Miller MW 4150 Owner's Manual
IMPORTANT
contents
the
of
safety
installing,
ment.
only
operation
trained
unit.
understand
This
by
persons
persons
Contact
of
Read
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material
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and
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to
install,
distributor
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these
instructions.
understand
and
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or
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instructions
these
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the
manual,
Do
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the
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the
allow
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do
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on
before
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use
safe
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this
fully
June
Effective
1989
With
Serial
AUTO
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FORM:
No.
MODEL
ARC
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PRINTED
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COPY
CODE
IN
MILLER
ERS
MFG.
Box
P.O.
ST.
54912
USA
PRICE
$145
NO.
4579
U.S.A.
CO.
1079
ONE
YEAR
LIMITED
WARRANTY
COVERAGE
who
purchases
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free
be
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original
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any
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THIS
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THE
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DEFECTIVE
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AMENDMENT
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INSTALLATION
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AMENDMENT
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50-11
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Part
No.
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PARTS
LIST
RING,
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ORDERING
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RECEIVING-HANDLING
Before
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Assistance
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When
ways
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for
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distributor
Transportation
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provide
Number.
Section
SECTION
equipment,
have
occurred
or
damage
or
filing
and/or
Department.
information
the
Model
No.
1
1-1.
1-2.
1-3.
1-4.
check
during
with
settling
claims
the
about
Description
SAFETY
Introduction
General
Arc
Welding
Standards
carton
shipment.
the
deliverIng
may
equipment
this
equipment,
and
Serial
RULES
Precautions
Booklet
forany
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File
carrier.
obtained
be
manufactur-
or
Style
TABLE
FOR
OPERATION
Index
any
al
OF
the
Use
tion
mationislocated
Model
Serial
Date
following
Serial
and
________________________________________
or
Style
of
Purchase
CONTENTS
OF
ARC
or
spaces
Style
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on
to
Number
data
record
card
of
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your
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Model
the
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nameplate.
No._____________________________
______________________________
No.
Page
WELDING
POWER
SOURCE
1
1
3
5
Designa
The
infor
SECTION
SECTION
SECTION
2-1.
2-2.
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
4-1.
4-2.
4-3.
4-4.
4-5.
4-6.
4-7.
4-8.
4-9.
4-10.
4-11.
4-12.
4-13.
2-
SAFETY
General
Safety
3
Alert
INTRODUCTION
Volt-Ampere
Duty
Cycle
Description
Supplied
Additional
Optional
Consumable
4
INSTALLATION
Site
Selection
Transporting
Running
Optional
Shielding
Work
Cable
Weld
Polarity
MWG-200
Installation
Welding
Hub
Tension
Electrical
Welding
PRECAUTIONS
Information
Symbol
Curves
Equipment
Required
Equipment
Parts
Methods
Gear
Installation
SPW-1
Gas
Panel
Installation
Assembly
Selection
Welding
Of
Optional
Wire
Spool
Adjustment
Connections
Input
Wire
Threading
AND
And
Safety
And
Signal
Equipment
Installation
Gun
Connections
Spool
Installation
Gun
SIGNAL
Words
WORDS
..
6
6
8
8
8
8
9
10
10
10
10
11
11
12
13
14
14
15
16
16
16
17
Section
No.
Page
No.
SECTION
SECTION
SECTION
5-1.
5-2.
5-3.
5-4.
5-5.
6-1.
6-2.
6-3
7-1.
7-2.
7-3.
7-4.
7-5.
7-6.
7-7.
7-8.
7-9.
OPERATOR
5
Power
ThicknessNolts
Fine
Switch
Tuning/Wire
Fan-On-Demand
Optional
SEQUENCE
6
Gas
And
Gas
(Models
Shutting
7-
MAINTENANCE
Routine
Replacing
Drive
Replacing
Inspecting
Overload
Thermal
Printed
Spot
Metal
Gas
Metal
Metal
With
Down
Maintenance
Housing
Hub
Protection
Overload
Circuit
Arc
Arc
Drive
And
Troubleshooting
CONTROLS
And
Pilot
Light
Selector
Speed
Pulse
OF
OPERATION
Welding
Arc
Welding
Optional
&
Roll
Control
Panel
(GMAW)-Continuous
Welding-Pulsed
(GMAW)-Spot
SPW-1
TROUBLESHOOTING
And
Realignment
Assembly
Replacing
Protection
Board
Replacement
Controls
Panel
Wire
Inlet
Motor
Arc
Only)
Guide
Brushes
(GMAW-P)
19
19
19
19
19
20
22
23
23
24
26
26
26
27
27
27
27
SECTION
SECTION
SECTION
8-
Diagram
Diagram
9
9-1.
9-2.
9-3.
9-4.
9-5.
9-6.
10
10-1.
10-2.
10-3.
10-4.
10-5.
10-6.
ELECTRICAL
8-1.
Circuit
8-2.
Circuit
WELDING
Gas
Metal
Gas
Metal
Gas
Metal
Welds
Plug
Skip
Welding
Troubleshooting
AUTO
Pointers
Procedure
Procedures
How
To
Prevent
Procedures
Welding
Diagram
Diagram
TECHNIQUES
Arc
Arc
Arc
BODY
For
Welding
For
For
For
Frames
DIAGRAMS
Welding
Welding
Welding
The
REPAIR
Welding
Welding
Glass
Welding
And
SPW-1
For
&
Panel
TROUBLESHOOTING
(GMAW)Continuous
(GMAW)-Pulsed
(GMAW)-Spot
Gas
Metal
Arc
Welding
APPLICATION
Auto
Mild
Door
Breakage
Fenders
High
Sheet
Body
Steels
Panels
And
And
Strength
(HSS)
Process
Metal
Spatter
Quarter
Steels
Seam
On
Panels
Windows
30
30
31
32
33
34
34
34
37
37
37
38
38
38
Section
SECTION
LIST
No.
11
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
OF
CHARTS
Table
Chart
Chart
Table
Table
(GMAW)
Table
Table
Table
PARTS
11-1.
11-2.
11-3.
11-4.
11-5.
11-6.
11-7.
11-8.
3-1.
3-1.
3-2.
3-2.
6-1.
6-2.
7-1.
