AUTO ARC BENCHMARK User manual

June
1989
FORM:
121
989A
OWN
ERS
MANUAL
II
IT?
VTLiQFL_____
/ 1~J
I V..~ I
MILLER ELECTRIC
MFG.
CO.
718 S. BOUNDS
SI,
P.O.
Box
1079
APPLETON,
WI
54912
USA
ADDITIONAL
COPY
PRICE
$1.40
lMpOfl~TANT
_____________
Read
and
understand
the
entire
content3
of this
manual,
with
special
emphasis
on
the
safety
material
throughout
the
manual,
before
installing,
operating,
or
maintaining
this
equip
ment.
Thts
unit
and
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
safe
operation
of
welding
equipment.
Do
not
allow
un
trained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these instructions.
Effective
With
Serial No.
JJ368979
MODEL
BENCHMARKTM
BENCHMARKTM
Pro
MWG-160
Gun
NWSA CODE NO.
4579
PRINTED
IN
U.S.A.

- -~ -~
ONE
YEAR
LIMITED
WARRANTY
COVERAGE

Miller
Electric
Mfg.
Co.
warrants
to
the
buyer
who
purchases
this
Auto
Arc
Welder
(~Welder)
for
personal,
familyorhousehold
purposes
(Consumer)
thatthis Welderwill
be
free from
defects
in
material
andworkmanship
fora
period
of
one
year
from
the
date of
purchase.
This
warranty
covers
only
the
original purchaser
of
this
Welder.
Miller Electric
does
not
authorize
any
party,
including
its
authorized
distributors,
to offer
any
other
warranty
on
behalf
of
Miller
Electric.
Upon expiration
of the
warranty
period,
Miller
Electric
shall have
no
further
liabil
ity
related to
the
Welder,
excepton
warranty
claims
made
during
the
warranty period.
THIS
WARRANTY
IS OFFERED
IN
LIEU
OF
ANY OTHER
EXPRESS
WARRANTY;
AND,
EXCEPT
TO THE
EXTENT
PROHIBITED
BY
APPLICABLE
LAW,
THE
DURATION OF
ALL
IMPLIED
WARRANTIES,
INCLUDING
BUT
NOT
LIMITED
TO
THE
IMPLIED
WARRANTIES
OF MERCHAN
TABILITY AND FITNESS
FOR
A
PARTICULAR
PURPOSE,
IS
LIMITED TO THE DURATION OF
THIS WARRANTY.
Some
states
do
not
allow limitations
on
how
long
an
implied
warranty
lasts,
so
the
above limitation
may
not
apply
to
you.
This
warranty gives
you
specific
legal
rights,
and
you may
also
have other
rights
which
vary
from
state
to
state.
Except
as
specified
below,
Millers
warranty
does
not
apply
to
components having
normal
useful life
of less
than
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
parts
that
come
in
contact
with the
welding
wire
including
nozzles
and
nozzle insulators where failure
does
not result from defect
in
workmanship
or
material.
Miller shall be
required
to
honorwarranty
claims
on
warranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
within
the
following
periods
from
the date of
delivery
of
Equipment
to
the
original
user:
1.
Arc
welders,
power
sources,
and
components ...
1
year
2.
Original
main
power
rectifiers
3
years
(labor

1
year
only)
3.
All
welding
guns,
feeder/guns
and
torches
90
days
4.
Replacement
or
repair
parts,
exclusive
of
labor
60
days
WHAT IS
NOT COVERED

This
warranty
does
not
extend
to
any
Welder
subjected
to
misuse,
neglect,
accident,
or
in-
warranty
repair
by
anyone except
Miller
Electric.
Further,
this
warranty
only
extends
to those
purchasing
the Welder
for
per
sonal,
family
or
household
purposes.
Commercial
and
indus
trial
users
are
given
a
different
warranty.
REMEDY
FOR DEFECTIVE
WELDER

Upon receipt
of
any
defective
Welder,
Miller
Electric
will,
at
its
option,
repair
or
re
place
the
defective
Welder
at
its
expense,
refund
or
credit the
purchase
price
(less
reasonable
depreciation
based
on
actual
use),
or
reimburse the Consumer
for
the
cost
of
repair
or
re
placement
at
an
approved
Miller
Electric
warranty
station,
pro
vided that
the
purchaser
of that Welder
has
followed the
proce
dure
for
obtaining
warranty
performance
set forth below. The
Welder
so
repaired
or
used
as a
replacement
will be
shipped
to
the
purchaser
of
the
defective
Welder,
with
transportation
charges
prepaid
to
any
destination in
the continental United
States
(transportation
charges
on
shipments
to Alaska
or
Hawaii
will
be
paid
only
to
the
nearest
port
of
export).
THE
PURCHASERS REMEDIES
FOR
A
DEFECTIVE
WELDER,
TO
THE
EXTENT PERMITTED
BY
APPLICABLE
LAW,
ARE
LIMITED
TO
THE REMEDY PROVIDED BY THIS
WARRANTY:
AND,
TO THE
EXTENT ENFORCEABLE
UNDER
APPLICABLE
LAW,
MILLER
ELECTRIC SHALL
IN
NO
EVENT
BE LIABLE
FOR
CONSEQUENTIAL,
INCIDEN
TAL OR SPECIAL DAMAGES
ARISING
OUT
OF
THE
USE
OF,
OR INABILITY TO
USE,
THE
WELDER,
WHETHER
BASED
ON BREACH OF THIS
WARRANTY,
MILLER
ELECTRICS
NEGLIGENCE OR
OTHER
TORT,
OR
ON
ANY
THEORY
OF
STRICT LIABILITY.
Some
states
do
not
allow
the
exclusion
or
limitation of
conse
quential
or
incidental
damages,
so
the
above
limitations
may
not
apply
to
you.
PROCEDURE
FOR
OBTAINING WARRANTY
PERFORM
ANCE
As
soon
as
any
defect
in
a
Welder
becomes
known,
the
pur
chaser
of the
Welder
must,
within
thirty
(30)
days,
notify
an
approved
Warranty
Station
or
Miller
Electric
in
writing
of
the
defect.
The
purchaser
must
then,
within
the
one
year
warranty
period,
return
the
Welder
to
Miller
Electric
at
the
following
ad
dress:
Miller
Electric
Mfg.
Co.
1635 W.
Spencer
St.
P.O.
Box
1079
Appleton,
Wisconsin
54912
All
transportation
charges
to
Warranty
Station
or
Miller
Electric
must
be
prepaid.

ERRATA
SHEET
After
this manual
was
printed,
refinements
In
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
IMPORTANT: This
model
comes
equipped
with
V-Grooved
drive rolls installed.
AMENDMENT TO
SECTION
3
SPECIFICATIONS
Amend
90
Ampere
Model
portion
of
Chart
3-2.
Duty
Cycle
90
Ampere
Models
0)
uJ
LI
10
16
20 2630 40 60
SOiO6OO1OO
X
DUTY
CYCLE
B.124
655-A
AMEN
DMENT
TO
SECTION
4INSTALLATION
Amend
step
10 of
Section
4-5.
INSTALL
AND
THREAD
THE
WIRE
10.
Route
the
welding
wire into the wire inlet
guide,
along
the drive roil
groove,
and into the
wire
outlet
guide
in
the
gun
cable.
AMENDMENT
TO
SECTION
7-
MAINTENANCE
&
TROUBLESHOOTING
Amend
Figure
7-1.
Wire
Drive
Assembly
And
Replacement
(see
Page
2
on
this
Errata
Sheet)
(For
70
Ampere
Models,
Effective With
Serial
No.
JK646341.
For
90
Ampere
Models,
Effective
With Serial
No.
JJ368979.)
Amend
Section
7-7.
REPLACING
THE WIRE
INLET
GUIDE
(Figure
7-1
on
this Errata
Sheet)
(For
70
Ampere Models,
Effective With
Serial
No.
JK646341.
For
90
Ampere
Models,
Effective
With
Serial
No.
JJ368979.)
160
126
100
76
60
375
0

Pressure
Pressure
Roll
Cover
Cotter
Pin
Drive
Roll
Setscrew
TC-121
488.A
FIgure
7-1.
WIre
Drive
Assembly
And
Replacement
a
WARNING:
HOT SURFACES
can cause severe
burns.

