Handler 125 and H-9B Gun Owner's Manual

8/7/2019 Handler 125 and H-9B Gun Owner's Manual

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OM-947 212 149H201007

Processes

Arc Welding Power Source AndWire Feeder

Description

MIG (GMAW) Welding (Optiona

Flux Cored (FCAW) Welding

Handler 125And H-9B Gun

R

File: Flux Cored (FCAW)


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Hobart Welders manufactures a full line

of welders and welding related equipment.

For information on other quality Hobart products, contact your local Hobart

distributor to receive the latest full line catalog or individual specification sheets.

To locate your nearest distributor or service agency call 1-877-Hobart1 or

visit our website at www.HobartWelders.com.

For Technical Help call 1-800-332-3281.

Thank you and congratulations on choosing Hobart. Now you can get the

job done and get it done right. We know you dont have time to do it anyother way.

This Owners Manual is designed to help you get the most out of your

Hobart products. Please take time to read the Safety precautions. They

will help you protect yourself against potential hazards on the worksite.

Weve made installation and operation quick

and easy. With Hobart you can count on years

of reliable service with proper maintenance.

And if for some reason the unit needs repair,

theres a Troubleshooting section that will help

you figure out what the problem is. The partslist will then help you to decide the exact part

you may need to fix the problem. Warranty and

service information for your particular model

are also provided.

Hobart is registered to theISO 9001 Quality SystemStandard.

Working as hard as youdo every power sourcefrom Hobart is backed bythe best warranty in thebusiness.

From Hobart to You

Hob_Thank 2009

09

Register your product a

HobartWelders.com

Protect Your Investmen


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TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols For Installation, Operation, And Maintenance 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4. California Proposition 65 Warnings 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5. Principal Safety Standards 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . . . . . . .2-1. Symboles utiliss 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2. Dangers relatifs au soudage larc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance 7. . . . .2-4. Proposition californienne 65 Avertissements 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5. Principales normes de scurit 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6. Informations relatives aux CEM 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 DEFINITIONS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1. Symbols And Definitions 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 SPECIFICATIONS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1. Specifications 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2. Duty Cycle And Overheating 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3. Volt-Ampere Curves 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 INSTALLATION 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1. Installing Work Clamp 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2. Process/Polarity Table 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3. Changing Polarity 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4. Installing Gas Supply 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5. Installing Wire Spool And Adjusting Hub Tension 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6. Serial Number And Rating Label Location 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7. Selecting A Location And Connecting Input Power For 115 VAC Model 17. . . . . . . . . . . . . . . . . . . . . . . .5-8. Installing Contact Tip And Nozzle 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-9. Threading Welding Wire 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 6 OPERATION 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Controls 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2. Operating The Gun 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3. Weld Parameter Chart 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 MAINTENANCE &TROUBLESHOOTING 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1. Routine Maintenance 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2. Overload Protection 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3. Drive Motor Protection 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4. Changing Drive Roll Or Wire Inlet Guide 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5. Replacing Gun Contact Tip 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6. Cleaning Gun Liner 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7. Replacing Gun Liner 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-8. Troubleshooting Table 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SECTION 8 ELECTRICAL DIAGRAM 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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TABLE OF CONTENTS

SECTION 9 WIRE WELDING GUIDELINES 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1. Typical FCAW Process Connections 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2. Typical MIG Process Connections 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Typical Control Settings 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-4. Holding And Positioning Welding Gun 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5. Conditions That Affect Weld Bead Shape 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6. Gun Movement During Welding 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7. Poor Weld Bead Characteristics 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-8. Good Weld Bead Characteristics 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-9. TroubleshootingExcessive Spatter 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10. Troubleshooting Porosity 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11. Troubleshooting Excessive Penetration 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-12. Troubleshooting Lack Of Penetration 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-13. Troubleshooting Incomplete Fusion 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-14. Troubleshooting Burn-Through 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-15. Troubleshooting Waviness Of Bead 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-16. Troubleshooting Distortion 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-17. Troubleshooting Guide For Semiautomatic Welding Equipment 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 PARTS LIST 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WARRANTY


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OM-947 Page 1

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USINGsom _201003

7

Protect yourself and others from injury read and follow these precautions.

1-1. Symbol Usage

DANGER! Indicates a hazardous situation which, ifnot avoided, will result in death or serious injury. Thepossible hazards are shown in the adjoining symbolsor explained in the text.

Indicates a hazardous situation which, if not avoided,could result in death or serious injury. The possiblehazards are shown in the adjoining symbols or ex-plained in the text.

NOTICE Indicates statements not related to personal injury.

. Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRICSHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-bols and related instructions below for necessary actions to avoid thehazards.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manualto call attention to and identify possible hazards. When yousee the symbol, watch out, and follow the related instructions

to avoid the hazard. The safety information given below isonly a summary of the more complete safety informationfound in the Safety Standards listed in Section 1-5. Read andfollow all Safety Standards.

Only qualified persons should install, operate, maintain, andrepair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocksor severe burns. The electrode and work circuit is

electrically live whenever the output is on. The inputpower circuit and machine internal circuits are alsolive when power is on. In semiautomatic or automaticwire welding, the wire, wire reel, drive roll housing,and all metal parts touching the welding wire areelectrically live. Incorrectly installed or improperlygrounded equipment is a hazard.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection.D Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the workor ground.

D Do not use AC output in damp areas, if movement is confined, or ifthere is a danger of falling.

D Use AC output ONLY if required for the welding process.

D If AC output is required, use remote output control if present onunit.D Additional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damplocations or while wearing wet clothing; on metal structures suchas floors, gratings, or scaffolds; when in cramped positions suchas sitting, kneeling, or lying; or when there is a high risk of unavoid-able or accidental contact with the workpiece or ground. For theseconditions, use the following equipment in order presented: 1) asemiautomatic DC constant voltage (wire) welder, 2) a DC manual(stick) welder, or 3) an AC welder with reduced open-circuit volt-age. In most situations, use of a DC, constant voltage wire welderis recommended. And, do not work alone!

D Disconnect input power or stop engine before installing orservicing this equipment. Lockout/tagout input power according toOSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install and ground this equipment according to itsOwners Manual and national, state, and local codes.

D Always verify the supply ground check and be sure that input

power cord ground wire is properly connected to ground terminal indisconnect box or that cord plug is connected to a properlygrounded receptacle outlet.

D When making input connections, attach proper grounding conduc-tor first double-check connections.

D Keep cords dry, free of oil and grease, and protected from hot metaland sparks.

D Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill.

D Turn off all equipment when not in use.D Do not use worn, damaged, undersized, or poorly spliced cables.D Do not drape cables over your body.D If earth grounding of the workpiece is required, ground it directly

with a separate cable.D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.D Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will bepresent.

D Use only well-maintained equipment. Repair or replace damagedparts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level.D Keep all panels and covers securely in place.D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.D Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverter weld-ing power sources AFTER removal of inputpower.D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Sectionbefore touching any parts.

HOT PARTS can burn.

D Do not touch hot parts bare handed.D Allow cooling period before working on equip-

ment.D To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves andclothing to prevent burns.


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OM-947 Page 2

Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.

FUMES AND GASES can be hazardous.

D Keep your head out of the fumes. Do not breathe the fumes.D If inside, ventilate the area and/or use local forced ventilation at the

arc to remove welding fumes and gases.D If ventilation is poor, wear an approved air-supplied respirator.D Read and understand the Material Safety Data Sheets (MSDSs)

and the manufacturers instructions for metals, consumables,coatings, cleaners, and degreasers.D Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch-person nearby. Welding fumes and gases can displace air andlower the oxygen level causing injury or death. Be sure the breath-ing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-erations. The heat and rays of the arc can react with vapors to formhighly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized, lead, orcadmium plated steel, unless the coating is removed from the weldarea, the area is well ventilated, and while wearing an air-suppliedrespirator. The coatings and any metals containing these elementscan give off toxic fumes if welded.

Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks fly off from theweld.

D Wear an approved welding helmet fitted with a proper shade offilter lenses to protect your face and eyes from arc rays andsparks when welding or watching (see ANSI Z49.1 and Z87.1listed in Safety Standards).

D Wear approved safety glasses with side shields under yourhelmet.

D Use protective screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistantmaterial (leather, heavy cotton, or wool) and foot protection.