7-2.
LIST
Main
Assembly
Baffle,
Drive
Assembly,
Panel,
Panel,
SPW
1
Circuit
Running
AND
TABLES
Specifications
Volt-Ampere
Duty
Cycle
Conductor
Input
Suggested
Checking
Maintenance
Troubleshooting
-
Air
W/Components
-
Rear
Front
Card,
W/Components
-
W/Components
Panel
Spot
PC5O
Gear
Curves
And
Parameters
Parameters
Weld
Schedule
Wire
(Optional)
Fuse
For
Size
Continuous
Gas
Metal
Arc
Welding
Page
40
42
44
45
46
48
49
50
21
23
23
28
No.
7
7
7
17
SECTION
1
SAFETY
RULES
FOR
OPERATION
OF
ARC
WELDING
POWER
SOURCE
1-1.
INTRODUCTION
We
learn
by
experience.
sonal
experience,
harmful,
teach
ers
Safe
practices
welding
search,
evolved
and
tion,
wasteful,
you.
and
development,
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developed
cutting
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equipment
practices.
unwise.
describedinthis
equipmentisimproperly
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son
Some
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Read
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Comply
ticular
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Failuretoobserve
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These
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ting;
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The
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ment
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Prevention
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Ignite
may
and
workpleces
1-3A.2.
gloves.
First
aid
facilities
available
be
close
working
should
enrichment
NEVER
welded
used,
must
materials
is
for
immediate
by
and
skin
overhead
on
be
worn
be
used
not
result
can
or
Prevent
in
ANSI
ventilate
and
beryllium-bear
(or
cut)
fumes.
each
or
wear
an
be
must
used.
that
coating
well
is
ventilated
respirator.
it
is
being
an
air-supplied
should
change
gas
of
gases
accidentally
the
space
can
form
to
and
and
WELD
the
energy
be
oxygen
cylinders
gas
supply
in
the
opened
is
safe
be
decomposed
PHOSGENE,
irritating
eye
of
the
arc
perchloroethylene
or
welding
can
113336
the
eyes
cover
them.
and
for
each
burns.
or,
when
by
per
from
depletion
them
with
Standard
with
may
pro
Adequate
person
in
air-sup
emittoxic
removed
if
and,
ventilated
respira
avoided.
con
into
a
at
source
if
space
or
before
a
prod
also
can
cut
where
or
cutting
penetrate
1
Page
to
atmospheres
trichloroethylene
C.
Fire
and
Causes
bythe
rial;
short
BE
through
and
goggled
To
Keep
and
cause
If
the
Avoid
lators.
at
protect
fire-resistant
Walls
not
work
shields.
Fire
guishing
ing
of
fire
flame,
arc,
misuse
circuits.
AWARE
cracks,
through
operator.
prevent
equipment
electrical
(in
short
combustibles
if
work
nt
pai
If
the
least
35
against
touching
be
welded
should
watcher
equipment
or
cutting
a.
appreciable
containing
or
Explosion
and
explosion
flying
of
compressed
THAT
flying
along
wall
or
Sparks
fires
and
clean
parts)
circuits.
are
practicable,
rooms,
spray
work
cannot
feet
away
ignition
covers
combustibles
on
(or
be
protected
must
be
if:
construction)
b.
appreciable
feet
but
can
c.
openings
within
(concealed
35
feet
sparks
d.
combustibles
metal
Hot
work
ensure
have
been
After
work
glowing
An
empty
produce
be
never
been
cleaned
7
in
Standards
This
includes:
solvent
bles
solubility)
trogen
113
336
Page
or
conducted
permit
supervisors
embers,
container
flammable
welded
water
or
carbon
or
partitions
should
taken.
is
done,
and
on
describedinAWS
as
Index.
a
thorough
washing,
followed
dioxide,
2
heat.
minute
even
perchloroethylene.
Prevention
combustibles
are:
sparks,
gases
hot
slag
and
or
sparksorfalling
slag
windows
out
can
fly
pipes,
floor
through
openings,
and
explosion:
and
operable,
metallic
of
in
out
or
cut).
do
area,
to
an
tanks,
dip
be
moved,
of
reach
with
shields.
Walls,
area
suitable
on
by
standing
and
during
combustibles
within
are
combustibles
be
ignited
orvisible)
may
expose
adjacent
can
be
obtained
approvalthat
check
that
or
flames.
held
toxic
or
cut,
steam
that
combustibles,
vapors
unless
depending
by
purging
and
free
particles
NOT
weld
free
of
storage
move
of
sparks
and
opposite
ceilings,
heat-resistant
with
some
suitable
time
by
for
(including
35
feet
further
are
by
sparks
in
combustibles
to
walls,
be
ceilings,
ignited
before
adequate
is
area
orcaustic
using
free
when
container
Standard
on
and
inerting
protective
amounts
reached
heated
cylinders;
slag
of
of
combustibles.
can
or
sight
35
feet.
oil,
cut.
or
areas,
mate
pass
doors,
of
grease,
that
Move
venti
and
the
can
combustibles
and
heat;
snug-fitting,
sides
should
and
floor
near
covers
fire
extin
afterweld
building
than
35
floors
orwalls
roofs,
radiant
by
operation
precautions
of
sparks,
that
or
heated,
A6.O,
cleaning
the
must
has
listed
(or
combusti
with
can
first
ni
equip-
or
to
or
to
of
or
a
ment
working
A
container
(see
smell
Hollow
welding
Explosive
may
as
D.
Standard
manual,
HANDLING
DERS,
1.
Regulator
regulator
any
with
Never
other
Remove
pair
indicate
Leaks-if
Excessive
with
Faulty
when
release.
Repair.
for
where
recommended
as
level
with
preceding
or
sight
castings
or
cutting.
atmospheres.
contain
gasoline).
Compressed
precautions.
andthose
listed
Pressure
relief
from
downstream
one
or
connect
than
more
that
faulty
close
(first
a
faulty
gas
Creep-if
downstream
Gauge-if
pressurized,
Do
NOT
repair
to
special
personnel.
2.
Cylinders
Cylinders
and
Avoid
third
produce
dent.
ICC
assurance
dled.
