Page 3 - TABLE OF CONTENTS; WARNING
TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards ...
Page 5 - SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING; Symbol Usage; Arc Welding Hazards; ELECTRIC SHOCK can kill.; FUMES AND GASES can be hazardous.
OM-194 430 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. T...
Page 6 - WELDING can cause fire or explosion.
OM-194 430 Page 2 Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks fly off from theweld. ARC RAYS can burn eyes and skin. D Wear a welding helmet fitted with a proper shade of filter to protectyour face and eyes...
Page 7 - Additional Symbols For Installation, Operation, And Maintenance; Principal Safety Standards
OM-194 430 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or nearcombustible surfaces. D Do not install unit near flammables. D Do not overload building wiring – be sure power supply system isproperly siz...
Page 8 - EMF Information
OM-194 430 Page 4 1-5. EMF Information Considerations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flows through welding cables, will cause electro-magnetic fields. There has been and still is some concern about suchfields. However, after examining...
Page 9 - Signification des symboles; Dangers relatifs au soudage à l’arc; UN CHOC ÉLECTRIQUE peut tuer.
OM-194 430 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédureprésente des risques de danger ! Ceux-ci sont identifiéspar des symboles adjacents aux directives. Y Identifie un mes...
Page 10 - LE BRUIT peut affecter l’ouïe.
OM-194 430 Page 6 Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RAYONS DE L’ARC peuvent pro-voquer ...
Page 13 - SECTION 2 – INSTALLATION; Specifications; A or V
OM-194 430 Page 9 SECTION 2 – INSTALLATION 2-1. Specifications Amps Input at Rated Output, 60 Hz, Single-Phase Rated Output Max. OpenCir- cuit Voltage 200 V 230 V 460 V 575 V KVA KW 250 A at 28 VDC, 40% Duty Cycle 200 A at 28 VDC, 60% Duty Cycle 32 50 2.3* 44 2* 22 1* 18 0.8* 10 0.46* 7.7 0.13* Wire...
Page 14 - Welding Gun Duty Cycle And Overheating; CAUTION
OM-194 430 Page 10 2-3. Welding Gun Duty Cycle And Overheating CAUTION WELDING LONGER THAN RATED DUTY CYCLE can damage gun and void warranty. • Do not weld at rated load longer than shown below. • Using gasless flux cored wire reduces gun duty cycle. warn7.1 8/93 Duty Cycle is percentage of 10minute...
Page 15 - Installing Running Gear; Installing Welding Gun
OM-194 430 Page 11 2-5. Installing Running Gear ST-801 856-A Install running gear as shown. Tools Needed: 2-6. Installing Welding Gun Ref. ST-801 789-A 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen securing knob. Insert gunend through opening until it bottomsagainst drive assembly. Tightenkn...
Page 16 - Setting Gun Polarity For Wire Type
OM-194 430 Page 12 2-7. Setting Gun Polarity For Wire Type Tools Needed: 3/4 in Ref. 194 425 1 2 4 3 1 Polarity Changeover Label 2 Wire Drive Assembly 3 Positive (+) Output Terminal 4 Negative (–) Output Terminal Always read and follow wiremanufacturer’s recommendedpolarity. Close door. Ref. ST-801 ...
Page 19 - -13. Selecting A Location And Connecting Input Power
OM-194 430 Page 15 2-12. Electrical Service Guide Input Voltage 200 230 460 575 Input Amperes At Rated Output 50 44 22 17 Max Recommended Standard Fuse Or Circuit Breaker Rating InAmperes 80 70 35 25 Min Input Conductor Size In AWG/Kcmil 8 8 10 12 Max Recommended Input Conductor Length In Feet (Mete...
Page 21 - SECTION 3 – OPERATION; Controls
OM-194 430 Page 17 SECTION 3 – OPERATION 3-1. Controls 1 Wire Speed Control The scale around the control is per-cent, not wire feed speed. 2 Voltage Control The scale around the control isactual voltage. See Section 3-2, or inside weldingpower source door, for weld param-eters chart. 3 Pilot Light 4...