ARC RAYS can burn eyes and skin.

Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flying sparks, hotworkpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode to metal objects can causesparks, explosion, overheating, or fire. Check and be sure the area issafe before doing any welding.

WELDING can cause fire or explosion.

D Remove all flammables within 35 ft (10.7 m) of the welding arc. Ifthis is not possible, tightly cover them with approved covers.

D Do not weld where flying sparks can strike flammable material.D Protect yourself and others from flying sparks and hot metal.D Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.D Watch for fire, and keep a fire extinguisher nearby.D Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.D Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (seeSafety Standards).

D Do not weld where the atmosphere may contain flammable dust,gas, or liquid vapors (such as gasoline).

D Connect work cable to the work as close to the welding area aspractical to prevent welding current from traveling long, possiblyunknown paths and causing electric shock, sparks, and firehazards.

D Do not use welder to thaw frozen pipes.

D Remove stick electrode from holder or cut off welding wire atcontact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavyshirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,from your person before doing any welding.

D After completion of work, inspect area to ensure it is free of sparks,glowing embers, and flames.

D Use only correct fuses or circuit breakers. Do not oversize or by-pass them.

D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51Bfor hot work and have a fire watcher and extinguisher nearby.

FLYING METAL or DIRT can injure eyes.

D Welding, chipping, wire brushing, and grindingcause sparks and flying metal. As welds cool,they can throw off slag.

D Wear approved safety glasses with sideshields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off shielding gas supply when not in use.D Always ventilate confined spaces or use

approved air-supplied respirator.

ELECTRIC AND MAGNETIC FIELDS (EMF)can affect ImplantedMedical Devices.

D Wearers of Pacemakers and other ImplantedMedical Devices should keep away.

D Implanted Medical Device wearers should consult their doctorand the device manufacturer before going near arc welding, spotwelding, gouging, plasma arc cutting, or induction heatingoperations.

NOISE can damage hearing.

Noise from some processes or equipment candamage hearing.

D Wear approved ear protection if noise level ishigh.

Shielding gas cylinders contain gas under highpressure. If damaged, a cylinder can explode. Sincegas cylinders are normally part of the weldingprocess, be sure to treat them carefully.

CYLINDERS can explode if damaged.

D Protect compressed gas cylinders from excessive heat, mechani-cal shocks, physical damage, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationarysupport or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits.D Never drape a welding torch over a gas cylinder.D Never allow a welding electrode to touch any cylinder.D Never weld on a pressurized cylinder explosion will result.D Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them andassociated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve.D Keep protective cap in place over valve except when cylinder is in

use or connected for use.D Use the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.

D Read and follow instructions on compressed gas cylinders,associated equipment, and Compressed Gas Association (CGA)publication P-1 listed in Safety Standards.


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OM-947 Page 3

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

D Do not install or place unit on, over, or nearcombustible surfaces.

D Do not install unit near flammables.D Do not overload building wiring be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING EQUIPMENT can injure.

D Use lifting eye to lift unit only, NOT runninggear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift andsupport unit.

D If using lift forks to move unit, be sure forks are long enough toextend beyond opposite side of unit.

D Keep equipment (cables and cords) away from moving vehicleswhen working from an aerial location.

D Follow the guidelines in the Applications Manual for the RevisedNIOSH Lifting Equation (Publication No. 94110) when manu-ally lifting heavy parts or equipment.

OVERUSE can cause OVERHEATINGD Allow cooling period; follow rated duty cycle.D Reduce current or reduce duty cycle before

starting to weld again.D Do not block or filter airflow to unit.

FLYING SPARKS can injure.

D Wear a face shield to protect eyes and face.D Shape tungsten electrode only on grinder with

proper guards in a safe location wearing properface, hand, and body protection.

D Sparks can cause fires keep flammables away.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handlingboards or parts.

D Use proper static-proof bags and boxes tostore, move, or ship PC boards.

MOVING PARTS can injure.

D Keep away from moving parts.D Keep away from pinch points such as drive

rolls.

WELDING WIRE can injure.

D Do not press gun trigger until instructed to doso.

D Do not point gun toward any part of the body,other people, or any metal when threadingwelding wire.

MOVING PARTS can injure.

D Keep away from moving parts such as fans.D Keep all doors, panels, covers, and guards

closed and securely in place.

D Have only qualified persons remove doors, panels, covers, orguards for maintenance and troubleshooting as necessary.

DReinstall doors, panels, covers, or guards when maintenance isfinished and before reconnecting input power.

READ INSTRUCTIONS.

D Read and follow all labels and the OwnersManual carefully before installing, operating, orservicing unit. Read the safety information atthe beginning of the manual and in eachsection.

D Use only genuine replacement parts from the manufacturer.D Perform maintenance and service according to the Owners

Manuals, industry standards, and national, state, and localcodes.

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment.

D Have only qualified persons familiar withelectronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-ly correct any interference problem resulting from the installa-tion.

D If notified by the FCC about interference, stop using theequipment at once.

D Have the installation regularly checked and maintained.D Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding tominimize the possibility of interference.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere withsensitive electronic equipment such ascomputers and computer-driven equipmentsuch as robots.

D Be sure all equipment in the welding area iselectromagnetically compatible.

D To reduce possible interference, keep weld cables as short aspossible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.D Be sure this welding machine is installed and grounded

according to this manual.D If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,using line filters, or shielding the work area.


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1-4. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gaseswhich contain chemicals known to the State of California tocause birth defects and, in some cases, cancer. (CaliforniaHealth & Safety Code Section 25249.5 et seq.)

Battery posts, terminals and related accessories contain leadand lead compounds, chemicals known to the State ofCalifornia to cause cancer and birth defects or otherreproductive harm. Wash hands after handling.

This product contains chemicals, including lead, known tothe state of California to cause cancer, birth defects, or otherreproductive harm. Wash hands after use.

For Gasoline Engines:

Engine exhaust contains chemicals known to the State ofCalifornia to cause cancer, birth defects, or other reproduc-tive harm.

For Diesel Engines:

Diesel engine exhaust and some of its constituents areknown to the State of California to cause cancer, birth

defects, and other reproductive harm.

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from Global Engineering Documents (phone: 1-877-413-5184, website:www.global.ihs.com).Safe Practices for the Preparation of Containers and Piping for Weldingand Cutting, American Welding Society Standard AWS F4.1, from Glob-al Engineering Documents (phone: 1-877-413-5184, website:www.global.ihs.com).National Electrical Code, NFPA Standard 70, from National Fire Protec-tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:www.nfpa.org and www. sparky.org).Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,from Compressed Gas Association, 4221 Walney Road, 5th Floor,Chanti lly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).Safety in Welding, Cutting, and Allied Processes, CSA StandardW117.2, from Canadian Standards Association, Standards Sales, 5060Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:800-463-6727, website: www.csa-international.org).Safe Practice For Occupational And Educational Eye And Face Protec-tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-site: www.ansi.org).Standard for Fire Prevention During Welding, Cutting, and Other HotWork, NFPA Standard 51B, from National Fire Protection Association,Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.OSHA, Occupational Safety and Health Standards for General Indus-try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,and Part 1926, Subpart J, from U.S. Government Printing Office, Super-

intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954(phone: 1-866-512-1800) (there are 10 OSHA Regional Officesphone for Region 5, Chicago, is 312-353-2220, website:www.osha.gov).U.S. Consumer Product Safety Commission (CPSC), 4330 East WestHighway, Bethesda, MD 20814 (phone: 301-504-7923, website:www.cpsc.gov).Applications Manual for the Revised NIOSH Lifting Equation, The Na-tional Institute for Occupational Safety and Health (NIOSH), 1600Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:www.cdc.gov/NIOSH).

1-6. EMF Information

Electr ic current flowing through any conductor causes localized electric

and magnetic fields (EMF). Welding current creates an EMF fieldaround the welding circuit and welding equipment. EMF fields may inter-fere with some medical implants, e.g. pacemakers. Protectivemeasures for persons wearing medical implants have to be taken. Forexample, access restrictions for passersby or individual risk assess-ment for welders. All welders should use the following procedures inorder to minimize exposure to EMF fields from the welding circuit:

1. Keep cables close together by twisting or taping them, or using acable cover.

2. Do not place your body between welding cables. Arrange cablesto one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep head and trunk as far away from the equipment in the

welding circuit as possible.5. Connect work clamp to workpiece as close to the weld as

possible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wirefeeder.

