12VS XD Operator Manual - Red-D
Contents
1. ODG B EL 5 Gun Trigger Receptacle li s A 6 Voltage Sensing Clamp FP Connect voltage sensing clamp to workpiece Internal Side View 3 Ref 804 002 60 3 5 Connecting Shielding Gas 1 Gas Hose With 5 8 18 Right hand Thread Fittings Customer Supplied 2 Shielding Gas Cylinder Shielding gas pressure not to exceed 100 psi 689 kPa 3 Valve 4 Flowmeter Rear View Close valve on cylinder when fin ished welding Tools Needed S 5 8in Ref 804 003 A OM 224 175 Page 11 3 6 Connecting Weld Cable ESI From Wire Feeder I e o Rear View dmi ma A Turn Off wire feeder and 1 welding power source Stop engine on welding generator User Suppled Weld Cable Follow wire manufacturer s recom mendations for weld cable polarity 2 User Suppled Male Connector 3 User Suppled Female Connector Push female connector over male connector and turn 1 4 turn clock wise 804 004 A 3 7 Weld Cable Sizes2. sm E ad A Disconnect power Maintain more often Kerr before maintaining during severe conditions 3 Months WARNIN WARNIN Replace Damaged Or j Replace Damaged Unreadable 7 Gas Hose Labels Repair Or Replace Cracked Cables And Cords Clean Blow Out Or Drive Vacuum Inside Rolls 5 2 Overload Protection And Thermostat Protection N A Turn Off wire feeder and X welding power source Stop engine on welding generator 1 Circuit Breaker CB1 CB1 protects wire feeder from over load Correct problem and reset RA CB1 K E A Close and latch door Thermostat Protection Unit has internal thermostat protec e tion and will not feed wire if over heating occurs see Section 5 3 Internal Side View N 7 l Ref 804 006 B OM 224 175 Page 17 5 3 Troubleshooting pa Trouble Remedy Wire does not feed open circuit voltage available Check circuit breaker CB1 Reset CB1 Unit overheated Allow unit to cool Check sensing lead connection Check gun trigger plug connection Check gun trigger See gun Owner s Manual Have Factory Authorized Service Agent check Control board PC1 Wire feeds erratically Readjust hub tension Readjust drive roll pressure Clean or replace dirty or wor
3. 8 2 8 Information EMP e a erga ka RR Ka user Fa I C E PE E F 8 SECTION S INSTALLATION vcnir preron eR eR XR aa aa a EA NES eI 9 3 1 Specifications ru ER rae de xia kb a ae AA n es 9 3 2 Equipment Connection Diagram hn 9 3 3 Installing And Aligning Wire Guide And Drive Rolls 10 3 4 Connecting Welding Gun And Voltage Sensing Clamp 11 3 5 Connecting Shielding Gas 11 3 6 Connecting Weld Cable 22 4 12 3 7 Weld Cable SIZES ed e djal a 12 3 8 Installing And Threading Welding Wire 13 3 9 Display Board PC20 DIP Switch Settings 14 SECTION4 OPERATION eie aa Dei de E ERT 15 4 1 Ret dd ama a aaa aaa AE NA ama DR a 15 4 2 Wire Speed Control Settings www w re bbs ka URP RE ERE Rer 16 SECTION 5 MAINTENANCE 8 TROUBLESHOOTING nnnnnnnnnunnnna 17 Sils Routine Maintenance d be dne dux o ad 17 5 2 Overload Protection And Thermostat Protection 17 5 3 Troubleshooting icc urn kaa RE A pra k pa
4. DN Ref 804 006 A KNEE 1 2 3 4 X 5 5 5 DIP Switch Settings Display Hold ON Displays will hold their last value for five seconds after the trigger is re leased After the hold times out the Voltage Display will show open circuit voltage If the Wire Speed Amps Display is set to display Amps the amperage value will hold after the hold times out preset Wire Speed will be displayed Display Hold OFF Displays will not hold values Immedi ately when the trigger is released the Voltage Display will show open circuit voltage The Wire Speed Amps Display will display preset Wire Speed when the trigger is released Do Not Display Amperage Wire Speed Amps Display will dis play only Wire Speed Display Amperage Wire Speed Amps Display will dis play Amps while welding and Wire Speed while not welding If the hold function is enabled Amps will be dis played during hold also Wire Speed Inches Per Minute Displays Wire Speed in Inches per Minute Wire Speed Meters Per Minute Displays Wire Speed in Meters per Minute Information OFF Information is not displayed Information ON With switch in ON position at feeder power up feeder will display various sets of information Each set of infor mation will be displayed for three sec onds Display Board PC20 Software Part Number Top display will show the f
5. For distances longer than those shown in this guide call a factory applications representative at 920 735 4505 Weld Cable Size and Total Cable Copper Length in Weld Circuit T Not Exceeding 150 ft 200ft 250ft 300ft 350ft 400ft 100ft 30m orLess 45m 60m 70m 90m 105 m 120 m Weld Output Terminals A Turn off power before 10 60 60 100 connectingto weld out Welding pp Duty 10 100 Duty Cycle put terminals Amperes Cycle Cycle A Do not use worn dam aged undersized or poorly spliced cables 100 4 20 4 20 4 20 3 30 2 85 1 50 1 0 60 1 0 60 150 3 30 3 30 2 85 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 85 1 50 1 0 60 2 0 70 3 0 95 4 O 120 4 O 120 250 2 85 1 50 1 0 60 2 0 70 3 0 95 4 0 120 prov 0 300 1 50 1 0 60 2 0 70 3 0 85 4 0 120 SE 2 ea 2 0 268 3 0 268 3 0 268 4 0 350 1 0 60 2 0 70 3 0 95 4 0 120 O teda oa a 2 2 ea 2 0 2ea 3 0 268 4 0 268 4 0 400 1 0 60 2 0 70 3 0 95 4 0 120 or ex ex ni 2 ea 2 0 2 ea 3 0 2 ea 4 0 3 ea 3 0 3 ea 3 0 500 2 0 70 3 0 95 4 0 120 3 70 2x95 2x120 3x95 3x95 This chart is a general guideline and may not suit all applications If cable overheats use next size larger cable Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circ
6. 232 080 A Figure 6 1 Circuit Diagram For Wire Feeder OM 224 175 Page 20 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge 025 in 22 Gauge 031 in 20 Gauge 037 in 18 Gauge 050 in 16 Gauge 063 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in OM 224 175 Page 21 SECTION 7 PARTS LIST A VAN AN M ERN Ref 804 007 H Figure 7 1 Complete Assembly OM 224 175 Page 22 Item Diagram Part No marking No Description Ouantity Figure 7 1 Complete Assembly saute Ras 221 050 Case Control Feeder Plastic 1 2 ER 208 015 Handle Rubberized Carrying 1 kisa neca 221051 Chassis Control BOX 1 4 ssh PC20 220186 Circuit Card Assy Meter Suitcase W Program 1 179 851 Knob Pointer 1 670 Dia X 250 Id Push On W Spring 1 RNC EIAS 230 228 Bushing Strain Relief 120 150 Id X 500 Mtg Hole 1 V ER 214011 Cable Sensing 1 221 998 Cable Trigger 25ln
