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manual abstract
B. Drive rolls can injure fingers. C. Welding wire and drive parts are at welding voltage during operation – keep hands and metal objects clear. 1 Electric shock can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1.2 Protect yourself from electric shock by insulating yourself from work and ground. 1.3 Disconnect input plug or power before working on machine. 2 Breathing welding fumes can be hazardous to your health. 2.1 Keep your head out of the fumes. 2.2 Use forced ventilation or local exhaust to remove the fumes. 2.3 Use ventilating fan to remove fumes. 3 Welding sparks can cause explosion or fire. 3.1 Keep flammables away from welding. Don’t weld near flammables. 3.2 Welding sparks can cause fires. Have a fire extinguisher nearby and have a watch person ready to use it. 3.3 Do not weld on drums or any closed containers. 4 Arc rays can burn eyes and injure skin. 4.1 Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection. 5 Become trained and read the instructions before working on the machine or welding. 6 Do not remove or paint over (cover) the label. 2-1. Warning Label Definitions A B C 1 Read the Owner’s Manual. 2 Do not overtighten wire spool brake pressure. Tighten only until wire does not overspool from wire supply spool. 3 Do not overtighten drive roll pressure. Tighten only until drive roll will not slip (motor will not stall) on a stationary wire. 2-2. Rating Label For CE Products S/N: 24 5.0 Hz50/60 IP 23 V100 A400 X 100 % VU1 AI1 1 U2 I2 ST-178 794-A OM-1594 Page 10 2-3. Symbols And Definitions Some symbols are found only on CE products.Note A Amperes V Volts Alternating Current X Duty Cycle IP Degree Of Protection Hz Hertz Circuit Breaker Wire Feed Jog Output Trigger Gun Press To Set Increase Trigger Hold On Trigger Hold Off Purge Spot Weld Time Percent Run-In Burnback Time U1 Primary Voltage U2 Load Voltage Read Instructions I1 Primary Current I2 Rated Current Line Connection Water (Coolant) Input Water (Coolant) Output Fuse Continuous Spot Welding SECTION 3 – INTRODUCTION 3-1. Specifications Type of Input Power Welding Power Source Type Wire Feed Speed Range Wire Diameter Range Welding Circuit Rating Overall Dimensions Weight 24 Volts AC Single-Phase 5 Amperes 50/60 Hertz Constant Voltage (CV) DC For GMAW Or Constant Voltage(CV) / Constant Current (CC) DC For GMAW-P All Need 14-Pin And Contactor Control 70 To 875 ipm (1.8 To 22.2 mpm) .030 To .062 in (0.8 To 1.6 mm) Max Spool Capacity: 12 in (305 mm) All Models: 100% Duty Cycle, 100 Volts; Water-Cooled Models: 400 Amperes, Air-Cooled Models: 200 Amperes Length: 21-1/4 in (540 mm) Width: 9-1/2 in (241 mm) Height: 16 in (406 mm) 38 lb (17.2 kg) OM-1594 Page 11 3-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. Exceeding duty cycle can damage unit and void warranty. sduty1 5/95 6 Minutes Welding 4 Minutes Resting Continuous Welding Air-Cooled Models Water-Cooled Models 100% Duty Cycle At 400 Amperes Using Argon Continuous Welding 100% Duty Cycle At 200 Amperes Using Argon 60% Duty Cycle At 250 Amperes Using Argon OM-1594 Page 12 OM-1594 Page 13 SECTION 4 – INSTALLATION Be sure that contact tip, liner, and drive rolls are correct for wire size and type. See Parts List to change parts as needed. NOTE Many procedures apply to both guns covered in this manual. Where procedures differ, separate instructions are given. NOTE 4-1. Connections With A Constant Current (CC), Constant Voltage (CV) Or Constant Current/Constant Voltage (CC/CV) Welding Power Source Having A 14-Socket Receptacle 801 559 / Ref. 151 666-A 1 CC, CV Or CC/CV Welding Power Source 2 24 VAC/Contactor Control 14-Pin Plug 3 Workpiece 4 Voltage Sensing Lead Connect lead to workpiece for CC welding only. 5 Gun 6 Wire Feeder 7 24 VAC/Contactor Control Cord Do not use gas pressure above 50 psi (345 kPa). 8 Gas Cylinder 1 2 3 4 5 7 8 6 5 4-2. Air-Cooled Feeder Connections Ref. 801 578-A 1 Gas Fitting Route one end of 10 ft (3 m) gas hose to rear of unit, and connect hose to gas solenoid fitting. Connect remaining end of hose to regulator/flowmeter. 2 Weld Cable To Welding Power Source Select and prepare weld cable according to welding power source manual. 3 Weld Cable Grommet 4 Current Sensing (Reed) Relay 5 Weld Cable Terminal In Feeder Route one end of weld cable through grommet, through reed relay, and connect to weld cable terminal in feeder. Connect remaining end of cable to positive (+) weld output terminal on welding power source. Close and latch door. Tools Needed: 9/16 in 2 5 3 2 4 5 1 Rear Panel Top View Connect To Positive (+) Weld Output Terminal On Welding Power Source Connect To 14-Socket Receptacle On Welding Power Source OM-1594 Page 14 OM-1594 Page 15 4-3. Air-Cooled Gun Connections Ref. 801 577-A / 801 564 / Ref. 151 666-A 1 Gun Control Ca...