Craftsman 117.205710 User Manual
Operator’s Manual
210 AMP
MIG WELDER
Model No. 117.205710
OM-194 199E April 2001
CAUTION:
Safety Rules
Before using welder, read this
manual and follow all its Safety
Rules and Operating Instructions.
Installation
Operation
Maintenance
Parts
Español
Sears, Roebuck and Co., Hoffman Estates, IL 60179 U.S.A.
Visit the Craftsman web page: www.sears.com/craftsman
Warranty On Welding Gun or Cables,
Welder, and Welder's Transformer
Effective January 1, 2000
Full One Year Warranty for Craftsman Welding Gun or Cables. For one year from the date
of purchase, when the welding gun or cables are operated and maintained according to
the owner’s manual instructions, if the welding gun or cables fail due to a defect in
material or workmanship, Sears will repair or replace the welding gun or cables free of
charge. This warranty does not cover parts consumed in normal operation, such as
contact tips, nozzles, gun liners, and drive rolls.
Full Three Year Warranty on Craftsman Welder. For three years from the date of
purchase, when the welder is operated and maintained according to the owner’s manual
instructions, if the welder fails due to a defect in material or workmanship, Sears will
repair or replace the welder free of charge. This warranty does not cover the welding gun,
cables, or normal consumable parts.
WARRANTY SERVICE IS AVAILABLE BY SIMPLY CONTACTING THE NEAREST
SEARS SERVICE CENTER. This warranty applies only while this product is in use in the
Untied States.
This warranty gives you specific legal rights, and you may have other rights which may
vary from state to state.
Sears Roebuck and Co., Dept.817WA, Hoffman Estates, IL 60179
Owner’s Record
Please complete and retain with your personal records.
Model Name Serial/Style Number
Purchase Date (Date which equipment was delivered to original customer.)
Distributor
Address
City
State Zip
brand_1yr_warr_1/00
The following terms are
used interchangeably
throughout this manual:
MIG = GMAW
WARNING
This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)
TABLE OF CONTENTS
WARRANTY
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols for Installation, Operation, and Maintenance 3. . . . . . . . . . . . . . . . . . . . . .
1-4. Principal Safety Standards 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – INSTALLATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Specifications 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Volt-Ampere Curves 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Welding Power Source Duty Cycle And Overheating 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Welding Gun Duty Cycle And Overheating 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Installing Work Clamp 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Installing Gas Supply 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Installing Welding Gun 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8. Setting Gun Polarity 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-9. Installing Wire Spool And Adjusting Hub Tension 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10. Changing Input Voltage 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-11. Electrical Service Guide 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-12. Selecting A Location And Connecting Input Power 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-13. Threading Welding Wire 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-14. Weld Parameter 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-15. Aluminum Weld Parameter For Use With Optional Spool Gun 13. . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – OPERATION 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Front Panel Controls 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – MAINTENANCE & TROUBLESHOOTING 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Routine Maintenance 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Circuit Breakers CB1 And CB2 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Changing Drive Roll And Inlet Wire Guide 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Cleaning Or Replacing Gun Liner 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Replacing Switch And/Or Head Tube 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Replacing Gun Contact Tip 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Troubleshooting 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – ELECTRICAL DIAGRAM 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – MIG WELDING (GMAW) GUIDELINES 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Typical MIG Process Connections 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Typical MIG Process Control Settings 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Holding And Positioning Welding Gun 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Conditions That Affect Weld Bead Shape 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Gun Movement During Welding 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Poor Weld Bead Characteristics 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Good Weld Bead Characteristics 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Troubleshooting – Excessive Spatter 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9. Troubleshooting – Porosity 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-10. Troubleshooting – Excessive Penetration 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-11. Troubleshooting – Lack Of Penetration 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-12. Troubleshooting – Incomplete Fusion 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-13. Troubleshooting – Burn-Through 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-14. Troubleshooting – W aviness Of Bead 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-15. Troubleshooting – Distortion 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-16. Common MIG Shielding Gases 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 – PARTS LIST 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Español 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-194 199
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
som _nd_4/98
Y Marks a special safety message.
. Means “Note”; not safety related.
1-2. Arc Welding Hazards
Y The symbols shown below are used throughout this manual to
call attention to and 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
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-4. Read and follow all
Safety Standards.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
Y During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
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.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D 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).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D 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.
D When making input connections, attach proper grounding conduc-
tor first – double-check connections.
D Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not drape cables over your body.
power circuit and machine internal circuits are also
This 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.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower th e oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying op-
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the 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-194 199 Page 1
ARC RAYS can burn eyes and skin.
BUILDUP OF GAS can injure or kill.
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.
D Wear 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).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant mate-
rial (leather and wool) and foot protection.
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
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.
D Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D 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.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
workpiece, and hot equipment can cause fires and
FLYING METAL can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS 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.
D Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder – explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
OM-194 199 Page 2
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring – be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING UNIT can cause injury.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
OVERUSE can cause OVERHEATING
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
MOVING PARTS can cause injury.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the
equipment at once.
D Have the installation regularly checked and maintained.
D 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.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
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 Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
ARC WELDING can cause interference.
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
D To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
D Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
D Be sure this welding machine is installed and grounded
according t o this manual.
D If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
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 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-194 199 Page 3
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Ma g netic Fields
Welding current, as it flows through welding cables, will cause electromagnetic 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
committee’s judgment, has not demonstrated that exposure to power-
frequency 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 are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
OM-194 199 Page 4
2-1. Specifications
Rated Welding
Output
Amperage
Range
SECTION 2 – INSTALLATION
Amperes Input at
Maximum
Open-Circuit
Voltage DC
Voltage DC
Rated Load
Output, 60 Hz,
Single-Phase
200 V 230 V KVA KW
Weight
Overall
Dimensions
Length: 36 in
(915 mm)
150 A @ 23 Volts
DC, 60% Duty Cycle
30 – 185 33 30 (1.6)* 26 (1.4)* 6 (0.27)* 5 (0.13)*
165 lb
(75 kg)
Wire Type And Diameter
Solid Steel /
Stainless
Flux Cored Aluminum
Calculated Wire Speed
Range At No Load
Max Wire Feed Speed
While Welding
Steel
.023 – .035 in
(0.6 - 0.9 mm)
*While idling
Operating Temperature Range – –20C to +40C Storage Temperature Range – -30C to + 50C
.030 – .045 in
(0.8 – 1.2 mm)
.030 – .035 in
(0.8 – 0.9 mm)
138 – 795 IPM (3.5 – 20.3 m/min) 650 IPM (16.5 m/min)
2-2. Volt-Ampere Curves
Volt-ampere curves show minimum and maximum voltage and
amperage output capabilities of
unit. Curves of other settings fall between curves shown.
Width: 18 in
(457 mm)
Height: 27 in
(686 mm)
OM-194 199 Page 5
va_curve1 4/95 – SB-180 824
2-3. Welding Power Source Duty Cycle And Overheating
60% Duty Cycle At 150 Amperes
Duty Cycle is percentage of 10 mi n utes that unit can weld at rated load
without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
voltage, or duty cycle before
welding.
Y Exceeding duty cycle can
damage unit and void
warranty.
6 Minutes Welding 4 Minutes Resting
Overheating
0
15
Reduce Duty Cycle
Minutes
A or V
OR
2-4. Welding Gun Duty Cycle And Overheating
CAUTION
WELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty.
• Do not weld at rated load longer than shown below.
• Using gasless flux cored wire reduces gun duty cycle.
Definition .023 To .045 in (0.6 To 1.1 mm)
0
10
Minutes
Duty Cycle is percentage of 10
minutes that gun can weld at
rated load without overheating.
Hard Or Flux Cored Wires
100% Duty Cycle At 150 Amperes
100% Duty Cycle At 120 Amperes
Using CO
Using Mixed Gases
2
.023 To .045 in (0.6 To 1.1 mm) Hard Or Flux Cored Wires
60% Duty Cycle At 200 Amperes
Using CO
60% Duty Cycle At 150 Amperes
Using Mixed Gases
duty1 4/95 – SB-181 009
warn7.1 8/93
2
Continuous Welding
6 Minutes Welding 4 Minutes Resting
SB1.1 8/93
OM-194 199 Page 6
2-5. Installing Work Clamp
1 Work Cable
2 Boot
Slide boot onto work cable. Route
cable out front panel opening from
4
5
1
2
inside.
3 Negative (–) Output Terminal
Connect cable to terminal and
cover connection with boot.
4 Hardware
5 Work Clamp
Route cable through clamp handle
and secure as shown.
Close door.