7. OM 224 175D 2006 12 Processes J MIG GMAW Welding A 1 Flux Cored FCAW Welding AN VAS RED D ARC Descr iption Welderentals 1 800 245 3660 SuitCase 12VS RED D ARC OWNER S MANUAL File MIG GMAW 8 www red d arc com TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 AeA Symbol USAGE x e eR ne A Ra k E A elc a n aa EL Antal KE 1 1 2 Are Welding Hazards 2 one ka p SUR ENS ko OE a nA Ee 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 California Proposition 65 Warnings 3 1 5 Principal Safety Standards 2 4 1 6 EMF Information 23e aa Lad ead a aeta s ale ehh ot 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 Symboles utillS6s enc erp bee Vac gw RERO Nar Sed don ghe E qu de E pus 5 2 2 Dangers relatifs au soudage l arc 5 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements 7 2 5 Principales normes de s curit
8. P MOVING PARTS can cause injury Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Reinstall doors panels covers or guards when maintenance is finished and before re connecting input power READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit e Use only genuine Miller Hobart replacement parts H F RADIATION can cause interference e High freguency H F can interfere with radio navigation safety services computers and communications eguipment e Have only gualified persons familiar with electronic eguipment perform this installation e The user is responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the eguipmentat once Have the installation regularly checked and maintained Keep high freguency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven eguipment such as robots e Be sure all eguipment in the welding area is electromagneticall
9. the beginning of this manual Notes 24 GA 0239 O 22 GA 0299 m 20 GA 0359 18 GA 0478 16 G 0598 14 GA 0747 1 8 C 125 229895 10 GA 1345 3 16 0 1875 1 4 250 5 16 0 3125 024 030 035 MATERIAL THICKNESS GAUGE Notes SOCKET WRENCH SELECTION TABLE Qu SOCKET WRENCH SELECTION TABLE U S STANDARD METRIC Specifications Socket or Wrench Size Specifications Socket or Wrench Size A U S E alo Bol ni Tm ESO dani goli NI 1 4 in 250 in 3 8 in 7 16 in 6 mm 2362 in 10 mm 10 mm 5 16 in 3125 in 1 2 in 9 16 in 8mm 3150 in 14 mm 14 mm 3 8 in 375 in 9 16 in 5 8 in 10 mm 3937 in 17 mm 17 mm 7 6 in 4375 in 5 8 in 3 4 in 12 mm 4724 in 19 mm 19 mm 1 2 in 500 in 3 4 in 13 16 in 14 mm 5512 in 22mm 22 mm 9 16 in 5625 in 7 8 in 7 8 in 16 mm 6299 in 24 mm 24 mm 5 8 in 625 in 15 16 in 1in 18 mm 7087 in 27 mm 27 mm 3 4 in 750 in 1 1 8 in 1 1 8 in 22mm 8661 in 32 mm 32 mm 7 8 in 875 in 1 5 16 in 1 5 16 in 24 mm 9449 in 36 mm 36 mm 1in 1 000 in 1 1 2 in 1 1 2 in Warranty Effective Ja
10. Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors relays brushes slip rings or parts that fail due to normal wear 2 Items furnished by manufacturer but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty if any 3 Eguipmentthat has been modified by any party other than manufacturer or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MANUFACTURER S PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at manufacturer s option 1 repair or 2 replacement or where authorized in writing by manufacturer in appropriate cases 3 the reasonable cost of repair or replacement at an authorized service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Manufacturer s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at an authorized se
11. Slide drive roll onto drive roll carrier Turn nut one click Repeat procedure for top drive roll 4 Inlet Wire Guide Screw 5 Inlet Wire Guide One Piece Anti wear E The factory installed inlet wire guide is good for up to 5 64 inch diameter wire Loosen securing screw Align inlet guide so inlet guide screw is centered in groove in guide or so tip is as close to drive rolls as possible without touching Tighten screw Aligning Wire Guide And Drive Rolls View is from top of drive rolls look ing down with pressure assembly open 6 Drive Roll Securing Nut 7 Drive Roll 8 Wire Guide 9 Welding Wire 10 Drive Gear Turn screw in or out until drive roll groove lines up with wire guide Close pressure roll assembly Only bottom drive roll alignment is adjustable Turn adjustment screw in or out until groove in drive roll lines up with wire guide as shown Cleaning Drive Rolls Remove drive rolls and clean grooves using a wire brush Ref 804 001 B OM 224 175 Page 10 3 4 Connecting Welding Gun And Voltage Sensing Clamp A Turn Off wire feeder and po welding power source Stop engine on welding generator 1 Gun Securing Knob 2 Gun Block 2 3 Gun Outlet Wire Guide Loosen knob insert gun end into block Position outlet wire guide as close as possible to drive rolls with out touching Tighten knob 4 Gun Trigger Plug
12. When using small diameters wire or with in verter power sources it may be necessary to turn switch off to obtain smooth starts After adjusting the switches close and latch the door before welding Ref 804 006 B OM 224 175 Page 15 Wire Speed Control Settings 4 2 V 20 zzz 198 odAj seb pue pesn AIM jo d pue ezis ujBue ejqeo enp ABA Aew SIHSUIJIBLIBUI VI 00 gz pue uoDJy 9 64 SI XIU SEE anuju Jed seuoui ui UMOUS si peeds M ejqgissod JeAeueuM epoui pepueuluio2eil eui SI AO 310N Beiadwe pjam pauisap 196 9591 05 19 uo eDejoA 518 pue 19p98 uo peeds podj M jsn pe apow AD ui DuipjeM ueuM eBejjOA 518 polisop 196 snos uo eDejeduie pue Jepooj uo peeds pes aim 1sn pe epoui 99 ui ueuM z oz s 202 ozi eBereduv oor ose 00 ose oog ost oor PeedseM 8 H INL LLZ3 ed L 2900 8ZIs M os ost oor Peeds sm paads 8JIM peeds JIM peeds M eDeyoA peeds eJIM S SZ XIN 580 9 S04H3 ed L 8JIM 0500 5 8JIM 91 5 eu ye sBunjos oBejjoA 518 eBeJeduie pue apes ou ye Dues poods 1 eu 195 O ejqel siu esf 31851 HalaWNwVdVd QIM G39N3NNO234 OM 224 175 Page 16 SECTION 5 MAINTENANCE 8 TROUBLESHOOTING 5 1 Routine Maintenance
13. la pointe de contact Porter des v tements de protection exempts d huile tels que des gants en cuir une veste r sistante des pantalons sans revers des bottes et un casque Avant de souder retirer toute substance combustible de ses poches telles qu un allumeur au butane ou des allumettes Suivre les consignes de OSHA 1910 252 a 2 iv et de NFPA 51B pour travaux de soudage et pr voir un d tecteur d incendie et un ex tincteur proximit DES PARTICULES VOLANTES peuvent blesser les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier Porter des lunettes de s curit avec crans lat raux ou un cran facial OM 224 175 Page 6 distance e Les porteurs d un stimulateur cardiaque doi vent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points LE BRUIT peut endommager l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv es pour les oreilles si le niveau sonore est trop lev LES BOUTEILLES peuvent exploser si elles sont endommag es Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma g e elle peut exploser