About Implanted Medical Devices:Implanted Medical Device wearers should consult their doctor and thedevice manufacturer before performing or going near arc welding, spotwelding, gouging, plasma arc cutting, or induction heating operations.If cleared by your doctor, then following the above procedures is recom-mended.


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SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION

fre_som_2010037

Se protger et protger les autres contre le risque de blessure lire et respecter ces consignes.

2-1. Symboles utiliss

DANGER! Indique une situation dangereuse qui si onlvite pas peut donner la mort ou des blessures graves.Les dangers possibles sont montrs par les symbolesjoints ou sont expliqus dans le texte.

Indique une situation dangereuse qui si on lvite paspeut donner la mort ou des blessures graves. Les dan-gers possibles sont montrs par les symboles joints ousont expliqus dans le texte.

NOTE Indique des dclarations pas en relation avec des blessurespersonnelles.

. Indique des instructions spcifiques.

Ce groupe de symboles veut dire Avertissement! Attention! DANGERDE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECESCHAUDES. Consulter les symboles et les instructions ci-dessous yaffrant pour les actions ncessaires afin dviter le danger.

2-2. Dangers relatifs au soudage larc

Les symboles reprsents ci-dessous sont utiliss dans ce ma-nuel pour attirer lattention et identifier les dangers possibles. Enprsence de lun de ces symboles, prendre garde et suivre lesinstructions affrentes pour viter tout risque. Les instructionsen matire de scurit indiques ci-dessous ne constituentquun sommaire des instructions de scurit plus compltesfournies dans les normes de scurit numres dans la Sec-tion 2-5. Lire et observer toutes les normes de scurit.

Seul un personnel qualifi est autoris installer, faire fonc-tionner, entretenir et rparer cet appareil.

Pendant le fonctionnement, maintenir distance toutes lespersonnes, notamment les enfants de lappareil.

UNE DCHARGE LECTRIQUE peutentraner la mort.Le contact dorganes lectriques sous tension peutprovoquer des accidents mortels ou des brluresgraves. Le circuit de llectrode et de la pice estsous tension lorsque le courant est dlivr lasortie. Le circuit dalimentation et les circuits inter-nes de la machine sont galement sous tensionlorsque lalimentation est sur Marche. Dans le modede soudage avec du fil, le fil, le drouleur, le bloc decommande du rouleau et toutes les parties mtalli-ques en contact avec le fil sont sous tensionlectrique. Un quipement install ou mis la terrede manire incorrecte ou impropre constitue undanger.

D Ne pas toucher aux pices lectriques sous tension.D Porter des gants isolants et des vtements de protection secs et

sans trous.D Sisoler de la pice couper et du sol en utilisant des housses ou

des tapis assez grands afin dviter tout contact physique avec la

pice couper ou le sol.D Ne pas se servir de source lectrique courant lectrique dans leszones humides, dans les endroits confins ou l o on risque detomber.

D Se servir dune source lectrique courant lectrique UNIQUE-MENT si le procd de soudage le demande.

D Si lutilisation dune source lectrique courant lectrique savrencessaire, se servir de la fonction de tlcommande si lappareilen est quip.

D Dautres consignes de scurit sont ncessaires dans les condi-tions suivantes : risques lectriques dans un environnementhumide ou si lon porte des vtements mouills ; sur des structuresmtalliques telles que sols, grilles ou chafaudages ; en positioncoince comme assise, genoux ou couche ; ou sil y a un risquelev de contact invitable ou accidentel avec la pice souder oule sol. Dans ces conditions, utiliser les quipements suivants,

dans lordre indiqu : 1) un poste souder DC tension constante( fil), 2) un poste souder DC manuel (lectrode) ou 3) un poste souder AC tension vide rduite. Dans la plupart des situations,lutilisation dun poste souder DC fil tension constante est re-commande. En outre, ne pas travailler seul !

D Couper lalimentation ou arrter le moteur avant de procder lin-stallation, la rparation ou lentretien de lappareil. Dverrouillerlalimentation selon la norme OSHA 29 CFR 1910.147 (voir nor-mes de scurit).

D Installer le poste correctement et le mettre la terre convenable-ment selon les consignes du manuel de loprateur et les normesnationales, provinciales et locales.

D Toujours vrifier la terre du cordon dalimentation. Vrifier etsassurer que le fil de terre du cordon dalimentation est bienraccord la borne de terre du sectionneur ou que la fiche ducordon est raccorde une prise correctement mise la terre.

D En effectuant les raccordements dentre, fixer dabord le conduc-teur de mise la terre appropri et contre-vrifier les connexions.

D Les cbles doivent tre exempts dhumidit, dhuile et de graisse;protgezles contre les tincelles et les pices mtalliqueschaudes.

D Vrifier frquemment le cordon dalimentation afin de sassurerquil nest pas altr ou nu, le remplacer immdiatement sil lest.Un fil nu peut entraner la mort.

D Lquipement doit tre hors tension lorsquil nest pas utilis.

D Ne pas utiliser des cbles uss, endommags, de grosseur insuffi-sante ou mal pisss.

D Ne pas enrouler les cbles autour du corps.D Si la pice soude doit tre mise la terre, le faire directement

avec un cble distinct.

D Ne pas toucher llectrode quand on est en contact avec la pice,la terre ou une lectrode provenant dune autre machine.

D Ne pas toucher des porte lectrodes connects deux machines

en mme temps cause de la prsence dune tension vide dou-ble.D Nutiliser quun matriel en bon tat. Rparer ou remplacer sur-le-

champ les pices endommages. Entretenir lappareil conform-ment ce manuel.

D Porter un harnais de scurit si lon doit travailler au-dessus du sol.D Sassurer que tous les panneaux et couvercles sont correctement

en place.

D Fixer le cble de retour de faon obtenir un bon contact mtal-mtal avec la pice souder ou la table de travail, le plus prs pos-sible de la soudure.

D Isoler la pince de masse quand pas mis la pice pour viter lecontact avec tout objet mtallique.

D Ne pas raccorder plus dune lectrode ou plus dun cble demasse une mme borne de sortie de soudage.


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Il reste une TENSION DC NON NGLIGEABLE dansles sources de soudage onduleur UNE FOISlalimentation coupe.D Arrter les convertisseurs, dbrancher le courant lectrique et

dcharger les condensateurs dalimentation selon les instructionsindiques dans la partie Entretien avant de toucher les pices.

LES PICES CHAUDES peuventprovoquer des brlures.

D Ne pas toucher mains nues les partieschaudes.

D Prvoir une priode de refroidissement avant detravailler lquipement.

D Ne pas toucher aux pices chaudes, utiliser les outils recomman-ds et porter des gants de soudage et des vtements pais pourviter les brlures.

LES FUMES ET LES GAZ peuventtre dangereux.

Le soudage gnre des fumes et des gaz. Leurinhalation peut tre dangereux pour votre sant.

D Eloigner votre tte des fumes. Ne pas respirer les fumes.

D lintrieur, ventiler la zone et/ou utiliser une ventilation force auniveau de larc pour lvacuation des fumes et des gaz desoudage.

D Si la ventilation est mdiocre, porter un respirateur anti-vapeursapprouv.

D Lire et comprendre les spcifications de scurit des matriaux(MSDS) et les instructions du fabricant concernant les mtaux, lesconsommables, les revtements, les nettoyants et les dgrais-seurs.

D Travailler dans un espace ferm seulement sil est bien ventil ouen portant un respirateur alimentation dair. Demander toujours un surveillant dment form de se tenir proximit. Des fumes etdes gaz de soudage peuvent dplacer lair et abaisser le niveaudoxygne provoquant des blessures ou des accidents mortels.Sassurer que lair de respiration ne prsente aucun danger.

D Ne pas souder dans des endroits situs proximit doprationsde dgraissage, de nettoyage ou de pulvrisation. La chaleur etles rayons de larc peuvent ragir en prsence de vapeurs et for-mer des gaz hautement toxiques et irritants.

