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Handler 187 and H100S2-10 Gun Owner's Manual

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  • 8/7/2019 Handler 187 and H100S2-10 Gun Owner's Manual

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    Processes

    OM-228 187C 201004

    Handler 187

    And H100S210 Gun

    Arc Welding Power Source AndWire Feeder

    Description

    MIG (GMAW) Welding

    Flux Cored (FCAW) Welding

    R

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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 Nozzle, Contact Tip, And Adapter 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2. Installing Welding Gun 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3. Installing Work Clamp 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4. Process/Polarity Table 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5. Changing Polarity 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6. Installing Gas Supply 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7. Selecting A Location And Connecting Input Power 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8. Electrical Service Guide 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    5-9. Installing Wire Spool And Adjusting Hub Tension 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10. Threading Welding Wire 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    SECTION 6 OPERATION 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1. Controls 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2. Weld Parameter Chart 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    SECTION 7 MAINTENANCE & TROUBLESHOOTING 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1. Routine Maintenance 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2. Overload Protection 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3. Drive Motor Protection 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4. Changing Drive Roll Or Wire Inlet Guide 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5. Changing Nozzle, Contact Tip, Adapter And Liner, And Cleaning Gun Casing 26. . . . . . . . . . . . . . . . . . .7-6. Replacing Switch And/Or Head Tube 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7. Troubleshooting Table 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    SECTION 8

    ELECTRICAL DIAGRAM 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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    TABLE OF CONTENTS

    SECTION 9 MIG WELDING (GMAW) GUIDELINES 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1. Typical MIG Process Connections 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2. Typical MIG Process Control Settings 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    9-3. Holding And Positioning Welding Gun 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-4. Conditions That Affect Weld Bead Shape 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-5. Gun Movement During Welding 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-6. Poor Weld Bead Characteristics 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7. Good Weld Bead Characteristics 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-8. TroubleshootingExcessive Spatter 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-9. Troubleshooting Porosity 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10. Troubleshooting Excessive Penetration 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11. Troubleshooting Lack Of Penetration 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-12. Troubleshooting Incomplete Fusion 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-13. Troubleshooting Burn-Through 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-14. Troubleshooting Waviness Of Bead 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-15. Troubleshooting Distortion 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    9-16. Common MIG Shielding Gases 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-17. Troubleshooting Guide For Semiautomatic Welding Equipment 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    SECTION 10 PARTS LIST 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WARRANTY

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    OM-228 187 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 caneasily 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 cancause 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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    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 isproperly 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.

    D

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

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    OM-228 187 Page 4

    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 etsans trous.

    D Sisoler de la pice couper et du sol en utilisant des housses oudes 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 les

    zones 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 directementavec 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 correctementen 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.

    D

    Placer 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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    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 atRated Load Output

    230 V, 50/60 Hz,Single-Phase

    KVA KWWeightW/ Gun

    OverallDimensions

    130 A @ 21.5 VoltsDC, 30% Duty CycleAt 60 Hz Input 20%Duty Cycle At 50 Hz

    Input

    25 185 31 20.5 4.7 3.8868 lb

    (31 kg)

    Length: 19-1/2 in.(495 mm)

    Width: 10-5/8 in.(270 mm)

    Height: 12-3/8 in.(314 mm)

    Wire TypeAnd Diameter

    Solid/Stainless

    Flux Cored AluminumWire Feed Speed Range

    .023 .035 in.(0.6 0.9 mm)

    .030 .045 in.(0.8 1.2 mm)

    .030 .035 in.(0.8 0.9 mm)

    50 740 IPM (1.3 18.8 m/min) At No Load40 700 IPM (1.0 17.8 m/min) Feeding Wire

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    4-2. Duty Cycle And Overheating

    Duty Cycle is percentage of 10minutes that unit can weld at ratedload without 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

    Minutesduty1 4/95217 757-A

    30% duty cycle at 130 amps, 60 Hz20% duty cycle at 130 amps, 50 Hz

    3 Minutes Welding 7 Minutes Resting

    10 20 30 40 50 60 70 80 10010

    20

    40

    60

    80100130175200

    Duty Cycle %

    OutputAmperes

    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 10/91228 183-A

    0

    5

    10

    15

    20

    25

    30

    0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200

    12

    3456

    7

    Amperage

    Voltage

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    SECTION 5 INSTALLATION

    5-1. Installing Nozzle, Contact Tip, And Adapter

    246 669-A

    ! Turn off welding powersource.