14. 1 230 227 Bushing Strain Relief 900 Id X 550 625 Mtg Hole 1 10 25 A ee 604 645 Nut 375 32 56Hex 09H Stl Cad Use W Pots 1 1 us 220 442 Panel Front o kisama mie 1 TO cu ea 224 177 Nameplate Red D Arc W Meters 1 SE RE 222 797 Blank Snap In Nyl Rect Mtg Hole Black 1 14 Sly iiem 111 997 Switch Rocker Spst 10A 250VAC On Off Visi Red Rock 1 15 2 vus S221 216295 Switch Rocker Spdt 4VA 28VDC On Off On 187T 1 dO Le DS 208 076 Panel Inner ran 1 FAST 216315 Nameplate Inner 1 18 sise CB1 083432 Circuit Breaker Man Reset 1P 10A 250VAC Frict 1 19 ess 147 195 Nut 375 27 54Hex 25h Nyl Flange 625 1 20 53 S5 S6 217932 Switch Rocker Spst 4VA 28VDC On None Off 187 Ter 3 2d PC1 224675 Circuit Card Assy Motor Control W Program 1 22 uii HD1 218339 Transducer Current 600A Module Supply V 5V 1 29 wg M1 220195 Motor Right Angle 24VDC 145 RPM 37 5 Ratio W Plug 1 24 SE Ei ve ds 124 778 Knob 2 000 Bar W 312 18 Stud 1 000 Lg Plstc 1 29 sem 079 634 Pi HI AGE nisi v
15. Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 phone 703 412 0900 web site www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale 1 6 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 224 175 Page 4 Boulevard Rexdale Ontario Canada M9W 1R3 phone 800 463 6727 or in Toronto 416 747 4044 website www csa in ternational org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from Amer
16. Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessi ve des chocs m caniques des dommages physiques du lai tier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support sta tionnaire ou dans un porte bouteilles pour les emp cher de tom ber ou de se renverser e Tenirles bouteilles loign es des circuits de soudage ou autres circuits lectriques e Ne jamais placer une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifi que les maintenir ainsi que les l ments associ s en bon tat e D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille e Lecouvercle du d tendeur doit toujours tre en place sauf lors que la bouteille est utilis e ou qu elle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suf fisamment de personnes pour soulever et d placer les bouteil les Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P
17. apr s avoir pris les mesures pr c den tes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protec teurs dans la zone de travail 2 4 Proposition californienne 65 Avertissements Pour les moteurs essence A Les gaz d chappement des moteurs contiennent des produits chimiques dont l tat de Californie reconna t qu ils provoquent des cancers et des malformations cong nitales ou autres pro bl mes de procr ation A Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l Etat de Californie reconnait qu ils provoquent des malformations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants Pour les moteurs diesel A Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l tat de Californie comme provoquant des cancers et des malformations cong nitales ou au tres probl mes de procr ation Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimiques dont l Etat de Californie reconnait qu ils provoquent des can cers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipulation OM 224 175
18. ou des pi ces e Utiliser des pochettes et des bo tes antistati ques pour stocker d placer ou exp dier des cartes PC 7 amp DES ORGANES MOBILES peuvent provoquer des blessures e pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels gue des rouleaux de commande LES FILS DE SOUDAGE peuvent provoguer des blessures e Ne pas appuyer sur la g chette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres personnes ou toute pi ce m canique en enga geantle fil de soudage L 3 DES ORGANES MOBILES peuvent provoguer des blessures e S abstenir de toucher des organes mobiles tels a gue des ventilateurs e Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection e Seules des personnes qualifi es sont autoris es enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien e Remettreles portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS e Lire le manuel d utilisation avant d utiliser ou d intervenir sur l appareil e Utiliser uniquement des pi ces de rechange Miller Hobart LE RAYONNEMENT HAUTE FREQUENCE HF risque de provoquer des interf rences e Le rayonnement haute fr quence HF peut provoquer des interf rences avec le
19. utilis s Symbole graphique d avertissement Attention Cette pro A c dure comporte des risques possibles Les dangers ven tuels sont repr sent s par les symboles graphiques joints Indique un message de s curit particulier Ce groupe de symboles signifie Avertissement Attention Risques a d 4 d ELECTROCUTION ORGANES MOBILES et PARTIES CHAUDES Consulter les symboles et les instructions aff rentes ci dessous concernant les mesures prendre pour supprimer Signifie NOTE n est pas relatif la s curit les dangers 2 2 Dangers relatifs au soudage l arc A Les symboles repr sent s ci dessous sont utilis s dans ce manuel V rifier fr quemment le cordon d alimentation afin de s assurer qu il pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entrainer la mort instructions aff rentes pour viter tout risque Les instructions en e L quipement doit tre hors tension lorsqu il n est pas utilis mati re de s curit indiqu es ci dessous ne constituent qu un e Ne pas utiliser des c bles us s endommag s de grosseur insuffisante sommaire des instructions de s curit plus compl tes fournies ou mal piss s gans les normes oe de secite dans la Section 2 5 Lire et amp pas enrouler les c bles autour du cor
20. your person before doing any welding e Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby EIC FLYING METAL can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet OM 224 175 Page 2 a BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator HOT PARTS can cause severe burns Do not touch hot parts bare handed 9 e Allow cooling period before working on gun or torch e To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns MAGNETIC FIELDS can affect pacemakers e Pacemaker wearers keep away e Wearers should consult their doctor before going near arc welding gouging or spot welding operations NOISE can damage hearing Noise from some processes or eguipment can damage hearing e Wearapproved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from exces
21. 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s curi t 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Ne pas installer l appareil proximit de produits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimentationest correctement dimensionn e et prot g e avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil SUR a ar nn L EMPLOI EXCESSIF peut CHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement respecter le cycle op ratoire nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage Ne pas obstruer les passages d air du poste arr A ee amp LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes
22. 222 067 Insulator Rear Panel 1 DB pss 070 371 Blank Snap In Nyl 1 093 1 125 Mtg Hole Black 1 59 C1 C2 200606 Capacitor Elctit 1200 Uf 300 VDC Can 1 39 Dia 2 60 scere 210 133 Bracket Capacitor Support SC12 1 OT ciues ete ea se uana 207 678 Insulator Capacitors 1 222 103 SUPPOH SPOOl cor er Re pone wed D drla na enr he Bee aa 1 Od ike 225 069 Hub Spool W Threads 1 64 sli rkI4REN 209 450 Nut HUD ius pues EUER pdt eee dee dE 1 172919 Knob Brake Adjust 1 172 918 gt Spring ires nt 1 tt 058 424 Washer Fibre Brake 1 68 os aus 201 309 Washer Anti T in ioo scs ce RAE a 2 Sue ud ex Y re 223 814 Label Warn Gen Precaution Suitcase 1 196 956 Label Warning Electric Shock And Pinch Wordless 1 ap ASS 222 306 Label Warning General Precautionary Static Vert 2 69 52 32 an tice 145 217 Screw K40x 12 Pan Hd Phl Stl Pld Pt Thread Forming 2 TO ERE 220 805 Nut 750 14 Knurled 1 68Dia 41HNyl 1 B
23. A fea en don dd 081 895 Nut 010 32 Rubber 75Dia 811 Insert In 38Hole 5 41275 aate utu 182 445 Nut Conduit 1 000 Npt Pld 1 688 Od X 200 Thk 1 RE PEE 208 000 Washer Shldr 260id 0 6300dx 125t 3270dx 062t Nyl 4 TA OE eode mes 222181 Grommet Scr No 8 10 Panel Hole 281 Sq 031 High 5 TA s 222 294 Clip Wire Cord 380 Bundle 250Hole 105 Thk Bik 2 TO E cree wb 211 989 Fitting W Screen 1 CL pagos espe iex 107 983 Blank Snap In Nyl 500 Mtg Hole Black 1 8 hae usi 221 030 Guide Wire Inlet Anti Wear One Pc 023 To 5 64 1 PLG10 131052 Housing Rept Skts Service Kit 1 EE PLG22 115092 Housing Plug Skts Service Kit 1 PLG7 130 203 Housing Plug Skts Service Kit 1 PLG8 115092 Housing Plug Skts Service Kit 1 PLG5 201665 Housing Plug Skts Service Kit 1 T PLG3 130 203 Housing Plug Skts Service Kit 1 PLG4 191 054 Housing Rept Skts Service Kit 1 PLG6 115094 Hou
24. EER TS AK 12 9 oN TRIGGER gl RC2 WHT RC6 2 ALD lt RC4 1 gi zam s ra RC10 2DE MES COMMAND e994 HOUSING T RC10 3 gt gt 2 EM lt lt RC22 3 RC4 2 i mm lt Rc10 10 gt gt 4 lt RC22 7 METER BOARD ae lt RC5 4 RC10 12 gt 10 COM lt RC22 8 PC20 _ pa Rco 1 gt gt H DU lt RC21 1 RC21 PLG21 RC22 PLG22 4 lt RC5 3 RCI 2 gt gt 4 ROAD lt RCI CM 55 CC RCB 7 Rcs 5 gt i e m RC10 8 gt gt aye Z7 lt lt RC8 8 RC10 4 gt gt s JO8 4 lt RCB 10 MOTOR BOARD o PURGE m RC10 5 gt gt 4 lt RC5 2 AB 4 TP1 e RC3 PLG3 RC10 8 gt sed 3 p RC4 PLG4 RG10 7 9 42 TRIGGER Pi RC5 PLG5 v HOLD OPT lt RC5 1 RC6 PLG6 OFF J RC7 PLG7 LL T RC17 1 lt lt lt 150 lt lt RC3 5 kit CD RC17 2 lt lt 2 PDB lt RC3 3 RC10 PLG10 75 LIEV ja 10 COM RC7 1 RC17 3 lt lt lt RC3 4 Q ce RC7 8 gt gt a s HIGH m lt RC8 5 S5 g M f does 215 s LOW m RC7 2 gt gt 22 7 lt lt RCB 6 SOFT START WELD CABLE ON OT RCB 3 PB c2 let lt oti LIV TN 4 TS OFF cm 10 lt lt RCB 1 RC7 12 gt Z 7 A WARNING Do not touch live electrical parts Sa Disconnect input power or stop S engine before servicing 9 Do not operate with covers removed ELECTRIC e Have only gualified persons install SHOCK HAZARD use or service this unit
25. Page 7 2 5 Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site In ternet www global ihs com Principales normes de s curit Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 t l phone 703 412 0900 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association Standards Sales 178 Rexdale 2 6 Information EMF Considerations sur le soudage et les effets de basse fr quence et des champs magnetigues et lectriques Le courant de soudage pendant son passage dans les c bles de souda ge causera des champs lectromagn tiques II y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir examin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comi
26. Shaft X 035 Thk 1 Aag Large ni us 222 159 Spring TORSION i e ADE a 1 222 396 Insulator Motor 1 AD it 224697 Contactor 12VDC W Bus Bars Includes 1 46 PLG5 201 665 Housing Plug Skts Service Kit 1 47 TP2 220 221 Thermostat Open 140C Close 110C Snap Action 2 48 ess iex tape a 183 387 Washer Cone 380idx 8600dx 109t Stl Pld 4000Lbs 4 49 eese er ta 223 862 Nut M10 1 5 17Hex 8H Brs Din 934 2 DO S RE Ne dor dod 222 001 Bracket Mtg Contactor 1 su 221 347 Grommet Bus Bar 1 52 600 324 Cable Weld Cop Strd 4 0 Epdm Jkt 18 in DI da 215980 Bushing Strain Relief 709 984 Id X1 375 Mtg Hole 1 DA ox nina xd 221 052 Shtoud WIPE i4 cosa ele ru ra Cane a Re aa an dota 1 eee co te 207 679 Insert Corner 1 OM 224 175 Page 23 Item Diagram Part No marking No Description Ouantity Figure 7 1 Complete Assembly Continued 56 inate ta GS1 215284 Valve 12VDC 1Way 750 14 Thd 1 8 Orf 100PSI 1 5T d ILE ists
27. Subpart J de U S Government Printing Office Superinten dent of Documents Box 371954 Pittsburgh PA 15250 il y a 10 bureaux regionaux le telephone de la region 5 Chicago est 312 353 2220 site Internet www osha gov 1 Maintenir les c bles ensemble en les tordant ou en les enveloppant 2 Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les c bles le plus loin possible de 5 Connecter la pince sur la piece aussi pr s que possible de la sou dure En ce gui concerne les stimulateurs cardiagues Les porteurs de stimulateur cardiague doivent consulter leur medecin avant de souder ou d approcher des operations de soudage Si le mede cin approuve il est recommand de suivre les proc dures pr c dentes SECTION 3 INSTALLATION 3 1 Specifications Type ot Welding Wire Feed Wire Input Max Wire Power Welding IP Overall z Input S Speed Diameter Circuit Rati Spool Dimensi ns Weight Power Range Range Tau anng Capacity Type Rating Length 21 in Constant i Open Circuit Voltage CV y rino joe niga Ss 533 mm Arc Voltage Or Constant boso 023 To 5 64 in At s 23 45 lb 20 4 kg Width 9 in 35 Ib 14 110 Current CC p mpm 0 6 To2mm pis Cyel 12 in 304 mm 229 mm 16 kg Volts DC DC Power epen
28. T running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit A LU OVERUSE can cause OVERHEATING e Allowcooling period follow rated duty cycle ee e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit se STATIC ESD can damage PC boards 7 e Puton grounded wrist strap BEFORE handling ASS boards or parts s e Use proper static proof bags and boxes to store move or ship PC boards K MOVING PARTS can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Donotpress gun trigger until instructed to do so e Do not point gun toward any part of the body other people or any metal when threading welding wire L 3 1 4 California Proposition 65 Warnings A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling
29. an displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 224 175 Page 1 ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear an approved welding helmet fitted with a proper shade of fil ter lenses to protect your face and eyes when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from
30. aque rester danger eX D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soi gneusementavec des protections homologu es Ne pas souder dans un endroit o des tincelles peuvent tomber sur des substances inflammables Se prot ger ainsi que toute autre personne travaillant sur les lieux contre les tincelles et le m tal chaud Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures Afin d liminer tout risque de feu tre vigilant et garder toujours un extincteur la port e de main Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr pa r s correctement conform ment AWS F4 1 voir les normes de s curit Brancher le c ble de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques d lectrocution d tincelles et d incendie Ne pas utiliser le poste de soudage pour d geler des conduites gel es En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil
31. arche avec la pi ce souder ou la table de travail le plus pr s possible de la Dans le mode de soudage avec du fil le fil le d rouleur le bloc de soudure commande du rouleau et toutes les parties m talliques en contact isoler la pince de masse quand pas mis la pi ce pour viter le contact avec le fil sont sous tension lectrique Un quipement install ou mis avec tout objet m tallique la terre de mani re incorrecte ou impropre constitue un danger e Ne pas raccorder plus d une lectrode ou plus d un c ble de masse e Ne pas toucher aux pi ces lectriques sous tension e Porter des gants isolants et des v tements de protection secs et sans trous e S isoler de la pi ce couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol e Ne pas se servir de source lectrique courant lectrique dans les zo nes humides dans les endroits confin s ou l o on risque de tomber Se servir d une source lectrique courant lectrique UNIQUEMENT si le proc d de soudage le demande e Si utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip une m me borne de sortie de soudage Il reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur quand on a coup l alimentation Arr ter les convertisseur
32. as BS eee Sko ta 1 DOS cA ne 151 828 Pin Cotter Hair 042 X 750 2 cS 085 243 Knob Adjust Tension 1 250 Dia X 312 18 Thrd Stl 1 28 out n s 089 477 Spring Cprsn 770 Od X 100 Wire X 715 Pld 1 085 244 Washer Cupped 328idx 8120dx16gax 125 Lip 1 30 089 562 Fastener Pinned osse shaakalid 1 i Mos sr 166 071 Lever Mtg Pressure Gear 1 32 t 160072 lt Spacer Gear soe i a aeda aata ara Mali 1 oin ME MU TD 172 075 Carrier Drive Roll W Components 24 Pitch 1 602 009 Screw 250 20x1 25 Soc Hd Hex Gr8 Pin 1 SRE 010 224 Pin Spring Cs 187 X 1 000 1 niox 144 172 Ftg Hose Brs Barbed M 3 16 Tbg X 250 20 1 OT 079 625 Washer Wave 500idx0 7500dx 015T Stl Lbs 2 CT En NS kola 092 865 Key Stl 1215 1230 X 750 1 JO ov sete reas 172076 Carrier Drive Roll W Components Keyed 24 Pitch 1 O OE ERA EN 121271 Screw 250 20x 50 Soc Hd Hex Gr8 Pin Lkg Patch 1 A PE PEN 098 615 Hose Sae 187 Id X 410 Od X 20 000 1 ATE RNA 605 308 Ring Rtng Ext 500
33. ctions of gas valve GS1 Check continuity of coil Replace GS1 if necessary Have Factory Authorized Service Agent check Control board PC1 Clear blockage in gas hose or replace hose Clear blockage in welding gun Wire remains energized after trigger is released Check contactor W1 to see if contacts are frozen closed Gun trigger is pressed gas does not flow wire is not energized wire feeds If a welding arc is not established in 3 seconds after the gun trigger is activated the unit will feed wire without energizing the contactor or gas valve If the gun trigger is still activated after two minutes the wire will stop feeding This is to prevent complete despoolling of the wire as in the case of a damaged gun OM 224 175 Page 18 Trouble Remedy Information on display board is not accu Have Factory Authorized Service Agent check Control board PC1 rate Check transducer HD1 and connections and replace if necessary Display on display board does not light Have Factory Authorized Service Agent check Control board PC1 Replace display board Segments on the display board are Replace display board missing 5 4 Diagnostics Error Indicators Shown On Display RED LED on Motor Board PC1 HLP 14 4 Blinks Motor Constant Blinking Overload Error HLP 15 3 Blinks Bus Bar Overheat Error Error Indications Error conditions are indicated by a HLP mes
34. d RR REG pev Panes Aedes 18 5 4 Diagnostics 19 SECTION 6 ELECTRICAL DIAGRAM Rx yx x edie neers tee ee RE EE RE ERR REX 20 SECTION 7 PARTS LIST 222 0 saamaks x BER e MR LIRE 22 RED D ARC Welderentals 1 800 245 3660 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 3 05 A Warning Protect yourself and others from injury read and follow these precautions 1 1 A Symbol Usage Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols Marks a special safety message 5 Means Note not safety related 1 2 Arc Welding Hazards A A A RF The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 5 Read and follow all Safety Standards Only gualified persons should install operate maintain and repair this unit During operation keep everybody especially children away ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the outpu
35. ding On My eye Seem Source Onl Arc Voltage Height 15 1 2 in y 394 mm 3 2 Equipment Connection Diagram NI A Turn Off wire feeder and welding power source Stop engine on welding generator 1 A Use only with CC CV DC Power Sources 10 1 Constant Current CC or Constant Voltage CV Welding Power Supply 2 Weld Cable To Feeder 3 Ground Cable To Workpiece Weld cable and ground cable con nections to power source DCEN DCEP are dependant on wire type Since feeder is not polarity sen sitive there is no need for an electrode polarity switch 4 Workpiece 5 Voltage Sensing Clamp Connect voltage sensing clamp to workpiece 6 Gun 7 Gun Trigger Receptacle 8 Wire Feeder 9 Gas Hose 10 Gas Cylinder Use of shielding gas is dependant on wire type Shielding gas pressure not to exceed 100 psi 689 kPa Ref 804 000 B OM 224 175 Page 9 3 3 Installing And Aligning Wire Guide And Drive Rolls N Pa X 6 Tools Needed 8 16 in Installing Wire Guide And Drive Rolls Aligning Wire Guide And Drive Rolls Correct 10 Incorrect Installing Wire Guide And Drive Rolls 1 Drive Roll Nut 2 Drive Roll Carrier Turn nut one click until lobes of nut line up with lobes of drive roll carrier 3 Drive Roll
