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OM-198 076A
April 2000
Processes
MIG (GMAW) Welding
®
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source And
Wire Feeder
Auto Arc XLT 135 / 165
For Warranty Claims And Technical Support, Contact:
Milweld Inc., National Distributor
P.O. Box 338, Hortonville, WI 54944-0338
Tel 920-779-0916 Fax 920-779-0924
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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 . . . . . . .
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions Means “Note”; not safety related. to avoid the hazards. 1-2. Arc Welding
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. weld. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 li
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1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cau
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1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. 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 3. Do not coil or drape cables around your body. years of resea
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SECTION 1 − CONSIGNES DE SECURITE − LIRE AVANT UTILISATION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Identifie un message de sécurité particulier. risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous au
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LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation. (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées Veiller toujours à bien aérer les espaces
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1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou à proxi- Rester à l’écart des organes mobiles comme le mité de surfaces infllammables. ventilateur. Maintenir fermés et fixement en place les portes, Ne pas installer l’appareil à proximité de produits inflammables panneaux, recouvrements et dispositifs de Ne pa
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1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. Règles de sécurité en soudage, coupage et procédés conne
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SECTION 2 − SPECIFICATIONS 2-1. Specifications A. 115 VAC Model Amperes Input at Maximum Open- Rated Welding Amperage Rated Load Output Weight Overall Circuit Voltage KVA KW Output Range 115 V, 60 Hz, Single- W/ Gun Dimensions DC Phase Length: 18-7/8 in (479 mm) 90 A @ 19 Volts DC, 20 2.90 2.50 55 lb 20% Duty Cycle Width: 10-5/8 in (25 kg) 30 − 135 28 (270 mm) 63 A @ 21 Volts DC, 15* 2.20* 1.77* 20% Duty Cycle* Height: 12-3/8 in (314 mm) Solid/ Flux Cored/ Wire Feed Speed Range Stainless Alumin
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2-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) A. 115 VAC Model opens, output stops, and cooling fan runs. Wait fifteen minutes for 200 unit to cool. Reduce amperage or duty cycle before welding. 135 Exceeding duty cycle can 100 damage unit or gun and void warranty. 80 60 40 20 10 2 4168 80 40 600 100 1 20 Duty Cycle % 20% duty cycle at 90 amps 2 Minutes Welding 8 Minutes Resting B.
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2-3. Volt-Ampere Curves The volt-ampere curves show the A. 115 VAC Model minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. 30.0 25.0 20.0 Range 4 15.0 Range 3 Range 2 10.0 Range 1 5.0 0.0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 LOAD AMPS B. 230 VAC Model 30.0 25.0 20.0 Range 4 Range 3 15.0 Range 2 Range 1 10.0 5.0 0.0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 19
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SECTION 3 − INSTALLATION 3-1. Installing Welding Gun 1 Drive Assembly 2 Gun Securing Thumbscrew 3 Gun End 4 Loosen thumbscrew. Insert gun end through opening until it bottoms against drive assembly. Tighten thumbscrew. 4 Gun Trigger Leads 2 3 Insert leads, one at a time, through gun opening on front panel. Connect female friction terminals to matching male terminals in unit. Polarity is not important. Close door. 1 Ref. 802 440 3-2. Installing Work Clamp 1 Nut 3 2 Work Cable From Unit 1 3 Work C
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3-3. Process/Polarity Table Cable Connections Process Process P Polarity olarity Cable To Gun Cable To Work GMAW − Solid wire with shield- DCEP − Reverse polarity Connect to positive (+) out- Connect to negative ( −) output ing gas put terminal terminal FCAW − Self-shielding wire − DCEN − Straight Polarity Connect to negative ( −) Connect to positive (+) output no shielding gas output terminal terminal 3-4. Changing Polarity 1 Lead Connections For Direct Current Electrode Positive (DCEP) 2 Lead
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3-5. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other station- Tools Needed: ary support so cylinder cannot fall and break off valve. 5/8, 1-1/8 in 1 Cap 2 Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. Gas flow 1 blows dust and dirt from valve. Close valve. 3 Cylinder 4 Regulator/Flowmeter 2 Install so face is vertical. 5 Regulator/Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection 3 Connect customer supplied
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3-6. Selecting A Location And Connecting Input Power For 115 VAC Model 1 Rating Label 2 Grounded Receptacle A 115 volt, 20 ampere individual 2 18 in 1 branch circuit protected by time-de- (460 mm) lay fuses or circuit breaker is re- quired. 3 Plug From Unit Select extension cord of 14 AWG for up to 50 ft (15 m) or 12 AWG for 3 50 up to 200 ft (61 m). Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. 18 in (460 mm) 802 4
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3-7. Selecting A Location And Connecting Input Power For 230 VAC Model 1 Rating Label Supply correct input power. 2 Plug 3 Receptacle Connect plug to receptacle. 4 Line Disconnect Device 18 in (457 mm) of space for airflow 4 See Section 3-8. Special installation may be L1 required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. L2 Always connect grounding conductor first. = GND/PE 1 3 2 L2 L1 230 VAC, 1 Do not move or operate unit where it could tip.