D Ne pas souder des mtaux munis dun revtement, tels que laciergalvanis, plaqu en plomb ou au cadmium moins que le revte-ment nait t enlev dans la zone de soudure, que lendroit soitbien ventil, et en portant un respirateur alimentation dair. Lesrevtements et tous les mtaux renfermant ces lments peuventdgager des fumes toxiques en cas de soudage.

LES RAYONS DE LARC peuventprovoquer des brlures dans lesyeux et sur la peau.Le rayonnement de larc du procd de soudaggnre des rayons visibles et invisibles intense

(ultraviolets et infrarouges) susceptibles de provoquer des brlure

dans les yeux et sur la peau. Des tincelles sont projetes pendant lsoudage.

D Porter un casque de soudage approuv muni de verres filtrantsappropri pour protger visage et yeux pour protger votre visageet vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1et Z87.1 numr dans les normes de scurit).

D Porter des lunettes de scurit avec crans latraux mme sousvotre casque.

D Avoir recours des crans protecteurs ou des rideaux pourprotger les autres contre les rayonnements les blouissementset les tincelles ; prvenir toute personne sur les lieux de ne pasregarder larc.

D Porter des vtements confectionns avec des matires rsistan-tes et ignifuges (cuir, coton lourd ou laine) et des bottes deprotection.

LE SOUDAGE peut provoquer unincendie ou une explosion.Le soudage effectu sur des conteneurs ferms telsque des rservoirs, tambours ou des conduites peutprovoquer leur clatement. Des tincelles peuvent

tre projetes de larc de soudure. La projection dtincelles, despices chaudes et des quipements chauds peut provoquer desincendies et des brlures. Le contact accidentel de llectrode avecdes objets mtalliques peut provoquer des tincelles, une explosion,un surchauffement ou un incendie. Avant de commencer le soudage,vrifier et sassurer que lendroit ne prsente pas de danger.

D Dplacer toutes les substances inflammables une distance de10,7 m de larc de soudage. En cas dimpossibilit les recouvrirsoigneusement avec des protections homologus.

D Ne pas souder dans un endroit l o des tincelles peuvent tombersur des substances inflammables.

D Se protger et dautres personnes de la projection dtincelles etde mtal chaud.

D Des tincelles et des matriaux chauds du soudage peuventfacilement passer dans dautres zones en traversant de petitesfissures et des ouvertures.

D Surveiller tout dclenchement dincendie et tenir un extincteur proximit.

D Le soudage effectu sur un plafond, plancher, paroi ou sparation

peut dclencher un incendie de lautre ct.D Ne pas effectuer le soudage sur des conteneurs ferms tels que

des rservoirs, tambours, ou conduites, moins quils naient tprpars correctement conformment AWS F4.1 (voir les nor-mes de scurit).

D Ne soudez pas si lair ambiant est charg de particules, gaz, ou va-peurs inflammables (vapeur dessence, par exemple).

D Brancher le cble de masse sur la pice le plus prs possible de lazone de soudage pour viter le transport du courant sur unelongue distance par des chemins inconnus ventuels en provo-quant des risques dlectrocution, dtincelles et dincendie.

D Ne pas utiliser le poste de soudage pour dgeler des conduites ge-les.

D En cas de non utilisation, enlever la baguette dlectrode du porte-lectrode ou couper le fil la pointe de contact.

D Porter des vtements de protection dpourvus dhuile tels que desgants en cuir, une chemise en matriau lourd, des pantalons sansrevers, des chaussures hautes et un couvre chef.

D Avant de souder, retirer toute substance combustible de vos po-ches telles quun allumeur au butane ou des allumettes.

D Une fois le travail achev, assurezvous quil ne reste aucunetrace dtincelles incandescentes ni de flammes.

D Utiliser exclusivement des fusibles ou coupecircuits appropris.Ne pas augmenter leur puissance; ne pas les ponter.

D Une fois le travail achev, assurezvous quil ne reste aucunetrace dtincelles incandescentes ni de flammes.

D Utiliser exclusivement des fusibles ou coupecircuits appropris.Ne pas augmenter leur puissance; ne pas les ponter.

D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) etNFPA 51B pour les travaux chaud et avoir de la surveillance et unextincteur proximit.

DES PIECES DE METAL ou DESSALETES peuvent provoquer desblessures dans les yeux.

D Le soudage, lcaillement, le passage de la pice la brosse enfil de fer, et le meulage gnrent des tincelles et des particulesmtall iques volantes. Pendant la priode de refroidissement dessoudures, elles risquent de projeter du laitier.

D Porter des lunettes de scurit avec crans latraux ou un cranfacial.


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LES ACCUMULATIONS DE GAZrisquent de provoquer des blessuresou mme la mort.D Fermer lalimentation du gaz protecteur en cas

de non-utilisation.D Veiller toujours bien arer les espaces confi-

ns ou se servir dun respirateur dadductiondair homologu.

Les CHAMPS LECTROMAGNTIQUES (CEM)peuvent affecter les implants mdicaux.

D Les porteurs de stimulateurs cardiaqueset autres implants mdicaux doivent rester distance.

D Les porteurs dimplants mdicaux doivent consulterleur mdecin et le fabricant du dispositif avant de sapprocherde la zone o se droule du soudage larc, du soudagepar points, du gougeage, de la dcoupe plasmaou une opration de chauffage par induction.

LE BRUIT peut endommager loue.Le bruit des processus et des quipements peutaffecter loue.

D Porter des protections approuves pour lesoreilles si le niveau sonore est trop lev.

Des bouteilles de gaz protecteur contiennent du gazsous haute pression. Si une bouteille est endom-mage, elle peut exploser. Du fait que les bouteillesde gaz font normalement partie du procd de

soudage, les manipuler avec prcaution.

LES BOUTEILLES peuvent explosersi elles sont endommages.

D Protger les bouteilles de gaz comprim dune chaleur excessive,des chocs mcaniques, des dommages physiques, du laitier, desflammes ouvertes, des tincelles et des arcs.

DPlacer les bouteilles debout en les fixant dans un support station-naire ou dans un porte-bouteilles pour les empcher de tomber oude se renverser.

D Tenir les bouteilles loignes des circuits de soudage ou autrescircuits lectriques.

D Ne jamais placer une torche de soudage sur une bouteille gaz.

D Une lectrode de soudage ne doit jamais entrer en contact avecune bouteille.

D Ne jamais souder une bouteille pressurise risque dexplosion.

D Utiliser seulement des bouteilles de gaz protecteur, rgulateurs,tuyaux et raccords convenables pour cette application spcifique ;les maintenir ainsi que les lments associs en bon tat.

D Dtourner votre visage du dtendeur-rgulateur lorsque vousouvrez la soupape de la bouteille.

D Le couvercle du dtendeur doit toujours tre en place, sauf lorsque

la bouteille est utilise ou quelle est relie pour usage ultrieur.D Utiliser les quipements corrects, les bonnes procdures et suffi-

samment de personnes pour soulever et dplacer les bouteilles.

D Lire et suivre les instructions sur les bouteilles de gaz comprim,lquipement connexe et le dpliant P-1 de la CGA (CompressedGas Association) mentionn dans les principales normes de scu-rit.

2-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance

Risque DINCENDIE OUDEXPLOSION.D Ne pas placer lappareil sur, au-dessus ou

proximit de surfaces inflammables.D Ne pas installer lappareil proximit de pro-

duits inflammables.

D Ne pas surcharger linstallation lectrique sassurer quelalimentation est correctement dimensionne et protge avantde mettre lappareil en service.

LA CHUTE DE LQUIPEMENT peutprovoquer des blessures.D Utiliser lanneau de levage uniquement pour

soulever lappareil, NON PAS les chariots, lesbouteilles de gaz ou tout autre accessoire.

D Utiliser un quipement de levage de capacitsuffisante pour lever lappareil.

D En utilisant des fourches de levage pour dplacer lunit, sassu-rer que les fourches sont suffisamment longues pour dpasserdu ct oppos de lappareil.

D Tenir lquipement (cbles et cordons) distance des vhiculesmobiles lors de toute opration en hauteur.

D Suivre les consignes du Manuel des applications pour lquationde levage NIOSH rvise (Publication N94110) lors du levagemanuelle de pices ou quipements lourds.

LEMPLOI EXCESSIF peutSURCHAUFFER LQUIPEMENT.D Prvoir une priode de refroidissement ; res-

pecter le cycle opratoire nominal.D Rduire le courant ou le facteur de marche

avant de poursuivre le soudage.