36. e terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre En effectuant les raccordements d entr e fixer d abord le conducteur de mise la terre appropri et contre v rifier les connexions vanis plaqu en plomb ou au cadmium moins que le rev tement n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxi ques en cas de soudage OM 224 175 Page 5 LES ACCUMULATIONS DE GAZ risguent de provoguer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confi n s ou se servir d un respirateur d adduction d air homologu LES RAYONS D ARC peuvent entrai ner des br lures aux yeux et la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provo quer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage e Porter un casque de soudage approuv muni de verres filtrants ap propri pour prot ger visage et yeux pendant le soudage voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des lunettes de s curit avec crans lat raux m me sous
37. ican National Standards Institute 11 West 42nd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 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 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them Arrange cables to one side and away from the operator Do not coil or drape cables around your body Boo m Keep welding power source and cables as far away from opera tor as practical 5 Connect work clamp to workpiece as close to the weld as possi ble About Pacemakers Pacemaker wearers consult your doctor before welding or going near welding operations If cleared by your doctor then following the above procedures is recommended SECTION 2 CONSIGNES DE SECURITE LIRE AVANT UTILISATION fre som 3 05 A Avertissement se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes 2 1 Symboles
38. irst three digits bottom display will show last three digits of the Display board PC20 software revision level Motor Board PC1 Software Part Number Top display will show the first three digits bottom display will show last three digits of the Motor board PC1 software revision level Accumulated Weld Time This is the time the feeder has actual ly been used for welding This infor mation will be displayed in two halves First being years and days second in hours and minutes Top display will show years hours bot tom display will show days minutes OM 224 175 Page 14 SECTION 4 OPERATION 4 1 Controls im VOLTAGE al J 5 olo E N 0 A SPEED AMPS li E WIRE O Pip m olo WIRE SPEED Front Panel 9 7 OFF LO olo CCh 8 7 ja N 4 Z N Z A N ON HI olo CVE Internal Control Panel DIOID 9 Internal Side View NR LJ KI A A Ayo 1 Power Control Switch 2 Trigger Hold Switch Optional Trigger hold allows operator to weld without holding gun trigger To use trigger hold function place trigger hold switch in the ON position The operator must hold the trigger for a mini mum of 2 seconds but no longe
39. les nettoyants et les d graisseurs situations l utilisation d un poste souder DC fil tension constante e Travailler dans un espace ferm seulement s il est bien ventil ou en est recommand e En outre ne pas travailler seul portant un respirateur alimentation d air Demander toujours un sur Couper l alimentation ou arr ter le moteur avant de proc der veillant d ment form de se tenir proximit Des fum es et des gaz de l installation la r paration ou l entretien de l appareil D verrouiller soudage peuvent d placer l air et abaisser le niveau d oxyg ne provo l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de quant des blessures ou des accidents mortels S assurer que l air de s curit respiration ne pr sente aucun danger e Installer le poste correctement et le mettre la terre convenablement Ne pas souder dans des endroits situ s proximit d op rations de d selon les consignes du manuel de l op rateur et les normes nationales graissage de nettoyage ou de pulv risation La chaleur et les rayons de provinciales et locales l arc peuvent r agir en pr sence de vapeurs et former des gaz haute i ZA a i ment toxigues et irritants e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer Ne pas souder des m taux munis d un rev tement tels que l acier gal que le fil de terre du cordon d alimentation est bien raccord la borne d
40. lusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province brand warr 2006 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which eguipment was delivered to original customer Distributor Address City State Zip RED D AR Welderentals 1 800 245 3660 www red d arc com Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or eguipment manufacturer s Transportation Department PRINTED IN USA 1 06
41. n drive roll see Section 3 3 Remove weld spatter around nozzle opening Replace contact tip or liner See gun Owner s Manual Change to correct size and type drive roll see Section 3 3 Incorrect size or worn wire guides see Section 3 3 Check wire drive motor brushes Have Factory Authorized Service Agent check control board PC1 Motor runs slowly Check and replace contact tip or liner if necessary Have Factory Authorized Service Agent check Control board PC1 If soft start is not on motor will switch to slower speed if current is not sensed by HD1 When soft start is on motor will run slow until weld current is sensed by HD1 Unit does not switch out of Soft Start Check transducer HD1 and connections and replace if necessary Wire feeds when Jog switch is pressed but not when gun trigger is pressed Check gun trigger connection at wire feeder Check gun trigger leads and trigger switch See gun Owner s Manual Have Factory Authorized Service Agent check Control board PC1 Wire stubbing on low end using a con stant current power source or feeder re sets Make sure CC CV switch is in CC position see Section 4 1 Increase power source inductance setting if available Increase output setting of power source or decrease wire feed speed Gas does not flow or does not stop flow ing wire feeds Check gas valve Check coil voltage and conne
42. ng Power Sources Process Controllers Semi Automatic and Automatic Wire Feeders Inverter Power Sources Unless Otherwise Stated Water Coolant Systems Integrated Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer EX X 3 1 Year Parts and Labor Unless Specified Motor Driven Guns w exception of Spoolmate Spoolguns Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Coolers and Electronic Controls Recorders Water Coolant Systems Non Integrated Flowgauge and Flowmeter Regulators No Labor HF Units Grids Spot Welders Load Banks Arc Stud Power Sources amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT amp SAF models Field Options NOTE Field options are covered for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater Bernard BrandedMig Guns No Labor Weldcraft Branded TIG Torches No Labor Subarc Wire Drive Assemblies 4 6 Months Batteries 0 X X 5 90 Days Parts and Labor MIG Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No Labor Spoolmate Spoolguns Canvas Covers x
