Miller Electric SPW-1, MW 4200, MW 4150 User Manual

AUTO

ARCJ~

May

1991

Effective

With

FORM:OM-113

Serial

No.

336D

KA898403

MODEL:

AUTO

AUTO
SPW-1

ARCfi

ARCfi

MW
MW

4150

4200

OWNERS

IMPORTANT:

special

installing,

instructions

operation

operate,

understand

SB-087

313D

Read

and

understand

the

emphasis

on

safety

operating,ormaintaining

for

of

maintain

or

are

welding

these

use

only

by

equipment.

this

unit.

instructions.

the

material

persons

Do

Contact

this

not

entire

trained

allow

your

contents

throughout

equipment.

and

experienced

untrained

distributor

MANUAL

before

and
in

the

to

Install,

not

with

these

safe

fully

of

the

This

persons

if

this

manual,

unit

you

manual,

do

MILLER

AMIerGroupLld..Company

Appleton,

Tel.

ELECTRIC

Box

1079

WI

414-734-9821

54912

USA

Mfg.

PRINTED

IN

Co.

U.S.A.

-~

~

ONE

This

warranty

COVERAGE

buyer

personal,

Welderwillbefreefromdefectsinmaterialandworkmanshipfor

a

period

covers

tric

tributors,

tric.
shall

warranty

is

madebyMILLER

other

or

cessories

their

rantedbytheir

purchase,

hour

MILLER
ranted
within

ment

1

2

3.

4.

5.

provided

of

such

WHAT

any

warranty



rized

original

In

with
therefore

ment

p

cases,



authorized

supersedes

who

purchases

family

of

one

the

only

does

Upon

have

respective

original

authorize

not

offer

to

expiration

further

no

claims

items

manufactured

and

other

manufacturer

except

warranty.

shall

Equipment

the

following

the

to

original

A

Id

rc

we

ers,

rnai

Ibr

AU

welding

that

MILLER

failure.

IS

NOT

subjected

repair

stations.

guns,

by

Replacement

Batteries

Welder

service

purchaser

the

case

respect

shall

where

or,

(3)

of

to

the

MILLER

the

be,

authorized

reasonable



MILLER

household

or

year

any

made

manufacturers,

Deutz

be

required

in

periods

power

power

or

COVERED

anyone

of

MILLERs

quality

at

YEAR

all

previous

Electric

this

AUTO

purposes

from

the

date

purchaser

any

party,

other

warranty

of

the

warranty

relatedtothe

liability

the

during

with

respect

by

items

the

user:

feeder/guns

repair

this

MILLERs

service

are

engines

to

event

from

sources,

reIiers

parts,

notified

is



to

misuse,

except

Further,

Welder.

breach

of

any

in
cost

station

sold

for

of

This

thiswarranty

writing

AUTO

Mfg.

ARC

of

of

this

including

on

warranty

to

engines,

others.

subject

if

any.

two

years

which

honor

failure
the

date

d

an

and

exclusive

in

writing

warranty

neglect,

MILLER

of

warranty

goods,

option

by

of

repair

or

Welder

(Consumer)

purchase.

Welder.

behalfofMILLER

period,

Such

All

have

warranty

resulting

comporien

torches

within

the

(1)

MILLER

or

(4)

LIMITED

EFFECTIVE:

ARC

warranties

Co.

warrants

(Welder)

that

This

warranty

MILLER

its

authorized

MILLER

Welder,

period.

trade

engines,

to

the

engines

from

a

of

deliveryofEquip-

of

labor.60

does

accident,

Electric

only

or

exclusive

repair

replacement

payment

Electric

except

No

warranty

accessories

trade

warranties

are

of

date

original

one

year,

claims

on

fromadefect

s

.

90

6

months

thirty

(30)

extend

not

its

or

extendstothe

other

any

remedies

or

(2)

replace-

in

appropriate

of

or

andisexclusive

to

this

Elec-

dis-

Elec-

war-

2000

war-

1

year

years

days
days

days

or

autho-

duty

at

credit

FEBRUARY

the

for

on

ac-

of

to

in-

an

WARRANTY

1989

17,

withnoother

for

the

purchase

actual

upon
and

expense.

FOB.,

Factory

rized

service

tion

costs

apparentdefectorfailure,

the

warranty

WARRANTY

THIS
EXPRESS
PROHIBITED

IMPLIED

ALL

LIMITED
TABILITYAND

LIMITED

ANY

EXPRESS

ANY

AND

SENTATION

BREACH

FOR

PROVISION,

OF

LAW,

INCLUDING

ABILITY

WITH

RESPECT

NISHED

LLE

Some

states

warranty

This

warranty

other

have

THE

PURCHASERS

WELDER,

ARE

LAW,

WARRANTY.

APPLICABLE

EVENT
OR
INABILITY

BE

SPECIAL

BREACH

LIGENCE

STRICT

LIABILITY.

use)

MILLERs

facility,

of

any

claim

WARRANTY;

THE

TO

THE

TO

IMPLIED

AS

MIGHT

CUSTOM

ANY

OR

OF

MILLER

BY

lasts,

gives

rights

TO

LIMITED

TO

LIABLE

DAMAGES

TO

THIS

OF

OR

guarantees

price

upon

at

Appleton,

therefore,

will

kind

procedures

IS

APPLICABLE

BY

WARRANTIES,

IMPLIED

FITNESS

DURATION

WARRANTY

WARRANTY.

TO

PERFORMANCE,

OF

CONTRACT

ARISE

OF

IMPLIED

FITNESS

TO

IS

allow

not

do

the

above

so

you

which

EXTENT

THE

TO

THE

MILLER

LAW,

FOR

THE

USE,

WARRANTY,

OTHER

(less

return

option

be

MILLER

OFFERED

AND,

FORAPARTICULAR

TRADE

ANY

EXCLUDED

specific

vary

REMEDIES

THE

EXTENT

ARISING

WELDER,

TORT,

orwarranties

reasonable

of

the

goods

of

WI

no

allowed.

to

WARRANTIES

OF

or

repair

FOB.

or

compensation

Upon

shall

instructtheclaimanton

followed.

be

IN

LIEU

EXCEPT

THE

LAW,

INCLUDING

WARRANTY.

THIS

NOT

PROVIDED

GUARANTY

AND

WHICH,

BY

IMPLICATION,

OR

COURSE

WARRANTY

FOR

PARTICULAR

AND

. 

limitationsonhow

limitation

legal

from

PERMITTED
REMEDY

EQUIPMENT

ALL

AND

may

rights,

statetostate.

FOR

PROVIDED

ENFORCEABLE

ELECTRIC

CONSEQUENTIAL,

OUT

OF

WHETHER

MILLER

ON

OR

Consumers

MILLER

for

transporta

of

ANY

THE

or

notice

EXTENT

expressed

depreciation

at

replacement

at

a

receipt

OF

TO

DURATION

BUT

OF

MERCHAN

PURPOSE,

HEREIN

REPRE

OR

ANY

REMEDY

BUT

FOR

OPERATION

OF

DEALING,

OF

MERCHANT-

PURPOSE,

DISCLAIMED

an

long

not

apply

and

you

may

A

DEFECTIVE

BY

APPLICABLE

BY

SHALL

INCIDENTAL

THE

USE

BASED

ELECTRICS

ANY

THEORY

implied.

based

risk

will

be

autho-

OTHER

OF

NOT

THIS

FUR

BY

implied

to

you.

also

THIS

UNDER

IN

NO

OR

OF,

ON

NEG

OF

j

A

of

IS

-~

~

ERRATA

SHEET

After

data

to

AMENDMENT

Amend

unit

This

six

every

manual

this

appearing

Section

is

equipped

months

was

TO

SECTION

7-lA.

ROUTINE

withanexhaust

using

printed,

later

SAE

in

this

MAINTENANCE

7

MAINTENANCE:

oil.