D Ne pas obstruer les passages dair du poste.

LES TINCELLES PROJETESpeuvent provoquer des blessures.

D Porter un cran facial pour protger le visage etles yeux.

D Affter llectrode au tungstne uniquement lmeuleuse dote de protecteurs. Cette

manuvre est excuter dans un endroit srlorsque lon porte lquipement homologu deprotection du visage, des mains et du corps.

D Les tincelles risquent de causer un incendie loigner toute sub-stance inflammable.

LES CHARGES LECTROSTATI-QUES peuvent endommager les cir-cuits imprims.

D tablir la connexion avec la barrette de terreavant de manipuler des cartes ou des pices.

D Utiliser des pochettes et des botes antista-tiques pour stocker, dplacer ou expdier descartes de circuits imprimes.


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Les PICES MOBILES peuventcauser des blessures.D Ne pas sapprocher des organes mobiles.D Ne pas sapprocher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuventprovoquer des blessures.D Ne pas appuyer sur la gchette avant den

avoir reu linstruction.D Ne pas diriger le pistolet vers soi, dautres

personnes ou toute pice mcanique enengageant le fil de soudage.

Les PICES MOBILES peuventcauser des blessures.D Sabstenir de toucher des organes mobiles tels

que des ventilateurs.D Maintenir ferms et verrouills les portes,

panneaux, recouvrements et dispositifs deprotection.

D Lorsque cela est ncessaire pour des travaux dentretien et dedpannage, faire retirer les portes, panneaux, recouvrements

ou dispositifs de protection uniquement par du personnel qua-lifi.D Remettre les portes, panneaux, recouvrements ou dispositifs de

protection quand lentretien est termin et avant de rebrancherlalimentation lectrique.

LIRE LES INSTRUCTIONS.

D Lire et appliquer les instructions sur lestiquettes et le Mode demploi avant linstal-lation, lutilisation ou lentretien de lappareil.Lire les informations de scurit au dbut dumanuel et dans chaque section.

D Nutiliser que les pices de rechange recommandes par leconstructeur.

D Effectuer lentretien en respectant les manuels dutilisation, lesnormes industrielles et les codes nationaux, dtat et locaux.

LE RAYONNEMENT HAUTEFRQUENCE (H.F.) risque deprovoquer des interfrences.

D Le rayonnement haute frquence (H.F.) peutprovoquer des interfrences avec les qui-pements de radionavigation et de com-munication, les services de scurit et les ordi-nateurs.

D Demander seulement des personnes qualifies familiarisesavec des quipements lectroniques de faire fonctionner linstalla-

tion.D Lutilisateur est tenu de faire corriger rapidement par un lectricien

qualifi les interfrences rsultant de linstallation.D Si le FCC signale des interfrences, arrter immdiatement lap-

pareil.D Effectuer rgulirement le contrle et lentretien de linstallation.D Maintenir soigneusement ferms les portes et les panneaux des

sources de haute frquence, maintenir les clateurs une distan-ce correcte et utiliser une terre et un blindage pour rduire lesinterfrences ventuelles.

LE SOUDAGE LARC risque deprovoquer des interfrences.

D Lnergie lectromagntique risque deprovoquer des interfrences pour lquipementlectronique sensible tel que les ordinateurs etlquipement command par ordinateur tel queles robots.

D Veiller ce que tout lquipement de la zone de soudage soitcompatible lectromagntiquement.

D Pour rduire la possibilit dinterfrence, maintenir les cbles desoudage aussi courts que possible, les grouper, et les poseraussi bas que possible (ex. par terre).

D Veiller souder une distance de 100 mtres de tout quipe-ment lectronique sensible.

D Veiller ce que ce poste de soudage soit pos et mis la terreconformment ce mode demploi.

D En cas dinterfrences aprs avoir pris les mesures prcden-tes, il incombe lutilisateur de prendre des mesures suppl-mentaires telles que le dplacement du poste, lutilisation de c-

bles blinds, lutilisation de filtres de ligne ou la pose de protec-teurs dans la zone de travail.

2-4. Proposition californienne 65 Avertissements

Les quipements de soudage et de coupage produisent desfumes et des gaz qui contiennent des produits chimiquesdont ltat de Californie reconnat quils provoquent des mal-formations congnitales et, dans certains cas, des cancers.(Code de sant et de scurit de Californie, chapitre 25249.5et suivants)

Les batteries, les bornes et autres accessoires contiennentdu plomb et des composs base de plomb, produits chimi-ques dont ltat de Californie reconnat quils provoquent des

cancers et des malformations congnitales ou autresproblmes de procration. Se laver les mains aprs manipu-lation.

Ce produit contient des produits chimiques, notamment duplomb, dont ltat de Californie reconnat quils provoquent

des cancers, des malformations congnitales ou dautresproblmes de procration. Se laver les mains aprsutilisation.

Pour les moteurs essence :

Les gaz dchappement des moteurs contiennent des pro-duits chimiques dont ltat de Californie reconnat quilsprovoquent des cancers et des malformations congnitalesou autres problmes de procration.

Pour les moteurs diesel :

Les gaz dchappement des moteurs diesel et certains deleurs composants sont reconnus par ltat de Californie com-me provoquant des cancers et des malformationscongnitales ou autres problmes de procration.


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OM-947 Page 9

2-5. Principales normes de scuritSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,de Global Engineering Documents (tlphone : 1-877-413-5184, siteInternet : www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Weldingand Cutting, American Welding Society Standard AWS F4.1, de GlobalEngineering Documents (tlphone : 1-877-413-5184, site internet :www.global.ihs.com).National Electrical Code, NFPA Standard 70, de National Fire Protec-tion Association, Quincy, MA 02269 (tlphone : 800-344-3555, site

Internet : www.nfpa.org et www.sparky.org).Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan-tilly, VA 20151 (tlphone : 703-788-2700, site Internet :www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA StandardW117.2, de Canadian Standards Association, Standards Sales, 5060Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (tlphone :800-463-6727, site internet : www.csa-international.org).Safe Practice For Occupational And Educational Eye And Face Protec-tion, ANSI Standard Z87.1, de American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (tlphone : 212-642-4900,site Internet : www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other HotWork, NFPA Standard 51B, de National Fire Protection Association,P.O. Box 9101, Quincy, MA 02269-9101 (tlphone : 617-770-3000,site Internet : www.nfpa.org).

OSHA, Occupational Safety and Health Standards for GeneralIndustry, Title 29, Code of Federal Regulations (CFR), Part 1910,Subpart Q, and Part 1926, Subpart J, de U.S. Government Printing

Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA15250-7954 (tlphone : 1-866-512-1800) (il y a 10 bureauxrgionauxle tlphone de la rgion 5, Chicago, est 312-353-2220, siteInternet : www.osha.gov).

U.S. Consumer Product Safety Commission (CPSC), 4330 East WestHighway, Bethesda, MD 20814 (tlphone : 301-504-7923, site inter-net : www.cpsc.gov).Applications Manual for the Revised NIOSH Lifting Equation, TheNational Institute for Occupational Safety and Health (NIOSH), 1600Clifton Rd, Atlanta, GA 30333 (tl[hone : 1-800-232-4636, site internet:www.cdc.gov/NIOSH).

2-6. Informations relatives aux CEM

Le courant lectrique qui traverse tout conducteur gnre des champslectromagntiques (CEM) certains endroits. Le courant de soudage

cre un CEM autour du circuit et du matriel de soudage. Les CEMpeuvent crer des interfrences avec certains implants mdicauxcomme des stimulateurs cardiaques. Des mesures de protection pourles porteurs dimplants mdicaux doivent tre prises: par exemple, desrestrictions daccs pour les passants ou une valuation individuelledes risques pour les soudeurs. Tous les soudeurs doivent appliquer lesprocdures suivantes pour minimiser lexposition aux CEM provenantdu circuit de soudage:

1. Rassembler les cbles en les torsadant ou en les attachant avecdu ruban adhsif ou avec une housse.

2. Ne pas se tenir au milieu des cbles de soudage. Disposer lescbles dun ct et distance de loprateur.

3. Ne pas courber et ne pas entourer les cbles autour de votrecorps.

4. Maintenir la tte et le torse aussi loin que possible du matriel ducircuit de soudage.

5. Connecter la pince sur la pice aussi prs que possible de lasoudure.

6. Ne pas travailler proximit dune source de soudage, nisasseoir ou se pencher dessus.

7. Ne pas souder tout en portant la source de soudage ou ledvidoir.

En ce qui concerne les implants mdicaux :

Les porteurs dimplants doivent dabord consulter leur mdecin avantde sapprocher des oprations de soudage larc, de soudage parpoints, de gougeage, du coupage plasma ou de chauffage par induc-tion. Si le mdecin approuve, il est recommand de suivre lesprocdures prcdentes.