43. nly well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual e Wear a safety harness if working above floor level Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical Insulate work clamp when not connected to workpiece to prevent contact with any metal object Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter type welding power sources after removal of input power Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers 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 c
44. not work alone Disconnect input power or stop engine before installing or servicing this eguipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards Properly install and ground this eguipment according to its Owner s Manual and national state and local codes Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet When making input connections attach proper grounding conduc tor first double check connections Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill APA This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable Do not touch electrode if you are in contact with the work ground or another electrode from a different machine Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present Use o
45. nuary 1 2006 Eguipment with a serial number preface of LG or newer This limited warranty supersedes all previous manufacturers warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below warrants to its original retail purchaser that new eguipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped from factory THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES MERCHANTABILITY AND FITNESS Within the warranty periods listed below manufacturer will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Manufacturer must be notified in writing within thirty 30 days of such defect or failure at which time manufacturer will provide instructions on the warranty claim procedures to be followed Manufacturer shall honor warranty claims on warranted eguipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the eguipment was delivered to the original retail purchaser or one year after the eguipment is sent to the distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutti
46. ps e USA Pa 3 A e Sila piece soud e doit tre mise la terre le faire directement avec un A Seulun personnel qualifi est autoris installer faire fonction c ble distinct ner entretenir et r parer cet appareil S Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre A Pendantle fonctionnement maintenir distance toutes les per ou une lectrode provenant d une autre machine H n n x A sonnes notamment les enfants de l appareil Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide doubl e UNE DECHARGE ELECTRIQUE peut e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le 0 entrainer la mort champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Le contact d organes lectriques sous tension peut oi Porter un harnais de s curit si l on doit travailler au us du sol provoquer des accidents mortels ou des br lures a se r r js t S kak mi dd s a nt xn graves Le circuit de l lectrode et de la pi ce est dese el que tous GS PANNEAUX et couvercies sont correcementen sous tension lorsque le courant est d livr la place A p sortie Le circuit d alimentation et les circuits internes de la machine Fixer le cable de retour de fa on obtenir un bon contact metal metal sont galement sous tension lorsque l alimentation est sur M
47. r than 6 sec onds before releasing it Welding will contin ue when trigger is released To stop welding press and release the trig ger 3 Jog Purge Switch Pressing the Jog switch allows the operator to jog wire without energizing the contactor or gas valve Pressing the Purge switch allows the opera tor to purge gas lines before welding and to preset gas flow rate at the flowmeter 4 Voltmeter Displays actual arc voltage or open circuit voltage at the feeder 5 Wire Speed Amperage Meter Displays wire speed in Inches per Minute To display wire speed in Meters per Minute see Section 3 9 Amperage displayed at the feeder is approxi mate Refer to power source for actual am perage To display Amperage see Section 3 9 6 Wire Speed Control Use control to adjust wire speed within the speed range selected by the wire speed range switch located on the inner control panel 7 HI LO Speed Range Switch Use switch to select speed range High range is 50 to 780 Inches per minute Low range is approximately half of high range 8 CC CV Switch Use switch to match feeder with the output of the power source 9 Soft Start Switch The Soft Start feature provides a smooth start during most weld conditions When the trigger is pulled the wire speed is approxi mately 2596 of the weld wire speed as set by the wire speed control knob After an arc is established the wire speed increases to the weld wire speed
48. rvice facility as determined by manufacturer Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL MANUFACTURER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EGUIPMENT FURNISHED BY MANUFACTURER IS EXCLUDED AND DISCLAIMED BY MANUFACTURER Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or conseguential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exc
49. s quipe ments de radio navigation et de communica tion les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l instal lation e Lutilisateur est tenu de faire corriger rapidement par un lectri cien qualifi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l appareil e Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique peut g ner le fonctionnement d appareils lectroniques comme des ordinateurs et des robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 m tres de tout quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e En cas d interf rences
