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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 voltage, or duty cycle before welding. Exceeding duty cycle can damage unit and void warranty. Overheating 0 15 A or V OR Reduce Duty Cycle Minutes duty1 4/95 – 181 009 60% Duty Cycle At 150 Amperes 2-3. Volt-Ampere Curves Volt-amperecurves show minimum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall between curves shown. va_curve1 4/95 – 180 824 2-4. Installing Welding Gun 1 Drive Assembly 2 Gun Securing Knob 3 Gun End Loosen knob. Insert gun end through opening until it bottoms against drive assembly. Tighten knob. 4 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. Close door. 3 2 4 Ref. 802 285-A OM-929 Page 10 2-5. Setting Gun Polarity For Wire Type Tools Needed: 3/4 in Shown As Shipped – Set For Electrode Positive (DCEP) For Solid Steel Or Aluminum Wires (GMAW Process). Reverse Lead Connections – For Electrode Negative (DCEN) For Flux Cored Wires (FCAW Process). Drive Assembly Becomes Negative S-185 249 Wire Drive Assembly Lead To Positive (+) Output Terminal Work Clamp Lead To Negative (–) Output Terminal GUN POLARITY CHANGEOVER CONNECTIONS 1 1 Polarity Changeover Label 2 Wire Drive Assembly 3 Positive (+) Output Terminal 4 Negative (–) Output Terminal Always read and follow wire manufacturer’s recommended polarity. Close door. 2 43 Ref. 802 472 OM-929 Page 11 2-6. Installing Gas Supply Ref. 801 789 / Ref. 149 827-B / Ref. 158 697-A 1 Tools Needed: 2 CO2 Gas 4 5 1 Argon Gas OR 3 Chain gas cylinder to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. 1 Regulator/FlowGauge Install so face is vertical. 2 Gas Hose Connection Fitting has 5/8-18 right-hand threads. 3 Flow Adjust Typical flow rate is 20 cfh (cubic feet per hour). Check wire manufacturer’s recommended flow rate (see Section 3-2). This flow gauge can be adjusted between 5 and 25 cfh. 4 CO2 Adapter Customer Supplied 5 O-Ring Install adapter with O-ring between regulator/flow gauge and CO2 cylinder. 1-1/8, 5/8 in 2-7. Installing Wire Spool And Adjusting Hub Tension 801 790 When a slight force is needed to turn spool, tension is set. 9/16 in Tools Needed: Small Spool Adapter AA OM-929 Page 12 2-8. Changing Input Voltage From 230 Volts To 200 Volts Ref. 801 878-B Cut cable ties as necessary. 1 230 Volt Lead 2 Tubing Locate lead marked 230 VAC. Slide tubing down and disconnect lead splice. Fold tubing over 230 volt lead stub and secure. 3 200 Volt Lead Locate lead marked 200 VAC. Slide tubing down, and connect 200 volt lead stub to top half of the former 230 volt lead, and secure with existing hardware. Slide tubing over connection and secure. Tools Needed: 1 2 3 5/16, 3/8 in 2-9. Electrical Service Guide Input Voltage 200 230 Input Amperes At Rated Output 30 26 Max Recommended Standard Fuse Rating In Amperes 1 Time-Delay 2 Normal Operating 3 35 45 3040 Min Input Conductor Size In AWG/Kcmil 10 10 Max Recommended Input Conductor Length In Feet (Meters) 97 (29) 128 (39) Min Grounding Conductor Size In AWG/Kcmil 10 10 Reference: 1999 National Electrical Code (NEC) 1 Consult factory for circuit breaker applications. 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). OM-929 Page 13 2-10. Selecting A Location And Connecting Input Power 801 876-B 1 Rating Label Supply correct input power. 2 Plug 3 Receptacle Connect plug to receptacle. 4 Input And Grounding Conductors Connect directly to line disconnect device if hard wiring is required. 5 Line Disconnect Device See Section 2-9. Special installation may be required where gasoline or volatile liquids are present – see NEC Article 511 or CEC Section 20. 4 2 L1L2 230 VAC, 1 3 L1 L2 Always connect grounding conductor first. = GND/PE 5 Do not move or operate unit where it could tip. 18 in (457 mm) of space for airflow 1 OM-929 Page 14 OM-929 Page 15 2-11. Threading Welding Wire Ref. 802 472 / 802 480 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Outlet Wire Guide 7 Gun Conduit Cable Lay gun cable out straight. Tools Needed: 6 in (150 mm) Pull and hold wire; cut off end. 4 in (102 mm) Tighten Remove gun nozzle and contact tip. Turn On. WOOD Press gun trigger until wire comes out of gun. Reinstall contact tip and nozzle Feed wire to check drive roll pressure. Tighten knob enough to prevent slipping. Cut off wire. Close door. Open pressure assembly. Push wire thru guides into gun; continue to hold wire. Close and tighten pressure assembly, and let go of wire. 7 1 2 3 6 4 5 Hold wire tightly to keep it from unraveling. OM-929 Page 16 SECTION 3 – OPERATION 3-1. Control...