20

refinements

manual.

fan

and

in

relies

equipment

TROUBLESHOOTING

&

Fan

Motor

on

forced

draft

design

for

occurred.

adequate

This

sheet

cooling.

The

lists

fan

motor

exceptions

needs

oiling

RECEIVING-HANDLING

OM-113

3360

5191

Before

age

claims

Assistance
from
ers

When

ways

unpacking

that

may

for

loss

for

the

distributor

Transportation

requesting

provide

Number.

Section

SECTION

equipment,

have

occurred

or

damage

or

filing

and/or

Department.

information

Model

the

No.

1

1-1.

1-2.

1-3.

1-4.

check

during

with

settling

the

about

Description



SAFETY

Introduction

General

Arc

Welding

Standards

carton

shipment.

the

delivering

claims

may

equipment

this

and

RULES

Precautions

Booklet

for

manufactur-

any

be

dam-

File

carrier.

obtained

equipment,

Serial

or

Style

TABLE

FOR

OPERATION

Index

any

al

OF

Use

the

tion

mation

Model

Serial

DateofPurchase

following

Serial

and

is

located

________________________________

or

Style

CONTENTS

OF

ARC

or

No.

WELDING

spaces

Style

the

on

____________________

_____________________

to

Number

data

POWER

record

of

card

the

your

the

or

Page

SOURCE

Model

unit.

The

nameplate.

No.

1
1
4

5

Designa

infor

SECTION

SECTION

SECTION

SAFETY

2-

2-1.

2-2.

General

Safety

3SPECIFICATIONS

3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.

Volt-Ampere
Duty

Description

Supplied

Additional

Optional

Consumable

4INSTALLATION

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.

Site

Transporting
Running

Optional

Shielding

Work
Weld

MWG-200

Installation

Welding

Hub

Electrical

Welding

PRECAUTIONS

Information

Alert

Cycle

Equipment

Required

Equipment

Selection

Gear
SPW-1

Gas

Cable

Polarity

Welding

Of

Wire

Tension

Input

Wire

And

Symbol

And

Curves

Equipment

Parts

OR

RELOCATION

Methods

Installation

Panel

Installation

Assembly

Selection

Gun

Optional

Installation

Spool

Adjustment

Connections

Threading

AND

SIGNAL

Safety

Words

Signal

Installation

Connections

Gun

Spool

WORDS

6
6

8

8

8

8

9
10
10

10

10

11
11

12

12
14

14

14

16
16
16

18

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.

5OPERATOR

Power

Thickness

Fine

Fan-On-Demand~

Optional

6

Gas

Switch

Volts

Tuning

Spot/Pulse

SEQUENCE

Metal

Welding-Pulsed

Gas

Metal

SPW-1

Shutting

7

MAINTENANCE

Routine

Replacing

Drive

Replacing

Panel

Down

Maintenance

Drive

Housing Realignment

Hub

Inspecting

Overload

Thermal
Printed

Protection

Overload

Circuit

Troubleshooting

CONTROLS

And

Wire

OF

Arc

Arc

Only)

And

Welding

Welding

Assembly

Board

Pilot

Light

Selector

Speed

OPERATION

Control

Panel

(GMAW)-Continuous

Arc

(GMAW-P)

(GMAW)-Spot

&

TROUBLESHOOTING

Roll

And

Replacing

Protection

Replacement

Controls

Wire

Inlet

Motor

Guide

Brushes

And

(Models

Gas

With

Metal

Optional

19

19

20
20

20

Arc

21

22
23

24

25
26

26

27
27

28

28
28

SECTION

SECTION

SECTION

8

Diagram

Diagram

Diagram

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.

8-2.

8-3.
8-4.
8-5.

WELDING

Gas

Metal

Gas

Metal

Gas

Metal

Welds

Plug

Skip

Welding

Troubleshooting

AUTO

Pointers
Procedure
Procedures

To

Prevent

How
Procedures

Welding

Circuit

Circuit

Circuit

Wiring

Circuit

Board

TECHNIQUES

Arc
Arc
Arc

BODY

For

Welding

For

For

For

Frames

DIAGRAMS

Diagram
Diagram
Diagram

Diagram
Diagram

PC5O

Welding
Welding
Welding

The

REPAIR

Welding

Welding

Glass

Welding

And

MW

For

MW

For

SPW-1

For

SPW-1

For

SPW-1

For

TROUBLESHOOTING

&

(GMAW)



(GMAW)-Pulsed

(GMAW)-Spot

Gas

APPLICATION

Auto

Mild

Door

Breakage

Fenders

High

Arc

Metal

Sheet

Body

Steels

Panels

And

Strength

Models

4150

Models

4200

Panel

Panel
Panel

Continuous

Welding

Metal

Spatter

And

Quarter

(HSS)

Dual

Timer/Pulser

Seam

Process

On

Panels

Steels

Windows

30

31
31

32

33

34
35
36
37
37
37

40

40
40

41

41
41

Section

No.

Page

No.

SECTION

Table

Table
Table

Table

Table

Table

11

Figure
Figure
Figure

Figure

Figure

Figure
Figure
Figure

Chart
Chart

4-1.

6-1.

6-2.

7-1.

7-2.



PARTS

11-1.

Main

11-2.

Baffle,

11-3.

Drive

11-4.

Panel,

11-5.

Panel,

11-6.

SPW

11-7.

Circuit

11-8.

Running

3-1.
3-1.

3-2.

Specifications
Volt-Ampere

Duty

Input

Suggested

Welding

Checking

Maintenance

Troubleshooting

LIST

Assembly

Air

w/Components

Assembly,

Rear

w/Components

Front

1

Spot

Card,

Gear

LIST

Cycle

Conductor

Parameters

(GMAW)

Weld

Wire

w/Components

Panel

(Optional)

Dual

Timer/Pulser

OF

CHARTS

Curves

And

Fuse

For

Parameters

Schedule

P050

AND

Size

Continuous

TABLES

Gas

Metal

42

44

46

47

48
50

51

52

7

7

7

17

Arc

22
23

24
29

SECTION

1



SAFETY

RULES

FOR

OPERATION

OF

ARC

WELDING

POWER

SOURCE

1-1.

We
sonal

harmful,

ers

Safe

welding

search,

evolved

tion,

INTRODUCTION

learn

by

experience,

wasteful,

teach

you.

practices

and

development,

reliable

and

equipment

for

son

Some

technical

rules.

Read

tempting

Comply

ticular

personal

Failure

ous

the

based

are

volumes

and

to

with

equipment

safety

to

observe

injury

equipment

These
1-General

ting;

Reference

are

cedures
in

most

The

Health

safe

and

2-Arc

also

available

than

the

Standards

complete.

National

Administration,

inspection

ment

installation,

1-2.

Difterent

and

radiation

manual,

facturers

specific

GENERAL

arc

fluxes

levels.

be

technical

concerning

A.

Burn

Prevention

Wear

protective

in

use

collar

avoid

shields

welding,

entry

helmet

underneath,

shirt

to

Wear

(protected

experience.

like

and

unwise.

developed

cutting

are

equipment

servicing

is

improperly

safe

understand

install,

these

death.

or

can

practices

practices.

practices

on

common

to

operate,

procedures

used

for

and

these

When

be

used

explain.

these

and

are

Precautions,

Welding

standards:

for

additional

those

given

Indexinthis

Electrical

Code,

local

requirements

and

use,

PRECAUTIONS

welding

can

produce

In

additiontothe

to

sure

Material

their

consult

Safety

data

material.

clothing-gauntlet

and

hat,

and

pocket

of

with

flaps,

sparks

safety

appropriate

clear

by

cover

Learning

child

a

Let

from

touching

experience

described

and

field

and

safe

Accidents

used

or

may

sense,

It

safe

service

or

as

their

instruction

the

safety

safe

practices

safety

with

confidence.

divided

common

(and

Published

in

to

Cutting)

and

this

manual.

manual.