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SECTION 3 DEFINITIONS

3-1. Symbols And Definitions

A Amperage V Voltage Hz Hertz NegativePositive Direct Current(DC) Single Phase Input

Output Voltage Input Off On

Do Not SwitchWhile Welding

Gas Metal ArcWelding (GMAW) Wire Feed

Flux Cored ArcWelding (FCAW)

SECTION 4 SPECIFICATIONS4-1. Specifications

Rated WeldingOutput AmperageRange

Maximum Open-Circuit Voltage

DC

Amperes Input at

Rated Load Output115 V, 60 Hz, Single-Phase

KVA KW WeightW/ Gun OverallDimensions

85 A @ 17.5 VoltsDC, 20% Duty Cycle

60 A @ 20 Volts DC,20% Duty Cycle*

30 125 2620

15*

2.90

2.20*

2.50

1.77*

50 lb(22.7 kg)

Length: 16-7/8 in.(429 mm)

Width: 9-7/8 in.(251 mm)

Height: 12-1/8 in.(308 mm)

Wire TypeAnd Dia

Flux Cored Solid/ Stainless** Wire Feed Speed Range

.030 .035 in.(0.8 0.9 mm)

.024 .030 in.(0.6 0.8 mm)

0 500 IPM (0 13 m/min) At No Load0 415 IPM (0 11 m/min) Feeding Wire

* CSA Rating** When shielding gas is required, MIG conversion kit 195 158 must be installed.


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4-2. Duty Cycle And Overheating

duty1 4/95210 517-B

Duty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating.

If unit overheats, thermostat(s)opens, output stops, and coolingfan runs. Wait fifteen minutes forunit to cool. Reduce amperage orduty cycle before welding.

NOTICE Exceeding duty cycle

can damage unit or gun and voidwarranty.

Overheating

0

15

A or V

ORReduce Duty Cycle

Minutes

20% duty cycle at 85 amps

2 Minutes Welding 8 Minutes Resting

OutputAmperes

Duty Cycle %1 4 10 20 40 60 1002 6 808

10

20

40

6080

100

200

135

4-3. Volt-Ampere Curves

The volt-ampere curves show theminimum and maximum voltageand amperage output capabilities ofthe welding power source. Curvesof other settings fall between thecurves shown.

ssb1.1 10/91210 518-B

8

10

12

14

16

18

20

22

24

26

28

0 10 20 30 40 50 60 70 80 90 100 110 120 130

Volt

age

Amperage

Range 1Range 2Range 3Range 4


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SECTION 5 INSTALLATION5-1. Installing Work Clamp

1 Nut2 Work Cable From Unit3 Work Clamp4 Screw5 Work Clamp Tabs

Bend tabs around work cable.6 Insulator Grip

Slide one insulating grip over workcable before connecting to clamp.

Slide insulating grips over handles.

Ref. 802 456

. Connection hardware must be tightened with proper tools. Do not justhand tighten hardware. A loose electrical connection will cause poorweld performance and excessive heating of the work clamp.

1

2

3

45

Tools Needed:

7/16 in.

6

7/16 in.


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5-2. Process/Polarity Table

Process PolarityCable Connections

Cable To Gun Cable To Work Clamp

FCAW Self-shielding wire no shielding gas

DCEN Straight Polarity Connect to negative ()output terminal

Connect to positive (+) outputterminal

GMAW* Solid wire withshielding gas

DCEP Reverse polarity Connect to positive (+) out-put terminal

Connect to negative () outputterminal

* Unit must have MIG conversion kit 195 158 installed.

5-3. Changing Polarity

1 Lead Connections For DirectCurrent Electrode Negative(DCEN)

2 Lead Connections For DirectCurrent Electrode Positive(DCEP)

Always read and follow wiremanufacturers recommended po-larity, and see Section 5-2.

Close door.

Ref. 210 428

1 2


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5-4. Installing Gas Supply

. This Section only applies to MIG units or units equipped with MIG kit.

Obtain gas cylinder and chain to running

gear, wall, or other stationary support socylinder cannot fall and break off valve.

1 Cap

2 Cylinder Valve

Remove cap, stand to side of valve, andopen valve slightly. Gas flow blows dustand dirt from valve. Close valve.

3 Cylinder

4 Regulator/Flowmeter

Install regulator/flowmeter to cylinder

valve. Be sure that gauge face is vertical forviewing and adjusting.

5 Regulator/Flowmeter Gas HoseConnection

6 Welding Power Source Gas HoseConnection

Connect gas hose betweenregulator/flowmeter gas hose connection,and fitting on rear of welding power source.

7 Flow Adjust

Turn flow adjust screw to increase ordecrease gas flow. Flow rate should be setwhen gas is flowing through welding powersource and welding gun. Turn Rangeswitch to Purge or Fan Only position. Pressgun trigger to start gas flow. Typical flowrate is 20 cfh (cubic feet per hour). Checkwire manufacturers recommended flowrate.

Tools Needed:

802 028 / Ref. 803 379-A

11/16, 1-1/8 in.

6

4

57

1

2

3

ShieldingGas


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5-5. Installing Wire Spool And Adjusting Hub Tension

When a slight force is neededto turn spool, tension is set.

1/2 in.

Tools Needed:

Ref. 802 971-C / 803 012 / 803 013 -B

Installing 8 in. (203 mm) Wire Spool

Installing 4 in. (102 mm) Wire Spool

When a slight force is neededto turn spool, tension is set.

Retaining ring used

with 8 in. (203 mm)spool only.

Adapter used with8 in. (203 mm)

spool only.

. Only applies to units equipped withoptional hub kit.


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5-6. Serial Number And Rating Label LocationThe serial number and rating information for this product is located on back. Use rating label to determine input power requirements and/or rated output.For future reference, write serial number in space provided on back cover of this manual.

5-7. Selecting A Location And Connecting Input Power For 115 VAC Model

1 Grounded Receptacle

A 115 volt, 20 ampere individualbranch circuit protected by time-de-lay fuses or circuit breaker is re-quired.

2 Plug From Unit

Select extension cord of 12 AWGfor up to 50 ft (15 m) or 10 AWG for50 up to 100 ft (30 m).

! Special installation may berequired where gasoline orvolatile liquids are present see NEC Article 511 or CECSection 20.

803 443-C

! Do not move or operate unitwhere it could tip.

18 in.

(460 mm)

18 in.(460 mm)

1

2


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5-8. Installing Contact Tip And Nozzle

Tools Needed:

Ref. 804 241-A

! Turn off welding power source.1 Nozzle

Remove nozzle.

2 Contact Tip

3 Tip Adapter

Thread welding wire through gun (seeSection 5-9).

Slide contact tip over wire and tightentip into tip adapter.

Install nozzle.1

2 3

Flux Nozzle MIG NozzleUse with flux cored wire only.Narrow design allows access intight spaces and provides bettervisibility of puddle during welding.

Use with solid or flux cored wire.

Push nozzle over contact tip andadapter until it is seated ontoadapter. Contact tip will beexposed approximately 7/16 in.(11.3 mm) when installed properly.

Push nozzle over contact tip andadapter until it is seated ontoadapter. End of contact tip will beflush with end of nozzle wheninstalled properly.


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5-9. Threading Welding Wire

1 Wire Spool2 Welding Wire3 Inlet Wire Guide4 Pressure Adjustment Knob5 Drive Roll6 Gun Cable

Lay gun cable out straight.

Tools Needed:

61

Pull and hold wire; cut off end.

4 in.(102 mm)

Remove gun nozzle and contact tip.

Open pressure assembly. Push wire thru guides into gun liner;continue to hold wire.

. Hold wire tightly to keep itfrom unraveling.