    1 Nozzle

    2 Contact Tip

    3 Tip Adapter

    . Wire size stamped on tipcheckand match wire size.

    Tools Needed:

    8 mm

    Head

    Tube

    8 mm

    1

    32

    5-2. Installing Welding Gun

    804 621-A

    1 Drive Assembly2 Gun Securing Thumbscrew3 Gun End

    Loosen thumbscrew. Insert endthrough opening until it bottomsagainst drive assembly. Tightenthumbscrew.

    Welding gun must be insertedcompletely to prevent leakage ofshielding gas.

    4 Gun Trigger Leads

    Insert leads, one at a time, throughgun opening on front panel.Connect female friction terminals tomatching male terminals in unit.Polarity is not important.

    Close door.

    CorrectIncorrect

    . Be sure that gun end is tight against drive assembly.

    3

    Gun Fully Seated

    3

    Gun Not Seated

    Exposed O-ringswill cause shielding

    gas leakage.

    4

    1

    2

    3

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    5-3. Installing Work Clamp

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

    Bend tabs around work cable.

    6 Insulating Sleeves

    Slide one insulating sleeve overwork cable before connecting toclamp.

    Slide insulating sleeves overhandles.

    802 456-A

    . 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.

    Tools Needed:

    7/16 in.

    7/16 in.

    1

    2

    3

    45

    6

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    5-4. Process/Polarity Table

    Process PolarityCable Connections

    Cable To Gun Cable To Work

    GMAW Solid wire with shield-ing gas

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

    Connect to negative () outputterminal

    FCAW Self-shielding wire no shielding gas

    DCEN Straight Polarity Connect to negative ()output terminal

    Connect to positive (+) outputterminal

    CHANGINGPOLARITY

    5-5. Changing Polarity

    ! Turn off welding powersource.

    1 Lead Connections For DirectCurrent Electrode Negative(DCEN)

    2 Lead Connections For DirectCurrent Electrode Positive(DCEP)

    Always read and follow wiremanufacturers recommendedpolarity, and see Section 5-4.

    Close door.

    Ref. 209 228 / Ref. 209 229

    1

    2

    DCENElectrode negative for

    flux cored wire

    DCEPElectrode positive for

    solid wire

    . Connection hardware must be tightenedwith proper tools. Do not just hand tightenhardware. A loose electrical connection

    will cause poor weld performance andexcessive heating at the terminal block.

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    5-6. Installing Gas Supply

    Obtain gas cylinder and chain torunning gear, wall, or otherstationary support so cylindercannot fall and break off valve.

    1 Cap

    2 Cylinder Valve

    Remove cap, stand to side of valve,and open valve slightly. Gas flowblows dust and dirt from valve.Close valve.3 Cylinder

    4 Regulator/Flowmeter

    Install so face is vertical.

    5 Regulator/Flowmeter GasHose Connection

    6 Welding Power Source GasHose Connection

    Connect supplied gas hosebetween regulator/flowmeter gashose connection, and fitting on rearof welding power source.

    7 Flow Adjust

    Flow rate should be set when gas isflowing through welding powersource and welding gun. Openfeedhead pressure assembly sothat wire will not feed. Press guntrigger to start gas flow.

    Typical flow rate is 20 cfh (cubicfeet per hour). Check wiremanufacturers recommendedflow rate.

    After flow is set, close feedheadpressure assembly.

    Tools Needed:

    Ref. 804 654-A / 802 441 / Ref. 804 623-B

    5/8, 1-1/8 in.

