.
Workpiece dirty.
speed.
voltage range.
Use shorter electrode extension
(stickout).
Remove all grease, oil, moisture, rust,
paint, undercoating,
and dirt from work surface before
welding.
Insufficient
shielding gas
Dirty welding
at
welding
arc.
wire.
Increase flow of
Use clean,
Eliminate
6-9.
Troubleshooting
shielding gas
dry welding
pickup
of oil
at
regulator/flowmeter and/or prevent
drafts
near
welding
arc.
wire.
or
lubricant
on
welding
wire from feeder
or
liner.
Porosity
Porosity
small cavities
or
holes
resulting from gas pockets
in weld metal.
S-0635
Possible Causes
Insufficient
shielding gas
at
welding
Corrective Actions
arc.
Increase flow of
Remove
shielding
gas at
regulator/flowmeter and/or prevent
drafts
near
welding
spatter from gun nozzle.
Check gas hoses for leaks.
Place nozzle 1/4 to 1/2 in
Hold gun
Wrong gas.
Use
Dirty welding
wire.
bead at end of weld until molten metal solidifies.
welding grade shielding gas; change
Use clean,
Eliminate
Workpiece dirty.
near
(6-13 mm) from workpiece.
dry welding
pick up of
oil
Remove au grease, oil,
to different gas.
wire.
or
lubricant
on
welding
wire from feeder
or
liner.
moisture, rust, paint, coatings, and dirt from work surface before
welding.
Use
Welding
wire extends too far out of nozzle.
OM-189 482
Page
28
Be
a more
sure
highly deoxidizirig welding
welding
wire extends not
more
wire
(contact supplier).
than 1/2 in
(13 mm) beyond
nozzle.
arc.
6-10.
Troubleshooting
Excessive Penetration
Excessive Penetration
I______
and
V
Excessive Penetration
hanging
weld metal
melting through
base metal
underneath weld.
Good Penetration
S-0639
-
Possible Causes
Excessive heat
Corrective Actions
input.
Select lower
voltage range
Increase travel
6-11.
Troubleshooting
t
II
I
Lack of Penetration
speed.
speed.
Lack Of Penetration
Lack Of Penetration
shallow
fusion between weld metal and
I
Tr
and reduce wire feed
~
I
basemetaJ.
Good Penetration
S-0638
Possible Causes
Improper joint preparation.
Improper
weld
technique.
Corrective Actions
Material too thick. Joint
preparation and design must provide access
maintaining proper welding wire extension and arc characteristics.
Maintain normal gun
Keep
Be
Insufficient heat
input.
arc on
sure
Select
leading edge
welding
Troubleshooting
Incomplete
0 to 15
of weld
wire extends not
wire feed
higher
Reduce travel
6-12.
angle of
degrees
to achieve maximum
to bottom of groove while
penetration.
puddle.
more
speed and/or
than 1/2 in
select
(13 mm) beyond
nozzle.
higher voltage range.
speed.
Fusion
Incomplete
Fusion
base metal
or a
failure of weld metal to fuse
completely
with
weld bead.
preceeding
S-0637
Possible Causes
Workpiece dirty.
Corrective Actions
Remove all grease, oil, moisture, rust,
paint, undercoating,
and dirt from work surface before
welding.
Insufficient heat
input.
Improper welding technique.
Select
Place
higher voltage range and/or adjust
stringer
Adjust
work
bead in proper
angle
or
widen groove to
Momentarily
hold
Keep
leading edge
arc on
Use correct gun
location(s)
arc on
angle
wire feed
at
joint during welding.
access
bottom
groove side walls when
of weld
of 0 to 15
speed.
during welding.
using weaving technique.
puddle.
degrees.
OM-1 89 482
Page
29
6-13.
Troubleshooting
Burn-Through
Burn-Through weld metal melting completely through
resulting in hal es where no metal remains.
base metal
S-0640
Possible Causes
Excessive heat
Corrective Actions
Select lower
input.
voltage
range and reduce wire feed
Increase and/or maintain
.
6.14.
Troubleshooting
steady
travel
speed.
speed.
Wa viness Of Bead
I
Waviness Of Bead
joint formed by
~T1
weld metal that is not
parallel and does not cover
base metal.
S-0641
Possible Causes
Welding
wire extends too far out of nozzle.
Unsteady
6-15.
Corrective Actions
hand.
Be
sure
Support
Troubleshooting
welding wire
hand
on
extends not
solid surface
more
or use
than 1/2 in
(13 mm) beyond nozzle.
two hands.
Distortion
contraction of weld metal
Distortion
base metal to move.
during welding
that forces
metal moves
in the direction of
the weld bead.
S-0642
Possible Causes
Excessive heat
input.
Corrective Actions
Use restraint
(clamp)
Make tack welds
Select lower
Weld in small
Page
30
along joint
before
voltage range and/or
Increase travel
OM-1 89 482
to hold base metal in
position.
starting welding operation.
reduce wire feed
speed.
speed.
segments
and allow
cooling
between welds.
