Miller AUTO ARC MW 4150 User manual

~Fftr~ A.rl__
, I
44J
I
~F
I
II%W~J.
MILLER
ELECTRIC MFG.
CO.
718
S.
BOUNDS
ST.
P.O.
Box
1079
APPLETON,
WI
54912
USA
ADDITIONAL
COPY
PRICE
$145
IMPORTANT
June
1989
Read
and
understand
the
entire
contents
of
this
manual,
with
special emphasis
on
the
safety
material
throughout
the
manual,
before
installing,
operating,
or
maintaining
this
equip
ment.
This
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.
FORM:
113
336B
Effective
With
Serial
No.
JK585798
MODEL
AUTO
ARC
MW
4150
sPW1
OWN
ERS
MANUAL
NWSA
CODE
NO. 4579
PRINTED
IN
U.S.A.

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 MERCI-IAN
TABILITYAND 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.
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
ONE
YEAR
LIMITED WARRANTY
COVERAGE

Miller
Electric
Mfg.
Co.
warrants
to the
buyer
REMEDY FOR DEFECTIVE
WELDERUpon
receipt
of
any
who
purchases
this
Auto Arc Welder
(Welder)
for
personal,
defective
Welder,
Miller Electric
will,
at
its
option,
repair
or
re
familyorhouseholdpurposes(Consumer)thatthisWelderwill
place
the
defective
Welderat
its
expense,
refund
orcredit
the
be
free
from
defects in material
andworkmanship
fora
period
of
purchase
price
(less
reasonable
depreciation
based
on
actual
one
year from
the date of
purchase.
This
warranty
covers
only
use),
or
reimburse the Consumer
for the
cost
of
repair
or
re
the
original purchaser
of this Welder. Miller
Electric
does
not
placement
atan
approved
Miller Electric
warranty
station,
pro-
authorize
any
party,
including
its
authorized
distributors,
to
offer
vided that
the
purchaser
of
that
Welder
has
followed
the
proce
any
other
warranty
on
behalf
of
Miller Electric.
Upon
expiration
dure
for
obtaining
warranty
performance
set
forth below.
The
of the
warranty
period,
Miller
Electric shall have
no
further liabil-
Welder
so
repaired
or
used
as
a
replacementwill
be
shipped
to
ityrelatedtothoWelder,exceptonwarrantyclaimsmadeduring
the
purchaser
of the defective
Welder,
with
transportation
the
warranty
period, 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).
All
transportation
charges
to
Warranty
Station
or
Miller
L
Electric
must be
prepaid.

ERRATA
SHEET
AMENDMENT
TO
SECTION 11

PARTS
LIST
Amend
Parts
List
as
follows:
After
this
manual
was
printed,
refinements
in
equipment
design
occurred. This
sheet
lists
exceptions
to
data
appearing
later
In
this
manual.
AMENDMENT
TO SECTION
4-
INSTALLATION
Amend
Step
4
of
Section
4-3.
RUNNING
GEAR
INSTALLATION
4.
Secure
wheels
in
place
with
supplied
retaining rings.
Amend
Figure
4-2.
Running
Gear
Installation
Cap
Screw
Cylinder
Bracket
Two
Front
Screw
Nut
Rack
Spreader
Bar
Cap
Screw
Casters
Nut
Wheel
Retaining
Ring
Figure
42.
Running
Gear
installatIon
**
Part
No.
Replaced
With
TC.049
808-E
Quantity Description
50-11 032 524
121
614
RING,
retaining
ext
.750
shaft
x
.082
(Effw/KA775591)
50-13 052
692
135
390
AXLE,
running
gear
(Eft w/KA775591)
**First
digit
represents
page
no
-
digits following
dash
represent
item
no.
BE
SURE
TO PROVIDE
MODEL AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
2
I

RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
forany
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
equipment,
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
INTRODUCTION
3-1.
Volt-Ampere
Curves
8
3-2.
Duty
Cycle
8
3-3.
Description
8
3-4.
Supplied
Equipment
8
3-5.
Additional
Required
Equipment
9
3-6.
Optional
Equipment 10
3-7.
Consumable
Parts
10
SECTION
4
INSTALLATION
4-1.
Site Selection
10
4-2.
Transporting
Methods
10
4-3.
Running
Gear
Installation
11
4-4.
Optional
SPW-1
Panel
Installation
11
4-5.
Shielding
Gas
Installation
12
4-6.
Work Cable
Assembly
13
4-7.
Weld
Polarity
Selection
14
4-8.
MWG-200
Welding
Gun
Connections
14
4-9.
Installation
Of
Optional
Spool
Gun
15
4-10.
Welding
Wire
Spool
Installation
16
4-11.
Hub
Tension
Adjustment
16
4-12.
Electrical
Input
Connections
16
4-13.
Welding
Wire
Threading
17

Section
No.
Page
No.
SECTION
5
OPERATOR
CONTROLS
5-1.
Power Switch And
Pilot
Light
19
5-2.
ThicknessNolts Selector
19
5-3. Fine
Tuning/Wire
Speed
Control
19
5-4.
Fan-On-Demand
19
5-5.
Optional Spot
Pulse Panel
Controls
19
SECTION
6
SEQUENCE OF OPERATION
6-1.
Gas
Metal Arc
Welding (GMAW)-Continuous
And
Gas
Metal Arc
Welding-Pulsed
Arc
(GMAW-P)
20
6-2.
Gas
Metal Arc
Welding
(GMAW)-Spot
(Models
With
Optional
SPW-1
Panel
Only)
22
6-3
Shutting
Down 23
SECTION
7-
MAINTENANCE
&
TROUBLESHOOTING
7-1.
Routine Maintenance
23
7-2.
Replacing
Drive
Roll And
Wire Inlet Guide
24
7-3. Drive
Housing
Realignment
26
7-4.
Replacing
Hub
Assembly
26
7-5.
Inspecting
And
Replacing
Motor Brushes
26
7-6.
Overload
Protection 27
7-7.
Thermal
Overload Protection
27
7-8. Printed Circuit
Board
Replacement
27
7-9.
Troubleshooting
27
SECTION
8-
ELECTRICAL
DIAGRAMS
Diagram
8-1.
Circuit
Diagram
30
Diagram
8-2.
Circuit
Diagram
For
SPW-1
Panel
30
SECTION
9
WELDING
TECHNIQUES
&
TROUBLESHOOTING
9-1.
Gas
Metal
Arc
Welding (GMAW)Continuous
Seam
31
9-2.
Gas
Metal
Arc
Welding
(GMAW)-Pulsed
32
9-3.
Gas
Metal Arc
Welding (GMAW)-Spot
33
9-4.
Plug
Welds
34
9-5.
Skip
Welding
34
9-6.
Troubleshooting
The
Gas
Metal Arc
Welding
Process
34
SECTION
10
AUTO BODY
REPAIR
APPLICATION
10-1.
Pointers
For
Welding
Auto
Body
Sheet
Metal
37
10-2.
Procedure
For
Welding
Mild
Steels
37
10-3.
Procedures
For
Welding
Door
Panels
37
10-4.
How
To
Prevent
Glass
Breakage
And
Spatter
On
Windows
38
10-5.
Procedures
For
Welding
Fenders
And
Quarter
Panels
38
10-6.
Welding
Frames
And
High
Strength
(HSS)
Steels
38

Section
No.
Page
No.
SECTION
11

PARTS
LIST
Figure
11-1.
Main
Assembly
40
Figure
11-2.
Baffle,
Air
-
W/Components
42
Figure
11-3.
Drive
Assembly,
Wire
44
Figure
11-4.
Panel,
Rear
-
W/Components
45
Figure
11-5.
Panel,
Front
-
W/Components
46
Figure
11-6.
SPW
1
Spot
Panel
(Optional)
48
Figure
11-7.
Circuit
Card,
PC5O
49
Figure
11-8.
Running
Gear
50
LIST OF CHARTS
AND
TABLES
Table
3-1.
Specifications
7
Chart
3-1.
Volt-Ampere
Curves
7
Chart
3-2.
Duty
Cycle
7
Table
3-2.
Input
Conductor
And Fuse
Size
17
Table
6-1.
Suggested
Parameters For
Continuous Gas
Metal
Arc
Welding
(GMAW)
21
Table
6-2.
Checking
Weld
Parameters
23
Table
7-1.
Maintenance Schedule
23
Table
7-2.
Troubleshooting
28