Occupational

industrial

also

provide

service.

processes,

difterent

flux

and

Sheets

Data

and

precautionary

high

safety-toe

and

wear

and

slag.

goggles

and

filter

glass).

safety

the

in

through

hot

a

experience

in

this

manual.

experience

installation,

occur

maintained.

not

always

others

is

wiser

may

to

practices

the

equipment.

applicable

manuals,

of

others.

cause

may

becomes

into

arc

a

two

welding

(only).

Standards

more

complete

They

ANSI

Z49.1isthe

codes,

basis

a

electrode

fumes,

information

gases,

electrode

(MSDS5)

gloves

designed

shoes.

cuffless

glasses

lenses

This

is

a

stove

of

the

use

have

opera

when

The

be

given.

require

follow

before

the

to

habit,

Sections:

and

on

safety

listed

are

Safety

and

for

equip

alloys,

in

manu

measures

Button

trousers

with

or

plates

MUST

per

oth

of

Re

rea

the

at

par

for

seri

the

cut

pro

and

local

and
this

for

for

side

for

is

welding

from

glass

Avoid

Hot

should

Medical

a

shift

treatment

Ear

in

others

Flammable

sons

B.

Severe

fumes,

that

adequate

Z49.1

or

radiant

when

or

oily

metal

never

first

qualified

first

unless

of

should

plugs

confined

a

work

intending

Toxic

Fume

discomfort,

vapors,

welding

ventilationasdescribed

listed

cutting,

such

medical

hair

oxygen.

Lead-,cadmium

and

ing

duce

local

the

plied

Metals

fumes

from

necessary,

Work

and,

tor.

Gas

Leaked

centration

confined

Leaving

to

downstream

left

re-entering

Vapors

by

highly

ucts.

decompose

pors

vent

mosphere

similar

harmful

exhaust

area

as

respirator.

coated

should

the

work

in

confined

a

if

necessary,

leaks

gas

dangerously.

space.

confined

open.

from

heatofthe

toxic

The

form

to

vapors

possible

Check

ultraviolet

prevent

the

wellasthe

while

in

it.

gas,

trichloroethylene

phosgene.

can

or

(and

chipping)

and

energy

broken,

greasy

as

be

handled

and

aid

aid

person

burnsofthe

flash

be

space.

overhead.

preparations

weld

to

Prevention

heat,

(or

cutting)

in

Standards

-,zinc-,

materials,

concentrationsoftoxic

ventilation

flying

or

pitted,

clothing.

electrode

eye

facilities

worn

A

illnessordeath

or

spattered.

A

without

treatment.

should

are

when

hard

hat

should

cut.

or

oxygen

produce.

may

Index.

mercury-,

when

be

must

eyes

working

enrichment

welded

operator

For

beryllium,

with

or

be

not

surface,

wearing

space

while

confined

a

in

valves

chlorinated

quantities

large

space,

accumulation

have

be

to

arc

and

(radiant)

drawn

be

where

the

containing

heated

the

wearing

Do

sure

(or

other

DO

radiant

both

unless

area

an

air-supplied

while

only

space

can

not

bring

shut

OFF

been

that

the

solvents

flame)

to

lung

energy
and

NOT

into

the

energy

to

metal.

spark

stubs

protect

may

and

the

Replace

1

See

-3A.2.

ignite

workpieces

eyes

cover

them.

gloves.

First

aid

facilities

be

available

closebyfor

and

should

not

can

Prevent

in

ANSI

NEVER

and

beryllium-bear

(or

fumes.

or

used,

must

wear

must

materials

coating

is

well

ventilated

immediate

skin

overhead

on

be

worn

be

used

result

or

ventilate

cut)

Adequate

each

an

be

used.

that

is

for

each

burns.

when

by

depletion

them

Standard

may

person

air-sup

emit

toxic

removed

and,

respirator.

it

is

an

air-supplied

should

change

gas

gas

of

gases

accidentally

space

can

form

and

eye

of

ventilated

being

be

avoided.

oxygen

cylinders

in

at

the

supply

opened

is

safe

be

decomposed

PHOSGENE,

irritating

the

arc

can

respira

into

source

space

before

prod

perchloroethylene

WELD

welding

cut

or

can

OM-113

where

or

cutting

penetrate

336

Page

and

or

per

from

with

with

pro

in

if

con

a

if

or

a

also

va

sol

at

to

1

atmospheres

trichloroethylene

Fire

C.

Causes

the

arc,

by

misuse

rial;

short

circuits.

BE

AWARE

through

and

through

goggled

To

prevent

equipment

Keep

and

(in

short

cause

If

combustibles

the

work

Avoid

paint

If

lators.

least

at

protect

fire-resistant

Walls

not

work
shields.

Fire

35

against

touching

be

welded

should

watcher

guishing

ingorcutting

a.

containing

or

and

Explosion

of

fire

and

explosion

flame,

flying

of

compressed

THAT

flying

cracks,

operator.

electrical

the

along

wall

or

Sparks

fires

and

clean

parts)

circuits.

are

if

practicable,

rooms,

spray

work

cannot

feet

away

ignition

covers

combustibles

on

(or

be

protected

be

must

equipment

if:

appreciable

perchioroethylene.

in

during

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
bles

solubility)

trogen

OM-113

or

conducted

permit

supervisors

embers,

container

flammable

welded

or

carbon

or

336

taken.

is

done,

as

water

Page

a

partitions

heat.

should

approval

and

on

described

Index.

thorough

washing,

followed

dioxide,

2

even

Prevention

are:

sparks,

gases

sparks

pipes,

floor

through

openings,

and

slag

explosion:

and

operable,

of

metallic

do

area,

to

an

area

tanks,

dip

be

moved,

of

reach

out

with

suitable

shields.

or

on

Walls,

cut).

heat-resistant

by

standing

combustibles

are

combustibles

be

by

and

within

ignited

or

expose

may

for

adjacent

can

be

obtained

that

check

that

flames.

that

held

combustibles,

toxic

or

vapors

cut,

in

steam

unless

AWS

or

depending

by

purging

and

minute

combustibles

hot

or

or

slag

and

falling

windows

out

can

free

particles

NOT

weld

free

of

storage

move

of

sparks

and

opposite

ceilings,

with

suitable

some

(including

feet

35

are

sparks

by

visible)

combustibles

to

walls,

be

ignited

before

adequate

is

area

when

container

Standard

caustic

or

on

and

protective

using

amounts

reached

heated

mate

cylinders;

can

slag

of

35

fly

of

or

combustibles.

areas,

combustibles

and

or

sight

feet.

oil,

grease,

that

cut.

heat;

pass

doors,

of

Move

venti

snug-fitting,

sides

should

floor

and

covers

fire

extin

time

after

weld

building

further

in

than

floors

ceilings,

by

walls

or

roofs,

radiant

operation

precautions

free

of

sparks,

that

or

has

A6.O,

must

listed

heated,

cleaning

combusti

the

inerting

with

equip-

and

the

can

or

near

35

can

first

(or

ni

or

to

or

of

to

a

ment

working

A

(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

container

preceding

or

sight

castings

or

cutting.

atmospheres.

contain

gasoline).

Compressed

precautions.

and

listed

Pressure

relief

from

downstream

more

or

one

connect

that

than

faulty

close

(first

a

faulty

gas

Creep-if

downstream

Gauge-if

pressurized,

NOT

Do

to

repair

special

personnel.

2.

Cylinders

Cylinders

damage

Avoid

third

produce

dent.

ICC

assurance

dled.