Page 22 - Weld Parameters
OM-194 430 Page 18 3-2. Weld Parameters Wire Type, Wire Operator Material Thickness Shielding Gas,And Flow Rate Diameter (inch) Operator Control Settings 3/8 in 5/16 in 1/4 in 3/16 in 10 ga 12 ga 14 ga 16 ga 18 ga 20 ga 22 ga 24 ga Volts – – – 20.0 19.5 19.0 18.0 18.0 18.0 17.5 17.0 17.0 .023 Feed S...
Page 23 - Installing Receptacle Module For Use With A Spool Gun (Optional)
OM-194 430 Page 19 3-3. Installing Receptacle Module For Use With A Spool Gun (Optional) ST-801 869-A 1 Knockout Panel Pierce front panel label at cornersof knockout and follow groves infront panel. The knockout is held inplace by a thin metal section half-way down each side. Be sure to cutlabel acr...
Page 24 - SECTION 4 – MAINTENANCE AND TROUBLESHOOTING; Routine Maintenance; Months; Circuit Breaker CB1
OM-194 430 Page 20 SECTION 4 – MAINTENANCE AND TROUBLESHOOTING 4-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. Repair or replacecracked weld cable. Clean and tighten weld terminals. 6 Months Blow out or vacuuminside. During heavyservice, clean mont...
Page 26 - Casing
OM-194 430 Page 22 4-7. Removing Nozzle, Contact Tip, And Adapter, Changing Liner, And Cleaning Gun Casing Ref. ST-800 797-C Y Turn off welding powersource/wire feeder. 1 Nozzle 2 Contact Tip 3 Adapter . Wire size stamped on tip –check and match wire size. HeadTube Tools Needed: 3/8 in Lay gun cable...
Page 27 - Replacing Switch And/Or Head Tube
OM-194 430 Page 23 4-8. Replacing Switch And/Or Head Tube Ref. ST-800 795-C 1 Remove handlelocking nut. 2 Remove switch housing. Note: If installing newswitch, push switch lead connectors onto terminal ofnew switch (polarity is not important). Install switchback into handle, and secure with handle l...
Page 28 - Troubleshooting
OM-194 430 Page 24 4-9. Troubleshooting Trouble Remedy No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 2-13). Replace building line fuse or reset circuit breaker if open (see Section 2-13). Reset circuit breaker CB1 (see Section 4-2). Secure gun trigger connecti...
Page 29 - SECTION 5 – ELECTRICAL DIAGRAM; Figure 5-1. Circuit Diagram For Welding Power Source
OM-194 430 Page 25 SECTION 5 – ELECTRICAL DIAGRAM SC-184 944-A Figure 5-1. Circuit Diagram For Welding Power Source
Page 30 - Notes
Page 31 - SECTION 6 – PARTS LIST
OM-194 430 Page 27 SECTION 6 – PARTS LIST . Hardware is common andnot available unless listed. 1 2 3 4 5 6 7 8 9 10 (Fig. 6 – 2) 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 29 30 31 32 33 34 35 28 36 37 38 39 40 41 801 783-B Figure 6-1. Main Assembly
Page 38 - Options and Accessories; Note
Options and Accessories BETA-MIG 2510 Olympic 30A Spool Gun #130 831-01-9 Ideal for aluminum welding jobs. 200 Amp,100% duty cycle, air-cooled, 1 lb spool gunwith 30 ft (9.1 m) cable assembly. Use withSpool Gun Module #043 084. Spool Gun Module #043 084 Required if welding with spool gun. Provides a...
Page 40 - Please complete and retain with your personal records.; Resources Available
PRINTED IN USA M o de l N a m e Se r i a l / St y l e N um be r P ur c ha se D a t e (Date whi c h equi pment was del i v ered to ori gi nal cus tomer.) Di st r i but o r A ddr e ss C i t y St a t e Z i p Please complete and retain with your personal records. Always provide Model Name and Serial/Sty...