Identifying
gas
content.
alter
or
is
illegal
Empties:
mark
must
damage
electrical
electrical
rails,
short
(See
DOT
or
marked
Notify
name,
and
Keep
MT;
keep
1-3C.)
of
gas
on
promptly.
in
A6.O.
Waterfilling
substitute
may
unknown
paragraph).
determineifitissafetoweld
to
containers
or
They
flammable
Gas
detailedinCGA
COMPRESSED
OF
in
11
Standards
for
contents
NOT
Do
must
can
explode.
Neverweld
dust,
gas,
Equipment
Comply
with
Index.
inerting.
or
Standard
Regulators
valve
is
designed
it
is
overpressure;
equipment.
relief
devices.
a
regulator
for
which
the
regulatorfrom
cylinder
valve).
not
Provide
to
a
cylinder
regulator
service
The
regulator:
leaks
externally.
delivery
valve
gauge
nor
attempt
manufacturers
techniques
be
handled
their
to
walls,
circuit
wires,
circuit
arcs
them;
must
when
do
marking
safety
content.
supplier
number,
hazardous.
valves
them
separate
pressure
closed.
pointer
returns
to
repair.
and
carefully
valves,
contact
or
welding
that
be
the
Use
only
not
rely
if
unmarked.
other
or
closed,
does
to
stop
Send
designated
tools
with
lead
may
each
on
cylinder
cylinders
on
markings
replace
from
below
just
shouldbecleaned
on
vented
where
vapors
sense
or
cut.
before
the
(such
in
depend
be
orcut
liquid
precautions
P-1,SAFE
GASES
to
intended
IN
protect
to
such
protection
CYLIN
only
protect
containing
was
designed.
immediatelyfor
following
not
pin
are
or
safety
cylinders
circuits.
color
NEVER
FULLS
symptoms
continues
off
move
after
pressure
faulty
regulators
repair
used
by
to
prevent
devices:
including
They
to
serious
a
cylinder.
is
properly
with
name
to
identify
DEFACE
on
a
cylinder.
caps
securely;
and
to
stop
center,
trained
leaks
It
return
this
the
gas
re
rise
pin
can
acci
is
an
han
gas
of
air
of
It
Prohibited
other
than
roller.
Locate
over.
or
Passageways
where
areas
Transporting
such
port
the
ground
or
magnets.
NOT
Do
and
stag,
contents
low
supplier.
Mixing
Never
such
cylinders
objects,
moving
valve.
valve
gases.
refill
where
Protect
falling
when
Stuck
cylinder
your
Cylinderfittings
Hose
3.
Prohibited
for
the
specified
is:
red
for
gases.
Use
ferrules
wireorother
nary
hoses
to
No
copper
to
tings
Avoid
hose
on,
splice
long
off
otherwise
or
Never
use.
intended
its
secure
cylinders
and
they
cylinders.
a
as
platform
their
by
expose
flame,
etc.
exceed
to
exposure
and
cylinders.
NOT
Do
that
Never
cylinder.
any
should
Never
use.
gas.
fuel
gas,
or
clamps
fittings.
tubing
hose.
to
runs
ground
to
damaged.
a
use
cylinder
NEVER
use,
so
they
work
areas.
struck.
be
may
With
a
crane,
orcradle.
valves
cylinders
particularly
can
green
or
that
may
130F.
exists.
weather.
use
a
not
to
try
never
hose
use
A
general
for
caps,
excessive
to
cause
valves
hammer
be
mix
be
oxygen,
designed
it
as
Use
kinks
from
substitute)
splices.
prevent
keep
or
as
cannot
Keep
cylinders
use
NOT
Do
or
by
rupture.
with
Cool
from
Replace
wrench
or
opened
gases
any
modified
otherthan
hose
identification
and
for
the
a
binding
standard
only
and
run
being
its
contents
a
support
be
a
secure
lift
cylinders
chains,
heat,
water
bumps,
caps
hand.
by
in
a
or
exchanged.
that
black
hose
to
abuse.
over,
for
or
knocked
of
clear
sup
off
slings,
sparks,
Do
al
not
spray
falls,
securely
to
open
Notify
cylinder.
designed
rule
inert
for
ordi
(not
connect
brass
fit
Suspend
stepped
outlet
with
a
Match
the
that
thatthe
CONNECT
gases
Tighten
nections,
Tighten.
retighten
Adapters.
plier)
two
use
LEFT
Regulatoroutlet
by
right
(with
5.
a
Pressurizing
Drain
fore
opening
justing
sive
compression
seat
engaged
Stand
Open
creases
reaches
lowing
seal
to
less
Use
safe
regulators.
Check
there-after.
uid*
leak.
bustible.
from
away
clean
lintless
regulator
regulator
regulator
a
to
a
cylinder
connections.
clean
If
connection
using
Use
between
wrenches
HAND
threads.
hand
grooved
regulator
cylinder
screw
to
open
slightly
side
to
cylinder
slowly.
regulator
position:
stem
against
than
one
pressure
and
efficient,
for
leaks
Brush
or
equivalent
Clean
off
people
to
label
inlet
regulator
and
cloth.
cylinder.
and
and
cylinderoutlet
designed
containing
When
smooth
and
leaks,
adapter
and
to
tighten
hose)
for
nut
on
fitting
connections
oxygen
or
properly
CGA
a
cylinder
(or
threads
hex
Steps:
of
residual
in
(clockwise).
heat
on
pressurization.
on
of
regulator
valve
When
gas
manifold
(or
at
high
single-stage
while
so
slowly
gauge
maximum)
For
oxygen,
possible
turn
to
permit
charts
soapy
(available
recommended
first
on
with
per
pressurization
soap
gallon
water
sources
Before
cylinder
any
of
connecting,
marking
for
a
particular
other
assembling
where
seats
disassemble,
wrench.
(available
and
if
marked
may
left
for
regulator,
adapter
shank)
through
valve)byturning
Draining
pressure
Leave
regulators.
opening
that
regulator
is
pressurized
leave
cylinder
and
inert
leak.
For
quick
emergency
from
your
pressure
solution
of
after
(capfull
water).
dried
test;
ignition.
area,
match.
NEVER
gas.
threaded
necessary.
clean,
from
your
is
one
required.