    6

    Argon Gas OrMixed Gas

    . DO NOT use Argon/Mixed gas regulator/flowmeterwith CO2 shielding gas. See Parts List for optionalCO2 gas regulator/flowmeter.

    Feedhead PressureAssembly Open

    Feedhead PressureAssembly Closed

    1

    2

    3

    4

    5

    7

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    5-7. Selecting A Location And Connecting Input Power

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

    ! Installation must meet all Na-tional and Local Codes have only qualified personsmake this installation.

    ! Disconnect and lockout/tag-out input power before con-necting input conductorsfrom unit.

    ! Always connect green orgreen/yellow conductor tosupply grounding terminalfirst, and never to a line ter-minal.

    1 Rating Label

    Supply correct input power.

    2 Black And White InputConductor (L1 And L2)

    3 Green Or Green/YellowGrounding Conductor

    4 Input Power Cord.5 Disconnect Device (switch

    shown in the OFF position)6 Disconnect Device Grounding

    Terminal7 Disconnect Device Line

    Terminals

    Connect green or green/yellowgrounding conductor to disconnectdevice grounding terminal first.

    Connect input conductors L1 andL2 to disconnect device lineterminals.

    8 Receptacle (NEMA 6-50R)

    Connect receptacle as shown.

    9 Over-Current Protection

    Select type and size of over-currentprotection using Section 5-8 (fuseddisconnect switch shown).

    Close and secure door on disconnectdevice. Remove lockout/tagoutdevice, and place switch in the Onposition.

    10 Plug (NEMA 6-50P)

    Connect plug to receptacle.

    ssb2.2* 1/94804 622-B

    18 in. (457 mm) ofspace for airflow

    L1L2

    230 VAC, 1

    8

    101

    1

    =GND/PE Earth Ground

    2L1

    L2

    5

    4

    3

    6

    7

    9

    ! Do not move or operateunit where it could tip.

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    5-8. Electrical Service Guide

    Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda-tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.

    Input Voltage (V) 230

    Input Amperes (A) At Rated Output 20.5

    Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes

    Circuit Breaker 1, Time-Delay Fuses 2 25

    Normal Operating Fuses3

    30Min Input Conductor Size In AWG 14

    Max Recommended Input Conductor Length In Feet (Meters)67

    (20)

    Min Grounding Conductor Size In AWG 14

    Reference: 2008 National Electrical Code (NEC) (including article 630)1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.2 Time-Delay fuses are UL class RK5 . See UL 248.3 Normal Operating (general purpose - no intentional delay) fuses are UL class K5 (up to and including 60 amps), and UL class H ( 65 amps and

    above).4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

    310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.

    5-9. Installing Wire Spool And Adjusting Hub Tension

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

    1/2 in.

    Tools Needed:

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

    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 usedwith 8 in. (203 mm)

    spool only.

    Adapter used with8 in. (203 mm)

    spool only.

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    5-10. Threading Welding Wire

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

    Lay gun cable out straight.

    Tools Needed:

    Pull and hold wire; cut off end.

    Remove gun nozzleand contact tip.

    Open pressure assembly. Make surefeed roll is set to correct groove tomatch wire size (see Section 7-4).

    Push wire thru guides into gun;continue to hold wire.

    . Hold wire tightly to keep itfrom unraveling.

    Ref. 804 623-B / Ref. 246 669-A

    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.

    Turn power on. Be sure that Voltage rangeswitch is set to range 1, 2, 3, 4, 5, 6, or 7 tofeed wire. Rotate knob until it clicks into det-ent. Wire will not feed if range switch is setbetween ranges.

    6 in.(150 mm)

    Tighten

    1234

    . Use pressure indicatorscale to set a desireddrive roll pressure.

    PressureIndicator

    Scale

    Tighten

    1234

    Close and tighten pressure assembly,and let go of wire.

    Be sure that tip matches wire diameter.Reinstall contact tip and nozzle.

    6

    1 3

    4

    52

    Be sure that wire is positioned in proper driveroll groove and wire is laying in the groove.