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.
Safe
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 theirinstruction
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
workpleces
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 (orcutting)
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
orcontaining
materials that
emittoxic
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
onlywhile
it is
being
ventilated
and,
if
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
trichloroethylene
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
113336
Page
1

to
atmospheres
containing
even
minute
amounts
of
trichloroethylene
or
perchloroethylene.
C.
Fire
and
Explosion
Prevention
Causes
of
fire and
explosion
are:
combustibles
reached
bythe
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
fires
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
pai
nt
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)
in
floors
orwalls
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
approvalthat
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:
a
thorough
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,
andthose
detailed
in
CGA
Standard
P-1,SAFE
HANDLING
OF
COMPRESSED
GASES
IN
CYLIN
DERS,
listed
11
in
Standards
Index.
1.
Pressure
Regulators
Regulator
relief
valve
is
designed
to
protect
only
the
regulator
from
overpressure;
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
regulatorfrom
service
immediatelyfor
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.
113
336
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,
stag,
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.
Cylinderfittings
should
never
be
modified
or
exchanged.
3.
Hose
Prohibited
use.
Never
use
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
fit
tings
to
splice
hose.
Avoid
long
runs
to
prevent
kinks
and abuse.
Suspend
hose off
ground
to
keep
it from
being
run
over,
stepped
on,
or
otherwise
damaged.
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
(capfull
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
113
336
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,
weidments
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
Ieatherjacket
or
sleeves,
flame-proof
apron,
and
fire-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
filter
plate
shade
no.
12
or
denser
must
be used when
welding.
Pace
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
-2C.
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
in
damp
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,
andwater
cir
culatorto
the
building
ground.
Conductors
must
be
ade
quate
to
carry
ground
currents
safely.
Equipment
made
113
336
Page
4

electrically
HOT
by
stray
current
may
shock,
possiblyfa
tally.
Do
NOTGROUNDto electrical
conduit,
orto
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
forwear,
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
power
output.
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
conducting
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
alt
cables
from
welding
power
source,
and
pull
all 115 volts line-cord
plugs.
Do
not
open
power
circuit
or
change
polarity
while
weld
ing.
It,
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
MENS
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
113 336
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. LeJeune
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,
Qui
ncy,
MA
02269.
9.
NFPA
Standard
70,
NATIONAL
ELECTRICAL
CODE
obtainable
from the
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
10. NFPA
Standard
51B,
CUTTING
AND
WELDING
PROCESSES
obtainable
from
the
National Fire
Protection
Association,
Batterymarch
Park,
Qui
ncy,
MA
02269.
11.
CGA
Pamphlet
P-i,
SAFE HANDLING
OF COM
PRESSED GASES
IN
CYLINDERS
obtainable
fromthe
Compressed
Gas
Association,
1235
Jeffer
son
Davis
Highway,
Suite
501,
Arlington,
VA
22202.
12.
GSA
Standard
W117.2,
CODE
FOR
SAFETY
IN
WELDING AND
CUTTING
obtainable
from
the
Ca
nadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W 1R3.
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.i,
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
for the 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
used
throughout
this
manual
to
call
attention
to
and
iden
tify
different
levels
of
hazard and
special
instructions.
a
This
safety
alert
symbol
is
used
with the
signal
words
WARNING
and
CAUTION
to
call
alien
tion
to
the
safety
statements.
a
WARNING
statements
identify
procedures
or
practices
which
must
be followed
to
avoid
seri
ous
personal injury
or
loss
of
life.
a
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.
113336
Page
6