RIGHT
be
identified
hand
threads
fuel
gas.
suitable
vent
prevents
seat
by
allowing
adjusting
cylinder
pressure
valveinfol
gases,
fuel
open
gas,
shutoff.
supplier)
settings
and
regularly
of
Ivory
Bubbles
soap
Wipe
check
and
or
gas
con
and
sup
and
be
ad
exces
screw
valve.
in
(gauge
fully
to
open
for
on
Liq
indicate
is
com
Coil
excess
Protect
sparks,
Examine
nections.
dicate
leaks.
Repair
ing
(1-2D3).
4.
Proper
Clean
cylinder
orifices
Except
hose
hose
and
slag,
hose
Immerse
or
leaky
Do
Connections
and
damage
for
hydrogen,
to
prevent
from
damage
open
regularly
pressured
hose
worn
NOT
tape.
valve
outlet
seats
crack
flame.
for
leaks,
by
before
valve
kinks
and
by
sharp
wear,
in
hose
cutting
of
impurities
connecting
momentarily,
tangles.
edges,
and
water;
out
area
that
and
by
loose
con
bubbles
and
may
in
splic
clog
regulator.
pointing
E.
User
Responsibilities
Remove
mediately
in
F.
Close
G.
Rope
cutting
leaky
for
equipment
Leaving
supply
gas
Rope
Staging-Support
staging-support
operation;
*Trademark
1-3.
ARC
WELDING
defective
or
repair.
See
manual.
EquIpment
at
source
rope
of
Proctor
User
Unattended
should
may
&
Gamble.
equipment
from
Responsibility
and
drain
gas.
be
not
used
burn.
service
statement
for
welding
113
336
Page
im
or
3
Comply
Arc
careless
high
bright
frared
pressed
unnecessary
accidents.
dards
A.
Comply
The
can
from
Skin
shielded
BURNED;
1.
Wear
arc)
essary,
Ieatherjacket
sistant
ton.
Bare
Button
ets
2.
Protect
electric
Welding
no.
face
Protect
Cracked
worn;
Cracked,
IMMEDIATELY.
pitted,
Flash
the
helmet
struck.
eyes
cause
area
3.
Enclosed
rate
round
ble
ticularly
113
with
precautions
Welding,
properly
operator
currents
and
hot.
energy
gases
risks
Precautions
referenced
Burn
Protection
with
precautions
welding
damage
arc
eyes,
light-colored
burns
resemble
are
arcs
COMPLY
Protective
long-sleeve
in
addition
additional
use
or
leggings.
skin
protection.
collar
to
to
prevent
Head
and
Eye
from
eyes
without
arc
helmet
12
denser
or
before
striking
filter
plate
broken
or
radiation
broken,
or
spattered.
goggles
helmet
not
to
give
be
Looking
(particularly
retinal
a
in
the
fieldofvision.
Protection
welding
or
the
operation
or
floor
at
4
Page
enclosed
room
screens
336
done,
invites
at
significant
Sparks
fly,
radiates,
be
and
in
index.
intense
used.
protects
are
may
is
penetrate
surfaces,
acute
more
severe
WITH
Clothing
clothing
to
gloves,
sleeves,
Avoid
outer
Wear
protect
entry
chest
of
sparks.
Protection
exposure
protection.
shield
or
must
be
arc.
with
a
helmet
can
pass
loose
or
Replace
with
side
some
lowered
at
burn
of
protection
an
arc
a
high
that
Nearby
area.
bay
with
panels.
Allow
level.
in
1-1,
is
trouble.
1-2,
safe
a
The
equipment
and
voltages.
fumes
weidments
The
described
1-2.
in
and
visibly
rise,
are
wise
himself
bright.
ultraviolet
here
lightweight
and
burn
the
sunburn,
and
PRECAUTIONS.
those
painful.
(particularly
and
hat,
protective
flame-proof
shoes
clothing
apron,
garments
substantial
dark,
and
to
containing
used
when
clear
cover
or
through
filter
plates
clear
cover
shields
the
over
momentarily
intensity
leave
may
Personnel
For
production
is
best.
and
neck
NEVER
arc.
filter
a
welding.
plate.
shield
to
cause
must
plate
MUST
the
to
face
with
gas-shielded
a
In
open
low-reflective,
for
free
air
this
section.
arc
and
others
and
Its
radiation
and
from
DONT
such
and
but
carries
is
very
and
com
avoids
from
in
stan
reflect
eyes.
gas-
GET
As
nec
fire-re
process,
The
hot,
operator
and
clothing,
skin
for
gas-shielded
(1-2A).
of
untreated
clothing.
button
pock
look
at
shade
plate
Pace
over
should
eyes
before
when
be
NOT
burns.
be
replaced
broken,
worn
should
an
under
arc
unprotected
arc)
a
areas,
dark
sepa
permanent
welding,
non-combusti
circulation,
in
cot
the
can
sur
par
as
an
be
is
Viewing
who
a
Others
flash
Before
bay
B.
Comply
Generator
air.
C.
Comply
the
will
be
working
goggles.
starting
doors
are
Toxic
Fume
with
engine
Carbon
Fire
and
with
looking
monoxide
Equipments
equipment.
Loose
cause
Never
sel.
ture
D.
Comply
E.
Exposed
ing
ment
conductor.
TOUCH
cable
fire.
a
strike
It
creates
lead
or
Compressed
with
can
Prevention
hot
or
fatally
DO
wet
a
Shock
circuit,
Provide
weld.
directly
in
area.
to
weld,
closed.
PreventIon
precautions
exhaust
Explosion
precautions
rated
capacity.
It
overheat
may
connections
on
an
arc
brittle
a
such
to
Gas
precautions
conductorsorother
in
ungrounded,
shock
NOT
surface
See
make
in1-2B.
must
kill.
can
Prevention
in
a
cylinder
area
a
rupture
Equipment
in1-2D.
a
person
STAND,
when
face
shields
weld.
the
at
all
that
may
that
sure
be
1
-2C.
Do
not
cables
can
under
persons
that
vented
overload
and
overheat
other
or
cause
rough
bare
electrically-HOT
whose
SIT,
LIE,
welding,
for
screen
to
cause
or
pressure
a
metal
body
LEAN
without
all
persons
are
wearing
or
flaps
the
outside
arc
welding
fire.
a
flash
and
ves
violent
rup
handling.
the
in
weld
equip
becomes
OR
ON,
suitable
a
protection.