Identifying

gas

content.

alter

or

is

illegal

Empties:

mark

must

to

electrical

rails,

short

(See

DOT

or

marked

Notify

name,

and

MT;

their

electrical

1-3C.)

of

gas

Keep

keep

promptly.

substitute

may

with

unknown

paragraph).

determine

to

containers

or

They

flammable

Gas

detailed

those

COMPRESSED

OF

in

ii

Standards

Regulators

valve

overpressure;

equipment.

relief

a

regulator

for

which

regulator

cylinder

regulator:

leaks

externally.

delivery

valve

pointer

gauge

nor

attempt

manufacturers

techniques

handled

be

walls,

circuit

wires,

circuit

arcs

when

content.

them;

must

do

marking

safety

on

supplier

number,

hazardous.

valves

them

separate

in

A6.O.

for

contents

NOT

Do
if

it

is

must

can

explode.

Never

weld

dust,

gas,

Equipment

Comply

is

devices.

from

valve).

closed.

returns

to

with

in

CGA

Index.

designed

it

is

Provide

to

a

cylinder

the

regulator

service

The

pressure

does

to

repair.

designated

and

tools

carefully

valves,

contact

or

or

with

or

welding

that

may

be

on

the

cylinderisproperly

Use

only

not

rely

if

unmarked.

other

markings

closed,

from

Waterfilling

just

inerting.

should

depend

safe

or

or

liquid

to

be

vented

cut

be

on

weld

where

vapors

precautions

Standard

GASES

to

intended

not

P-i,

IN

protect

such

containing

was

designed.

immediately

following

not

pin

stop

Send

symptoms

continues

off

move

after

faulty

repair

usedbytrained

are

to

prevent

safety

devices:

cylinders

circuits.

lead

each

cylinders

on

replace

to

a

cylinder.

color

to

NEVER

on

caps

FULLS

serious

with

identify

a

and

below

cleaned

of

sense

cut.

or

before

air

the

(such

in

this

SAFE

CYLIN

the

only

to

protect

protection

gas

for

re

to

rise

stop

pin

pressure

regulators

center,

leaks

and

including

can

They

acci

It

is

an

han

of

name

gas

DEFACE

cylinder.

It

securely;

return

Prohibited
other
roller.

Locate

over.

than

or

use.

its

secure

Passageways

where

areas

Transporting

such

port

the

ground

or

magnets.

Do

NOT

and

slag,

low

contents

where

Protect

falling

when

moving

Stuck

valve.DoNOT

cylinder

supplier.

your

Mixing

Never

Cylinder

3.

Prohibited

for

the

is:

red

gases.

Use

ferrules

wire

nary
hoses

No

copper

they

cylinders.

as

a

by

expose

flame,

such

exposure

cylinders

objects,

valve

gases.

refill

any

fittings

Hose

use.

specified

for

fuel

or

other

or

to

fittings.

tubing

tingstosplice

Avoid
hose

or

on,

Coil

excess

Protect

sparks,

Examine

nections.
dicate

Repair

(1-2D3).

ing

4.

Clean

orifices

Except

runs

long

off

groundtokeep

otherwise

hose

hose

and

slag,

hose

Immerse

leaks.

or

leaky

Do

Proper
cylinder

and

damage

for

hydrogen,

Never

use

intended

cylinders

and

work

be

may

With

platform

their

or

valves

cylinders

that

etc.

exceed

to

exists.

particularly

and

weather.

cylinders.

use

that

Never

can

not

try

cylinder.

should

Never

gas,

clamps

gas.

never

use

A

green

designed

general

substitute)

splices.

hose.

to

prevent

damaged.

to

prevent

from

damage

flame.

open

regularly

pressured

hose

worn

NOT

tape.

Connections

valve

outlet

seats

crack

a

use,

so

areas.

struck.

a

cradle.

or

to

may

130F.

hammer

a

be

mix

to

hose

for

oxygen,

Use

kinks

from

it

kinks

for

leaks,

by

of

before

valve

cylinder

NEVER

cannot

they

Keep

crane,

caps,

cause

valves

use

Do

NOT

or

excessive

rupture.

Cool

from

Replace

or

opened

any

gases

be

modified

other

than

hose

and

for

the

as

a

binding

standard

only

and

run

being

and

by

sharp

wear,

in

hose

cutting

water;

area

impurities

connecting

momentarily,

its

contents

or

as a

support

be

knocked

cylinders

by

with

clear

a

secure

lift

cylinders

chains,

heat,

Do

water

slings,

sparks,

not

spray

bumps,

caps

securely

wrench

identification

abuse.

to

hand.

by

in

a

cylinder.

or

exchanged.

that

designed

black

hose

(not

to

connect

brass

Suspend

over,

stepped

open

Notify

for

tangles.

out

that

and

loose

bubbles

and

may

splic

edges,

and

regulator.

pointing

for

or

of

sup

off

al

falls,

a

rule

inert

ordi

fit

by

con

in

clog

outlet

away

with

clean

a

Match

that

that

CONNECT
gases

Tighten

nections,

Tighten.

retighten

Adapters.

plier)

use

LEFT

Regulator

by

(with

Drain

fore

justing

sive

seat

engaged

Stand

Open

creases

reaches

lowing

to

less

Use

safe

regulatortocylinder.

the

regulator

the

regulator

a

to

a

cylinder

connections.

clean

If

connection

using

Use

between

wrenches

two

HAND

outlet

hand

right

grooved

5.

Pressurizing

regulator

opening

screw

compression

to

open

slightly

side

to

cylinder

slowly.

regulator

position:

seal

stem

than

one

pressure

and

efficient,

regulators.

for

Check
there-after.

uid*

or

leak.
bustible.

E.

User

Remove

mediately

in

equipment

F.

Leaving

Close

G.

Rope

Rope

cutting

*Trademark

leaks

Brush

equivalent

off

Clean

Responsibilities

leaky

for

supply

gas

Staging-Support

staging-support

operation;

from

people

lintless

label

inlet

regulator

and

cloth.

and

and

designed

containing

When

and

smooth

leaks,

properly

CGA

a

cylinder

threads.

(or

threads

hex

adapter

to

tighten

hose)

for

nut

on

fitting

and

Steps:

of

residual

cylinder

in

(clockwise).

heat

on

pressurization.

on

of

regulator

valve

When

manifold

(or

at

high

single-stage

slowly

gauge

maximum)

For

oxygen,

turn

to

charts

recommended

on

with

per

soapy

defective

or

manual.

possible

permit

(available

first

soap

gallon

water

See

User

against

repair.

Equipment

at

source

should

rope

may

Gamble.

of

Proctor

&

sources

Before

cylinder

cylinder

any

assembling

seats

of

connecting,

marking

outlet

match.

for

a

particular

other

threaded

where

disassemble,

wrench.

if

one

marked

may

left

for

fuel

suitable

from

(available

regulator,

adapter

connections
oxygen

or

gas

and

shank)

through

valve)

Draining

pressure

Leave

prevents

seat

adjusting

regulators.

while

that

so

leave

and

leak.

quick

opening

is

inert

from

cylinder

regulator

pressurized

cylinder

gases,

For

fuel

emergency

your

pressure

pressurization

solution

of

after

equipment

(capfull

water).

dried

test;

Bubbles

from

Responsibility

Unattended

and

drain

gas.

be

not

used

burn.

OM-113

ignition.

Wipe

check

area,

NEVER

gas

gas.

necessary.

clean,

your

is

required.

RIGHT

be

identified

hand

threads

gas.

vent

by

turning

exces

by

allowing

screw

valve.

pressure

(gauge

in

valve

open

open

gas,

shutoff.

supplier)

settings

and

regularly

of

Ivory

indicate

is

soap

for

com

service

statement

welding

336

Page

and

or

con

and

sup

and

be
ad

in

fol

fully

to

for

on

Liq

im

or

3

1-3.

Comply

Arc

careless

high
bright

frared

pressed

ARC

with

Welding,

operator

currents

and

energy

gases

unnecessary

accidents.

referenced

dards

A.