2-6. Installing Gas Supply
Tools Needed:
5/8, 1-1/8 in
6
3
4
7
5
Tools Needed:
OR
8 9
1/2, 3/4 in
Argon Gas
CO2 Gas
Obtain gas cylinder and chain to
running gear, wall, or other station-
1
ary support so cylinder cannot fall
and break off valve.
1 Cap
2 Cylinder Valve
2
Remove c ap, stand to side of valve,
and open valve slightly. Gas flow
blows dust and dirt from valve.
Close valve.
3 Cylinder
3
4 Regulator/Flowmeter
Install so face is vertical.
5 Regulator/Flowmeter Gas
Hose Connection
6 Welding Power Source Gas
Hose Connection
Connect customer supplied gas
hose between regulator/flowmeter
gas hose connection, and fitting on
1
rear of welding power source.
7 Flow Adjust
Typical flow rate is 20 cfh (cubic feet
per hour). Check wire manufactur-
2
er’s recommended flow rate.
8CO2 Adapter (Customer Sup-
plied)
9 O-Ring (Customer Supplied)
3
Install adapter with O-ring between
regulator/flowmeter and CO
cylinder.
ST-801 566-A
2
OM-194 199 Page 7
ST-801 571 / ST-802 028
2-7. Installing Welding Gun
1 Drive Assembly
2 Gun Securing Knob
3 Gun End
1
2
3
4
Loosen securing knob. Insert gun
end through opening until it bottoms
against drive assembly. Tighten
nut.
4 Gun Trigger Plug
Insert plug into receptacle, and
tighten threaded collar.
Close door.
2-8. Setting Gun Polarity
Ref. ST-801 567
1 Polarity Changeover Label
Always read and follow manufac-
ture’s recommended polarity.
1
Tools Needed:
3/4, 11/16 in
Ref. 190 821-A
OM-194 199 Page 8
2-9. Installing Wire Spool And Adjusting Hub Tension
Use compression spring with
8 in (200 mm) spools.
Tools Needed:
15/16 in
2-10. Changing Input Voltage
2
3
When a slight force is needed
to turn spool, tension is set.
1
ST-072573-B
Y Turn Off unit, and disconnect
input power.
Unit was shipped from factory set
for 230 volts.
1 Transformer T1
2 Rear Of Power Switch S1
3 Lead Marked 230 Volt And
Fan Motor Lead
Disconnect 230 volt lead and fan
motor lead from rear of S1. Leave
fan motor lead connected to 230
volt lead.
4 Lead Marked 200 Volt
Remove cable tie, and slide short
piece of sleeving off 200 volt lead,
and slide sleeving over end of 230
volt and fan motor leads. Fold
sleeving ov e r a n d s e c u r e i n p l a c e .
Connect 200 volt lead to S1 where
230 volt lead was removed.
Reinstall wrapper.
Tools Needed:
OM-194 199 Page 9
4
3/8, 7/16 in
ST-801 580-A
2-11. Electrical Service Guide
Input Voltage 200 230
Input Amperes At Rated Output 30 26
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes
Circuit Breaker 1, Time-Delay
Normal Operating
Min Input Conductor Size In AWG/Kcmil 10 10
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG/Kcmil 10 10
Reference: 1999 National Electrical Code (NEC)
1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose – no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
Y Caution: Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard.
2
3
35 30
45 40
97
(29)
128
(39)
2-12. Selecting A Location And Connecting Input Power
1 Rating Label
Supply correct input power.
Y Do not move or operate unit
where it could tip.
18 in (457 mm) of
space for airflow
Y Always connect grounding
conductor first.
= GND/PE
5
L1
L2
2 Plug
3 Receptacle
Connect plug to receptacle.
4 Input And Grounding
Conductors
Connect directly to line disconnect
device if hard wiring is required.
5 Line Disconnect Device
See Section 2-11.
Y Special installation may be
required where gasoline or
volatile liquids are present –
see NEC Article 511 or CEC
Section 2 0 .
1
1
4
2
3
L2
230 VAC, 1
L1
Ref. 801 568 / Ref. 800 797-C
OM-194 199 Page 10
2-13. Threading Welding Wire
6 in
(150 mm)
Tools Needed:
4 in
(102 mm)
Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun;
continue to hold wire.
Tighten
. Use pressure indicator
scale to set a desired
drive roll pressure.
Pressure
Indicator
Scale
Close and tighten pressure
1
2
3
4
Remove gun nozzle and contact tip. Turn On.
assembly, and let go of wire.