6-16. Common MIG
Shielding
Gases
This is
a general chart for common gases
shielding gases have been developed over
following table.
and where
they
are
the years. The most
used. Many different combinations (mixtures) of
commonly used shielding gases are listed in the
Application
Gas
Short
Spray
Arc Steel
Short
Circuiting
Steel
Circuiting
Stainless Steel
+
25%
CO2
CO2
Flat & Horizontal1 Fillet
All Positions
Flat & Horizontal1 Fillet
All Positions
Tn-Mix3
1
Circuiting
Aluminum
All Positions
Argon
Argon
Short
All
Positions2
All Positions
Globular Transfer
Pass
2
Single
3
90% HE
+
Welding Only
7-1/2% AR
+
2-1/2% CO2
OM-189 482 Page 31
SECTION 7- PARTS LIST
cJ
fl~ Hardware is
common
and
not available unless listed.
0)
LIC)
(\1
c~J
C)
C\I
U)
C)
C)
NC)
U-
ST-801 572
Figure
OM-189 482
Page
32
7-1. Main
Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure
1
089 899...
2
134464
3
+151565
Fig
7-2
SRi.... 181 012
180 920
Di,2.... 037 306
D3,4.... 037 305
LATCH, slide flush
LABEL,.warning general precautionary
WRAPPER
CENTER BAFFLE,
STAND-OFF
146 619
180 923
602 387
605 227
181 072
iii 443
15
125 785
16
180 916 ...BASE
17
147 893
18
186 758
121 614
AXLE, running gear
WHEEL, 1 Oin dia x 2.25
WASHER, flat .812 ID x 1.469 OD
RING, ring ext .750 shaft
180 989
STABILIZER
602 250
z
29
148 956
30
097 924
THERMOSTAT~ NC
CASTER, swvl 4.00 in plastic
TRANSFORMER, power main
PANEL, side lower
SWITCH, selector 6 position
RECEPTACLE W/SOCKETS
SWITCH, tgl DPST 40A 600VAC
PANEL, front
HANDLE, switch
KNOB, pointer
035 897
POTENTIOMETER
TP2.... 163 266
22
23
008 999
Ti
180 925
24
180 924
25
S2
153 197
26
RC2
048 282
27
Si
124 511
28
31
180 917
Ri
2
CAPACITOR, cer disc .Oiuf 1000VDC
THERMOSTAT, NC open 211F
MOTOR, fan 230V 60/50 Hz 3000RPM
BLADE, fan 6.000 4wg 30 deg .175 bore
PANEL, rear
BEZEL, front rear
BRACKET, boffle retainer
CHAIN, weldless 2/0 x 27
NUT, 750-14 knurled 1.68dia
CORD SET, 250V 6-50P 1 2ga 3/c
BUSHING, strain relief
VALVE, 24VAC 2 way
14
21
w/components
(consisting of)
RECTIFIER ASSEMBLY,
BRACKET RECTIFIER
152 862
180 918
20
1
026 947
005 656
.13.... PLG1
Assembly
DIODE, rect 150A 300VR
DIODE, rect 15OA300VS
GROMMET~ SCR .250 panel hole
Ci-4.... 048 420
TP1.... 604 515
FM
123 468
11
7-1. Main
Quantity
1
1
2
.4
.2
1
scr
1
NAMEPLATE, (order by model and serial number)
32
33
147 571
HANDLE
34
130 750
35
600318
CLAMP, work 300A
CABLE, weld copper (order by ft)
36
7-3
loft
MWG-160
1
165 745
HOUSING & PINS
2
173 374
REGULATOR/FLOWMETER, dual scale
HOSE, gas 5ft
1
Fig
183 581
1
a precautionary label, the label should also be ordered.
factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
+When
ordering
a
component originally displaying
To maintain the
OM-189 482
Page
33
Hardware is
common
and
not available unless listed.
1
2
4
10
5
6
7
9
8
11
~12
Fig.74
-
28
16
20
26
21
ST-801 631.C
Figure
OM-189 482
Page
34
7-2. Center Baffle
w/Components
Dia.
Item
No.
Part
No.
Mkgs.
Quantity
Description
Figure
058 427... RING,
7-2.
Baffle, Center w/Components (Fig 7-1 Item 4)
retaining spool
1
085 980... NUT, 625-11 .94 hex
605 941
WASHER, flat
1
1
...
186437... SPRING, cprsn .84500 x .110W
057 971
WASHER, flat .632 ID x 1.500 OD
...
057 745...
186435...
186 436...
180 915...
...10.
.
...
C6
181 013...
11
178 796
...12.
180 921
...13.
180 922
14.
158 832
...15.
083 147
180 927... REEL SUPPORT
17.
R2
057357... BUSHING, snap-in nyl .937 ID
091 685... RESISTOR, WW fxd 50W
W
189 486...
.
...
...20.
...21.
.
.
..
PCi
....
...22.
...23.
134 201
.
.
.
.
.
.
..
CB1
CB2
...
....
183 492...
....
180912...
.25.
097 421
...26.