Burn

Comply

The

can

from

Skin

shielded

with

welding

damage

light-colored

burns

arcs

BURNED;

1.

Protective

Wear

long-sleeve

in

addition

arc)

essary,

jacket

use

or

sleeves,

leggings.

Bare

skin

Button

ets

Protect

electric

Welding

no.12or

face

Protect

Cracked

worn;

Cracked,

IMMEDIATELY.

pitted,

Flash

helmet

helmet

struck.

eyes

cause
area

rate

round
ble

ticularly

OM-113

collar

to

prevent

2.

Eye

eyes

arc

helmet

denser

before

filter

or

radiation

or

spattered.

goggles

to

not

Looking

(particularly

retinal

a

in

the

Protection

3.

Enclosed

room

the

screens

at

336

WELDING

precautions

properly

invites

at

significant

hot.

Sparks

radiates,

may

risks

and

Precautions

in

Protection

precautions

is

intense

arc

penetrate

eyes,

surfaces,

resemble

are

more

COMPLY

Clothing

clothing

to

gloves,

additional

flame-proof

Avoid

outer

protection.

to

protect

of

entry

and

Head

from

or

must

plate

broken

can

exposure

protection.

shield

arc.

with

pass

or

without

striking

broken,

Replace

with

side

some

give

be

lowered

at

an

a

high

burn

field

of

vision.

of

Nearby

welding

or

area.

enclosed

operation

or

panels.

floor

level.

4

Page

in

1-1, 1-2,

is

done,

trouble.

voltages.

fumes

fly,

weidments

be

used.

The

protects

described

are

index.

1-2.

in

and

visibly

lightweight

and

acute

sunburn,

severe

WITH

and

PRECAUTIONS.

(particularly

and

hat,

protective

garments

Wear

dark,

and

chest

sparks.

Protection

to

containing

be

helmet

a

used

clear

when

cover

or

through

loose

filter

clear

cover

shields

protection

the

over

arc

momentarily

intensity

that

may

Personnel

For

production

is

best.

bay

with

low-reflective,

for

Allow

and

safe

a

The

rise,

himself

process,

equipment

The

ultraviolet

are

wise

operator

and

here

hot,

bright.

clothing,

burn

the

skin

those

painful.

for

shoes

(1

clothing

apron,

of

arc.

such

and

untreated

substantial

neck

and

NEVER

filter

a

welding.

plate.

shield

plates

MUST

to

to

the

face

should

cause

must

plate

be

eyes

before

with

when

worn

gas-shielded

leave

a

permanent

welding,

In

open

non-combusti

free

air

circulation,

this

section.

but

a

carries
is

arc

very

in

and

and

com

avoids

from

others

in

stan

and

radiation

Its

reflect

and

eyes.

from

DONT

gas-

GET

gas-shielded

As

leather

as

cotton.

nec

-2A).

fire-resistant

clothing.

button

pock

at

look

plate

Place

burns.

be

an

shade

over

NOT

be

replaced

broken,

under

the

should

the

arc

is

an

unprotected

can

arc)

dark

a

sepa

areas,

sur

par

Viewing

who

Others

flash

Before

bay

B.

Comply

Generator

air.

C.

Comply

the

will

be

working

goggles.

starting

doors

Toxic

with

Carbon

and

Fire

with

looking

are

Fume

engine

monoxide

Equipments

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,

protection.

To

protect

Wear

body

adequate

duckboard,

dry

can

tween

metal

able

through

A

voltage

ducting

objects

ing

trical

against

insulating

dry

and

clothing

insulation

avoided.

be

not

body

reduces

dangerous

the

will

object

include,

work

tools,

workpieces,

metal

object

1.

Grounding

Arc

welding

National

the

grounded

And

When

welding

culator

quate

according

Cutting.

installing,

power

the

to

to

carry

Provide

weld.

directly

in

area.

to

weld,

closed.

Prevention

precautions

exhaust

can

Explosion

precautions

rated

capacity.

It

overheat

may

connections

on

arc

brittle

a

Gas

a

area

rupture

to

an

a

such

precautions

conductors

in

ungrounded,

shock

a

NOT

STAND,

surface

shock:

gloves

Never

dry.

against

rubber

or

Sweat,

and

an

electrically

electrical

the

and

possibly

body.

between

exist

in

work

the

but

are

benches,

Never

etc.

unless

the

the

Equipment

equipment

Electrical

to

connect

source,

building

ground

control,

ground.

currents

face

shields

at

the

that

See

make

all

sure

-2B.

1

in

be

must

kill.

Prevention

1

-2C.

in

Do

not

cables

overheat

may

cylinder

that

can

under

Equipment

-2D.

in

1

other

or

electrically-HOT

person

when

whose

SIT,

welding,

and

work

electrical

when

mat

sea

HOT

resistance,

lethal

the

electrode

circuit.

limited

not

welding

the electrode

touch

welding

be

must

Code,

ANSI

the

grounded

and

Z49.1

frames

worktable,

Conductors

safely.

for

weld.

persons

that

screen

vented

overload

and

cause

other

or

cause

rough

bare

metalinthe

body

LEAN

LIE,

without

protection.

body

in

damp

shock.

dampness

or

water,

part

currents

Examples

to,

buildings,

power

power

the

Safety

of

each

Equipment

all

persons

are

wearing

flaps

outside

the

to

arc

welding

a

flash

or

pressure

violent

a

handling.

becomes

ON,

suitable

without

area

Stay

or

moisture

or

grounded

and

could

and

any

of

conduct

source

and

source

according

work

must

In

Welding

such

unit

water

and

be

must

fire.

and

ves

rup

weld

equip

Keep

on

sweat

flow

to

con

elec

cases,

any

is off.

ade

made

or

a

OR

a

be

en

to

be

as

cir

6.

7.

8.

9.

10.

11.

ANSI

Standard

THE

USE
ESSES
Standards

NY

10018.

AWS

Standard

CONTAINERS

TIBLES

Society,

NFPA

TEMS

550

Standard

FOR

PROCESSES

Protection

Quincy,

NFPA

CODE

tion

02269.

NFPA

PROCESSES

Protection

Quincy,

CGA
PRESSED

MA

Standard
obtainable

Association,

Standard

MA

Pamphlet

Z49.2,

OF

CUTTING

obtainable

Institute,

A6.0,

WHICH

obtainable

N.W.

51,

WELDING,

obtainable

Association,

02269.

Batterymarch

51B,

obtainable

Association,

02269.

P-i,

GASES

FIRE

from

1430

WELDING

HAVE

from

LeJeune

OXYGEN-FUEL

CUTTING,

NATIONAL

70,

from

the

CUTTING

SAFE

IN

CYLINDERS

PREVENTION

AND

WELDING

the

American

Broadway,

AND

HELD

the

American

Rd,

Miami,

AND

from

the

Batterymarch

ELECTRICAL

National

Park,

AND

from

the

Batterymarch

HANDLING

PROC

National

New

CUTTING

COMBUS

Welding

FL

33126.

GAS

ALLIED

National

Fire

Protec

Quincy,

WELDING

National

OF

obtainable

York,

SYS

Fire

Park,

MA

Fire

Park,

COM

IN

12.

13.

14.

15.

the

from

ferson

22202.

CSA

WELDING

Canadian

Sales,

Canada

NWSA

RAPHY

Supply

phia,

American

RECOMMENDED
PREPARATION

OF

HELD

from
LeJeune

ANSI

RATORY

American

Compressed

Davis

Standard

178

M9W

booklet,

obtainable

Association,

PA

19103.

CONTAINERS

HAZARDOUS

American

the

Rd,

Standard

Broadway,

Highway,

W117.2,

AND

CUTTING

Standards

Rexdale

Welding

Boulevard,

1

R3.