Allow
equipment
to
cool
before
cleaning.
1. Turn OFF
the welder.
2.
Open
the
left
side
access
door.
3.
Loosen the
drive
roll
pressure
adjustment
knob,
pivot
the
pressure
adjustment
arm
down~
away
from
the
cover.
Pivot
the
pressure
roll
assembly
up
until
it
is
in
the
open
position.
a
CAUTION:
LOOSE
WELDING WIRE
can cause
Injury.

Keep
firm
ho/don
wire
during
installation,
removal,
and
threading operations.
Spooled
wire has
a
tendency
to
unravel
rapidly
when
loosened from the
spool.
4.
Cut
the
welding
wire
at
the
point
where
it
enters
the
wire inlet
guide.
Pull
the
wire
out
through
the nozzle end
of
the
welding
gun.
5.
Remove
and
replace
the
inlet
guide.
IMPORTANT:
Wire
guides
should
be
installed
so
that
the
tip(s)
of
the
guide
is
as
close
to
the drive
roll
as
possible
without
touching.
6.
Thread
the
welding
wire
as
instructed
in
Section
4-5.
7.
Pivot
the
pressure
adjustment
arm
up
until ft
seats
on
top
of the
pressure
roll
assembly.
8.
Turn
the
pressure adjustment
knob
clockwise
until the drive
roll
assembly
is
secure.
Adjust
the
drive roll
pressure
just
enough
to
prevent
the
wire
from
slipping
on or
against
the
drive
roll
during operation.
9.
Close
and
secure
the
access
door.
AMENDMENT
TO
SECTION
8
ELECTRICAL
DIAGRAMS
Amend
Diagram
8.5.
Wiring
Diagram
For
90
Ampere
Models
(see
Page
3
on
this Errata
Sheet)
121
9B9APage2
Gun
Cable
Pressure Lever
Hinge
Pin
Pressure
Bearing
Screw
Pressure
Adjustment
~
Arm

Wire
inlet
Guide

Wiring
Diagram
No.
C-124
445-C
Diagram
8-5.
Wiring
Diagram
For
90
Ampere
Models

AMENDMENT
TO
SECTION
12
PARTS
LIST
Amend
Parts
List
as
follows:
Model
Quantity
Dia.
Part
Replaced
Benchmark
Mkgs.
No.
With
Description
Benchmark
Pro
41-2
010910 010910
WASHER,
flat-SAE
3/8
3
3
41-19
073
433
Deleted
Both
Models
(Eff w/JK664661)
41-20
010
678
Deleted
Both
Models
(Effw/JK664661)
41-21
GS1
003538
116996
VALVE,
ll5VAC2way
custom
port
1/8orf
(Etfw/JK664661)
1 1
41-22
010
296
Deleted
Both
Models
(Eff
w/JK664661)
41-29
121
088
126416
HANDLE,
molded
plastic
(Eff
w/JK71
6640)
1
1
41-
Added
126415
CLAMP,
saddle
(Eff
w/JK71
6640)
1 1
41-
Added
605
227
NUT,
nyl
hex
jam
.750
(Effw/JK664661)
1
1
42-54
119123
130900
BAFFLE,air(Effw/JK716640)
I
I
42-56
083
147
Deleted
BOTH
MODELS,
(Eff
w/JK71
66400)
45-5
Added
604
536
SCREW,
cap
stl
hexhd
.312-18
(Eff
w/JK646341)
1
45-6
Added
602
211
WASHER,
lock sfl
split
.312
(Etfw/JK646341)
1
45-7 Added
604 538
WASHER,
flat
st
SAE
.312
(Eff
w/JK646341)
2
45-8
118
871
129 893
INSULATOR,
housing-drive
(Effw/JK716640)
1 1
45-9
129
665
126838
DRIVE
ASSEMBLY,
wire
(Eff
w/JK646341)
1
45-11
118
928
124
817
HOUSING,
wire drive
(Eff
w/JK646341)
1
45- 604 534
Deleted
(Eff
wIJK646341)
45- 604
538
Deleted
(Eff w/JK646341)
45-
602
109
Deleted
(Effw/JK646341)
45-
120 678
058
549
GUIDE,
wire inlet
1/16
(Effw/JK646341)
1
45-
Added
604
537
NUT,
stl
hex full
fnsh
.312-18
(Eff
w/JK646341)
1
**First
digit
represents
page
no
-
digits
following
dash
represent
item
no.
BE
SURE
TO PROVIDE MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT PARTS.
121
989A
Paged

RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
dam-
Use the
following
spaces
to
record
the
Model
Designa
age
that
may
have
occurred
during
shipment.
File
any
tion and
Serial
or
Style
Number of
your
unit. The infor
claims for
loss
or
damage
with
the
delivering
carrier.
mation is located
on
the
data
card
or
the
nameplate.
Assistance
for
filing
or
settling
claims
may
be obtained
from the distributor and/or
the
equipment
manufactur-
Model
______________________________________
ers
Transportation
Department.
Serial
or
Style
No.
________________________
When
requesting
information
about this
equ!pment,
al
ways
provide
the Model
Description
and
Serial
or
Style
Date
of Purchase
____________________________
Number.
TABLE OF CONTENTS
Section
No.
Page
No.
SECTION 1

SAFETY
RULES
FOR OPERATION
OF ARC WELDING POWER
SOURCE
1-1.
Introduction
1
1-2.
General
Precautions
1
1-3.
Arc
Welding
3
1-4. Standards
Booklet
Index
5
SECTION
2-
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
2-1
.
General Information
And
Safety
6
2-2.
Safety
Alert
Symbol
And
Signal
Words
6
SECTION
3
SPECIFICATIONS
3-1.
Volt-Ampere
Curves
8
3-2.
Duty
Cycle
8
3-3.
Description
9
3-4.
Supplied
Equipment
9
3-5. Personal
Safety
Equipment
9
3-6.
Optional
Equipment
9
3-7.
Consumable/Replacement
Parts
10
SECTION
4
-
INSTALLATION
4-1.
Locate
The
Welder
10
4-2.
Install The
Work
Clamp
10
4-3.
Set
The
Welding
Polarity
11
4-4.
Install
The
Welding
Gun
11
4-5.
Install
And
Thread
The
Wire
11
4-6.
Adjust
The
Hub
Tension
12
4-7.
Shielding
Gas
Installation
12
4-8.
Connect
To Power
13
4-9.
Feed
The Wire
14
SECTION
5

OPERATOR
CONTROLS
5-1.
Power
Switch
14
5-2.
ThicknessNolts
Switch
14
5-3.
Fine
Tuning/Wire
Speed
Control
15