Ref. 803 444-A / Ref. 205 837

WOOD

Feed wire to check drive roll pressure.Tighten knob enough to prevent slipping.

Cut off wire. Close door.

Press gun trigger until wire comesout of gun.

2

Turn power on.

INPUTPOWER

6 in.(150 mm)

Tighten

Tighten

Be sure that wire is positionedin proper feed roll groove.

Close and tighten pressureassembly, and let go of wire.

Be sure that contact tip matches wire diameter.Reinstall tip adapter, if applicable, contact tipand nozzle.

3 5

4

. Tip adapter may also require removalto allow wire to feed out end of gun.

. Loosen knob completely, then rotatepressure adjustment knob in aclockwise direction until drive roll is

tight against the welding wire.Adjust drive roll pressure justtightly enough to prevent wirefrom slipping against drive rollduring operation.


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SECTION 6 OPERATION

6-1. Controls

1 Voltage Switch

Use control to select the weldvoltage range. As the thickness ofmaterial increases, a higher voltagerange must be selected (see weld

setting label in welding powersource or Section 6-3 asapplicable). Do not switch underload.

. Switch must click into detentposition for weld output.

2 Wire Feed Control

Use control to select a wire feedspeed. As Voltage switch setting in-creases, wire speed range also in-creases (see weld setting label inwelding power source or Section6-3 as applicable).

3 Power Switch

Ref. 229 999-C

3

2

1

6-2. Operating The Gun

Ref. 804 240-A

1 Trigger Switch

When pressed, energized wirefeeds and shielding gas flows (ifunit is equipped with optional gassolenoid).

1


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6-3. Weld Parameter Chart

210 428-D


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SECTION 7 MAINTENANCE &TROUBLESHOOTING

7-1. Routine Maintenance

! Disconnect powerbefore maintaining.

. Maintain more often

during severe condi-tions.

n = Check Z = Change ~ = Clean l = Replace* To be done by Factory Authorized Service Agent

Reference

3 Months

l Damaged Or Unreadable Labels l Repair Or ReplaceCracked Weld Cable

~ Clean And Tighten WeldTerminals

6 Months

OR

~ Inside Unit

7-2. Overload Protection

803 379-A

1 Supplementary Protector CB1

CB1 protects unit from overload. IfCB1 opens, unit shuts down.

Reset supplementary protector.1

7-3. Drive Motor Protection

Drive motor protection circuit protects drive motor from overload. If drive motor becomes inoperative, release guntrigger and wait until protection circuit resets allowing drive motor to feed wire again.


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7-4. Changing Drive Roll Or Wire Inlet Guide

1 Pressure Adjustment Knob2 Pressure Assembly

Pivot pressure adjustment knobdown, and lift pressure assemblyup.

3 Pivot Tube Plate4 Securing Screws5 Pressure Arm Pivot Tube

6 Inlet Wire GuideRemove screws and pivot tubeplate. Lift out pressure arm pivottube, and slide inlet wire guide out oftube.

Slide replacement wire guide intotube, and place tube back into driveassembly. Be sure tip of wire guideis as close to drive roll as possiblewithout touching.

Reinstall plate and tighten screws.

7 Retaining Knob

Rotate counterclockwise andremove knob.

8 Drive Roll

The drive roll consists of twodifferent sized grooves. Each sideis stamped with the proper size.

Select the groove that matches thewire size on the wire spool. Installdrive roll onto motor shaft so thatcorrect groove size stamp faces outaway from drive housing.

9 Retaining Knob Opening

Install retaining knob by placingopening over drive roll (openingfaces rear of unit). Rotate retainingknob clockwise to secure drive roll.

Position wire into outer groove ofdrive roll (see Section 5-9).

Tools Needed:

Ref. 802 444-B / 803 442-A

.024 Groove.030/.035VK

Groove

Stamped .024Stamped .030/.035

1

3 4

56

2

7

5/16 in.

89


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7-5. Replacing Gun Contact Tip

Tools Needed:

Ref. 804 241-A

! Turn Off power before replacingcontact tip.

1 Nozzle

Remove nozzle.

2 Contact Tip

3 Tip Adapter

Cut off welding wire at contact tip.Remove contact tip from tip adapter,and install new contact tip. Reinstallnozzle.

1

23


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7-6. Cleaning Gun Liner

804 241-A / 803 838-A

! Turn Off welding power source.1 Nozzle

2 Contact Tip

3 Adapter

HeadTube

Tools Needed:

8 mm

Lay gun cable out straight,and blow out liner.

Remove nozzle. Cut off wireat contact tip, and removecontact tip and tip adapter.

. Thread wire according toSection 5-9.

Reassemble drive coverand gun in reverse orderfrom taking it apart.

Open pressure assembly. Retractwire from liner onto spool.

. Hold wire tightly to keep itfrom unraveling. Secureend of wire at spool.

Remove screws (3) fromcover, and remove coverfrom wire drive assembly.

8 mm

1

2

3


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OM-947 Page 26

7-7. Replacing Gun Liner

Ref. 804 241-A / 803 497-A / 803 837-A / 803 899-A

Tools Needed:

8 mm / 10 mm

Remove nozzle. Cut off wireat contact tip, and removecontact tip and tip adapter.

Open pressure assembly. Retractwire from liner onto spool.

. Hold wire tightly to keep itfrom unraveling. Secureend of wire at spool.

Twist top and bottom handle locking ringscounterclockwise 1/4 turn. Slide bottom ringdown cable and top ring forward over headtube. Separate gun handle halves.

Loosen liner setscrew.

Loosen and removeretaining nut from liner.Pull liner out of guncable. If necessary, twistcable to ease removal.

! Turn Off welding power source.

Install retaining nut on one end of liner. Laygun cable straight on a flat surface. Insertbare end of liner (end without retaining nut)into wire drive end of cable. Push linertoward gun. If necessary, twist cable toease installation.

Remove screws (3) fromcover, and remove coverfrom wire drive assembly.

8 mm Remove black sleeving fromend of replacement liner.

HeadTube

8 mm

1

23


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OM-947 Page 27

7-7. Replacing Gun Liner (Continued)

When liner exits cable at gunhandle, guide liner into headtube. Continue to push liner untilit exits end of head tube.

Slide locking rings over top andbottom of handle, and secure bytwisting rings clockwise 1/4 turn.

Place other half of handle overhead tube and cable.

Be sure that cable is straight.Tighten liner setscrew. Cutliner so that 3/8 in. (10 mm)sticks out of head tube. Filedown any sharp points onliner after cutting to length.

3/8 in (10 mm)

Reassemble gun by placing head tubeand cable into one half of handle. Besure trigger is properly installed intotrigger slot.

Thread welding wire throughgun (see Section 5-9). Reinstalladapter, contact tip, and nozzle.

Reinstall cover onto wiredrive assembly, and securewith screws (3).

Insert retaining nut into adapter, and adjust liner stickout asshown. Tighten retaining nut. Reinstall cable end into drivehousing with retaining grooves inserted into the two retainingribs. Be sure to position gas hose up. Position liner in grooveso that end is flush with back of groove, adjust if necessary

13/16 in.(21 mm)

8 mm

8 mm


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7-8. Troubleshooting Table

Trouble Remedy

No weld output; wire does not feed; fandoes not run.

Secure power cord plug in receptacle (see Section 5-7).

Replace building line fuse or reset circuit breaker if open.

Place Power switch in On position (see Section 6-1).

Reset welding power source supplementary protector if open.

No weld output; wire does not feed; fanmotor continues to run.

Thermostat TP1 open (overheating). Allow fan to run with gun trigger switch off; thermostat closes whenunit has cooled (see Section 4-2).

Be sure that Voltage switch is not set between ranges (see Section 6-1).

Disassemble torch handle and check trigger switch lead connections, tighten or reconnect any looseconnections.

No weld output; wire feeds. Connect work clamp to get good metal to metal contact.

Check cable connection at work clamp and tighten hardware, if necessary (see Section 5-1).

Replace contact tip (see Section 7-5).

Check for proper polarity connections (see Section 5-3).

Low weld output. Connect unit to proper input voltage or check for low line voltage.

Place voltage switch in desired position (see Section 6-1).

If using an extension cord, check that wire size and length is the proper size for power rating of weldingpower source (see Section 4-1).