WELDING

Society

SAFE

FOR

from

1900

AND

Welding

Miami,

Z88.2,

PROTECTION,

National

New

Standards

York,

Gas

Association,

Suite

501,

CODE

FOR

obtainable

Association,

Rexdale,

SAFETY

the

National

Arch

Street,

Standard

PRACTICES

WELDING

AND

PIPING

SUBSTANCES,

Society,

FL

33126.

PRACTICE

obtainable

NY

10018.

1235

Arlington,

SAFETY

from

Standards

Ontario,

BIBLIOG

Welding

Philadel

AWSF4.1,

FOR

CUTTING

THAT

FOR

Institute,

HAVE

obtainable

550

RESPI

from

Jef

VA

IN

the

THE

NW.

the

1430

2-1.

A.

Information

bels,

design,

troubleshooting

followed

The

labeling

pear
B.

The

shooting

and

safety

stalled,

sons

codes

of

ing

GENERAL

General

presented

and

tags,

installation,

for

the

nameplate

front

the

at

the

appropriate

Safety

installation,

of

arc

procedures

of

others.

operated,

in

accordance

such

as,



Section

Power

1

Source.

plates

which

safe

of

this

operation,

welding

which

Therefore,

but

Safety

SECTION

INFORMATION

in

this
the

on

operation,

should

effective

and

unit

uses

controls.

panel

sectioninthe

equipment

ensure

maintained

and

with

this

limited

not

Rules



2

SAFETY

AND

SAFETY

manual

unit

and

on

pertainstoequipment

maintenance,

be

read,

understood,

of

this

use

international

The

symbols

text.

maintenance,

and

requires

personal

this

equipment

manual

those

to,

For

Operation

only

and

safety

qualified

by

all

listed

Of

PRECAUTIONS

various

la

and
and

equipment.

also

ap

trouble

for

symbols

practices

and

the

istobe

in

per

applicable

end

at

the

Arc

Weld

2-2.

The

used

tify

a

a

a

SAFETY

WORDS

following

throughout

different

This

words

tion

WARNING

practices

ous

CAUTION

practices
personal

IMPORTANT

necessary

ment.

AND

to

personal

for

SIGNAL

ALERT

alert

safety

this

manualtocall

of

levels

safety

WARNING

the

hazard

alert

safety

statements

which

injury

statements

which

injuryordamage

statements

the

most

WORDS

SYMBOL

symbol

and

symbol

and

CAUTION

statements.

be

must

loss

or

be

must

identify

efficient

AND

and

signal

attention

special

is

used

with

of

to

life.

this

procedures

procedures

identify

followed

identify

followed

special

operation

SIGNAL

words

are

to

and

iden

instructions.

the

signal

call

to

to

to

atten

avoid seri

avoid

minor

equipment.

instructions

of

this

equip

or

or

OM-113

336

Page

6

Do

HOT

NOT

ANY

electrically
tally.

carrying

Three-phase

equipment

available,

wiresofthe

ment
ment

tion

that

Before

conductors

frames

If

line

a

equipment

ground

is

plug

ceptacle,

ground

prong

Never

with

plug

2.

Fully

NOT

3.

Fully

join

welding

4.

Frequently

IMMEDIATELY

or

damaged

from

bared

taped

Keep

from

hot

5.

Terminals
should

6.

a.

before

connect

ground

will

become

can

welding,

at

connections.

cord

for

lead

to

added

the

prong

connect

plug,

remove

broken

a

Electrode

insulated

holders

use

Connectors

insulated

Cables

inspect

cable.

to

give

cable

dry,

metal

Terminals

and

have

insulating

Electrode

Equipment

Welding

metal

welding

mally

off

control

equipped
cally

and

touch

in

ject

the

welding

b.

Equipment
contactor)

by

stray

GROUND

flammable

or

gas

connection.

installing.

single-phase

3-phase

lead

to

electrically

shock,

are

possibly

check

touching

with

a

connection

the

grounded

for

connection

ground

If

only.

the

ground

off

Holders

electrode

with

lock-type

cable

lengths.

cables

REPLACE

insulation

Cables

resistance

free

and

sparks.

And

other

with

power

arc

welding

(GTAW)

are

equipped

of

the

the

HOT

when

the

welding

the

electrode

contact

power
without

current

to

electrical

Check

If

line.

Do

the

third

HOT-a

fatally.

ground

bare

ground

lead

the

to

lead

to

a

switchbox.

to

must

line

cord

a

grounded

prong

ground

prong.

holders

protruding

connectors

for

wear,

those

avoid

to

with

equivalent

of

oil

and

Other

Exposed

exposed

covers

secured

output

sources

(GMAW),

and

with

welding

electrode

the

power

gun

wire

with

the

source

output

shock,

may

conduit,

liquid

phase

only

equipment

NOT

connect

wire,

(live)

possibly

or

such

oilorfuel.

as

requirements

3-phase

to

the

the

or

dangerous

for

continuity.

metal

switchbox,

a

be

from

screws.

with

of

is

provided

If

a

grounded

connected

comes

with

mating

a

plug,

should

cracks

be

should

and

excessively

equipment

connect

three-prong

mating

receptacle.

used.

be used

possibly-lethal

to

original

Parts

of

electrical

before

control

use

gas

processes

output.

becomes

source

conducting

any

off.

is

on/off

areas

and

protected

operation.

(contactor)

with

tungsten

that

permit

switch

circuit

control

damaged

grease,

parts

on/off

for

similar

devices
power

wire

switchisclosed.

or

electrode

fa

to

a

pipe

of

power

two

only

equip
equip

condi

Be

sure

with

the

the

re

the

to

three-

a

or

use

Do

to

damage.

worn

shock

be

may

cable.

units

the

gas

arc

nor

on

When

so

electri

ON

is

Never

ob

unless

(no

is

a

Welding

metal

esses

output

ment

power

electrode

off.

7.

Safety

Safety

should

Before

shut

tag

Disconnect

pull

Do

ing.

against

Leaving

disconnect

Power

welding

F.

Magnetic

devices

not

installation,

OFF

all

switches)

all

115

not

open

in

an

If,

shock

equipment

disconnect

power

Protection

Devices

port

fields

operation.

equipment

before

going

operations.

1-4.

For

their

1.

STANDARDS

more

information,

latest

ANSI

AND

Welding

FL

33126.

2.

NIOSH,

ING

tainable

U.S.

D.C.

3.

OSHA,

29CFR

dent

Office,

4.

ANSI

OCCUPATION

FACE

can

way,

ANSI

5.

SAFETY-TOE

American

Broadway,

power

arc

welding

be

not

may

on-off

control

the

electrode

switch

Devices

such

disconnected

be

is

unless

as

inspection,

and

power

to

prevent

cables

all

volts

power

emergency,

burns,

all

power

source.

For

remove

from

line-cord

circuit

or

unattended.

to

switch

Wearers

(Pacemakers)

from

high

Persons

wearing

(pacemaker)

near

arc

welding,

BOOKLET

refer

revisions

Standard

and

Z49.1,

CUTTING

Society,

SAFETY

GAS

AND

from

Government

20402.

WELDING

the

SAFETY

obtainable

1910,

of

Documents,

Washington,

Standard

PROTECTION

National

New

Standard

AND

Standards

York,

FOOTWEAR

National

New

Z87.1,

NY

Z41

York,

sources

(SMAW)

equipped

is

turned

the

interlocks

accidental

welding

used

and

with

devices.

With

electrically

ON.

Never

welding

shunted

or

or

line

power

and

service,

fuses

turning

power

plugs.

or

it

must

flash

change

polarity

be

disconnected,

from

switch

Always

equipment.

be

must

currents

should

available

of

Electronic

can

electronic

consult

affect

gouging,

INDEX

the

to

following

as

comply

applicable:

SAFETY

obtainable

550

AND

N.W.

HEALTH

from

LeJeune

AND

Superintendent

Printing

AND

D.C.

10018.

.1,

Office,

HEALTH

from

U.S.