SECTION
3-
INTRODUCTION
Table
3-1.
SpecificatIons
Rated
Weld
Output
At
60%
Duty Cycle
Max.
Open-
Circuit
Voltage
input
At
Rated
Load
Output
60
Hz
Single-Phase
kw
Control
Circuit
Voltage
At
Gun
Electrode
Wire
Feed
Speed
Electrode
Wire
Diameter
Capability
At
kva 200V 230V 460V 575V
150
Amperes
At
23
Volts
DC
32 26.5 24
12 9.6
5.5
4.8
24
Volts
DC
60
to
486
1pm
(1.5
to
12.3
mpm)
.023/.025
in.
(0.6
mm)
.030
in.
10.~
mm~
.035
in.
~0.9
mmj
Dimensions
Weight
A:
Width
13-1/2
in.
(343 mm)
B:
Length
27
in.
Net
.
Ship
(686
mm)
205
lbs.
215
lbs.**
C:
Height
30
in.
(93 kg) (98
kg)
(762 mm)
*Add
2-3/4 lbs.
(1.25 kg)
for units
with
spot
~Add
5
lbs.
(2.27 kg)
for
units with
spot
TB-087
313-C
Figure
3-1.
Overall
Dimensions
Chart
3-1.
Volt-Ampere
Curves
In
.J
0
U
Chart
3-2.
Duty
Cycle
1RATED
OUTPUT
200
175
@.
150
4
U
125
-
~
~
- --
 
~-
0
25
50 75
100
125
150
DC AMPERES
6
HIGH
5
4
3
2
1
LOW
175 200
9-057
436-lA
100

30
35
40 50
60
70
00
90
100
%
DUTY CYCLE
9-057436-1
113
336
Page
7

3-1.
VOLT-AMPERE CURVES
(Chart
3-1)
3-3. DESCRIPTION
RATED
OUTPUT
The
volt-ampere
curves
show the
voltage
and
amper
age
output
capabilities
of
the
unit.
Voltage
and
amper
age
adjustment
is
provided
by
the FINE
TUNING/WIRE
SPEED
control.
Curves
of
other
setting
fall
between
the
curves
shown.
With
the
use
of
the
volt-ampere
curves,
it is
possible
to
determine
the
weld
amperage
at
any
particular
load
volt
age.
3-2.
DUTY
CYCLE
(Chart
3-2)
The
duty
cycle
is
the
percentage
of
a
ten
minute
period
that
a
welding
power
source can
be
operated
at
a
given
output
without
overheating
and
damaging
to
the
unit.
This
welding
power
source
is
rated
at
60
percent
duty
cycle
when
operated
at
150
amperes.
The
unit
can
be
operated
at
150
amperes
for
six
consecutive
minutes,
but it
must
operate
at
no
load for
the
remaining
four
min
utes to
allow
proper
cooling.
If
the
welding
amperes
de
crease,
the
duty
cycle
increases.
Refer
to
the
Duty
Cycle
chart
(Chart
3-2)
to
determine
the
output
of the
welding
power
source
at
various
duty
cycles.
a
CAUTION:
EXCEEDING
DUTY
CYCLE
RAT
INGS
wIll
damage
the
weldIng
power
source.

Do
not
exceed
indicated
duty cycles.
This
unit is
a
single-phase
constant
voltage
dc
arc
weld
ing
power
source
and
wire
feedersystem.
This unit is
de
signed
for
Gas
Metal
Arc
Welding
(GMAW)
with
short
circuit
or
spray
transfer. it is
designed
primarily
for
use
as
a
dc
Electrode
Positive/Reverse
Polarity
machine.
Rated weld
output
is
150
amperes,
23
volts
dc,
at
60%
duty
cycle.
Models
with the
optional
SPOT
PULSE
WELD
PANEL
provide
the
controls
for
regulating spot
weld
time/pulse
on
time,
bumback
time,
and
pulse
off
time.
3-4.
SUPPLIED
EQUIPMENT
(Figure
3-2)
The
following
equipment
is
supplied
with the
welding
power
source
and
requires
customer
installation
or
as
sembly:
A.
Running
gear
with
gas
cylinder
rack
and
bracket.
B.
Wall
receptacle
(200/230
volt
models
only).
C.
Work
cable,
work
clamp,
and
jack plug.
D.
MWG-200
gun
with
5/8
inch
(16mm)
nozzle
and
two
contact
tubes
for each
wire size.
E.
Drive
rolls
for
.023/.025,
.030,
and .035
in.
(0.6,
0.8,
and 0.9
mm)
hard wire.
The
welding
power
source
is
factory
equipped
with
9
ft.
(2.7
mm)
power
cord
(with
plug
on
200/230
volt
models),
gas
valve,
and
facilities
for
a
Spool
gun.
Spreader
Bar
Figure
3-2.
Supplied
Equipment
Wall
Bracket
Receptacle
113336
Page
8

