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
OWNERS
IMPORTANT:
special
installing,
instructions
operation
operate,
understand
SB-087
313D
Read
and
understand
the
emphasis
on
safety
operating,ormaintaining
for
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or
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instructions.
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Do
Contact
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not
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allow
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contents
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and
experienced
untrained
distributor
MANUAL
before
and
in
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to
Install,
not
with
these
safe
fully
of
the
This
persons
if
this
manual,
unit
you
manual,
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MILLER
AMIerGroupLld..Company
Appleton,
Tel.
ELECTRIC
Box
1079
WI
414-734-9821
54912
USA
Mfg.
PRINTED
IN
Co.
U.S.A.
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7
MAINTENANCE:
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Model
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No.
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1-1.
1-2.
1-3.
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Description
SAFETY
Introduction
General
Arc
Welding
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Precautions
Booklet
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TABLE
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Index
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Use
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DateofPurchase
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________________________________
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CONTENTS
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The
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No.
1
1
4
5
Designa
infor
SECTION
SECTION
SECTION
SAFETY
2-
2-1.
2-2.
General
Safety
3SPECIFICATIONS
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
Volt-Ampere
Duty
Description
Supplied
Additional
Optional
Consumable
4INSTALLATION
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
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Polarity
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Of
Wire
Tension
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Symbol
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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.
5OPERATOR
Power
Thickness
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Metal
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7
MAINTENANCE
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Maintenance
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(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
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Procedure
Procedures
To
Prevent
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Procedures
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Wiring
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Arc
Arc
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DIAGRAMS
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Diagram
Diagram
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Diagram
PC5O
Welding
Welding
Welding
The
REPAIR
Welding
Welding
Glass
Welding
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MW
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MW
For
SPW-1
For
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For
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For
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Gas
APPLICATION
Auto
Mild
Door
Breakage
Fenders
High
Arc
Metal
Sheet
Body
Steels
Panels
And
Strength
Models
4150
Models
4200
Panel
Panel
Panel
Continuous
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Metal
Spatter
And
Quarter
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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
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1
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Cycle
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CHARTS
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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,
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Safe
welding
search,
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INTRODUCTION
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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
bles
solubility)
trogen
OM-113
or
conducted
permit
supervisors
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
manufacturers
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
130F.
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
DONT
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
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,
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
MENS
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
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