50. s d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indi qu es dans la partie Entretien avant de toucher les pi ces LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereuse pour la sant e D autres consignes de s curit sont n cessaires dans les conditions e Ne pas mettre sa t te au dessus des vapeurs Ne pas respirer ces va suivantes risques lectriques dans un environnement humide ou si l on peurs porte des v tements mouill s sur des structures m talliques telles que e A l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de Sols grilles ou chafaudages en position coinc e comme assise ge l arc pour l vacuation des fum es et des gaz de soudage noux ou couch e ou s il y a un risque lev de contact in vitable ou Sila ventilation est m diocre porter un respirateur anti vapeurs approu accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser v les quipements suivants dans l ordre indiqu 1 un poste souder DC e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et tension constante fil 2 un poste souder DC manuel lectrode les instructions du fabricant concernant les m taux les consommables les ou 3 un poste souder AC tension vide r duite Dans la plupart des rev tements
51. sage on the display or by the blinking of the Red LED on Motor Board PC1 To view the Red LED turn Off power source remove shroud and turn power source On The Red LED blinks in a 2 5 second cycle The number of blinks in this period indicates the type of error If an error condi tion does not exist on the motor board the Red LED is on steady Communication Error The communication error occurs 2 5 seconds after a loss of communication between the motor board and the meter board The user may continue to weld with this error The error may be cleared by turning power Off wait ing a minimum of two seconds and turning power On Motor Overload Error The motor overload error can indicate that the motor has been drawing too much current for too long To remedy this reduce the wire feed speed or the wire feeder torgue load duty cycle The error may be cleared by turning power Off waiting a minimum of two seconds and turning power On Bus Bar Overheat Error The bus bar overheat error can be caused by the arc drawing too much current for too long To remedy this re duce the weld amperage or duty cycle OM 224 175 Page 19 SECTION 6 ELECTRICAL DIAGRAM i CB1 1 OFF gt VOLI SENSE LEAD re Reto 16 gt en s POWER M
52. sing Plug Skts Service Kit 1 Maa PLG9 21 131055 Housing Rcpt Skts Service Kit 2 PLG17 222397 Housing Plug Skts Service Kit 1 a RC2 080 328 Rept W Skts Free Hanging 1 When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your eguipment use only Manufacturer s Suggested Replacement Parts Model and serial number reguired when ordering parts from your local distributor OM 224 175 Page 24 Table 7 1 Drive Roll amp Wire Guide Kits 2 Drive Roll NOTE 7 Base selection of drive rolls upon the following recommended usages V Grooved rolls for hard wire U Grooved rolls for soft and soft shelled cored wires U Cogged rolls for extremely soft shelled wires usually hard surfacing types V Knurled rolls for hard shelled cored wires Drive roll types may be mixed to suit particular requirements example V Knurled roll in combination with U Grooved Inlet Wire PartNo Type 079 597 053 698 056 193 OKON S 0859 OM 224 175 Page 25 Notes Work like a Pro Pros weld and cut safely Read the safety rules at
53. sive heat mechani cal shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance VA y FIRE OR EXPLOSION hazard 4 Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NO
54. t sp cial ruban bleu du National Research Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lec triques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn tiques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes OM 224 175 Page 8 Boulevard Rexdale Ontario Canada M9W 1R3 t l phone 800 463 6727 ou Toronto 416 747 4044 site Internet www csa international org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 de American National Standards Institute 11 West 42nd Street New York NY 10036 8002 telephone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart A and Part 1926
55. t is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded eguipment is a hazard Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if reguired for the welding process If AC output is required use remote output control if present on unit Additional safety precautions are reguired when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following eguipment in order presented 1 a semiautomatic 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 welder is recommended And do
56. the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from
57. ular mils per ampere lt mm for metric use S 0007 F OM 224 175 Page 12 3 8 Installing And Threading Welding Wire Installing Wire And Adjusting CL Hold wire tightly to keep it Mub Tension from unraveling 1 Retaining Nut 2 Hub Tension Adjustment Knob Remove retaining ring and install spool so hub pin fits spool hole Re install retaining nut Adjust tension knob so only a slight force is needed to turn spool Threading Welding Wire 3 Pressure Assembly Adjustment Knob Lay gun cable out straight Open pressure assembly hold wire tightly and cut off end Push wire through guides into gun Close and tighten pressure assem bly Press jog switch until wire 3 comes out gun Feed wire against wooden surface and tighten knob so wire does not slip Cut off wire and close door LOT 150 mm Pull and hold wire cut off end Tighten JA A Clockwise Z Ha r z Ref 804 005 B OM 224 175 Page 13 3 9 Display Board PC20 DIP Switch Settings DIP Switch Factory Settings X Indicates Switch does not Affect This Function DIP switch is located behind front panel as shown FE
58. vo tre casque e Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc Porter des v tements confectionn s avec des mati res r sistantes et ignifuges cuir coton lourd ou laine et des bottes de protection LE SOUDAGE peut provoquer un RIZ incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels DES PIECES CHAUDES peuvent provoquer des br lures graves Ne pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche e Ne pas toucher aux pi ces chaudes utiliser les outils recom mand s et porter des gants de soudage et des v tements pais pour viter les br lures que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peuvent provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion une surchauffe ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardi
59. ycompatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic eguipment e Be sure this welding machine is installed and grounded according to this manual e Ifinterference 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 For Gasoline Engines A Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For Diesel Engines A Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm OM 224 175 Page 3 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 Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org Safe Handling of
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