Press gun trigger until wire
comes out of gun. Reinstall
contact tip and nozzle.
OM-194 199 Page 11
Tighten
WOOD
Feed wire to check drive roll pressure.
Tighten knob enough to prevent slipping.
1
2
3
4
Cut off wire. Close
and latch door.
Ref. ST-801 570-A / ST-801 083 / S-0627-A
2-14. Weld Parameter
Wire Type,
Shielding Gas,
And Flow Rate
Wire
Diameter
(inch)
.023
Material Thickness
Operator
Controls
3/8 in
(9.5
mm)
1/4 in
(6.4
mm)
3/16 in
(4.8
mm)
1/8 in
(3.2
mm)
12 ga 14 ga 16 ga 18 ga 20 ga 22 ga
Voltage Tap – – 6 5 4 3 3 2 2 1 1
Wire Speed – – 100 80 65 55 45 35 25 15 5
E70S-6
CO
2
20 cfh+
E70S-6
75% Argon
75% Argon
25% CO
2
20 cfh+
20 cfh+
E71T-GS
E71T-GS
Flux Core
ER 308
Stainless Steel
90% HE /
90% HE /
7.5% Argon /
2.5% CO
20 cfh+
2
2
Voltage Tap 6 5 4 3 3 2 2 1 1 – –
.030
Wire Speed 80 70 60 55 45 35 25 15 5 – –
Voltage Tap 6 5 4 3 3 2 2 2 – – – –
.035
Wire Speed 70 60 50 45 40 30 20 10 – – – –
Voltage Tap – – 5 4 3 3 2 2 1 1 1
.023
Wire Speed – – 90 80 70 60 50 40 35 25 12
Voltage Tap 6 5 4 3 3 2 2 1 1 1
.030
Wire Speed 85 75 65 55 50 45 35 20 5 0
Voltage Tap 6 5 4 3 3 2 2 1 1 – –
.035
Wire Speed 80 70 60 45 40 30 20 10 0 – –
Voltage Tap 6 5 5 4 4 3 2 1 – – – –
.030
Wire Speed 80 70 65 55 50 30 20 10 – – – –
Voltage Tap 6 5 4 3 3 2 1 – – – – – –
.035
Wire Speed 60 50 40 30 25 20 10 – – – – – –
Voltage Tap 5 4 4 4 3 3 3 2 2 2
.023
Wire Speed 95 85 80 60 50 50 50 30 20 20
Voltage Tap 5 5 4 3 3 2 2 2 1 – –
.030
Wire Speed 70 70 70 50 45 50 45 40 0 – –
Voltage Tap 6 5 5 4 3 2 2 2 – – – –
.035
Wire Speed 65 40 40 30 30 25 20 10 – – – –
*Do not change Voltage switch position while welding. Wire Speed is a starting value only, and can be adjusted while welding. Weld conditions also
depend on other variables such as stickout, travel speed, weld angle, cleanliness of metal, etc.
OM-194 199 Page 12
2-15. Aluminum Weld Parameter For Use With Optional Spool Gun
Wire Type, Wire
Wire Type,
Shielding Gas,
And Flow Rate
4043 AL
4043 AL
100% Argon
5356 AL
5356 AL
100% Argon
Diameter
Wire
(inch)
.030
.035
.030
.035
Material Thickness
Operator
Controls
Voltage Tap 5 5 4 3 2
Wire Speed 88 88 73 55 45
Voltage Tap 6 6 5 4 2
Wire Speed 95 85 68 59 34
Voltage Tap – 5 4 3 2
Wire Speed – 100 90 80 70
Voltage Tap 6 6 5 4 2
Wire Speed 100 92 85 70 60
3/8 in (9.5 mm) 1/4 in (6.4 mm)
3/16 in
(4.8 m m)
1/8 in (3.2 mm) 14 ga
OM-194 199 Page 13
SECTION 3 – OPERATION
3-1. Front Panel Controls
Controls For Standard Units
1 Wire Speed Control
Use control to select a wire feed
speed. Scale around control is not
actual wire feed speed, but is for
reference only.
2 Voltage Switch
The higher the selected number,
the thicker the material that can be
welded (see Section 2-14). Do not
switch under load.
3 Power Switch
1
2
3
Ref. ST-180 930
OM-194 199 Page 14
SECTION 4 – MAINTENANCE & TROUBLESHOOTING
4-1. Routine Maintenance
Replace
Damaged Or
Unreadable
Labels
Blow Out Or
Vacuum Inside
4-2. Circuit Breakers CB1 And CB2
Y Disconnect power
before maintaining.