    4 in.(120 mm)

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    SECTION 6 OPERATION

    6-1. Controls

    1 Wire Speed ControlUse control to select a wire feed speed. AsVoltage switch setting increases, wirespeed range also increases (see weldsetting label in welding power source orSection 6-2, as applicable).2 Power Switch

    3 Voltage Switch

    The higher the selected number, thethicker the material that can be welded(see weld setting label in welding powersource or Section 6-2, as applicable). Donot switch under load.

    . Switch must click into detentposition.

    4 Trigger Switch

    When pressed, energized wire feeds andshielding gas flows.

    Ref. 228 178-A / Ref. 246 668-A

    2

    3

    1

    4

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    Notes

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    6-2. Weld Parameter Chart

    Flux CoredE71T11

    Set Polarityfor (DCEN)

    Solid WireER70S6

    Set Polarity

    for (DCEP)

    Solid WireER70S6

    Set Polarityfor (DCEP)

    StainlessSteel

    Set Polarityfor (DCEP)

    Aluminum**Set Polarityfor (DCEP)

    Good for windy oroutdoor applications

    Produces less spatter.

    Better appearance

    ~ 1/35

    1/30

    2/40

    1/40

    3/40

    3/40

    1/30

    3/30

    3/15

    ~

    ~ ~

    ~

    ~

    ~

    ~

    ~

    ~

    ~

    ~

    ~

    ~

    ~

    ~

    ~

    CFH

    ~

    ~

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    227 010-A

    227010

    ~

    ~

    ~

    ~

    ~

    ~

    ~

    ~

    ~

    ~

    ~

    ~

    2/40

    1/25

    4/60

    3/50

    5/40

    5/40

    5/40

    4/60

    3/50

    3/30

    5/80

    5/60

    5/50

    5/60

    5/50

    5/40

    5/50

    4/35

    6/90

    6/60

    6/50

    6/80

    6/50

    6 / 40*

    6/60

    5/35

    6 / 70*

    7 / 50*

    7 / 90*

    7 / 50*

    5/40 6/40

    7/70

    7 / 40*

    7 / 50*

    7 / 60*

    6 / 35*

    7 / 80*

    7 / 60*

    7 / 50*

    7 / 40*

    1/35

    3/50

    2/50

    4/40

    3/35

    4/40

    6/604/503/40

    6/504/303/35

    7 / 50*7/405/404/30

    7/906/902/90

    7/906/902 / 100

    3/35

    ~

    ~

    ~

    1/40 2/40

    5/35

    3/25 4/25

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    SECTION 7 MAINTENANCE & TROUBLESHOOTING

    7-1. Routine Maintenance

    ! Disconnect powerbefore maintaining.

    . Maintain more oftenduring severe conditions.

    3 Months

    Replaceunreadablelabels.

    Repair orreplacecrackedweld cable.

    Clean andtighten weldterminals.

    6 Months

    Blow out or

    vacuum inside.During heavyservice, cleanmonthly.

    Or

    7-2. Overload Protection

    802 441

    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

    ! Turn off welding powersource.

    1 Inlet Wire Guide SecuringScrew

    2 Inlet Wire Guide

    Loosen screw. Slide tip as close todrive rolls as possible withouttouching. Tighten screw.

    3 Retaining Pin

    To remove drive roll, push drive rollin and rotate it (1/4 turn) to the openslot and slide it out over theretaining pin.

    To secure drive roll, locate open slotand push drive roll completely overretaining pin, then rotate drive roll(1/4 turn) to closed slot.

    4 Drive Roll

    The drive roll consists of twodifferent sized grooves. Thestamped markings on the endsurface of the drive roll refers to thegroove on the opposite side of the

    drive roll. The groove closest to themotor shaft is the proper groove tothread (see Section 5-10).