To
protect
Wear
body
adequate
duckboard,
dry
can
tween
metal
able
through
A
voltage
ducting
ing
objects
trical
against
dry
insulating
and
clothing
insulation
be
not
avoided.
body
reduces
dangerous
the
will
object
include,
work
tools,
workpieces,
metal
object
1.
Grounding
Arc
welding
the
National
grounded
And
When
welding
culatorto
quate
according
Cutting.
installing,
power
the
to
carry
shock:
gloves
dry.
against
rubber
or
Sweat,
and
an
electrically
the
electrical
and
body.
exist
between
in
the
work
but
benches,
Never
etc.
unless
the
Equipment
the
equipment
Electrical
to
connect
source,
building
ground.
ground
and
Never
work
electrical
when
mat
sea
resistance,
possibly
the
circuit.
limited
not
are
welding
touch
welding
must
be
Code,
ANSI
Z49.1
the
frames
control,
currents
worktable,
Conductors
body
in
damp
dampness
water,
HOT
part
lethal
electrode
Examples
to,
power
the
electrode
power
grounded
and
the
Safety
of
each
safely.
Equipment
protection.
area
shock.
moisture
or
or
and
currents
and
buildings,
source
source
Keep
without
Stay
or
sweat
grounded
could
to
any
of
conduct
elec
cases,
and
is
according
work
must
In
Welding
unit
such
andwater
be
must
made
on
be
en
flow
con
any
off.
cir
ade
a
to
be
as
electrically
tally.
carrying
HOT
NOTGROUNDto
Do
ANY
Three-phase
equipment
available,
wires
ment
ment
tion
that
Before
conductors
frames
If
line
a
equipment
ground
plug
ceptacle,
ground
prong
Never
plug
2.
Electrode
Fully
NOT
3.
Connectors
Fully
join
welding
4.
Cables
Frequently
IMMEDIATELY
or
damaged
from
taped
Keep
from
5.
Terminals
Terminals
should
6.
a.
before
connect
of
the
ground
will
become
can
welding,
connections.
at
cord
for
leadtothe
is
added
the
prong
plug,
remove
broken
with
a
insulated
holders
use
insulated
inspect
bared
cable.
to
give
cable
hot
metal
and
have
Electrode
Equipment
3-phase
are
connect
cable
dry,
insulating
Welding
metal
welding
mally
off
control
equipped
cally
and
touch
ject
the
welding
b.
Equipment
contactor)
stray
current
by
electrical
flammable
or
gas
connection.
Check
installing.
single-phase
Do
line.
lead
to
the
third
electrically
shock,
possibly
check
touching
with
a
ground
connection
grounded
for
connection
ground
If
only.
Holders
the
to
the
ground
off
electrode
with
lock-type
ground
bare
to
switchbox.
must
lead
line
a
grounded
prong
ground
holders
protruding
connectors
lengths.
cables
REPLACE
insulationtoavoid
Cables
resistance
free
and
And
other
power
arc
welding
(GTAW)
are
equipped
of
the
HOT
when
the
welding
the
electrode
in
contact
forwear,
those
with
equivalenttooriginal
of
oil
and
sparks.
Other
Exposed
exposed
covers
with
output
sources
(GMAW),
and
with
the
welding
electrode
the
power
gun
wire
with
the
power
without
source
shock,
may
conduit,
such
liquid
phase
requirements
If
only
3-phase
equipment
NOT
connect
or
wire,
(live)
HOT-a
dangerous
fatally.
for
continuity.
metal
lead
a
switchbox,
to
a
be
cord
of
is
provided
If
a
grounded
connected
comes
mating
from
a
plug,
prong.
should
screws.
shouldbeused
cracks
with
excessively
possibly-lethal
Parts
of
electrical
before
control
use
gas
processes
that
output.
becomes
source
is
conducting
any
is
off.
on/off
areas
and
closed.
damaged
grease,
parts
secured
on/off
for
similar
devices
power
wire
switch
or
electrode
output
possiblyfa
orto
a
pipe
oil
fuel.
or
as
of
equip
equip
condi
Be
is
two
sure
to
the
the
power
only
equipment
with
the
connect
the
three-prong
to
re
the
mating
withathree-
receptacle.
or
use
be
used.
Do
to
and
damage.
worn
shock
be
may
cable.
protected
units
operation.
(contactor)
with
the
gas
When
electri
is
Never
unless
arc
nor
on
so
ON
ob
(no
tungsten
permit
switch
circuit
control
a
Welding
metal
esses
output
ment
power
electrode
off.
7.
Safety
Safety
should
Before
shut
switches)
tag
Disconnect
all
pull
Do
not
ing.
against
Leaving
disconnect
Power
welding
F.
port
Magnetic
Devices
devices
be
not
installation,
OFF
all
115
volts
open
in
an
It,
shock
equipment
all
disconnect
power
Protection
Devices
fields
operation.
equipment
before
(pacemaker)
going
operations.
1-4.
STANDARDS
For
more
information,
their
latest
revisions
1.
ANSI
Standard
CUTTING
Society,
2.
NIOSH,
AND
GAS
from
the
ernment
3.
OSHA,
29CFR
Documents,
Washington,
4.
ANSI
Standard
OCCUPATION
FACE
PROTECTION
National
NY
York,
5.
ANSI
Standard
SAFETY-TOE
American
New
way,
6.
ANSI
Standard
USE
OF
power
arc
may
on-off
electrode
the
switchisturned
suchasinterlocks
disconnectedorshunted
power
to
prevent
cables
alt
line-cord
power
emergency,
burns,
power
source.
For
sources
welding
not
unless
be
equipped
control
the
(SMAW)
devices.
is
electrically
welding
inspection,
and
remove
accidental
from
welding
plugs.
circuit
or
change
it
must
from
flash
or
unattended.
to
equipment.
switch
must
Wearers
or
line
be
of
(Pacemakers)
from
Persons
near
obtainable
N.W.
550
SAFETY
WELDING
Superintendent
Printing
SAFETY
obtainable
1910,
D.C.