3-5. ADDITIONAL
REQUIRED EQUIPMENT
(Figure
3-3)
The
additional
equipment
required
to
complete
the
Gas
Metal Arc
Welding
(GMAW)
setup
can
be
obtained
from
your
local
welding
supplies
distributor.
A.
Gas
CylInder
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
welding
power
source/gun
combination.
A
mixture of 75
percent
argon
and 25
percent
carbon dioxide
also
gives
favorable
results.
Obtain
a
cylinder
of selected
shielding
gas
from
your
supplier.
B.
Regulator/Flowmeter
Regulator/f
lowmeters
provide
a
constant
shielding
gas
pressure
and flow
rate
during
the
welding
process.
Be
cause
gases
have
different
properties,
each
regulator/
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/flow-
meter
for
the
type
of
gas
used.
C.
Gas
Hose
Measure distance
from
gas
cylinder
to
welding
power
source.
Obtain
good quality
5/8
in.
(16 mm)
outside di
ameter,
S.A.E.
gas
hose,
and
install
5/8-18
rIght
hand
thread
fittings
on
both ends of hose.
D.
Wire
Spool
For
GMAW
Process
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
Soci
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 than
E7OS-3. Obtain
a
spool
of
selected
wire.
E.
Personal
Safety
Equipment
When
using
this
welding
power
source,
wear a
welding
helmet,
fitted with
the
proper
filter
lens,
to
protect
the
eyes
from the
welding
arc.
Also
wear
protective
clothing,
safety glasses,
and
gloves
to
prevent injury.
F.
OffseVPunchlng
Tool
(Figure
3-4)
The
repair
of
automotive sheet
steel
is easier
when
an
Offset/Punching
tool is used.
This tool has
a
dual
pur
pose,
rotating
head.
The
damaged
area
is
cut
away
and
the
jaws
of
the offset
portion
of
the head
are
placed
over
the
sheet
steel.
When
pressure
is
applied
to
the
handles,
the
tool
indents
a
small
offset
in
the sheet
steel.
A
new
piece
of
sheet
steel,
cut
to
size,
is
placed
in
position
to
overlap
the
off
set
portion.
The
new
piece
of
sheet steel
is
welded
into
place,
sanded,
filled
with
body
putty,
and
finish
sanded.
The head
of
the
tool
can
be
rotated
one-half
turn
to
be
used
as a
punching
tool.
The
punching
tool
expedites
riveting
operations.
The
use
of
this toolwill
keep
material
use
and
finishing
time
to
a
minimum.
Figure
3-4.
Offset/Punching
Tool

Gas
Cylinder
Wire

Helmet
Spool
Gloves
1/~
Gas
Hose
Safety
:
Regulator!
Glasses
Figure
3-3.
Additional
Required
Equipment
113
336
Page
9

3-6.
OPTIONAL
EQUIPMENT
3-7.
CONSUMABLE
PARTS
The
following equipment
can
be
obtained
to
extend the
capabilities
of
the basic unit
or
to
suit
special applica
tions:
A.
SPW-1,
Spot,
Pulser,
Continuous
Panel
(in
cludes
three
spot
nozzles)
(for
installation
see
Section
4-3)
B.
Spoolgun
C. Gun
cable
holder
D.
25
ft
(7.6 m)
power
cord
extension
The
following
parts
are
subject
to
wear
ordamage
in
nor
mal
use:
A.
Contact
tubes
B.
Nozzles
C.
Gun
liner
D.
Drive
rolls
SECTION
4-INSTALLATION
Select
an
installation
site
which
provides
the
following:
1.
Correct
input
power
supply (see
unit
nameplate)
2.
Shielding
gas
supply
3.
Adequate
ventilation
and fresh
air
supply
4.
No
flammables
5.
A
clean
and
dry
area
6.
Proper
temperature
that
avoids
extremes
of
heat
or
cold
7.
Proper
airflow
around
unit
8.
Adequate
space
for
opening
side
access
doors
for
installation,
maintenance,
and
repair
functions.
Base
mounting
holes
provide
the
capability
to
install
and
secure
the unit
on
a
running
gear
or
in
a
permanent
loca
tion.
4A
WARNING:
FIRE
OR
EXPLOSION
can
result
from
placing
unit
on
or over
combustible
surfaces;
RESTRICTED
AIRFLOWcan
cause
overheating
and
possible
damage
to
Internal
parts.