Section
No.
Page
No.
SECTION
6
OPERATION
6-1.
Gas Metal
Arc
Welding
(GMAW)
15
6-2.
Flux
Cored
Arc
Welding
(FCAW)
18
6-3.
Shutting
Down
18
SECTION 7-
MAINTENANCE &
TROUBLESHOOTING
7-1.
Routine
Maintenance
18
7-2. Drive Roll
Cleaning
19
7-3. Cable
Inspection
19
7-4.
Welding
Gun
Inspection
And Maintenance
19
7-5.
Replacing
The
Drive
Roll
19
7-6.
Replacing
The
Pressure
Bearing
19
7-7.
Replacing
The Wire
Inlet
Guide
20
7-8.
Short
Circuit
Shutdown
(90
Ampere
Models
Only)
21
7-9.
Circuit
Board
Replacement
(90
Ampere
Models
Only)
21
7-10.
Replacing
The
Contact
Tube 22
7-11. Gun Wire And
Liner
Replacement
22
7-12.
Fuse
Fl
(70
Ampere
Models
Only)
22
7-13.
Thermal
Overload
Protection
23
7-14.
Troubleshooting
23
SECTION
8
ELECTRICAL DIAGRAMS
Diagram
8-1.
Circuit
Diagram
For
70
Ampere
Models
24
Diagram
8-2.
Circuit
Diagram
For 90
Ampere
Models
25
Diagram
8-3.
Circuit
Diagram
For 90
Ampere
Model
Short
Circuit
And
Burnback Control Board
PCi
25
Diagram
8-4.
Wiring
Diagram
For 70
Ampere
Models
26
Diagram
8-5.
Wiring
Diagram
For 90
Ampere
Models
27
SECTION
9
PROJECT INSTRUCTIONS
9-1.
Overview
28
9-2.
Dust
Pan
29
9-3.
Shop
Stool
30
9-4.
Adjustable
Support/Stand
31
9-5. Trailer
Dolly
32
SECTION
10 WELDING
TECHNIQUES
&
TROUBLESHOOTING
10-1.
Gas
Metal
Arc
Welding
(GMAW)

Continuous
Seam
33
10-2.
Troubleshooting
The Gas Metal
Arc
Welding (GMAW)
Process
....
34.
SECTION 11

AUTO
BODY REPAIR
APPLICATION
11-1.
Pointers
For
Welding
Auto
Body
Sheet
Metal
38
11-2.
-Procedure For
Welding
Mild
Steels
38
11-3.
Procedures
For
Welding
Door
Panels
38
11-4.
How To Prevent
Glass
Breakage
And
Spatter
On
Windows
39
11-5.
Procedures
For
Welding
Fenders
And
Quarter
Panels
39
11-6.
Welding
Frames
And
High
Strength
(HSS)
Steels
39

Section
No.
Page
No.
SECTION
12
PARTS LIST
Figure
12-1.
Main
Assembly
40
Figure
12-2.
Circuit
Card,
Shutdown/Burnback
PCi
43
Figure
12-3.
Drive
Assembly,
Wire
(Benchmark
Pro
Illustrated)
44
Figure
12-4~
Exploded
View
Of
MWG-160B
Gun
46
LIST
OF
CHARTS
AND
TABLES
Table
3-i.
Specifications
7
Chart
3-1.
Volt-Ampere
Curves
8
Chart
3-2.
Duty
Cycle
8
Table
4-1.
Maximum Allowable Extension Cord
Lengths
14
Table
6-1.
Suggested
Welding
Settings
16
Table
7-1.
Maintenance Schedule
18
Table
7-2.
Troubleshooting
23
Table
9-i.
Dust Pan
Material
List
29
Table
9-2.
Shop
Stool
Material List
30
Table
9-3.
Adjustable
Support/Stand
Material
List
31
Table
9-4.
Trailer
Dolly
Material List
32

SECTION
1

SAFETY
RULES
FOR
OPERATION
OF
ARC
WELDING
POWER
SOURCE
1-1.
INTRODUCTION
We learn
by
experience.
Learning
safety
through
per
sonal
experience,
like
a
child
touching
a
hot
stove
is
harmful, wasteful,
and unwise.
Let
the
experience
of
oth
ers
teach
you.
Sat
e
practices
developed
from
experience
in
the
use
of
welding
and
cutting
are
described
in
this
manual.
Re
search,
development,
and
field
experience
have
evolved
reliable
equipment
and
safe
installation,
opera
tion,
and
servicing
practices.
Accidents
occur
when
equipment
is
improperly
used
or
maintained. The
rea
son
for
the
safe
practices
may
not
always
be
given.
Some
are
based
on common
sense,
others
may
require
technical volumes
to
explain.
It is wiser
to
follow
the
rules.
Read
and
understand
these
safe
practices
before
at
tempting
to
install,
operate,
or
service the
equipment.
Comply
with these
procedures
as
applicable
to
the
par
ticular
equipment
used
and
their
instruction
manuals,
for
personal
safety
and
for
the
safety
of
others.
Failure
to
observe
these
safe
practices
may
cause
seri
ous
injury
or
death. When
safety
becomes
a
habit,
the
equipment
can
be
used with confidence.
These safe
practices
are
divided
into
two
Sections:
1-General
Precautions,
common
to
arc
welding
and
cut
ting;
and 2-Arc
Welding
(and
Cutting)
(only).
Reference
standards:
Published
Standards
on
safety
are
also
available
for
additional
and
more
complete
pro
cedures than
those
given
in
this
manual.
They
are
listed
in
the
Standards
Index in
this manual.
ANSI
Z49.1
is
the
most
complete.
The
National Electrical
Code,
Occupational
Safety
and
Health
Administration,
local
industrial
codes,
and
local
inspection
requirements
also
provide
a
basis for
equip
ment
installation,
use,
and
service.
1-2.
GENERAL
PRECAUTIONS
Different
arc
welding
processes,
electrode
alloys,
and
fluxes
can
produce
dIfferent
fumes,
gases,
and
radiation levels.
In
addItion
to
the
InformatIon
In
this
manual,
be
sure
to
consult
flux
and
electrode
manu
facturers
Material
Safety
Data
Sheets
(MSDSs)
for
specifIc
technIcal
data
and
precautIonary
measures
concerning
theIr
materIal.
A.
Burn
PreventIon
Wear
protective
clothing-gauntlet
gloves
designed
for
use
in
welding,
hat,
and
high
safety-toe
shoes.
Button
shirt
collar and
pocket
flaps,
and
wear
cuffless
trousers
to
avoid
entry
of
sparks
and
slag.
Wear
helmet
with
safety
goggles
and
glasses
with
side
shields
underneath,
appropriate
filter
lenses
or
plates
(protected
by
clear
cover
glass).
This
is
a
MUST
for
welding
or
cutting,
(and
chipping)
to
protect
the
eyes
from
radiant
energy
and
flying
metal.
Replace
cover
glass
when
broken,
pitted,
or
spattered.
See 1
-3A.2.
Avoid
oily
or
greasy
clothing.
A
spark
may
ignite
them.
Hot
metal
such
as electrode
stubs
and
workpieces
should
never
be handled
without
gloves.
Medical
first
aid and
eye
treatment.
First
aid facilities
and
a
qualified
first aid
person
should
be
available
for
each
shift
unless
medical
facilities
are
close
by
for
immediate
treatment
of flash
burns
of
the
eyes
and
skin
burns.
Ear
plugs
should be
worn
when
working
on overhead
or
in
a
confined
space.
A
hard
hat
should
be
worn
when
others
work
overhead.
Flammable
hair
preparations
should
not
be
used
by
per
Sons
intending
to
weld
or
cut.
B.
ToxIc Fume
Prevention
Severe
discomfort,
illness
or
death
can
result
from
fumes,
vapors,
heat,
or
oxygen
enrichment
or
depletion
that
welding
(or
cutting)
may
produce.
Prevent
them
with
adequate
ventilation
as
described
in
ANSI
Standard
Z49.1
listed
in
Standards
Index.
NEVER
ventilate
with
oxygen.
Lead
-,cadmium-, zinc-,
mercury-,
and
beryllium-bear
ing
and
similar
materials,
when
welded
(or
cut)
may
pro
duce harmful
concentrations of
toxic
fumes.
Adequate
local
exhaust
ventilation
must
be
used,
or
each
person
in
the
area
as
well
as
the
operator
must
wear
an
air-sup
plied
respirator.
For
beryllium,
both
must
be
used.
Metals
coated with
or
containing
materials
that
emit
toxic
fumes
should
not
be
heated
unless
coating
is
removed
from
the
work
surface,
the
area
is
well
ventilated
and,
if
necessary,
while
wearing
an
air-supplied
respirator.
Work
in
a
confined
space
only
while
it is
being
ventilated
and,
it
necessary,
while
wearing
an
air-supplied
respira
tor.
Gas
leaks
in
a
confined
space
should
be
avoided.
Leaked
gas
in
large
quantities
can
change
oxygen
con
centration
dangerously.
Do
not
bring
gas
cylinders
into
a
confined space.
Leaving
confined
space,
shut OFF
gas
supply
at
source
to
prevent
possible
accumulation
of
gases
in
the
space
if
downstream
valves
have
been
accidentally
opened
or
left
open.
Check
to
be
sure
that the
space
is
safe
before
re-entering
it.
Vapors
from
chlorinated
solvents
can
be
decomposed
by
the heat of
the
arc
(or
flame)
to
form
PHOSGENE,
a
highly
toxic
gas,
and
other
lung
and
eye
irritating
prod
ucts.
The ultraviolet
(radiant)
energy
of
the
arc
can
also
decompose
trichloroethyie
ne
and
perchloroethylene
vapors
to
form
phosgene.
DO
NOT
WELD
or cut
where
solvent
vapors
can
be
drawn
into
the
welding
or
cutting
atmosphere
or
where
the
radiant
energy
can
penetrate
121
989
Page
1