    Tools Needed:

    Ref. 803 714-A

    .023/.025 Groove.030/.035 Groove

    Stamped .024 Stamped .030/.035

    3

    1

    2

    4

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    7-5. Changing Nozzle, Contact Tip, Adapter And Liner, And Cleaning Gun Casing

    246 669-A

    ! Turn off welding powersource.

    1 Nozzle

    2 Contact Tip

    3 Tip Adapter

    . Wire size stamped on tipcheck

    and match wire size.

    Tools Needed:

    8 mm, 10 mm

    Lay gun cable outstraight beforeinstalling new liner.

    Remove nozzle,contact tip, andadapter.

    Unscrew andremove liner.

    Blow outgun casing.

    Cut off wire anddisconnect gunfrom feeder.

    5/8 in.(16 mm)

    LinerStickout

    InstallLiner

    Reassemble gun inreverse order fromtaking it apart.

    10 mm

    HeadTube

    8 mm

    1

    32

    . Thread wire according towelding power source/wirefeeder manual.

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    7-6. Replacing Switch And/Or Head Tube

    243 840-A

    Tools Needed:

    15 mm

    Remove screws (5)and nuts (4).

    Remove handle halves.

    Hand-tighten head tube into cable connector. Place head tube in vice and tighten untilnuts are tight.

    Remove from vice. Reposition handle halves, andinstall switch housing.

    ! Turn Off welding power source/wire feeder and disconnect gun.

    Remove switch housing. Install newswitch and connect leads (polarity isnot important). Reassemble inreverse order. If replacing head tube,continue to end of figure.

    1 2

    3

    8

    6 7

    Remove screw onopposite side.

    Secure headtube in vice.

    Loosen jam nut.Remove from viceand turn head tubeout by hand.

    4

    5

    phillips

    Reinstall screwsand nuts.

    9

    Reinstall screw onopposite side.

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    7-7. Troubleshooting Table

    Trouble Remedy

    No weld output; wire does not feed; fan

    does 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 (see Section 7-2).

    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).

    Check Voltage range switch position. Rotate knob until it clicks into detent at desired range setting.

    Secure gun trigger leads (see Section 5-2).

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

    Replace contact tip (see Section 7-5).

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

    Check thumbscrew securing gun end to feed head adapter and tighten if necessary.

    Wire does not feed; wire is not ener-gized; wire feeds unevenly.

    Check contact tip. Check for kinks in gun cable and liner.

    Check gun trigger plug connection at welding power source/wire feeder.

    Check, and if necessary, replace gun trigger switch (see Section 7-6).

    Check contact tip. Check for kinks in gun cable. Blow out liner and gun casing (see Section 7-5).

    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).

    Electrode wire feeding stops duringwelding.

    Straighten gun cable and/or replace damaged parts.

    Adjust drive roll pressure (see Section 5-10).

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

    Readjust hub tension (see Section 5-9).

    Be sure that wire is positioned in proper drive roll groove and wire is laying in the groove.

    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 or Section 7-5).

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

    Secure gun trigger leads or repair leads (see Section 5-2).

    Check and clear any restrictions at drive assembly and liner (see Section 5-10 or Section 7-5).

    Release gun trigger and allow gun and motor protection circuitry to reset (see Section 7-3).

    Gun is not secured to feed head. Check thumbscrew securing gun end to feed head adapter and tightenif necessary.

    Have nearest Factory Authorized Service Agent check drive motor.

    Weld porosity. Remove weld spatter buildup in nozzle.

    Check O-rings on gun connector and replace if damaged.

    Make sure inner head tube is tight in cable connector.

    Check gun connector to be sure it is fully inserted into drive assembly.

    Check shielding gas flow/supply.

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    Notes

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    SECTION 8 ELECTRICAL DIAGRAM

    Figure 8-1. Circuit Diagram

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    228 180-A

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    SECTION 9 MIG WELDING (GMAW) GUIDELINES

    mig1 200912

    Wire Feeder/Power Source

    Workpiece

    Gun

    Regulator/Flowmeter

    Gas

    Shielding Gas

    Work Clamp

    9-1. 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.