Standards
10018.
National
York,
CUTTING
high
wearing
arc
welding,
BOOKLET
refer
and
Z49.1,
LeJeune
AND
Office,
U.S.
20402.
Z87.1,
AND
Z41.1,
FOOTWEAR
NY
Z49.2,
currents
electronic
should
consult
gouging,
the
to
comply
SAFETY
from
HEALTH
AND
of
Washington,
AND
HEALTH
from
Government
SAFE
EDUCATIONAL
obtainable
Institute,
STANDARD
Standards
10018.
FIRE
AND
WELDING
with
used
similar
and
with
welding
With
such
HOT
ON.
Never
power
and
circuit
out.
service,
of
fuses
(or
turning
power
polarity
equipment,
lock
ON
source,
while
disconnected,
switch
Always
be
Electronic
can
INDEX
following
as
the
Rd,
arcing.
shut
available
affect
pacemaker
life
with
their
or
spot
standards
applicable:
IN
WELDING
American
Miami,
IN
ARC
CUTTING
Documents,
D.C.
STANDARDS,
the
Superintendent
Printing
PRACTICES
from
the
1430
Broadway,
FOR
obtainable
Institute,
PREVENTION
1430
PROCESSES
shielded
proc
power
equip
when
the
touch
the
source
breakers
red-
or
of
power.
and
weld
guard
OFF
and
the
near
Life
Sup
support
doctor
welding
AND
Welding
FL
33126.
WELDING
obtainable
U.S.
Gov
20402.
Office,
FOR
EYE
AND
American
New
MENS
from
the
Broad
IN
THE
is
or
of
113
336
Page
5
obtainable
Institute,
AWS
7.
CONTAINERS
TIBLES
ciety,
NFPA
8.
TEMS
PROCESSES
Protection
MA
NFPA
9.
CODE
Association,
02269.
10.
NFPA
PROCESSES
Protection
MA
11.
CGA
PRESSED
1430
Standard
obtainable
N.W.
550
Standard
FOR
Association,
02269.
Standard
obtainable
Standard
Association,
02269.
Pamphlet
the
American
from
Broadway,
A6.0,
WHICH
from
LeJeune
51,
WELDING,
obtainable
70,
from
Batterymarch
51B,
obtainable
P-i,
GASES
National
New
York,
WELDING
HAVE
the
Rd,
OXYGEN-FUEL
HELD
American
Miami,
CUTTING,
the
from
Batterymarch
NATIONAL
National
the
Park,
CUTTING
the
from
Batterymarch
SAFE
IN
HANDLING
CYLINDERS
Standards
NY
AND
CUTTING
COMBUS
Welding
FL
33126.
GAS
AND
National
Park,
ELECTRICAL
Protection
Fire
Quincy,
WELDING
AND
National
Park,
obtainable
10018.
ALLIED
Qui
Qui
OF
COM
SYS
ncy,
So
Fire
MA
Fire
ncy,
fromthe
son
GSA
12.
WELDING
nadian
178
M9W
NWSA
13.
PHY
Association,
19103.
14.
American
RECOMMENDED
PREPARATION
OF CONTAINERS
HAZARDOUS
American
Miami,
ANSI
15.
TORY
can
New
Compressed
Davis
Highway,
Standard
AND
Standards
Rexdale
1R3.
booklet,
obtainable
Welding
Welding
FL
33126.
Standard
PROTECTION,
National
NY
York,
Gas
Suite
W117.2,
CUTTING
Association,
Boulevard,
WELDING
from
the
Arch
1900
Society
SAFE
WELDING
FOR
AND
SUBSTANCES,
Society,
Z88.2,
Standards
10018.
PRACTICE
Association,
501,
Arlington,
CODE
FOR
obtainable
Standards
Rexdale,
SAFETY
National
Street,
Standard
PRACTICES
PIPING
obtainable
THAT HAVE
obtainable
N.W.
550
Institute,
Jeffer
1235
VA
22202.
the
IN
Ca
SAFETY
from
Sales,
Ontario,
Welding
Philadelphia,
Canada
BIBLIOGRA
Supply
PA
AWSF4.i,
FOR
THE
CUTTING
AND
HELD
from
the
LeJeune
FOR
from
1430
RESPIRA
the
Broadway,
Rd,
Ameri
2-1.
GENERAL
A.
General
Information
bels,
design,
troubleshooting
followed
The
nameplate
labeling
pear
B
.
Safety
The
installation,
shooting
and
procedures
safety
stalled,
sons
codes
Section
of
Power
ing
presented
and
tags,
installation,
for
the safe
the
front
the
at
appropriate
of
arc
of
others.
operated,
in
accordance
such
as,
1
Safety
Source.
plates
which
of
operation,
welding
which
Therefore,
but
SECTION
INFORMATION
in
this
the
on
operation,
should
and
effective
this
unit
uses
controls.
panel
section
equipment
ensure
and
maintained
with
this
limited
not
Rules
2-
SAFETY
AND
SAFETY
manual
unit
and
pertains
maintenance,
be
read,
understood,
of
this
use
international
The
symbols
in
the
text.
maintenance,
requires
personal
this
equipment
only
by
manual
to,
For
and
those
listedatthe
Operation
PRECAUTIONS
various
on
to
equipment
equipment.
symbols
also
and
trouble
practices
and
safety
istobe
qualified
all
applicable
Of
Arc
and
and
per
end
Weld
la
for
ap
the
in
2-2.
SAFETY
WORDS
The
following
used
throughout
different
tify
a
a
a
IMPORTANT
necessary
ment.
SIGNAL
AND
ALERT
safety
this
levelsofhazard
This
safety
words
tiontothe
WARNING
WARNING
practices
ous
personal
CAUTION
practices
personal
statements
for
the
WORDS
alert
symbol
manualtocall
alert
symbol
safety
which
statements.
statements
must
injury
statements
which
must
or
injury
most
damage
efficient
SYMBOL
and
attention
and
special
is
and
CAUTION
identify
be
followed
loss
or
identify
be
followed
identify
operation
AND
signal
instructions.
with
used
procedures
of
life.
procedures
to
this
to
equipment.
special
SIGNAL
words
iden
and
to
the
signal
call
to
to
of
alien
seri
avoid
avoid
minor
instructions
this
equip
are
or
or
113336
Page
6
SECTION
Table
INTRODUCTION
3-
3-1.