to
atmospheres
containing
even
minute amounts
of
trichloroethyiene
or
perchioroethylene.
C.
Fire
and
Explosion
Prevention
Causes
of fire
and
explosion
are:
combustibles
reached
by
the
arc,
flame,
flying
sparks,
hot
slag
or
heated
mate
rial;
misuse of
compressed
gases
and
cylinders;
and
short
circuits.
BE AWARE
THAT
flying
sparks
or
falling
slag
can
pass
through
cracks,
along
pipes,
through
windows
or
doors,
and
through
wall
or
floor
openings,
out
of
sight
of the
goggled
operator.
Sparks
and
slag
can
fly
35
feet.
To
prevent
tires
and
explosion:
Keep equipment
clean
and
operable,
free
of
oil,
grease,
and
(in
electrical
parts)
of
metallic
particles
that
can
cause
short
circuits.
If
combustibles
are
in
area,
do
NOT
weld
or
cut.
Move
the
work
if
practicable,
to
an area
free
of
combustibles.
Avoid
paint
spray
rooms,
dip
tanks,
storage
areas,
venti
lators.
If
the
work
cannot
be
moved,
move
combustibles
at
least
35 feet
away
out
of reach
of
sparks
and
heat;
or
protect
against
ignition
with
suitable
and
snug-fitting,
fire-resistant
covers or
shields.
Walls
touching
combustibles
on
opposite
sides should
not
be welded
on
(or
cut).
Walls,
ceilings,
and
floor
near
work
should be
protected
by
heat-resistant
covers or
shields.
Fire watcher
must
be
standing
by
with
suitable
fire extin
guishing
equipment
during
and
for
some
time
afterweld
ing
or
cutting
if:
a.
appreciable
combustibles
(including
building
construction)
are
within
35 feet
b.
appreciable
combustibles are
further than
35
feet
but
can
be
ignited
by sparks
c.
openings
(concealed
orvisible)
infloorsorwalls
within
35
feet
may
expose
combustibles
to
sparks
d.
combustibles
adjacent
to
walls,
ceilings,
roofs,
or
metal
partitions
can
be
ignited
by
radiant
or
conducted
heat.
Hot work
permit
should
be
obtained
before
operation
to
ensure
supervisors approval
that
adequate
precautions
have been taken.
After work is
done,
check
that
area
is
free
of
sparks,
glowing
embers,
and flames.
An
empty
container
that
held
combustibles,
or
that
can
produce
flammable
or
toxic
vapors
when
heated,
must
never
be welded
on or
cut,
unless
container has first
been cleaned
as
described
in
AWS
Standard
A6.O,
listed
7 in
Standards
index.
-
This includes:
athorough
steam
orcaustic
cleaning (or
a
solvent
or
water
washing, depending
on
the combusti
bles
solubility)
followed
by
purging
and
inerting
with
ni
trogen
or
carbon
dioxide,
and
using protective equip-
ment
as
recommended
in
A6.O.
Waterfilling just
below
working
level
may
substitute
for
inerting.
A
container
with
unknown
contents
should
be cleaned
(see
preceding
paragraph).
Do
NOT
depend
on
sense
of
smell
or
sight
to
determine
if
it is
safe
to
weld
or
cut.
Hollow
castings
or
containers
must
be
vented
before
welding
or
cutting.
They
can
explode.
Explosive
atmospheres.
Neverweld
orcut
where
the
air
may
contain
flammable
dust,
gas,
or
liquid
vapors
(such
as
gasoline).
D.
Compressed
Gas
Equipment
Standard
precautions.
Comply
with
precautions
in
this
manual,
and those
detailed
in
CGA Standard
P-i,SAFE
HANDLING
OF
COMPRESSED
GASES
IN
CYLIN
DERS,
listed
ii
in
Standards
Index.
1.
Pressure
Regulators
Regulator
relief
valve
is
designed
to
protect
only
the
regulatorfromoverpressure;
it
is
not
intended
to
protect
any
downstream
equipment.
Provide such
protection
with
one or
more
relief
devices.
Never
connect
a
regulator
to
a
cylinder
containing
gas
other
than
that
for
which the
regulator
was
designed.
Remove
faulty
regulator
from service
immediately
for
re
pair (first
close
cylinder
valve).
The
following
symptoms
indicate
a
faulty
regulator:
Leaks-if
gas
leaks
externally.
Excessive
Creep-if
delivery
pressure
continues
to
rise
with downstream
valve
closed.
Faulty
Gauge-if
gauge
pointer
does
not
move
off
stop
pin
when
pressurized,
nor
returns to
stop
pin
after
pressure
release.
Repair.
Do
NOT
attempt
to
repair.
Send
faulty regulators
for
repair
to
manufacturers
designated repair
center,
where
special
techniques
and tools
are
Used
by
trained
personnel.
2.
Cylinders
Cylinders
must
be handled
carefully
to
prevent
leaks
and
damage
to
their
walls,
valves,
or
safety
devices:
Avoid
electrical
circuit
contact
with
cylinders
including
third
rails,
electrical
wires,
or
welding
circuits.
They
can
produce
short
circuit
arcs
that
may
lead
to
a
serious acci
dent.
(See
1-3C.)
ICC
or
DOT
marking
must
be
on
each
cylinder.
It is
an
assurance
of
safety
when
the
cylinder
is
properly
han
dled.
Identifying
gas
content.
Use
only
cylinders
with
name
of
gas
marked
on
them;
do
not
rely
on
color
to
identify
gas
content.
Notify supplier
if
unmarked.
NEVER
DEFACE
or
alter
name,
number,
or
other
markings
on a
cylinder.
It
is
illegal
and
hazardous.
Empties:
Keep
valves
closed,
replace
caps
securely;
mark
MT;
keep
them
separate
from
FULLS
and
return
promptly.
121 989
Page
2

