Lincoln Electric NR-203MP, NR-232, NR-202, NR-211-MP, NR-203 Nickel (1%) Welding Instruction Manual

...
INNERSHIELD
®
ELECTRODES
Welding Guide
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TABLE OF CONTENTS
SAFETY PRECAUTIONS ..........................3-11
INTRODUCTION...........................................12
RECOMMENDED EQUIPMENT.......................15
WELDING PREPARATIONS........................16-17
Choose the Proper Innershield Gun............................16
Prepare the Work.........................................................17
Optimizing Feeding......................................................17
WELDING TECHNIQUES..............................18-24
Set the CTWD..............................................................18
Set the Wire Feed Speed (WFS).................................19
Start the Arc.................................................................19
Set the Voltage............................................................19
Travel Speed ...............................................................19
Loading 13-14 Lb. Coils on a 2” Spindle......................20
Handling Poor Fitup.....................................................21
Use the Proper Drag Angle..........................................21
Use the Proper Wire Angle to Joint .............................21
Making Vertical Up Welds ......................................22-23
Making Downhill and Vertical Down Welds .................23
Working with NS-3M....................................................24
OPERATING GUIDE.......................................25-29
Troubleshooting......................................................25-26
Effect of Operating Variables..................................26-27
Welder Qualification Test.............................................27
Storing Innershield Electrode .................................28-29
WELDING PROCEDURES...............................30-39
OPERA TING PROCEDURES..........................40-45
INNERSHIELD GUN P ARTS............................46-47
LINCOLN WELDING SCHOOL.......................48-49
WARNING
The serviceability of a product or structure utilizing this type of information is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying this type of information. These variables include, but are not limited to, welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements.
CALIFORNIA PROPOSITION 65 WARNINGS
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
Mar ‘95
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines
The
Above For Gasoline
Engines
-SAFETY-
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FOR ENGINE powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.
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1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.
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1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.
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1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.
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1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.
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1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.
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1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
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ELECTRIC AND MAGNETIC FIELDS may be dangerous
2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting,
(Cont’d on page 5)
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ELECTRIC SHOCK can kill. (Cont’d)
kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.
3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.
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FUMES AND GASES can be dangerous.
5.a.Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.
5.b.
Do not weld in locations near chlorinated hydrocarbon
vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors
to form phosgene, a highly toxic gas, and other irritating products.
5.c. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
WELDING SPARKS can cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.
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WELDING SPARKS can cause fire or explosion.
(Cont’d)
6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even
though
they have been “cleaned”. For information, purchase “Recommended Safe Practices for the
Preparation
for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
CYLINDER may explode if damaged.
7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
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CYLINDER may explode if damaged. (Cont’d)
7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY powered equipment.
8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.
PRÉCAUTIONS DE SÛRETÉ
Pour
votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.
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b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonctionnement.
d. Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au soudage
à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.
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7. Quand on ne soud
e pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
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INNERSHIELD®
Innershield is an arc welding process that uses a continuously fed wire to supply filler metal to the arc. The wire is not solid, but is tubular. Agents necessary to shield the arc from the surrounding atmosphere are placed inside the tube. No additional shielding is required. Innershield was originally used as a replacement for stick welding. Innershield can provide higher productivity and enhance quality when compared to stick welding. It offers increased arc-on time due to the continuous nature of the process. There are also fewer starts and stops, which are frequent sources for defects.
Although the Innershield process has been displaced in many areas by gas-shielded processes, Innershield continues to be an important process for steel fabrication in many markets. Innershield is the primary means for structural steel building erection in the United States. In any shop or shipyard where wind is a problem, Innershield can be a viable solution. Pipeline fabrication is often done with Innershield because it is done outdoors and shielding gas is sometimes difficult to get to these locations.
Lincoln Electric, the originator of the Innershield process, makes Innershield wire in a proprietary manner. The manufacturing processes that Lincoln Electric uses has specific benefits that you can see in every pound of wire you use. The Innershield wires Lincoln Electric produces are very stiff and have excellent column strength. This allows for excellent feedability. Lincoln Electric also fills the wire in a proprietary manner. This step ensures that you get the right amount of fill in every inch of wire. Lincoln Electric is the worldwide leader in Innershield. You can see that when you use our products, meet with our sales reps, or call the factory for support.
w
INTRODUCTION
Current carrying contact tip
Arc
Molten slag
Solidified slag
Solidified
eld
metal
Molten
weld metal
Insulated Guide
Wire core consists of powdered metal, vapor (or gas) forming materials, deoxidizers and scavengers.
Arc shield composed of vaporized and slag forming compounds protects metal transferring through arc.
Metal droplets covered with a thin slag coating, forming molten puddle.
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INNERSHIELD FEATURES
• Can be used in wind speeds of up to 30 mph without losing mechanical properties.
• Gas bottles are unnecessary.
• Stiff wire with high column strength.
BENEFITS OVER GAS-SHIELDED PROCESSES
• Innershield does not require gas shielding.
• No external shielding eliminates gas cost.
• No shielding gas means no cylinder handling, changeout, and rental saving time and money.
• No shielding gas means simpler guns and feeders for lower maintenance costs.
• No shielding gas means no tenting to keep wind away saving labor costs.
• Innershield Wires are stiff.
• Stiff wire is excellent for feedability.
• Stiff wire allows for longer guns to be used, saving labor.
costs moving feeders and welders.
• Stiff wire allows the welder to break off the wire without
clippers.
