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Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. ssb1.1 10/91 – SB-187 997 OM-1318 Page 9 OM-1318 Page 10 2-3. Welding Power Source 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 unit to cool. Reduce amperage or duty cycle before welding. Exceeding duty cycle can damage unit or gun and void warranty. 30% Duty Cycle At 130 Amperes Overheating 0 15 A or V OR Reduce Duty Cycle Minutes duty1 4/95 – SB-180 844 300 250 200 150 100 75 50 10 15 20 25 30 40 50 60 70 80 100 DC AMPERES % DUTY CYCLE 3 Minutes Welding 7 Minutes Resting 2-4. 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 10 minutes that gun can weld at rated load without overheating. Continuous Welding SB1.1 8/93 0 10 Minutes Definition .023 To .045 in (0.6 To 1.1 mm) Hard Or Flux Cored Wires 100% Duty Cycle At 100 Amperes Using CO2 .023 To .045 in (0.6 To 1.1 mm) Hard Or Flux Cored Wires 60% Duty Cycle At 100 Amperes Using Mixed Gases 6 Minutes Welding 4 Minutes Resting SECTION 3 – INSTALLATION 3-1. Installing Work Clamp 1 Insulator 2 Bolt 3 Smaller Hole 4 Work Clamp Tabs Bend tabs around work cable. 5 Work Cable From Unit 6 Nut 1 2 3 4 5 6 Ref. ST-025 190-D Tools Needed: 3/8, 7/16 in 3-2. Installing Welding Gun And Changing Polarity 1 Drive Assembly 2 Gun Securing Bolt 3 Gun End Loosen securing bolt. Insert gun end through opening until it bottoms against drive assembly. Tighten bolt. 4 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. 5 Jumper Links Place jumper links in position shown for desired polarity. Close door. Tools Needed: 2 1 3 4 Ref. ST-801 987 5/16 in Straight Polarity DCEN Reverse Polarity DCEP Flux Cored Wires (FCAW–Without Gas) Solid Steel Or Aluminum Wires (GMAW–With Gas) Follow wire manufacturer’s recommendation. 5 OM-1318 Page 11 3-3. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. 1 Cap 2 Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. Close valve. 3 Cylinder 4 Regulator/Flowmeter Install so face is vertical. 5 Gas Hose Connection Fitting has 5/8-18 right-hand threads. 6 Gas Fitting Install gas hose between gas hose connction on regulator/flowmeter and gas fitting on rear of welding power source. 7 Flow Adjust Typical flow rate is 20 cfh (cubic feet per hour). Check wire manufacturer’s recommended flow rate. 8 CO2 Adapter 9 O-Ring Install adapter with O-ring between regulator/flowmeter and CO2 cylinder. Tools Needed: CO2 Gas 8 9 3 1 2 4 5 7 1 2 3 Argon Gas OR ssb3.1* 12/92 – ST-158 697-A / ST-801 986 5/8, 1-1/8 in 6 OM-1318 Page 12 OM-1318 Page 13 3-4. Electrical Service Guide Input Voltage 230 Input Amperes At Rated Output 20 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Circuit Breaker 1, Time-Delay 2 20 Normal Operating 3 30 Min Input Conductor Size In AWG/Kcmil 14 Max Recommended Input Conductor Length In Feet (Meters) 66 (20) Min Grounding Conductor Size In AWG/Kcmil 14 Reference: 1999 National Electrical Code (NEC) 1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse. 2 “Time-Delay” fuses are UL class “RK5” . 3 “Normal Operating” (general purpose – no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and above). Caution: Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard. 3-5. Selecting A Location And Connecting Input Power 1 Rating Label Supply correct input power. 2 Plug 3 Receptacle Connect plug to receptacle. 4 Line Disconnect Device See Section 3-4. Special installation may be required where gasoline or volatile liquids are present – see NEC Article 511 or CEC Section 20. ssb2.2* 1/94 – ST-801 988 / 802 401 1 18 in (457 mm) of space for airflow L2 L1 L1 L2 2 230 VAC, 1 Always connect grounding conductor first. = GND/PE 4 3 Do not move or operate unit where it could tip. OM-1318 Page 14 3-6. Installing Wire Spool And Adjusting Hub Tension S-0499 15/16 in Standard Wire Spool 1 Lb Wire Spool When a slight force is needed to turn spool, tension is set. Tools Needed: Standard Wire Reel Part No. 183 312 Part No. 135 615 OM-1318 Page 15 3-7. Installing Drive Roll, Wire Guide And Threading Welding Wire 1 Drive roll Choose correct drive roll for wire type, and align drive roll with flat spot on shaft. Slide drive roll onto shaft and secure with...