Do
not
locate unit
over
combustible surfaces.

Maintain
at
least
18
inches
(457
mm)
of
unrestricted
space
on
all
sides of
unit,
and
keep
underside
free of obstructions.

Do
not
place
any
filtering
device
over
the
in
take air
passages
that
provide
airflow
for
cooling
this unit.
Warranty
is
void
if
any
type
of
filtering
device
is
used
at
intake
air
passages.
4-2.
TRANSPORTING
METHODS
This
welding
power
source
is
equipped
with
a
lifting
eye
for
moving
the
unit
during
installation.
Weight
capacity
of
the
lifting
eye
only
allows
for
supporting
the
welding
power
source.
4~
WARNING:
ELECTRIC
SHOCK
can
kill.

Do
not
touch
live
electrical
parts.

Disconnect
input
power
conductors
from
deenergized
supply
line
BEFORE
moving
weld
ing
power
source.
FALLING
EQUIPMENT
can
cause
serIous
personal
injury
and
equipment
damage.

Use
lifting
eye
to
lift
unit
only,
NOT
running
gear,
gas
cylinders,
or
any
other
heavy
accessories
or devices.

Use
equipmentof
adequate
capacity
to
lift
the
unit

If
lifting
or
moving
this
unit
with
lift forks
under
the
base,
be
sure
that
lift
forks
are
long
enough
to
extend
beyond
opposite
side
of
the
base.
Using
lift
forks
too
short
can
damage
internal
parts
if
tips
of the
lift
forks
penetrate
the
unit
base,
or may
cause
personal
injury
and/or
equipment
damage
if
unit
falls
off
the
lift
forks.
4-1.
SITE
SELECTION
(Figure
4-1)
18 in.
(457
mm)
TB-072
513-C
Figure
4-1.
LocatIon
113 336
Page
10

4-3.
RUNNING GEAR
INSTALLATION
(FIgure
4-2)
a
UNCONTROLLED
TILTING OR
TIPPING of
unit
can
result
In
personal
Injury
or
equip
ment
damage.

Use
equipment
of
adequate
capacity
to
lift
the
unit.

If
using
lift
forks
to
handle
this
unit,
be
sure
the
lift
forks
are
long
enough
to
extend
out
of
the
op
posite
side of the base.

Do
not
place
any
part
of the
body
under
the
unit
while
it is
suspended.
Place
blocks
underf
rame
of unit
before
installing
running
gear.
1.
Install the
two
4
in.
(102
mm)
casters
and
spreader
bar
onto
the
front
corners
of the
welding
power
source
base
as
shown
in
Figure
4-2
using
3/8
in.
hardware.
2.
Block the unit
up
securely
in
middle
to
ease
installa
tion
of
rear
wheel/gas
cylinder
rack
assembly.
3.
Slide
axle
through cylinder
rack,
and install
a
wheel
on
each end of
axle with
a
3/4
in. flat
washer
on
each
side of
wheel.
4. Secure
wheels
in
place
with
cotter
pins by
bending
both
legs
of
cotter
pin
around
the axle
in
one
direc
tion
or
by
bending
one
leg
clockwise
and the
other
Running
leg
counterclockwise
(legs
should
conform
to
con
tour
of axle
as
tightly
as
possible).
5.
Install
cylinder
rack
onto
welding
power
source
base
using
5/16-18
x
3/4
cap
screws
and
associated
hardware
(see
Figure
4-2).
6.
Remove
the
two
front
cap
screws
in
top
of
welding
power
source
wrapper
and
discard.
Install
running
gear
handle
onto wrapper
using
1/4-20
x
3/4
cap
screws
as
shown
in
Figure
4-2.
7.
Install
cylinder
bracket
onto
rear
panel
of welding
power
source
as
shown
in
Figure
4-2
using
1/4-20x
3/4
cap
screws
and
existing
holes
in
rear
panel.
8.
Install
safety
chain
onto
cylinder
bracket.
4-4.
OPTIONAL
SPW-1
PANEL
INSTALLATION
(Figure
4-3)
a
WARNING:
ELECTRIC SHOCK
can
kill.