BENEFITS OVER STICK WELDING
• Innershield is a continuous process.
• This means less starts and stops, saving money and increasing quality.
• This allows the welder to spend more time welding, not changing rods, decreasing labor costs.
• Innershield has higher deposition efficiency.
• Innershield does not produce “stubs” like the stick process. Stubs are materials you purchase and then throw away.
PRODUCT ADVANTAGES
SEISMIC APPLICATIONS:
Constant voltage (CV) power sources are recommended for use with all Innershield electrodes.
NR-211-MP THICKNESS RESTRICTIONS:
Wire Diameter Max. Plate Thickness
.035”, .045” (0.9, 1.2mm) 5/16” (7.9mm) .068”, 5/64”, 3/32” 1/2” (12.7mm) (1.7, 2.0, 2.4mm)
NR-212 is designed to be used on plate up to 3/4” (19.1mm) thick.
SINGLE PASS LIMITATIONS
Certain FCAW-S electrodes are limited to single pass applications. These include, but are not limited to NR-1, NR-5, NR-131 and NR-152.
APPLICATION INFORMATION
SEISMIC STRUCTURAL WELDING APPLICATIONS
The electrodes below have been tested in accordance with FEMA 353 - Recommended Specifications and Quality Assurance
Guidelines for Steel Moment-Frame Construction for Seismic Applications. FEMA 353 test certificates are available upon
request. These certificates contain mechanical test results at low and high heat input levels and diffusible hydrogen classifications. The electrodes indicated with a * also have electrode exposure time on the certificate.
Electrode Diameters
NR-203-MP .068”, 5/64" NR-203 Nickel (1%) 5/64", 3/32” NR-232* .068", .072", 5/64" NR-305* 3/32" NR-311Ni 5/64”, 3/32”, 7/64"
ELECTRODE EXPOSURE
FEMA 353 and other specifications which limit electrode exposure may require monitoring electrode exposure time and/or conditions after removal from a sealed package.
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PRODUCT LIMITATIONS
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INTERMIXING
When Innershield (FCAW-S) weld deposits are intermixed with weld deposits from other welding processes, a decrease in weld metal Charpy V-notch (CVN) toughness properties may occur. For applications requiring CVN properties, intermix testing with the specific electrodes is recommended to ensure the intermixed weld metal meets the required CVN requirements.
TACK WELDING
The following electrodes are recommended for tack welding prior to Innershield welding:
• All Innershield (FCAW-S) wires
• SMAW: Fleetweld 35LS, Jetweld LH70, Jetweld 2, Excalibur 7018
• GMAW solid electrodes
AGING:
The AWS filler metal specification for these products (A5.20 & A5.29) permit aging of test specimens. When conducting welding procedure or operator qualification tests, it is recommended that aging be applied, whenever permitted by the appropriate code. For example, when qualifying procedures to AWS D1.1 Structural Welding Code, see Paragraph 5.10.4.
Preheat and interpass temperature control are recommended for optimum mechanical properties, crack resistance and hardness control. This is particularly important on multiple pass welds and heavier plate. Job conditions, prevailing codes, high restraint, alloy level and other considerations may also require preheat and interpass temperature control.
ARC GOUGING
When Arc Gouging Innershield welds, black smudges or spots may appear on the surface of the groove. The condition is aggravated when the carbon is allowed to touch the surface. This black residue does not indicate the presence of porosity or poor weld quality. It can be easily removed by wire brushing or light grinding.
PRODUCT LIMITATIONS
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CHOOSE THE PROPER INNERSHIELD GUN
Lincoln Innershield Guns
Rated Amperage, Duty Cycle and Wire Sizes
For proper CTWD use the appropriate insulated guide. For
specific information on wire size and cable length, please see
your local Lincoln representative.
K126-1, -2 Gun with 62° Nozzle
350 Amps at 60% Duty Cycle Wire Size: .062–3/32”(1.6-2.4mm)
K206 Gun
350 Amps at 60% Duty Cycle Wire Size: .062–3/32"(1.6-2.4mm)
K116 -2 Gun
600 Amps at 60% Duty Cycle Wire Size .120–7/64”(3.0-2.8mm)
K361-10 Gun
350 Amps at
60% Duty Cycle Wire Size .068–5/64”(1.7-2.0mm)
K289-1, -4
500 Amps at 60% Duty Cycle Wire Size: .120–7/64"(3.0-5.6mm)
K309 Gun
250 Amps at 60% Duty Cycle Wire Size:.062–3/32"(1.6-2.4mm)
K115-1, -2, -3, -4, -5 Guns with 82° Nozzle
450 Amps at 60% Duty Cycle Wire Size: .068–.120”(1.7-3.0mm)
K115-8, -10 Guns with 45° Nozzle
450 Amps at 60% Duty Cycle Wire Size: .068–.120”(1.7-3.0mm)
K264-8 Gun with 30° Long Tube for LN-23P
250 Amps at 60% Duty Cycle Wire Size: .068–5/64”(1.7-2.0mm)
K345 -10 Gun with 90° Standard Tube for LN-23P
350 Amps at 60% Duty Cycle Wire Size: .068–5/64”(1.7-2.0mm)
K355-10 Gun with 90° Tube for LN-23P
250 Amps at 60% Duty Cycle Wire Size: .068–5/64”(1.7-2.0mm)
Fume Extraction Guns
LN-23P Guns
Innershield Guns
Fume Extraction Gun
INNERSHIELD GUNS
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