SpecificatIons
Rated
Weld
Output
At
60%
Duty
Cycle
150
Amperes
At
Volts
23
DC
Max.
Open-
Circuit
Voltage
32
Rated
At
input
Hz
60
Single-Phase
At
200V 230V 460V
26.5
24
12
Load
Output
575V
9.6
kva
5.5
kw
4.8
Control
Circuit
Voltage
Gun
At
24
Volts
DC
*Add
2-3/4
~Add5lbs.
Electrode
Wire
Feed
Speed
60to486
1pm
to
(1.5
mpm)
Dimensions
Width
A:
13-1/2
(343
B:
Length
27
in.
(686
C:
Height
30
in.
(762
lbs.
12.3
in.
mm)
mm)
mm)
(1.25
(2.27
205
(93
kg)
kg)
.023/.025
.030
.035
Weight
Net
lbs.
kg)
for
units
units
for
Electrode
Wire
Diameter
Capability
in.
(0.6
10.~
in.
in.
215
with
with
mm~
mmj
~0.9
.
Ship
lbs.**
(98
kg)
spot
spot
mm)
TB-087
313-C
3-1.
6
5
4
3
2
1
Overall
HIGH
LOW
436-lA
Figure
Chart
3-1.
Volt-Ampere
In
.J
0
U
50
25
0
100
75
DC
AMPERES
125
Curves
150
175
200
9-057
Dimensions
Chart
200
-
175
150
@.
4
U
125
100
30
~
40
35
3-2.
%
~
50
DUTY
Duty
Cycle
1RATED
60
CYCLE
OUTPUT
-
--
~-
113
00
9-057436-1
336
90
Page
100
7
70
3-1.
VOLT-AMPERE
The
volt-ampere
output
age
adjustment
age
SPEED
curves
With
determine
age.
3-2.
The
that
output
This
cycle
shown.
the
DUTY
duty
a
welding
without
welding
when
operated
but
it
must
utes
crease,
Refer
the
allow
to
to
output
cycles.
CAUTION:
a
INGS
curves
capabilities
is
control.
use
cycle
the
of
the
weld
CYCLE
is
power
Curves
the
overheating
power
operated
150
at
amperes
operate
proper
the
duty
cycle
the
Duty
of
the
welding
wIll
Do
not
exceed
CURVES
RATED
show
of
the
of
by
other
provided
volt-ampere
amperage
(Chart
percentage
source
source
at
no
cooling.
Cycle
EXCEEDING
damage
3-2)
can
and
is
150
at
for
load
If
increases.
chart
power
the
indicated
(Chart
OUTPUT
the
voltage
unit.
Voltage
the
FINE
setting
curves,
at
any
of
be
damaging
rated
amperes.
six
consecutive
for
the
the
welding
(Chart
source
DUTY
weldIng
duty
3-1)
and
and
TUNING/WIRE
fall
between
it
is
possible
minute
to
percent
unit
amperes
to
at
various
CYCLE
power
load
at
four
determine
particular
ten
a
operated
60
at
The
remaining
3-2)
cycles.
amper
amper
the
to
volt
period
a
given
the
unit.
duty
be
can
minutes,
min
de
duty
RAT
source.
3-3.
DESCRIPTION
This
unit
ing
power
signed
circuit
or
dc
Rated
Electrode
weld
cycle.
a
duty
Models
provide
on
time,
3-4.
SUPPLIED
The
following
power
source
sembly:
A.
B.
C.
D.
E.
The
welding
(2.7
mm)
valve,
gas
is
a
single-phase
source
for
Gas
transfer.itis
spray
output
with
the
the
controls
bumback
equipment
and
Running
bracket.
Wall
receptacle
Work
cable,
MWG-200
two
contact
Drive
rolls
and
0.8,
power
cord
power
and
facilities
constant
wire
and
Metal
feedersystem.
Arc
Welding
designed
Positive/Reverse
is
150
amperes,
optional
EQUIPMENT
gear
SPOT
for
regulating
and
time,
is
requires
with
pulse
supplied
customer
(200/230
work
clamp,
with
gun
tubes
for
0.9
source
(with
5/8
for
.023/.025,
hard
mm)
is
factory
plug
for
a
Spool
PULSE
spot
off
(Figure
gas
volt
and
inch
each
.030,
wire.
200/230
on
voltage
dc
This
(GMAW)
primarily
Polarity
volts
23
WELD
weld
time.
3-2)
with
the
installation
cylinder
models
jack
plug.
and
nozzle
size.
.035
(16mm)
wire
equipped
volt
gun.
weld
arc
unit
is
de
with
short
for
use
as
machine.
60%
at
dc,
PANEL
time/pulse
welding
or
as
rack
and
only).
and
in.
(0.6,
with
ft.
9
models),
113336
Page
Spreader
Bar
Wall
Receptacle
Figure
8
3-2.
Supplied
Equipment
Bracket
3-5.
ADDITIONAL
(Figure
The
Metal
your
A.
Two
Welding
dioxide
welding
percent
favorable
gas
B.
Regulator/f
pressure
cause
flowmeter
mixture
changed
adapters
meter
3-3)
additional
Arc
local
Gas
types
equipment
Welding
welding
CylInder
of
are
gas
(GMAW)
(GMAW)
is
source/gun
and
results.
supplier.
the
Obtain
from
(C02)
power
argon
your
Regulator/Flowmeter
lowmeters
and
flow
gases
for
have
is
designed
of
gases.
from
installed.
are
the
type
one
REQUIRED
requiredtocomplete
be
can
setup
supplies
of thin
gas
25
rate
different
distributor.
generally
gauge
recommended
combination.
a
cylinder
during
carbon
a
the
percent
provide
properties,
be
used
to
used
sheet
of
constant
welding
with
with
for
A
dioxide
selected
each
a
specific
Regulator/flowmeters
to
of
gas
gas
Obtain
used.