Prohibited
use.
Never
use a
cylinder
or
its
contents
for
other
than
its
intended
use,
NEVER
as
a
support
or
roller.
Locate
or
secure
cylinders
so
they
cannot
be
knocked
over.
Passageways
and
work
areas.
Keep
cylinders
clear
of
areas
where
they
may
be struck.
Transporting cylinders.
With
a
crane,
use
a secure
sup
port
such
as a
platform
orcradle. Do
NOT
lift
cylinders
off
the
ground
by
their
valves
or
caps,
or
by
chains,
slings,
or
magnets.
Do
NOT
expose
cylinders
to
excessive
heat,
sparks,
slag,
and
flame,
etc.
that
may
cause
rupture.
Do
not
al
low
contents to
exceed
130F. Cool with
water
spray
where
such
exposure
exists.
Protect
cylinders
particularly
valves
from
bumps,
falls,
falling
objects,
and
weather.
Replace
caps
securely
when
moving cylinders.
Stuck
valve.
Do NOT
use a
hammer
or
wrench
to
open
a
cylinder
valve that
can
not
be
opened
by
hand.
Notify
your
supplier.
Mixing
gases.
Never
try
to
mix
any
gases
in
a
cylinder.
Never
refill
any
cylinder.
Cytindertittings
should
never
be
modified
or
exchanged.
3.
Hose
Prohibited
use.
Neveruse hose
otherthan
that
designed
for
the
specified
gas.
A
general
hose
identification rule
is:
red for
fuel
gas,
green
for
oxygen,
and black for
inert
gases.
Use ferrules
or
clamps
designed
for
the
hose
(not
ordi
nary
wire
or
other
substitute)
as
a
binding
to
connect
hoses
to
fittings.
No
copper
tubing
splices.
Use
only
standard brass
I
it
tings
to
splice
hose.
Avoid
long
runs
to
prevent
kinks and abuse.
Suspend
hose
oft
ground
to
keep
it from
being
run
over,
stepped
on,
or
otherwise
damag~ed.
Coil
excess
hose
to
prevent
kinks
and
tangles.
Protect
hose
from
damage
by
sharp edges,
and
by
sparks,
slag,
and
open
flame.
Examine
hose
regularly
for
leaks,
wear,
and loose
con
nections.
Immerse
pressured
hose
in
water;
bubbles
in
dicate
leaks.
Repair
leaky
or worn
hose
by
cutting
area
out
and
splic
ing (1-2D3).
Do
NOT
tape.
4.
Proper
Connections
Clean
cylinder
valve
outlet
of
impurities
that
may
clog
orifices
and
damage
seats
before
connecting
regulator.
Except
for
hydrogen,
crack
valve
momentarily, pointing
outlet
away
from
people
and
sources
of
ignition.
Wipe
with
a
clean
lintless cloth.
Match
regulator
to
cylinder.
Before
connecting,
check
that the
regulator
label
and
cylinder
marking
area,
and
thatthe
regulator
inlet and
cylinderoutlet
match. NEVER
CONNECT
a
regulator
designed
for
a
particular
gas
or
gases
to
a
cylinder
containing
any
other
gas.
Tighten
connections. When
assembling
threaded
con
nections,
clean
and
smooth
seats
where
necessary.
Tighten.
If
connection
leaks,
disassemble,
clean,
and
retighten
using properly
fitting
wrench.
Adapters.
Use
a
CGA
adapter
(available
from
your
sup
plier)
between
cylinder
and
regulator,
if
one
is
required.
use
two
wrenches
to
tighten
adapter
marked
RIGHT
and
LEFT
HAND
threads.
Regulatoroutlet
(or
hose)
connections
may
be identified
by
right
hand
threads
for
oxygen
and
left
hand
threads
(with grooved
hex
on
nut
or
shank)
for
fuel
gas.
5.
Pressurizing
Steps:
Drain
regulator
of
residual
gas
through
suitable
vent
be
fore
opening cylinder (or
manifold
valve)
by
turning
ad
justing
screw
in
(clockwise).
Draining prevents
exces
sive
compression
heat
at
high
pressure
seat
by
allowing
seat to
open
on
pressurization.
Leave
adjusting
screw
engaged slightly
on
single-stage
regulators.
Stand to
side
of
regulator
while
opening
cylinder
valve.
Open
cylinder
valve
slowly
so
that
regulator
pressure
in
creases
slowly.
When
gauge
is
pressurized
(gauge
reaches
regulator maximum)
leave
cylinder
valve
in
fol
lowing
position:
For
oxygen,
and
inert
gases,
open
fully
to
seal
stem
against
possible
leak.
For fuel
gas,
open
to
less
than
one
turn to
permit
quick
emergency
shutoff.
Use
pressure
charts
(available
from
your
supplier)
for
safe and
efficient,
recommended
pressure
settings
on
regulators.
Check
for
leaks
on
first
pressurization
and
regularly
there-after. Brush
with
soap
solution
(capfuli
of
Ivory
Liq
uid*
or
equivalent
per
gallon
of
water).
Bubbles
indicate
leak.
Clean
off
soapy
water
after
test;
dried
soap
is
com
bustible.
E.
User
ResponsibilIties
Remove
leaky
or
defective
equipment
from
service
im
mediately
for
repair.
See
User
Responsibility
statement
in
equipment
manual.
F.
Leaving
Equipment
Unattended
Close
gas
supply
at
source
and
drain
gas.
G.
Rope
Staging-Support
Rope
staging-support
should
not
be
used for
welding
or
cutting
operation;
rope
may
burn.
*Trademark
of
Proctor
&
Gamble.
1-3.
ARC
WELDING
121
989
Page
3

Comply
with
precautions
in
1-1,
1-2,
and
this section.
Arc
Welding,
properly
done,
is
a
safe
process,
but
a
careless
operator
invites trouble.
The
equipment
carries
high
currents at
significant
voltages.
The
arc
is
very
bright
and
hot.
Sparks
fly,
fumes
rise,
ultraviolet
and
in
frared
energy
radiates,
weldments
are
hot,
and
com
pressed
gases
may
be
used.
The
wise
operator
avoids
unnecessary
risks and
protects
himself and others
from
accidents.
Precautions
are
described
here and
in
stan
dards
referenced
in
index.
A.
Burn
Protection
Comply
with
precautions
in 1-2.
The
welding
arc
is
intense and
visibly
bright,
Its
radiation
can
damage
eyes,
penetrate
lightweight
clothing,
reflect
from
light-colored
surfaces,
and
burn the skin and
eyes.
Skin
burns
resemble
acute
sunburn,
those from
gas-
shielded
arcs are
more
severe
and
painful.
DONT
GET
BURNED;
COMPLY
WITH
PRECAUTIONS.
1.
Protective
Clothing
Wear
long-sleeve
clothing (particularly
for
gas-shielded
arc)
in
addition
to
gloves,
hat,
and
shoes
(1
-2A).
As
nec
essary,
use
additional
protective
clothing
such
as
leather
jacket
or
sleeves,
flame-proof
apron,
and
I
ire-re
sistant
leggings.
Avoid
outer
garments
of untreated
cot
ton.
Bare skin
protection.
Wear
dark,
substantial
clothing.
Button
collar
to
protect
chest
and
neck and button
pock
ets to
prevent
entry
of
sparks.
2.
Eye
and
Head
Protection
Protect
eyes
from
exposure
to
arc.
NEVER
look
at
an
electric
arc
without
protection.
Welding
helmet
or
shield
containing
a
filler
plate
shade
no.
12
or
denser
must
be
used
when
welding.
Place
over
face
before
striking
arc.
Protect
filter
plate
with
a
clear
cover
plate.
Cracked
or
broken
helmet
or
shield should NOT
be
worn;
radiation
can
pass
through
to
cause
burns.
Cracked,
broken,
or
loose
filter
plates
must
be
replaced
IMMEDIATELY.
Replace
clear
cover
plate
when
broken,
pitted,
or
spattered.
Flash
goggles
with
side shields
MUST
be
worn
under
the
helmet
to
give
some
protection
to
the
eyes
should
the
helmet
not
be
lowered
over
the face
before
an
arc
is
struck.
Looking
at
an
arc
momentarily
with
unprotected
eyes (particularly
a
high
intensity
gas-shielded arc)
can
cause
a
retinal
burn
that
may
leave
a
permanent
dark
area
in
the
field
of
vision.
3.
Protection
of
Nearby
Personnel
Enclosed
welding
area.
For
production welding,
a
sepa
rate
room
or
enclosed
bay
is
best.
In
open
areas,
sur
round
the
operation
with
low-reflective,
non-combusti
ble
screens
or
panels.
Allow
for
free
air
circulation,
par
ticularly
at
floor
level.
Viewing
the weld. Provide
face
shields
for
all
persons
who
will
be
looking directly
at
the
weld.
Others
working
in
area.
See
that all
persons
are
wearing
flash
goggles.
Before
starting
to
weld,
make
sure
that
screen
flaps
or
bay
doors
are
closed.
B.
Toxic Fume Prevention
Comply
with
precautions
in
1
-2B.
Generator
engine
exhaust
must
be
vented
to
the
outside
air.
Carbon
monoxide
can
kill.
C.
Fire and
Explosion
Prevention
Comply
with
precautions
in
1-2G.
Equipments
rated
capacity.
Do
not
overload
arc
welding
equipment.
It
may
overheat
cables
and
cause
a
fire.
Loose
cable connections
may
overheat
or
flash
and
cause
a
fire.
Never
strike
an arc on a
cylinder
or
other
pressure
ves
sel.
It creates
a
brittle
area
that
can
cause
a
violent
rup
ture
or
lead
to
such
a
rupture
under
rough
handling.
D.
Compressed
Gas
Equipment
Comply
with
precautions
in
1
-2D.
E.
Shock
Prevention
Exposed
hot
conductors
or
other
bare
metal in
the
weld
ing
Circuit,
or
in
ungrounded,
electrically-HOT
equip
ment
can
fatally
shock
a
person
whose
body
becomes
a
conductor.
DO NOT
STAND,
SIT,
LIE,
LEAN
ON,
OR
TOUCH
a
wet
surface when
welding,
without
suitable
protection.
To
protect
against
shock:
Wear
dry
insulating
gloves
and
body
protection.
Keep
body
and
clothing
dry.
Never
work
indamp
area without
adequate
insulation
against
electrical
shock.
Stay
on
a
dry
duckboard,
or
rubber
mat
when
dampness
or sweat
can
not
be
avoided.
Sweat,
sea
water,
or moisture
be
tween
body
and
an
electrically
HOT
part
or
grounded
metal
reduces
the electrical
resistance,
and
could
en
able
dangerous
and
possibly
lethal
currents
to
flow
through
the
body.
A
voltage
will
exist
between the
electrode
and
any
con
ducting
object
in
the
work
circuit.
Examples
of
conduct
ing
objects
include,
but
are
not limited
to,
buildings,
elec
trical
tools,
work
benches,
welding
power
source
cases,
workpieces,
etc.
Never touch
the
electrode
and
any
metal
object
unless
the
weldIng
power
source
Is
off.
1.
Grounding
the
Equipment
Arc
welding equipment
must
be
grounded
according
to
the
National
Electrical
Code,
and
the
work
must
be
grounded
according
to
ANSI
Z49.1
Safety
In
Welding
And
Cutting.
When
installing,
connect
the
frames
of
each unit
such
as
welding
power
source,
control,
worktable,
and
water
cir
culatorto
the
building
ground.
Conductors
must
be
ade
quate
to
carry
ground
currents
safely. Equipment
made
121 989
Page
4