...27.
171 986...
...
097416...
.
..
CR1
....
072 817...
Fig
...28.
.
..
PLG3
.
..
RC3
...
....
7-4...
.12
1
SPRING, cprsn 2.430 OD x .90 wire x 2.500
HUB, spool
WASHER, brake stl
BAFFLE, center
CAPACITOR ASSEMBLY, (consisting of)
CAPACITOR, elctlt 20000uf
BUSS BAR, positive
BUSS BAR, negative
SCREW, .010-32 x .50 hex hd-slt S
GROMMET, scr No. 8/10 panel hole
16.
...18.
1
x
1
1
2
1
1
6
1
1
12
8
1
x
1
1.l25mtg hole
1
CONTACTOR, def prp 40A 3P
CIRCUIT CARD ASSEMBLY, control
STAND-OFF SUPPORT, PC card
CIRCUIT BREAKER, man reset 1OA 250V
CIRCUIT BREAKER, man reset 5A250V
TERMINAL, pwr output red
TERMINAL, pwr output black
RELAY, end 24VAC DPDT 20
DRIVE ASSEMBLY, wire
1
1
4
1
1
1
1
1
1
115093...CONNECTOR&SOCKETS
1
131 059...CONNECTOR&PINS
1
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-189 482
Page
35
Item
No.
Part
No.
Description
Figure
1
.
110793
7-3.
Quantity
Complete Assembly (MWG-160 Gun)(Fig
HANDLE ASSEMBLY
110795
3
4
5
6
7
8
8
8
9
9
36)
1
TUBE, head (consisting of)
110780 ....NUT,MlOxl
110779
JACKET, head tube
110781
STOP, nozzle
128878
ADAPTER, head tube nozzle
118570
SPRING, nozzle (3 pack)
154826
TIP, contact .023 (6 pack)
154825
TIP, contact .030 (6 pack)
154824
TIP, contact .035 (6 pack)
154822
NOZZLE, slip type 1/2 orifice
154821
NOZZLE, slip type 3/8 orifice
2
7-1 Item
I
1
2
1
1
1
1
1
1
TRIGGER SWITCH ASSEMBLY
TERMINAL, frict uninsul fern 22-l8ga
10
110794
11
080565
12
110792
13
110797
14
167440
15
120715
16
079974
17
110796
CABLE, lOft
SLEEVE, rubber
LINER, monocoil .023-.035 wire lOft (consisting of)
COLLET, liner .035 wire
0-RING, 1/2 ID x .103
CONNECTOR, gun/feeder
18
079878
CONNECTOR&PINS
19
048834
CONNECTOR, circ clamp
1
2
1
1
1
1
2
1
1
str rlf
sz
11
Amp
206062-4
1
9
Hardware is
common
8
and
not available unless listed.
10
1
16
1
3
I
18
19
Ref. ST-lW 832-0
Figure
7-3.
Complete Assembly (MWG-160 Gun)
OPTIONAL
To maintain the factory original performance of your equipment, use only Manufacturers
Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1 89 482
Page
36
Item
No.
Part
No.
Description
Figure
180926
180929
126838
092 237
090415
085 244
085 242
090416
124817
10
090443
111 622
11
112031
151 828
124778
14
174609
15
090423
16
058 549
17
010224
7-4. Drive
Assembly,
Quantity
Wire
(Fig
7-2 Item
29)
MOTOR, gear 24VDC
HOUSING, motor drive
DRIVE ASSEMBLY, wire (consisting of)
KNOB, adjustment tension
SPRING, cprsn .720 OD x .072 wire x 1.250
WASHER, cupped stl .328 ID x .812 OD x .125 lip
FASTENER, pinned
PIN, hinge
HOUSING, wire drive
BEARING, ball rdl sgl row .315 x .866 x .27 (consisting of)
SPACER, bearing .196 ID x .310 OD x .500 collar
LEVER, pressure roll
PIN, cotterhair.054x.750
KNOB, T 2.000 bar w/.312-18 St
...SCREW,M61.0x20
ROLL, drive V groove .023-.035
GUIDE, wire inlet 1/16
PIN, spring CS .187x 1.000
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
Hardware is
common
and
not available unless listed.
3
iT
13
L
15
ST-181 053
Figure
7-4. Drive
Assembly,
Wire
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-189 482
Page
37
Owners Record
S
Please complete and retain witb your personal records.
Model Name
Serial/Style Number
Purcbase Date
(Date
which
equipment
was
delivered to
original customer.)
Distributor
Address
City
State
lip
Resources Available
Always provide Model Name and Serial/Style Number.
Cuutact your Distributor for:
Welding Supplies
Options
and Consumables
and Accessories
Personal
Safety Equipment
Service and
Repair
Replacement Parts
Owners
Circuit
Ceulaci tbe fleliverieg Carrier for:
File
a
ment.
For assistance in
filing
contact your distributor
manufacturers
PRINTED IN USA
settling claims,
and/or equipment
or
Transportation Department.
Manuals
Diagrams
claim for loss
or
damage during ship
S