Electrode wire feeding stops duringwelding.

Straighten gun cable and/or replace damaged parts.

Adjust drive roll pressure (see Section 5-9).

Change to proper drive roll groove (see Section 7-4).

Readjust hub tension (see Section 5-5).

Replace contact tip if blocked (see Section 7-5).

Clean or replace wire inlet guide or liner if dirty or plugged (see Section 7-4).

Replace drive roll or pressure bearing if worn or slipping (see Section 7-4).

Check and clear any restrictions at drive assembly and liner (see Section 7-6).

Release gun trigger and allow gun and motor protection circuitry to reset.

Have nearest Factory Authorized Service Agent check drive motor.


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SECTION 8 ELECTRICAL DIAGRAM

230 950-A

Figure 7-1. Circuit Diagram


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SECTION 9 WIRE WELDING GUIDELINES

9-1. Typical FCAW Process Connections

! Weld current can damageelectronic parts in vehicles.Disconnect both batterycables before welding on avehicle. Place work clamp asclose to the weld as possible.

Wire Feeder/Power Source

fcaw 1/2003 / Ref. 803 444-A

Self-Shielding FluxCore Wire

Workpiece

Gun

Work Clamp

9-2. Typical MIG Process Connections

! Weld current can damageelectronic parts in vehicles.Disconnect both batterycables before welding on avehicle. Place work clamp asclose to the weld as possible.

Wire Feeder/Power Source

Regulator/Flowmeter

Gas HoseShieldingGas

light mig 5/967 / Ref. 803 444-A

Solid Wire

Workpiece

Gun

Work Clamp


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9-3. Typical Control Settings

. These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be surethey comply to specifications.

3.5 x 125 A = 437 ipm

2 x 125 A = 250 ipm

1.6 x 125 A = 200 ipm

30 90 A

40 145 A

50 180 A

Convert MaterialThickness toAmperage (A)

Material thickness determines weldparameters.

.035 in

Recommendation Wire Speed(Approx.)

1/8 or 0.125 in

(0.001 in = 1 ampere)0.125 in = 125 A

Wire Size Amperage Range

0.023 in

0.030 in

0.035 in

Select Wire Size

WireSize

0.023 in

0.030 in

0.035 in

3.5 in per ampere

2 in per ampere

1.6 in per ampere

Select Wire Speed(Amperage)

125 A based on 1/8 inmaterial thickness

ipm = inches per minute

Low voltage: wire stubs into work

High voltage: arc is unstable (spatter)

Set voltage midway between high/low voltage

Select Voltage

Ref. 803 441-C

Voltage controls height and width ofweld bead.

Wire speed (amperage) controls weldpenetration (wire speed = burn-off rate)


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9-4. Holding And Positioning Welding Gun

. Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in (13 mm)past end of nozzle, and tip of wire is positioned correctly on seam.

1 Hold Gun and Control GunTrigger

2 Workpiece3 Work Clamp4 Electrode Extension (Stickout)

1/4 to 1/2 in (6 To 13 mm)5 Cradle Gun and Rest Hand onWorkpiece

23

5

4

90 90

0-15

45

45

1

0-15

S-0421-A

End View of Work Angle Side View of Gun Angle

GROOVE WELDS

End View of Work Angle Side View of Gun Angle

FILLET WELDS


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OM-947 Page 33

9-5. Conditions That Affect Weld Bead Shape

. Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed(weld current), and voltage.

Slow

FILLET WELD ELECTODE EXTENSIONS (STICKOUT)

ELECTRODE EXTENSIONS (STICKOUT)

GUN ANGLES AND WELD BEAD PROFILES

10 10

GUN TRAVEL SPEED S-0634

Push Perpendicular Drag or Pull

Short Normal Long

Short Normal Long

Normal Fast

Electrode directedahead of bead

Electrode pointedback into bead

Direction Of Welding

. The Drag or Pull technique is generally recommended when welding with flux-cored tubular wire.


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OM-947 Page 34

9-6. Gun Movement During Welding

. Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps,a weave bead or multiple stringer beads works better.

1 Stringer Bead SteadyMovement Along Seam

2 Weave Bead Side To SideMovement Along Seam

3 Weave Patterns

Use weave patterns to cover a widearea in one pass of the electrode.

S-0054-A

3

1 2

9-7. Poor Weld Bead Characteristics

1 Large Spatter Deposits2 Rough, Uneven Bead3 Slight Crater During Welding4 Bad Overlap5 Poor Penetration

5

42 3

1

S-0053-A

9-8. Good Weld Bead Characteristics

1 Fine Spatter2 Uniform Bead3 Moderate Crater During

Welding

Weld a new bead or layer for each1/8 in (3.2 mm) thickness in metalsbeing welded.

4 No Overlap5 Good Penetration into Base

Metal

S-0052-B

2 3

1

4

5


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OM-947 Page 35

9-9. Troubleshooting Excessive Spatter

Excessive Spatter scattering of molten metal particles thatcool to solid form near weld bead.

S-0636

Possible Causes Corrective Actions

Wire feed speed too high. Select lower wire feed speed.

Voltage too high. Select lower voltage range.

Electrode extension (stickout) too long. Use shorter electrode extension (stickout).

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.

Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Dirty welding wire. Use clean, dry welding wire.

Eliminate pickup of oil or lubricant on welding wire from feeder or liner.

9-10. Troubleshooting Porosity

Porositysmall cavities or holes resulting from gas pocketsin weld metal.

S-0635


Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Remove spatter from gun nozzle.

Check gas hoses for leaks.

Place nozzle 1/4 to 1/2 in (6-13 mm) from workpiece.

Hold gun near bead at end of weld until molten metal solidifies.

Wrong gas. Use welding grade shielding gas; change to different gas.

Dirty welding wire. Use clean, dry welding wire.

Eliminate pick up of oil or lubricant on welding wire from feeder or liner.

Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.

Use a more highly deoxidizing welding wire (contact supplier).

Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

9-11. Troubleshooting Excessive Penetration

Good Penetration

Excessive Penetration weld metal melting through base metaland hanging underneath weld.

Excessive PenetrationS-0639


Excessive heat input. Select lower voltage range and reduce wire feed speed.

Increase travel speed.


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9-12. Troubleshooting Lack Of Penetration

Lack Of Penetration shallowfusion between weld metal andbase metal.

Lack of Penetration Good PenetrationS-0638


Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while

maintaining proper welding wire extension and arc characteristics.Improper weld technique. Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.

Keep arc on leading edge of weld puddle.

Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

Insufficient heat input. Select higher wire feed speed and/or select higher voltage range.

Reduce travel speed.

9-13. Troubleshooting Incomplete Fusion

Incomplete Fusion failure of weld metal to fuse completely withbase metal or a preceeding weld bead.

S-0637


Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface beforewelding.

Insufficient heat input. Select higher voltage range and/or adjust wire feed speed.

Improper welding technique. Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

Use correct gun angle of 0 to 15 degrees.

9-14. Troubleshooting Burn-Through

Burn-Throughweld metal melting completely through base metalresulting in holes where no metal remains.

S-0640


Excessive heat input. Select lower voltage range and reduce wire feed speed.

Increase and/or maintain steady travel speed.


41/48

OM-947 Page 37

9-15. Troubleshooting Waviness Of Bead

Waviness Of Bead weld metal that is not parallel and does not coverjoint formed by base metal.

S-0641


Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.

Unsteady hand. Support hand on solid surface or use two hands.

9-16. Troubleshooting Distortion

Distortion contraction of weld metal during welding that forcesbase metal to move.

Base metal movesin the direction of

the weld bead.S-0642


Excessive heat input. Use restraint (clamp) to hold base metal in position.

Make tack welds along joint before starting welding operation.

Select lower voltage range and/or reduce wire feed speed.

Increase travel speed.

Weld in small segments and allow cooling between welds.

9-17. Troubleshooting Guide For Semiautomatic Welding Equipment

Problem Probable Cause Remedy

Wire feed motor operates, butwire does not feed.

Too little pressure on wire feed rolls. Increase pressure setting on wire feed rolls.

Incorrect wire feed rolls. Check size stamped on wire feed rolls, replace to matchwire size and type if necessary.

Wire spool brake pressure too high. Decrease brake pressure on wire spool.

Restriction in the gun and/or assembly

Date post:	08-Apr-2018
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