electrically
HOT
by
stray
current
may
shock,
possibly
fa
tally.
Do
NOT
GROUND to
electrical
conduit,
or
to
a
pipe
carrying
ANY
gas
or
flammable
liquid
such
as
oil
or
fuel.
Three-phase
connection.
Check
phase requirements
of
equipment
before
installing.
If
only 3-phase
power
is
available,
connect
single-phase
equipment
to
only
two
wires
of the
3-phase
line. Do
NOT
connect
the
equip
ment
ground
lead
to
the
third
(live)
wire,
or
the
equip
ment
will
become
electrically
HOT-a
dangerous
condi
tion that
can
shock,
possibly
fatally.
Before
welding,
check
ground
for
continuity.
Be
sure
conductors
are
touching
bare
metal of
equipment
frames
at
connections.
If
a
line
cord with
a
ground
lead
is
provided
with
the
equipment
for
connection
to
a
switchbox,
connect
the
ground
lead
to
the
grounded
switchbox. If
a
three-prong
plug
is
added for
connection
to
a
grounded
mating
re
ceptacle,
the
ground
lead
must
be
connected
to
the
ground
prong
only.
If
the
line
cord
comes
with
a
three-
prong
plug,
connect
to
a
grounded
mating
receptacle.
Never
remove
the
ground
prong
from
a
plug,
or
use a
plug
with
a
broken
off
ground
prong.
2.
Electrode
Holders
Fully
insulated
electrode holders
should
be
used. Do
NOT
use
holders with
protruding
screws.
3.
Connectors
Fully
insulated
lock-type
connectors
should
be
used
to
join
welding
cable
lengths.
4.
Cables
Frequently
inspect
cables
for
wear,
cracks
and
damage.
IMMEDIATELY
REPLACE
those with
excessively
worn
or
damaged
insulation
to
avoid
possibly-lethal
shock
from
bared
cable.
Cables
with
damaged
areas
may
be
taped
to
give
resistance
equivalent
to
original
cable.
Keep
cable
dry,
free of
oil
and
grease,
and
protected
from
hot
metal and
sparks.
5.
Terminals
And
Other
Exposed
Parts
Terminals
and
other
exposed
parts
of
electrical
units
should
have
insulating
covers
secured
before
operation.
6.
Electrode
a.
Equipment
with
output
on/off
control
(contactor)
Welding
power
sources
for
use
with
the
gas
metal
arc
welding (GMAW),
gas
tungsten
arc
welding
(GTAW)
and
similar
processes
nor
mally
are
equipped
with
devices
that
permit
on-
off
control of
the
welding
poweroutput.
When
so
equipped
the
electrode
wire
becomes
electri
cally
HOT
when
the
power
source
switch
is ON
and
the
welding
gun
switch
is
closed.
Never
touch
the
electrode
wire
or
any
conducttng
ob
ject
in
contact
with
the
electrode
circuit
unless
the
welding
power
source
is
off.
b.
Equipment
without
output
on/off
control
(no
contactor)
Welding
power
sources
used with
shielded
metal
arc
welding (SMAW)
and
similar
proc
esses
may
not
be
equipped
with
welding
power
output
on-off
control
devices.
With
such
equip
ment
the
electrode
is
electrically
HOT
when
the
power
switch
is
turned ON.
Never
touch
the
electrode
unless
the
welding
power
source
is
off.
7.
Safety
Devices
Safety
devices
such
as interlocks
and
circuit
breakers
should
not
be
disconnected
or
shunted
out.
Before
installation,
inspection,
or
service,
of
equipment,
shut OFF
all
power
and
remove
line
fuses
(or
lock
or
red-
tag
switches)
to
prevent
accidental
turning
ON
of
power.
Disconnect
all cables
from
welding
power
source,
and
pull
all 115
volts line-cord
plugs.
Do
not
open power
circuit
or
change
polarity
while
weld
ing.
If,
in
an
emergency,
it
must
be
disconnected,
guard
against
shock
burns,
or
flash from
switch
arcing.
Leaving
equipment
unattended.
Always
shut OFF
and
disconnect
all
power
to
equipment.
Power
disconnect
switch
must
be
available
near
the
welding
power
source.
F.
Protection
For
Wearers
of
ElectronIc
LIfe
Sup
port
DevIces
(Pacemakers)
Magnetic
fields from
high
currents
can
affect
pacemaker
operation.
Persons
wearing
electronic
life
support
equipment
(pacemaker)
should
consult with
their
doctor
before
going
near arc
welding,
gouging,
or
spot
welding
operations.
1-4.
STANDARDS
BOOKLET
INDEX
For
more
information,
refer
to
the
following
standards
or
their
latest
revisions
and
comply
as
applicable:
1.
ANSI
Standard
Z49.1,
SAFETY
IN
WELDING
AND
CUTTING
obtainable
from
the
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126.
2.
NIOSH,
SAFETY
AND
HEALTH
IN
ARC
WELDING
AND
GAS
WELDING
AND
CUTTING
obtainable
from
the
Superintendent
of
Documents,
U.S.
Gov
ernment
Printing
Office,
Washington,
D.C.
20402.
3.
OSHA,
SAFETY
AND
HEALTH
STANDARDS,
29CFR
1910,
obtainable
from
the
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
4.
ANSI
Standard
Z87.1,
SAFE
PRACTICES
FOR
OCCUPATION
AND
EDUCATIONAL
EYE
AND
FACE
PROTECTION
obtainable
from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
5.
ANSI
Standard
Z41.1,
STANDARD
FOR
MENS
SAFETY-TOE
FOOTWEAR
obtainable
from
the
American
National
Standards
Institute,
1430
Broad
way,
New
York,
NY
10018.
6.
ANSI
Standard
Z49.2,
FIRE
PREVENTION
IN
THE
USE
OF
CUTTING
AND
WELDING
PROCESSES
121
989
Page
5