3 Months
6 Months
1
2
Repair Or
Replace
Cracked
Cables And
Cords
Remove drive roll
and apply light coat
of oil or grease to
drive motor shaft.
. Maintain more often
during severe conditions.
Clean And
Tighten
Weld
Terminals
Y Turn Off unit.
1 Circuit Breaker CB1
CB1 protects the transformer from
overload. If CB1 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.
4-3. Changing Drive Roll And Inlet Wire Guide
Tools Needed:
2
OM-194 199 Page 15
Ref. ST-801 567
1 Drive Roll
Choose correct drive roll for wire
type, and install as shown.
2 Inlet Wire Guide
Remove guide by pressing on
barbed area, 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.
1
Ref. ST-801 569-A
4-4. Cleaning Or Replacing Gun Liner
Y Disconnect gun first.
Head Tube
Remove nozzle, contact tip, and
adapter.
3/8 in
Tools Needed:
3/8 in
Lay gun cable out straight
before installing new liner.
Blow out gun casing.
Remove liner.
To Reassemble Gun:
Insert new liner.
Install and tighten wire outlet guide.
Cut liner off 3/4 in (20 mm) (3/8 in
[9.5 mm] for aluminum) from head
tube.
Install adapter, contact tip, and
nozzle.
Ref. ST-800 797-C
OM-194 199 Page 16
4-5. Replacing Switch And/Or Head Tube
Y Disconnect gun first.
1 Remove handle
locking nut.
4 Secure head
tube in vice.
3 Slide handle.
2 Remove switch housing. Note: If installing new
switch, push switch lead connectors onto terminal of
new switch (polarity is not important). Install switch
back into handle, and secure with handle locking nut.
If replacing head tube, continue to end of figure.
5 Loosen jam nut. Remove
from vice and turn head
tube out by hand.
6 Install existing shock washer onto
new head tube. Hand-tighten head
tube into connector cable.
8 Remove from vice. Reposition
handle and install switch housing.
Secure with handle locking nut.
7 Place head tube in vice and tighten
until nuts are tight.
Tools Needed:
OM-194 199 Page 17
3/4 in
Ref. ST-800 795-C
4-6. Replacing Gun Contact Tip
Y Turn Off unit.
1 Nozzle
2 Contact Tip
Cut off welding wire at contact tip.
Remove nozzle.
Remove contact tip and install new
contact tip. Reinstall nozzle.
Tools Needed:
2
1
4-7. Troubleshooting
Welding Trouble Remedy
No weld output; wire does not feed. Secure power cord plug in receptacle (see Section 2-12).
Check and replace power switch if necessary.
Check circuit breakers CB1 and/or CB2, and reset if necessary (see Section 4-2).
Replace building line fuse or reset circuit breaker if open (see Section 2-12).
Secure gun plug in receptacle or repair leads, or replace trigger switch (see Section 2-7 and/or 4-5).
Thermostat TP1 open (overheating). Allow fan to run; the thermostat will close when the unit has cooled
(see Section 2-3).
No weld output; wire feeds. Connect work clamp to get good metal to metal contact.
Ref. 800 797-C
Replace contact tip (see Section 4-6).
Low weld output. Connect unit to proper input voltage or check for low line voltage (see Section 2-12).
Low, high, or erratic wire speed. Readjust front panel settings (see Section 3-1).
Change to correct size drive roll (see Section 11-3).
Readjust drive roll pressure (see Section 2-13).
Replace inlet guide, contact tip, and/or liner if necessary (see Sections 4-3, and 4-4).
Wire Drive/Gun Trouble Remedy
Electrode wire feeding stops during
welding.
Straighten gun cable and/or replace damaged parts (see Section 4-4).
Adjust drive roll pressure (see Section 2-13).
Readjust hub tension (see Section 2-9).
Replace contact tip if blocked (see Section 4-6).
Clean or replace wire inlet guide or liner if dirty or plugged (see Section 4-4).
Replace drive roll if worn or slipping (see Section 11-3).
Secure gun plug in receptacle or repair leads, or replace trigger switch (see Section 2-7 and/or 4-5).
Check and clear any restrictions at drive assembly and liner (see Section 4-4).
Have nearest Factory Authorized Service Agent check drive motor.
OM-194 199 Page 18
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