    Ref. 801 909-A

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    9-2. Typical MIG Process 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 in.material 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

    Voltage controls height andwidth of weld bead.

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

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    9-3. 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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    9-4. 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 SPEEDS-0634

    Push

    Perpendicular Drag

    Short Normal Long

    Short Normal Long

    Normal Fast

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    9-5. 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

    9-6. 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

    9-7. 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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    9-8. 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.

    Incorrect polarity. Check polarity required by welding wire, and change to correct polarity at welding power source.

    9-9. Troubleshooting Porosity

    Porositysmall cavities or holes resulting from gas pocketsin weld metal.

    S-0635

    Possible Causes Corrective Actions

    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.

    9-10. Troubleshooting Excessive Penetration

    Good Penetration

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

    Excessive PenetrationS-0639

    Possible Causes Corrective Actions

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

    Increase travel speed.

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    9-11. Troubleshooting Lack Of Penetration

    Lack Of Penetration shallowfusion between weld metal andbase metal.

    Lack of Penetration Good PenetrationS-0638

    Possible Causes Corrective Actions

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

    Incorrect polarity. Check polarity required by welding wire, and change to correct polarity at welding power source.

    9-12. Troubleshooting Incomplete Fusion

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

    S-0637

    Possible Causes Corrective Actions

    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.

    9-13. Troubleshooting

    Burn-Through

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

    S-0640

    Possible Causes Corrective Actions

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

    Increase and/or maintain steady travel speed.

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    9-14. Troubleshooting Waviness Of Bead

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

    S-0641

    Possible Causes Corrective Actions

    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.

    9-15. 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

    Possible Causes Corrective Actions

    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.

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    9-16. Common MIG Shielding Gases

    This is a general chart for common gases and where they are used. Many different combinations (mixtures) ofshielding gases have been developed over the years. The most commonly used shielding gases are listed in thefollowing table.

    Application

    GasSpray Arc Steel Short Circuiting Steel

    Short CircuitingStainless Steel

    Aluminum

    Argon X

    Argon + 25% CO2 X

    80% or greater Argon +balance CO2 or Oxygen

    X X1

    100% CO2 X

    Tri-Mix2 X

    1 Limited short circuiting use

    2 90% HE + 7-1/2% AR + 2-1/2% CO2

    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. Check and replace cable, gun, and contact tip ifdamaged. Check size of contact tip and cable liner,replace if necessary.

    Wire curling up in front of thewire feed rolls (bird nesting).

    Too much pressure on wire feed rolls. Decrease pressure setting on wire feed rolls.

    Incorrect cable liner or gun contact tip size. Check size of contact tip and check cable liner lengthand diameter, replace if necessary.

    Gun end not inserted into drive housing properly. Loosen gun securing bolt in drive housing and push gunend into housing just enough so it does not touch wirefeed rolls.

    Dirty or damaged (kinked) liner. Replace liner.

    Wire feeds, but no gas flows. Gas cylinder empty. Replace empty gas cylinder.Gas nozzle plugged. Clean or replace gas nozzle.

    Gas cylinder valve not open or flowmeter not adjusted. Open gas valve at cylinder and adjust flow rate.

    Restriction in gas l ine. Check gas hose between flowmeter and wire feeder, andgas hose in gun and cable assembly.

    Loose or broken wires to gas solenoid. Have Factory Authorized Service Agent repair wiring.

    Gas solenoid valve not operating. Have Factory Authorized Service Agent replace gassolenoid valve.

    Incorrect primary voltage connected to welding powersource.

    Check primary voltage and relink welding power sourcefor correct voltage.

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    Problem RemedyProbable Cause

    Welding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worndrive rolls if necessary.

    Wrong size gun liner or contact tip. Match liner and contact tip to wire size and type.

    Incorrect voltage setting for selected wire feed speed onwelding power source.

    Readjust welding parameters.

    Loose connections at the gun weld cable or work cable. Check and tighten all connections.

    Gun in poor shape or loose connection inside gun. Repair


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