Government

20402.

SAFE

PRACTICES

EDUCATIONAL

obtainable

Institute,

STANDARD

obtainable

Standards

NY

10018.

the

OM-113

with

shielded

similar

welding

such

HOT

when

touch

source

circuit

breakers

out.

of

equipment,

lock

(or

ON

of

power.

source,

while

arcing.

OFF

shut

near

Life

pacemaker

life

their

spot

standards

IN

WELDING

the

American

support

welding

with

or

Rd,

IN

CUTTING

of

WELD

ARC

Documents,

Washington,

STANDARDS,

Superinten

Printing

EYE

from

Institute,

1430

FOR

the

336

Ameri

Broad

MENS

from

proc

power

equip

the

the

is

red-

or

and

weld

guard

and

the

Sup

doctor

or

Miami,

ob

FOR

AND

the

1430

5

Page

SECTION

Table

3

SPECIFICATIONS

3-1.

SpecificatIons

Rated

~

Duty

150

Amperes

At

Volts

23

DC

Cycle

M

Ci~cuit

e

Voltag

32

200V

26.5

Input

60

Amperes

230V

Rated

At

Hz

Single-Phase

460V

24

12

At

Load

Output

575V

9.6

kva

5.5

kw

4.8

Control

Circuit

Voltage

At

Gun

24

Volts

DC

Dimensions

Width

A:

B:

C:

Electrode

Wire
Feed

Speed

60to486

(1.5

mpm)

13-1/2

mm)

(343

Length

in.

27

mm)

(686

Height

in.

30

mm)

(762

ipm

to

in.

12.3

.023/.025

.030
.035

Net

205

lbs.*

(93

kg)

Electrode

Wire

Diameter

Capability

in.

(0.6

in.

(0.8

in.

(0.9

Weight

Ship

215

lbs.~

(98

mm)

mm)
mm)

kg)

for

units

*Add

~Add

Overall

SB.146

3-1.

6

5

4
3
2

1LOW

I~I3H

888

Figure

Chart

3-1.

Volt-Ampere

0

>

C)

0

Curves

Dimensions

200

Cl)
w

w

0.

160

0

-J

w

100

~

30

2-3/4

5

.

lbs.

lbs.

Chart

(1.25

(2.27

RATED



40

kg)

3-2.

OUTPUT,

--

Z

DUTY

kg)

for

Duty



60

-

-

CYCLE

units

Cycle





60

with

with

spot

spot

panel.







70

-





-~

60

90100

SB-I

46

687

OM-113

336

Page

7

3-1.

The

age
age

SPEED

curves

With

determine

age.

3-2.

The

that

output

welding

when
atedat150

must

allow
the

Refer

the

VOLT-AMPERE

volt-ampere

output

adjustment

control.

shown.

the

DUTY

duty

a

welding

without

power

operated

operate

proper

duty

cycle

to

the

output

cycles.

CAUTION:

a

RATINGS

source.



(~3*

curves

capabilities

is

provided

Curves

of

the

use

the

weld

amperage

CYCLE

is

cycle

Do

the

power

overheating

source

at

150

amperes

load

at

no

cooling.

increases.

Duty

Cycle

of

the

welding

will

exceed

not

CURVES

RATED

show

the

of

the

unit.

the

by

of

other

volt-ampere

at

(Chart

3-2)

percentage

source

for

If

EXCEEDING

can

and

is

rated

amperes.

six

consecutive

for

the

the

welding

chart

power

at

remaining

(Chart

damage

indicated

(Chart

OUTPUT

voltage

Voltage

FINE

TUNING

setting

curves,

any

fall

particular

of

ten

a

be

operated

damaging

60

percent

The

unit

amperes

3-2)

DUTY

welding

duty

at

cycles.

source

the

3-1)

and

and

between

it

is

possible

load

minute

at

the

unit.

duty

be

can

minutes,

four

minutes

decrease,

determine

to

various

CYCLE

amper

amper

WIRE

volt-

period

a

given

This

cycle

oper

but

duty

power

the

to

to

it

3-3.

unit

This

ing

power

signed

circuit

dc

a

Rated

cycle.

duty

Models

provide

on

time,

3-4.

The

following

power

sembly:

A.

B.

C.

D.

E.

The

welding

(2.7

m)

valve,

gas

DESCRIPTION

is

a

single-phase

source

Gas

for

spray

output

with

the

controls

the

burnback

transfer.

or

Electrode

weld

SUPPLIED

equipment

source

and

Running

bracket.

Wall

receptacle

Work

cable,

MWG-200

contact

two

Drive

rolls

and

0.8,

power

cord

power

and

constant

and

wire

feeder

Metal

Arc

Welding

It

is

designed

Positive/Reverse

is

150

amperes,

optional

gear

SPOT/PULSE

for

regulating

and

time,

EQUIPMENT

is

requires

with

customer

(200/230

work

clamp,

with

gun

tubes

for

for

.023/.025,

0.9

facilities

mm)

source

(with

plug

for

hard

is

a

voltage

system.

spot

off

pulse

(Figure

supplied

cylinder

gas

volt

and

in.

5/8

(16

each

wire

.030,

wire.

factory

on

200/230

Spool

dc

This

(GMAW)

primarily

Polarity

23

volts

WELD

weld

time.

3-2)

with

the

installation

models

jack

plug.

nozzle

mm)

size.

and

.035

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

9

ft.

models),

OM-113

336

Page

Spreader

Bar

Wall

Receptacle

3-2.

Figure

8

Supplied

Equipment

Bracket

3-5.

The

Metal

your

A.

Two

Welding

dioxide

welding

percent

favorable

gas

B.

Regulator/flowmeters

pressure

cause

flowmeter

mixture

changed

adapters

meter

ADDITIONAL

ure

3-3)

additional

Arc

Welding

local

welding

Gas

Cylinder

of

types

(GMAW)

(002)

power

argon

results.

from

your

equipment

gas

is

source/gun

and

supplier.

(GMAW)

supplies

are

generally

of

the

gas

25

Obtain

REQUIRED

thin

percent

Regulator/Flowmeter

provide

flow

gases

of

for

and

is

from

are

the

rate

have

different

designed

gases.

one

type

gas

of



installed.

to

Regulator/flowmeters

Obtain

gas

Cylinder

required

setup

distributor.

gauge

recommended

combination.

carbon

a

cylinder

a

during

the

properties,

be

used

another

to

the

used.

Gas

to

can

used

sheet

of

constant

welding

with

proper

EQUIPMENT

obtained

Gas

Metal

steel.

use

mixture

also

shielding

the

Carbon

with

complete

be

with

for

A

dioxide

selected

shielding

process.

each

regulator!

a

specific

cannot

unless

the

regulator/flow-

(Fig

Gas

from

Arc

this

of

75

gives

gas
Be

gas

be

proper

C.

Gas

Hose

Measure

source.

ameter,

thread

D.

Selection

Metal

choose

ing

ety

cated
classes

E7OS-6
flatter

wire.

E.

When

or

helmet,

eyes

safety

F.

The

distance

Obtain

S.A.E.

fittings

Wire

Spool

of

Arc

Welding

from,

thin

gauge

(AWS)

classification

the

on

recommended

provides

bead

Personal

using

fitted

the

from

glasses,

Offset/Punching

of

repair

OffsetlPunching

rotating

pose,

The

damaged

of

portion

When

small

a

steel,

set

portion.

place,

The
used

riveting

use

the

pressure

offset

cut

to

size,

The

sanded,

headofthe

as

a

punching

operations.

and

finishing

from

good

gas

both

on

For

the

correct

but

certain

sheet

label

a

more

E7OS-3.

than

Safety

this

welding

with

the

welding

and

automotive

toolisused.

head.

area

head

is

applied

in

the

is

new

filled

tool

time

gas

quality

and

hose,

endsofhose.