Gas
Cylinder
another
the
unless
proper
EQUIPMENT
the
Gas
Metal
Carbon
with
also
from
Arc
this
gives
obtained
Gas
steel.
use
mixtureof75
shielding
shielding
process.
gas
Be
regulator/
or
gas
cannot
the
be
proper
regulator/flow-
C.
Measure
source.
ameter,
thread
D.
Selection
Metal
choose
ing
ety
cated
classes
E7OS-6
flatter
wire.
E.
When
helmet,
eyes
safety
F.
The
Offset/Punching
pose,
The
portion
When
small
a
steel,
set
place,
The
used
riveting
use
Hose
Gas
distance
Obtain
S.A.E.
fittings
Wire
Arc
from,
thin
gauge
(AWS)
on
provides
bead
Personal
using
fitted
from
glasses,
good
gas
both
on
the
For
correct
Spool
of
Welding
but
certain
sheet
classification
the
label
recommended
a
than
Safety
this
welding
with
the
welding
and
OffseVPunchlng
of
repair
rotating
damaged
pressure
cut
portion.
sanded,
head
as
and
automotive
toolisused.
head.
area
of
the
head
is
applied
in
offset
to
a
the
is
size,
The
new
filled
of
the
tool
punching
operations.
finishing
time
from
gas
quality
hose,
endsofhose.
GMAW
welding
(GMAW).
wires
steel.
for
of
the
are
fluid
more
E7OS-3.
Equipment
power
the
proper
arc.
gloves
Tool
is
cut
away
are
to
sheet
placed
piece
with
body
can
tool.
The
use
to
cylindertowelding
in.
5/8
and
The
GMAW
wire
E7OS-6
Obtain
Also
to
(Figure
sheet
placed
the
steel.
in
of
be
The
of
minimum.
a
(16
install
Process
wire
is
There
are
best
are
American
wires
spool.
and
a
source,
filter
wear
weld
lens,
protective
(wetter)
prevent
3-4)
steel
This
tool
and
the
over
handles,
A
new
position
sheet
steel
and
putty,
rotated
one-half
punching
this
toolwill
mm)
5/8-18
important
many
suited
Two
spool
wear
injury.
is
easier
has
jaws
the
the
piece
to
overlap
tool
outside
rIght
In
types
for
Welding
is
usually
AWS
E7OS-3.
puddle
of
selected
a
welding
to
protect
clothing,
when
dual
a
of
the
sheet
tool
indents
of
the
is
welded
finish
sanded.
turn
expedites
material
keep
power
di
hand
Gas
weld
Soci
indi
wire
The
and
the
pur
offset
steel.
sheet
off
into
to
to
a
an
be
Gas
Figure
Hose
3-3.
Helmet
1/~
Safety
Glasses
Additional
Wire
Spool
Regulator!
:
Required
Gloves
Equipment
Figure
3-4.
Offset/Punching
Tool
113
336
Page
9
3-6.
OPTIONAL
The
following
capabilities
tions:
A.
B.
C.
D.
of
SPW-1,
cludes
Section
Spoolgun
Gun
cable
25
ft
(7.6
EQUIPMENT
equipment
the
basic
Spot,
three
spot
4-3)
holder
m)
power
be
can
unit
or
Pulser,
nozzles)
cord
obtained
to
suit
special
Continuous
installation
(for
extension
to
extend
applica
Panel
the
(in
see
3-7.
The
following
mal
use:
A.
B.
C.
D.
CONSUMABLE
parts
Contact
Nozzles
Gun
liner
Drive
rolls
are
tubes
PARTS
subject
to
wear
ordamage
in
nor
4-1.
SITE
SELECTION
Figure
(Figure
4-1.
LocatIon
4-1)
SECTION
18
in.
mm)
(457
TB-072
4-INSTALLATION
4A
4-2.
513-C
This
for
the
power
WARNING:
from
surfaces;
overheating
parts.
Do
Maintain
unrestricted
underside
Do
take
this
Warranty
used
TRANSPORTING
welding
moving
the
lifting
eye
source.
FIRE
placing
unit
RESTRICTED
and
locate
not
least
at
space
freeofobstructions.
not
place
air
passages
unit.
is
void
intake
at
power
unit
only
air
source
during
allows
OR
EXPLOSION
on
or
AIRFLOWcan
possible
unit
any
that
if
passages.
METHODS
installation.
combustible
over
inches
18
all
sides
on
filtering
provide
type
any
is
equipped
for
supporting
combustible
over
damage
(457
of
unit,
device
airflow
of
filtering
with
Weight
result
can
cause
to
Internal
surfaces.
mm)
and
keep
the
over
for
cooling
device
a
lifting
capacity
the
welding
of
in
is
eye
of
Select
1.
2.
3.
4.
5.
6.
7.
8.
an
Correct
Shielding
Adequate
No
flammables
A
clean
Proper
cold
Proper
Adequate
installation,
Base
mounting
336
the
Page
secure
tion.
113
installation
input
power
supply
gas
ventilation
and
dry
temperature
airflow
around
space
maintenance,
holes
unit
on
a
running
10
site
which
supply
and
area
that
unit
for
opening
provide
provides
(see
fresh
avoids
and
the
capability
orina
gear
unit
air
extremes
side
repair
the
following:
nameplate)
supply
of
access
permanent
doors
functions.
to
install
heat
loca
for
and
WARNING:
4~
Do
Disconnect
not
deenergized
ing
power
FALLING
personal
Use
gear,
or
accessories
Use
unit
If
lifting
the
base,
to
extend
Using
if
parts
base,
equipment
ELECTRIC
touch
live
input
supply
source.
EQUIPMENT
injury
lifting
gas
and
to
eye
cylinders,
or
devices.
equipmentof
or
moving
lift
tips
or
be
beyond
forks
may
sure
of
that
opposite
too
the
cause
damage
SHOCK
electrical
power
line
BEFORE
can
equipment
lift
unit
or
adequate
this
unit
lift
forks
side
short
can
lift
forks
personal
if
unit
falls
can
parts.
conductors
moving
cause
damage.
NOT
only,
other
any
capacity
with
lift
forks
are
long
of
the
damage
penetrate
injury
off
the
kill.
from
weld
serIous
running
heavy
lift
to
under
enough
base.
internal
the
and/or
lift
forks.
the
unit
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