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OM-219 316C 2006 −10
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
®
Description
Arc Welding Power Source And
Wire Feeder
MW 140 Plus
And H-10 Gun
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 Insta
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TABLE OF CONTENTS SECTION 9 − MIG WELDING (GMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 9-1. Typical MIG Process Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 9-2. Typical MIG Process Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 9-3. Holding And Positioning Welding Gun .
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Warning: Protect yourself and others from injury — read and follow these precautions. 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 necessa
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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 an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching HOT PART
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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. Have only qualified persons remove doors, Do not overload building wiring − be sure power supply system is panels, covers, or guards for main
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1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: from Global Engineering Documents (phone: 1-877-413-5184, website: 800 −463 −6727 or in Toronto 416 −747 −4044, website: www.csa −in- www.global.ihs.com). ternational.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American Na
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som _3/05 Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comporte des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints. Ce groupe de symboles signifie Avertissement ! Attention ! Risques Indique un message de sécurité particulier
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LES RAYONS D’ARC peuvent entraî- LES ACCUMULATIONS DE GAZ ner des brûlures aux yeux et à la peau. risquent de provoquer des blessures Le rayonnement de l’arc du procédé de soudage ou même la mort. génère des rayons visibles et invisibles intenses Fermer l’alimentation du gaz protecteur en cas (ultraviolets et infrarouges) susceptibles de provo- de non-utilisation. quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. Veiller toujours à bien aérer l
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2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO- DES ORGANES MOBILES peuvent SION. provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou S’abstenir de toucher des organes mobiles tels à proximité de surfaces inflammables. que des ventilateurs. Ne pas installer l’appareil à proximité de Maintenir fermés et verrouillés les portes, produits inflammables. panneaux, recouvrements et dispositifs de pro
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2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone : de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou à Toronto 416-747-4044, site Internet : ternet : www.global.ihs.com). www.csa-international.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87
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SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Amperage Voltage Hertz Negative V A Hz Direct Current Positive Single Phase Input (DC) Output Voltage Input Off On Do Not Switch Gas Metal Arc Wire Feed While Welding Welding (GMAW) SECTION 4 − SPECIFICATIONS 4-1. Specifications 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: 19-1/2 in (495 mm) 90 A @ 19 Volts DC
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4-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for 200 unit to cool. Reduce amperage or duty cycle before welding. 140 Exceeding duty cycle can 100 damage unit or gun and void 80 warranty. 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 Overheating A or V 0
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4-3. Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source. Curves 30.0 of other settings fall between the curves shown. 25.0 20.0 RANGE 4 15.0 RANGE 3 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 Amperage ssb1.1 10/91 − 217 624-A OM-219 316 Page 11 Voltage
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SECTION 5 − INSTALLATION 5-1. Installing Welding Gun 1 Drive Assembly 2 Gun Securing Thumbscrew 3 Gun End 4 Loosen thumbscrew. Insert end through opening until it bottoms against drive assembly. Tighten 3 thumbscrew. Welding gun must be inserted completely to prevent leakage of shielding gas. 4 Gun Trigger Leads Insert leads, one at a time, through gun opening on front panel. Connect female friction terminals to matching male terminals in unit. 12 Polarity is not important. Close door. Be sure
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5-3. 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 5-4. Changing Polarity 1 Lead Connections For Direct CHANGING Current Electrode Negative POLAR
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5-5. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. DO NOT use Argon/Mixed gas regulator/flowmeter 1 Cap with CO shielding gas. See Parts List for optional 1 2 2 Cylinder Valve CO gas regulator/flowmeter. 2 Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. Close valve. 4 3 Cylinder 4 Regulator/Flowmeter Install so face is vertical. 2 5 Regulat
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5-6. Selecting A Location And Connecting Input Power 1 Rating Label 2 Grounded Receptacle A 115 volt, 20 ampere individual branch circuit protected by time-delay fuses or circuit breaker is required. 3 Plug From Unit Select extension cord of 14 AWG for up to 50 ft (15 m) or 12 AWG for 50 up to 200 ft (61 m). Special installation may be Do not move or operate unit required where gasoline or where it could tip. volatile liquids are present − see NEC Article 511 or CEC Section 20. 2 18 in 1 (46
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5-7. Installing Wire Spool And Adjusting Hub Tension Installing 4 in (102 mm) Wire Spool When a slight force is needed to turn spool, tension is set. Installing 8 in (203 mm) Wire Spool Adapter used with 8 in (203 mm) spool only. When a slight force is needed to turn spool, tension is set. Retaining ring used with 8 in (203 mm) spool only. Tools Needed: 1/2 in 803 012 / 803 013 -B / Ref. 802 971-C OM-219 316 Page 16