GMAW

welding

(GMAW).

wires

The

steel.

for

GMAW

of

the

wire

are

fluid

Obtain

Equipment

power

proper

Also

arc.

Tool

sheet

cutaway

are

placed

to

sheet

steel.

in

of

piece

body

be

can

tool.

The

use

minimum.

to

a

to

the

gloves

is

placed

with

The

cylinder

in.

5/8

install

Process

wire

There

are

American

spool.

E7OS-6

(wetter)

source,

filter

wear

prevent

(Figure

steel

This

and

over

handles,

A

position

sheet

putty,

rotated

punching

of

this

tool

to

welding

(16

mm)

5/8-18

is

important

are

many

best

suited

Welding

wires

is

usually

Two

and

E705-3.

weld

puddle

a

spool

wear

to

lens,

protective

injury.

3-4)

is

easier

tool

hasadual

the

jaws

the

sheet

the

new

piece

to

overlap

steel

is

welded

finish

and

one-half

tool

will

keep

power

outside

di

right-hand

in

Gas

types

for

weld

Soci

indi

AWS

wire

The

and

of

selected

a

welding

protect

the

clothing,

when

an

pur.

of

the

offset

steel.

tool

indents

of

sheet

the off

into

sanded.

turn

to

be

expedites

material

to

a

Hose

Gas

Figure

3-3.

Helmet

Wire

Spool

Li.

Safety

Glasses

Additional

Regulator/Flowmeter

Required

Equipment

Gloves

/

1.

I

Figure

3-4.

Offset/Punching

Tool

OM-113

336

Page

9

3-6.

The

capabilities

tions:

OPTIONAL

following

of

A.

SPW-1,

cludes

Section

B.

Spool

Gun

C.

D.

25

ft.

EQUIPMENT

equipment

the

basic

Spot,

three

spot

4-4)

gun

cable

holder

(7.6

m)

can

unit

Pulse,

power

be

obtained

to

or

Continuous

nozzles)

cord

extension.

suit

(for

special

extend

to

applica

Panel

installation

the

(in

see

3-7.

The

following

mal

use:

A.

B.

C.

D.

CONSUMABLE

parts

Contact

Nozzles

liner

Gun

Drive

rolls.

are

tubes

PARTS

subject

to

wear

or

damage

in

nor

4-1.

Select

Base

secure

1.

2.

3.

4.

5.

6.

7.

8.

mounting

SITE

an

Correct

Shielding

Adequate

No

A

Proper

or

Proper

Adequate

for
tions.

location.

SELECTION

Figure

installation

input

gas

ventilation

flammables

clean

and

temperature

cold

airflow

space

installation,

holes

the

unit

on

(Figure

4-1.

site

which

supply

power

supply

area

dry

that

around

for

maintenance,

provide

a

running

SECTION

Location

provides

and

fresh

avoids

unit

opening

the

capability

gear

4-1)

(see

side

or

4

the

unit

air

supply

extremes

access

and

in

a

INSTALLATION

SB-087

313-0

following:

nameplate)

of

heat

doors

func

repair

install

to

permanent

and

a

4-2.

This

for

the
power

4~

~.

RELOCATION

OR

WARNING:

from

placing

surfaces;

cause

internal







Warranty

used

TRANSPORTING

welding

moving

lifting

source.

WARNING:



overheating

parts.

locate

not

Do

Maintain
unrestricted

underside

keep

Do

not

place

air

take

cooling

the

eye

Do

Disconnect

intake

at

power

unit

only

not

passages

this

void

is

during

touch

at

source

deenergized

welding

FALLING

personal



Use

gear,

accessories



Use

the



If

the

power

EQUIPMENT

injury

lifting

gas

equipment

unit.

or

lifting

base,

moving

enoughtoextendbeyond

base.

lift

if

or

forks

tips

may

damage

Using

parts

base,

equipment

FIRE

OR

unit

RESTRICTED

allows

on

and

unit

overcombustible

18

least

space

free

filtering

any

unit.

if

any

air

passages.

METHODS

is

equipped

installation.

for

ELECTRIC

live

electrical

input

power

supply

source.

and

equipment

lift

to

eye

cylinders,

devices.

or

of

adequate

this

be

sure

short

too

the

cause

lift

if

of

EXPLOSION

or

over

AIRFLOW

possible

inches

all

sides

on

of

obstructions.

device

that

provide

of

type

filtering

Weight

supporting

SHOCK

parts.

conductors

line

BEFORE

can

unit

only,

or

any

with

unit

lift

that

opposite

can

forks

damage

penetrate

personal

unit

falls

can

combustible

damage

surfaces.

(457

of

over

airflow

with

a

capacity

the

can

cause

damage.

NOT

other

capacity

lift

forks

forks

sideofthe

injury

off

the

result

can

mm)

and

unit,

in

the

for

device

lifting

eye

welding

kill.

from

moving

serious

running

heavy

lift

to

under

are

long

internal

unit

the

and/or

lift

forks.

to

of

is

of

OM-113

336

Page

10

4-3.

a

1.

2.

3.

4.

RUNNING

WARNING:

TIPPING

or

equipment



Use

unit.



If

using

lift

forks

opposite



Do

unit

Place

running

Install

the

bar

onto

er

source

hardware.

Blockthe

lation

of

Slide

axle

wheel

on

each

er

on

Secure

rings.

GEAR

UNCONTROLLED

of

unit

damage.

equipment

lift

forks

are

long

side

not

place

while

it

is

blocks

under

gear.

4

in.

two

the

front

baseashown

unit

up

securely

rear

wheel/gas

through

each

end

side

of

wheels

in

INSTALLATION

result

can

of

adequate

to

handle

enough

of

the

base.

of

part

any

suspended.

frame

of

(102

mm)

corners

in

Figure

in

cylinder

cylinder

of

wheel.

place

axle

with

with

in

personal

capacity

this

unit,

extend

to

the

body

unit

before

casters

of

the

4-2

middleto

rack

rack,

a

3/4

supplied

(Figure

TILTING

to

be

sure

out

under

installing

and

spread

welding

using

ease

assembly.

and

install

in.

flat

retaining

4-2)

OR

injury

lift

the

the

of

the

the

power

in.

3/8

instal

a

wash

6.

7.

8.

4-4.

a

Install

5.

base

using

ciated

Remove

power

ning

gear

screws

cap

Install

cylinder

power

x

3/4

cap

Install

OPTIONAL

(Figure

WARNING:



Do



Shut

connect

ging
ing.

Lockout/tagging

input

ing
locking
removing

and

red-tagging

necting

cylinder

5/16-18

hardware

the

two

source

source

safety

handle

as

screws

chain

wrapper

shown

bracket

as

SPW-1

4-3)

ELECTRIC

touch

not

down

welding

input

procedures

power

line

disconnect

fuses

device.

rack

onto

x

3/4

(see

Figure

front

cap

onto

wrapper

in

onto

and

onto

live

power

before

in

existing

PANEL

electrical

power

shown

procedures

plug

from

fuse

circuit

welding

screws

cap

4-2).

screws

and

discard.

using

rear

4-2.

panel

Figure

Figure

holes

cylinder

INSTALLATION

SHOCK

parts.

source,

employing

inspecting

consist

from

receptacle,

in

switch

box,

breaker

or

top

source

and

of

welding

Install

power

in

1/4-20

of

using

in

rear

welding

4-2

bracket.

kill.

can

and

lockout/tag

install.

or

of

remov

position,

open

or

shutting

other

discon

asso

run

x

3/4

1/4-20

panel.

dis

pad

off

Nut

Spreader

Bar

Casters

Cylinder

Nut

Washer

Cap

Screw

Safety

chain

Washers

Flat

Washers

Flat

Cylinder

Rack

Axle

SC-049

.wheel

808-E

Figure

4-2.

Running

Gear

Installation

OM-113

336

Page

11