obtainable from the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY 10018.
7.
AWS
Standard
A6.0,
WELDING
AND
CUTTING
CONTAINERS
WHICH
HAVE
HELD
COMBUS
TIBLES
obtainable
from the
American
Welding
So
ciety,
550
N.W.
LeJeurie
Rd,
Miami,
FL
33126.
8.
NFPA
Standard
51,
OXYGEN-FUEL
GAS
SYS
TEMS FOR
WELDING,.
CUTTING,
AND
ALLIED
PROCESSES
obtainable
from
the
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
9.
NFPA
Standard
70,
NATIONAL
ELECTRICAL
CODE obtainable
from the
National
Fire
Protection
Association,
Batterymarch
Park,
Qulncy,
MA
02269.
10.
NFPA
Standard
51B,
CUTTING
AND
WELDING
PROCESSES
obtainable
from
the National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
ii.
CGA
Pamphlet
P-i,
SAFE
HANDLING
OF
COM
PRESSED
GASES
IN
CYLINDERS
obtainable
from the
Compressed
Gas
Association,
1235 Jeffer
son
Davis
Highway,
Suite
501,
Arlington,
VA 22202.
12.
GSA Standard
Wii7.2,
CODE
FOR
SAFETY
IN
WELDING
AND
CUTTING
obtainable
from the
Ca
nadian
Standards
Association,
Standards
Sales,
178 Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W iR3.
13.
NWSA
booklet,
WELDING
SAFETY
BIBLIOGRA
PHY
obtainable
from
the
National
Welding
Supply
Association,
1900
Arch
Street,
Philadelphia,
PA
19103.
14.
American
Welding
Society
Standard
AWSF4.1,
RECOMMENDED
SAFE PRACTICES FOR
THE
PREPARATION
FOR
WELDING
AND
CUTTING
OF
CONTAINERS
AND
PIPING
THAT HAVE
HELD
HAZARDOUS
SUBSTANCES,
obtainable
from the
American
Welding
Society,
550 N.W. LeJeune
Rd,
Miami,
FL
33126.
15.
ANSI Standard
Z88.2,
PRACTICE
FOR
RESPIRA
TORY
PROTECTION,
obtainable from the
Ameri
can
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
SECTION
2-
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
2-1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual
and
on
various
la
bels,
tags,
and
plates
on
the unit
pertains
to
equipment
design,
installation,
operation,
maintenance,
and
troubleshooting
which
should
be
read, understood,
and
followed forthe
safe and
effective
use
of
this
equipment.
The
nameplate
of this unit
uses
international
symbols
for
labeling
the
front
panel
controls. The
symbols
also
ap
pear
at
the
appropriate
~section
in
the
text.
B.
Safety
The
installation,
operation,
maintenance,
and trouble
shooting
of
arc
welding
equipment
requires
practices
and
procedures
which
ensure
personal
safety
and the
safety
of others.
Therefore,
this
equipment
is
to
be
in
stalled,
operated,
and maintained
only by qualified
per
Sons
in
accordance
with
this
manual
and all
applicable
codes such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section 1

Safety
Rules For
Operation
Of
Arc Weld
ing
Power
Source.
2-2.
SAFETY
ALERT
SYMBOL
AND
SIGNAL
WORDS
The
following safety
alert
symbol
and
signal
words
are
usedthroughoutthis
manualtocall
attentionto
and iden
tify
different
levels of
hazard and
special
instructions.
a
a
a
This
safety
alert
symbol
is used with the
signal
words
WARNING
and
CAUTION
to
call
atten
tion
to
the
safety
statements.
WARNING
statements
identify procedures
or
practices
which
must
be followed
to
avoid
seri
ous
personal
injury
or
loss of life.
CAUTION
statements
identify procedures
or
practices
which
must
be followed
to
avoid
minor
personal
injury
or
damage
to
this
equipment.
IMPORTANT
statements
identify
special
instructions
necessary
for
the
most
efficient
operation
of this
equip
ment.
121 989
PageS

SECTION
3
SPECIFICATIONS
Table 3-1.
SpecifIcations
Wire
Welder
Model
Rated
Weld
Output
At
20%
Duty
Cycle

Max.
Open-
Circuit
Voltage
Input
At
Rated
Load
Output
60
Hz
Single-Phase
Control
Circuit
Voltage
At
Gun
Electrode
Wire
Feed
Speed
Electrode
Wire
Diameter
Capability
Weight
Amperes
At
70
Ampere
70
Amperes
At
16
Volts DC
29
115V
15
..!~.
2.2

..–~.
2
24
DC
Volts
28
to
163
1pm
(0.7
to
4.1
mpm)
.023
(0.58
mm)
.035
to
(0.89
mm)
Net
I
Ship
53
lbs.t
62
lbs.
(24
kg)
(28
kg)
68
lbs. 72
lbs.
(31
kg)
~
kg)
550
to 716
ipm
(13.8
to
17.9
mpm
90
Ampere
90
Amperes
At
18
Volts
DC
30 20
3
*
Includes
gun.
MWG-160 Gun
Ampere Rating
w~
C02
60%
Duty
Cycle
Wire
Diameter
Cable
Length
Cooling
Method
160
Amperes
.023
(0.58
mm)
to
.035
(0.89_mm)
10
ft.
(3.05
m)
Air
*Add
112
In.
(12.7
mm)
for feet.
TA.t21
485
15-1/2
In.
mm)
FIgure
3-1.
Overall
Dimensions
121
989
Page
7

3-1. VOLT-AMPERE
CURVES
(Chart
3-1)
RATED OUTPUT
The
volt-ampere
curves
show
the
minimum
and maxi
mum
voltage
and
amperage
output
capabilities
of
the
unit
from
the minimum and maximum
settings
of the
FINE
TUNING/WIRE
SPEED
control.
Chart
3-1.
Volt-Ampere
Curves
70
Ampere
Models
RANGE
Iii
4
~E~3
~
2~
~
I
~
~
I
~
~
~
~
~
I

90
Ampere
Models
3-2.
DUTY
CYCLE
A.
WIre
Welder
(Chart
3-2)
The
wire
welder
is rated
at
20
percent
duty
cycle;
there
fore,
the
unit
can
be
operated
at
rated
load
for
two
con
secutive
minutes
out
of
ten,
but it
must
idle
for the
remaining
eight
minutes
to
allow
proper
cooling.
Refer
to
the
Duty Cycle
Charts
(Chart
3-2)
to
determine
the
output
of the
welder
at
vanous
duty
cycles.
IMPORTANT:
Decreasing
welding
amperes
increases
duty cycle.
4A
CAUTION: EXCEEDING DUTY CYCLE
RATINGS
will
damage
the
wire
welder.

Do
not
exceed
indicated
duty
cycles.
Chart 3-2.
Duty
Cycle
70
Ampere
Models
 -
-
~
....

.