Do
not
touch
live
electrical
parts.

Shutdown
welding
powersource,
and
discon
nect
input
power
employing
lockout/tagging
procedures
before
inspecting
or
installing.
Lockout/tagging
procedures
consist
of
removing
input
power
plug
from
receptacle, padlocking
line disconnect
switch
in
open
position,
remov
ing
fuses
from fuse
box,
or
shutting
off and red-
tagging
circuit
breaker
or
other
disconnecting
device.
Cotter
Pin
TC-049
808-C
Figure
4-2.
Running
Gear
Installation
Two
Front
Cylinder
Bracket
____4..~
~
Cap
Screw
_v__
~
Cotter
Pin
~
Safety
Chain
Flat
Washers
Flat
Washers
Nut
Washer
Spreader
Bar
Cap
Screw
Casters
Wheel
113 336
Page
11

IMPORTANT: SPW-1
Spot
Panel
will
not
provide
spot
capabilities
for the
Spool
gun.
Retain all
hardware
re
moved
during
this
procedure
for
reinstallation. All
direc
tions,
such
as
left
or
right,
are
with
respect
to
the
opera
tor
facing
the
front
panel.
1.
Remove module
cover
plate
from
upper
right-hand
corner
of
front
panel.
2.
Locate
wiring
harness
clamped
to
air
baffle.
Re
move
wiring
harness
from
first
clamp
and
carefully
pull
end
of
wiring
harness with
connectors
through
opening
in
front
panel
-
it
will
come
though
approxi
mately
2
in.
(51
mm).
Disconnect
jumpered
connector
form
plug
PLG2.
Connect
receptacle
RC55
from
SPW-1
panel
to
PLG2.
Be
sure
the
connectors
are
locked
together
(see Figure
4-3).
5. Install
SPW-1
panel
into
upper
right
corner
of
front
panel,
and
secure
using
screws
removed
in
Step
1.
a
WARNING:
PRESSURIZED CYLINDERS
can
rupture
causing
serious
personal
injury
and
loss of
life;
FALLING
CYLINDERS
can cause
serious
Injury
and
equipment damage.

Keep
cylinders
away
from
any
welding
oroth
er
electrical circuits.

Never
allow
a
welding
electrode
to
touch
any
cylinder.

Always
fasten
cylinder
securely
to
running
gear
bracket,
a
wall,
or
other
stationary
support.
B.
Reguiator/Fiowmeter
(Customer
Supplied)
(Figure 4-4)
1.
With
the
cylinder correctly
installed,
remove
cylinder
cap
(see Figure
4-4).
Stand
to
one
side
of
the
cylin
der
valve,
and
open
the
valve
slightly.
When
gas
flows from
cylinder,
close valve. This
procedure
gets
rid
of
any
dust
or
dirt that
may
have
accumulated
around
the
valve
seat.
4-5.
SHIELDING
GAS
INSTALLATION
A.
Gas
Cylinder
(Customer
Supplied)
(Figure
3-3)
Secure
gas cylinder
to
running
gear using
safety
chain
on
cylinder
bracket.
If
the
running
gear
is
not to
be
used,
chain
cylinder
to
wall
or
other
stationary
support
to
pre
vent
the
cylinder
from
falling
over
and
breaking
off
the
valve.
3.
4.
Plug
~
PLG2
Receptacle
RC55
SPw-1

Spot
Panel
FIgure
4-3.
SPW-1
Panel
Installation
Gas
Hose
Connection
(5/8-18
Male
-
Fitting Required)
co2
Installation
Gas
Hose
Connection
(5/8-18
Male
Fitting
Required)
TB-lOg
492
Figure
4-4.
Typical
Regulator/Flowmeter
Installation
113336
Page
12