7
5 27
25 32
CC
50 00
9-121
475
90
Ampere
Models
20 2530
40 50607080
100
x
ou-rv
cvci~
B124
655
B.
WeldIng
Gun
The
duty
cycle
of
a
welding
gun
is the
percentage
of
a
ten
minute
period
that
a
gun
can
be
operated
at
a
given
load.
This
gun
is
rated
at
60%
duty cycle
using
C02
shielding
gas.
This
means
that
the
gun
can
be
operated
six
min
utes
out
of
every
ten
with
the
C02
shielding
gas.
The
re
maining
four
minutes the
gun
should
be
idle
to
perm~
proper cooling.
a
CAUTION:
EXCEEDING
THE
RATED
AMPERAGE
WITH
CO2
OR
FAILING
TO
REDUCE
THE
WELDING
AMPERAGE
OR
DUTY
CYCLE
WHEN
USING
A
MIXED
SHIELDING
GAS
can
result In
damage
to
the
gun.

Do
not
exceed
rated
amperage
when
using
C02.

Operate
at
30%
duty
cycle
when
using
mixed
shielding
gases
such
as
carbon
dioxide
and
argon.
5,
>
(0
0
CC
25
Co
75
SC
37 5
0
30
25
20
5
ID
5
0
Cl,
0
>
2
9-121
090
150
(0
~Th
~50
~
37.7
0
20
40
60
80 00
120
140
D.C. AMPERES
30
25
20
15
10
5
0
25
0
20
40
80
80
100
120
DC
AMPERES
9-124
648-A
121
989
Page
8

Figure
3-2.
SupplIed
Equipment
3-3.
DESCRIPTION 3-5.
PERSONAL SAFETY
EQUIPMENT
(Figure
3-3)
This
unit
is
a
single-phase,
constant
voltage,
dc
arc
welding
power
source/wire feeder.
The
wire
feed
system
is
designed
for
Gas Metal
Arc
Welding
(GMAW
or
MIG)
with
.023
to
0.25
in.
(0.58
to
0.64
mm)
hard
wire.The unit
Wear
a
welding
helmet with
a
#10
lens
to
protect
the
eyes
from the
welding
arc.
Also
wear
protective clothing,
safety glasses,
and
dry insulating gloves
to
protect
from
injury.
can
also
be
used
for Flux
Cored
Arc
Welding
(FCAW)
with
.030
in.
(0.76 mm)
and .035
in.
(0.89
mm)
flux cored
welding
wire.
The 70
Ampere
model
isusedwith
a
supplied
MWG-160
gun.
Rated
output
of
this
model
is 70
amperes,
16
volts
dc,
at
20%duty
cycle.
\
~
.,
~
The9oAmperemodelisusedwithasuppliedMWG-160
gun.
Rated
output
of this
model is
90
amperes,
18
volts
I
~
dc,
at
20%
duty cycle.
3-4.
SUPPLIED EQUIPMENT
(Figure 3-2)
Figure
3-3.
Personal
Safety
Equipment
The
following
equipment
has been
included
with the
welder:
3-6.
OPTIONAL
EQUIPMENT
1.
One
welding
gun.
A
Hardwire
Kit is
available
for
use
with
the
welder.
The
kit
equips
the welder
for
Gas
Metal
Arc
Welding
(GMAW)
2.
Five
contact
tubes.
with hard wire.
The
following
is
a
list
of
additional
equip
ment
that is
required
for
use
with
the
kit.
3.
One
work
clamp.
A.
Gas
Cylinder
4.
One,
2
lb.
(0.45
kg)
spooi
of
.023
in.
(0.58
mm)
AWS
Class
E7OS-6
steel.
Two
types
of
gas
are
generally
used
with
Gas
Metal
Arc
Welding
(GMAW)
of thin
gauge
sheet
steel.
Carbon
dioxide
(C02)
is
the
gas
recommended
for
use
with
this
5.
One,
28
minute
VHS
video
tape.
wire
welder/gun
combination.
A
mixture
of
75
percent
ar
The
welder
is
factory
equipped
with
a
7
ft.
(2.1
m)
input
gon
and
25
percent
carbon
dioxide
also
gives
favorable
results.
Obtain
a
cylinder
of
selected
welding
gas
from
power
cord with
plug.
your
supplier.
121 989
Page
9

B.
Regulator/Flowmeter
The
Regulator/flowmeters provide
a
constant
shielding
gas pressure
and flow
rate
during
the
welding
process.
Because
gases
have different
properties,
each
regula
tor/flowmeter is
designed
to
be used
with
a
specific
gas
or
mixture of
gases.
Regulator/flowmeters
cannot
be
changed
from
one
gas
to
another unless
the
proper
adapters
are
installed.
Obtain
the
proper
regulator/f
low-
meter
for the
type
of
gas
used.
C.
Gas
Hose
Measure
the distance from the
gas
cylinder
to
the wire
welder. Obtain
good quality
5/8
in.
(16
mm)
0.0.
S.A.E.
gas
hose,
and
install
5/8-18
right-hand
thread
fittings
on
both
ends of hose.
D.
Spool
Of
Wire
Selection
of the
correct
welding
wire is
important
in
Gas
Metal
Arc
Welding
(GMAW).
There
are
many
types
to
choose
from,
but certain wires
are
best
suited
for weld
ing
thin
gauge
sheet steel. The American
Welding
Sod
ety
(AWS)
classification
for
GMAW
wires
is
usually
indi
cated
on
the
label of
the
wire
spool.
Two
AWS
wire
classes
recommended
are
E7OS-6
and
E7OS-3.
The
E7OS-6
provides
a more
fluid
(wetter)
weld
puddle
and
a
flatter
bead;
however,
E7OS-3
is
acceptable
for
use
with
this welder.
E7OS-6
is the
recommended
wire for weld
ing high
strength
steel
in
auto
collision
repair
applica
tions,
and
is
supplied
with this
unit.
3-7.
CONSUMABLE/REPLACEMENT
PARTS
The
following
parts
are
subject
to
wear or
use
under
nor
mal
welding
conditions.
1.
Wire
2.
Contact tubes
3.
Nozzles
4.
Drive rolls
5. Liner
Spare
parts
are
available from
welding
equipment
dis
tributors.
SECTION
4-
INSTALLATION
4-1.
LOCATE
THE WELDER
(Figure
3-1)
a
CAUTION:
RESTRICTED
AIRFLOW
causes
overheating
and
possible damage
to
internal
parts.

Maintain
at
least 18
inches
(457mm)
of
unre
stricted
space
on
all sides
of
unit,
and
keep
underside
free of
obstructions.

Do
not
place
any
filtering
device
over
the
intake
air
passages
of this
welding
generator.
Warranty
is
void
if
any
type
of
filtering
device
is
used.
The
welder
should
be
positioned
to
provide adequate
airflow
for
cooling
during
operation
and
to
allow
room
to
open
the
access
door for
installation
and
adjustment
procedures.
The
service
life
and
efficiency
of this unit
are
reduced
when
the
unit is
subjected
to
high
levels
of
dust,
dirt,
moisture,
corrosive
vapors,
or
extreme
heat.
4-2.
INSTALL
THE WORK
CLAMP
(Figure
4-1)
A
lOft.
(3m)
work
cable with
lug
extends from the front of
the
unit.
Install the
supplied
work
clamp
onto
the
cable
as
follows:
-
1.
Turn
OFF
the
welder.
2.
Slide
one
of the
supplied
insulating
sleeves overthe
end of the
work
cable.
3.
Place the
end of the work
cable
into either
work
clamp
handle.
4.
Align
the
smaller hole
in
the handle
with
the
hole
in
the
work
cable terminal
lug.
5.
Secure
the terminal
lug
to
the
clamp
with
the
sup
plied
nut
and bolt.
6. Bend the
tabs
on
the end
of the
handle
around the
work cable.
7.
Slide
the
insulating
sleeve
on
the
cable
over
the
handle.
8.
Slide
the
remaining
insulating
sleeve
over
the
other
work
clamp
handle.
step
3
Step
TB-025
190-lA
Figure
4-1.
Work
Clamp
Installation
121
989
Page
10