Century OM-117071002, Operator'S Manual

Page 1: ...PART 0M I17071002 Operator s Manual 80 AMP WIRE FEED WELDER Made in U S A Form Number 811 597 000 Revision A August 1999 ...

Page 2: ... FOR WELDING 13 SETTING UP THE WORK PIECE 13 WELDING POSITIONS 13 PREPARING THE JOINT 13 GROUND CLAMP CONNECTION 14 LEARNING TO WELD 15 GET TO KNOW YOUR WELDER 15 HOLDING THE GUN 15 POSITION THE GUN TO THE WORKPIECE 15 DISTANCE FROM THE WORKPIECE 16 LAYING A BEAD 16 TYPES OF WELD BEADS 16 WELDING TECHNIQUES 17 TRAVELING THE GUN 17 TYPES OF WELD BEADS 17 WELDING POSITIONS 18 MULTIPLE PASS WELDING 1...

Page 3: ...f the step s that follow This symbol indicates that the helmet must be worn during the step s that follow to protect against eye damage and burns due to flash hazard This symbol indicates that the possibility of toxic gas hazard exists during operation of the step s that follow This symbol indicates that the possibility of being burned by hot slag exists during operation of the step s that follow ...

Page 4: ...g Do not allow the welder to be connected to the power source or attempt to weld if the welder welding 4 cables welding site or welder power cord are exposed to any form of atmospheric precipitation or salt water spray Do not carry coiled welding cables around shoulders or any other part of the body when they are plugged into the welder Do not modify any wiring ground connections switches or fuses...

Page 5: ...rea understands and follows these safety instructions as well REMEMBER Arc welding by nature produces sparks hot spatter molten metal drops hot slag and hot metal parts that can start fires burn skin and damage eyes Do not wear gloves or other clothing that contain oil grease or other flammable substances Do not wear flammable hair preparations Do not weld in an area until it is checked and cleare...

Page 6: ...toxic fumes such as galvanized 6 steel unless the coating is removed Make certain the area is well ventilated and the operator and all bystanders are wearing air supplied respirators Do not weld cut or heat lead zinc cadmium mercury beryllium or similar metals without seeking professional advice and inspection of the ventilation of the welding area These metals produce EXTREMELY TOXIC fumes which ...

Page 7: ...A Standard 29 CFR Part 1910 Subpart Q WELDING CUTTING AND BRAZING obtainable from your state OSHA office or U S Dept of Labor OSHA Office of Public Affairs Room N3647 200 Constitution Ave NW Washhington DC 20210 www osha gov CSA Standard W117 2 Code for SAFETY IN WELDING AND CUI rlNG obtainable from Canadian Standards Association 178 Rexdale Blvd Etobicoke Ontario M9W 1R3 www csa ca American Weldi...

Page 8: ...Y Welder 1 332 239 000 Face Shield 1 Face Shield Handle 1 Handle Screws 3 Shaded Lens 1 Clear Lens 1 930 405 000 Parts Bag 1 334 160 000 Contact Tip 0 030 2 334 203 000 Nozzle 1 331 469 001 Wire 030 Fluxcore 1 2 804 502 000 Card Registration 1 811 597 000 Manual Instruction 1 Weld Gun Nozzle Face Shield Contact Tip Figure 1 Welder Parts Accessories ASSEMBLE THE FACE SHIELD Press one of the lens re...

Page 9: ...d that will mate directly with the ac power source receptacle and the welder power cord without the use of adapters Make certain that the extension cord is properly wired and in good electrical condition Extension cords must fit the following wire size guidelines 0 25 ft requires 12 gauge Do not use an extension cord over 25 ft in length SELECTING THE WELDING WIRE This welder uses only four inch s...

Page 10: ...ke is to cause the spool of wire to stop turning at nearly the same moment that wire feeding stops After checking to make sure that your welder is disconnected from the ac power source free the leading end of the wire from the spool but do not let go of it until told to do so or the wire will unspool itself Using a wire cutter cut the bent end off the leading end of the wire so that only a straigh...

Page 11: ...ARNING ARC RAYS CAN INJURE EYES To reduce the risk of arc flash make certain that the wire coming out of the end of the gun does not come in contact with the ground clamp or any grounded material during the drive tension setting process or arcing will occur a b Pull the trigger on the gun Turn the drive tension adjustment knob clockwise increasing the drive tension until the wire seems to feed smo...

Page 12: ...e CSA rated output of 80 amps This means that you can weld for two 2 minutes out of 10 with the remaining eight 8 minutes required for cooling See the table 3 Table 3 Duty Cycle Ratings Duty Maximum Required Cycle Welding Resting Rating Time Time 20 2 minutes 8 minutes 40 4 minutes 6 minutes 60 6 minutes 4 minutes 80 8 minutes 2 minutes 100 10 minutes 0 minutes CAUTION Do not constantly exceed the...

Page 13: ... eyes and skin Prolonged exposure to a welding arc can cause blindness and burns Never strike an arc or begin welding unless you are adequately protected Wear flameproof welding gloves heavy long sleeved shirt cuffless trousers high topped shoes and a welding helmet I 1 I Figure 4 Work Surface and Equipment SETTING UP THE WORK PIECE WELDING POSITIONS Welding with an ac wire welder can be done in a...

Page 14: ...welding helmet or shield in place and are wearing the recommended protective clothing DO NOT CONTINUE unless you have read understand and intend to follow the entire SAFETY SUMMARY provided at the front of this manual Ground Clamp Connection The ground clamp connection is part of the current circuit A poor connection at the ground clamp will waste power and heat Scrape away dirt rust scale oil or ...

Page 15: ...find the one that seems to work best for you Position The Gun To The Workpiece There are two angles of the gun nozzle in relation to the work piece that must be considered when welding 1 Angle A Figure 7 can be varied but in most cases the optimum angle will be 60 degrees The point at which the gun handle is parallel to the work piece If angle A is increased penetration will increase If angle A is...

Page 16: ...roof welding gloves A heavy long sleeved shirt cuffless trousers high topped shoes and a welding helmet WARNING ELECTRIC SHOCK CAN KILL To prevent ELECTRIC SHOCK do not perform any welding while standing kneeling or lying directly on the grounded work TYPES OF WELD BEADS The following paragraphs discuss the most commonly used arc welding beads IMPORTANT The wire in this welder is always electrical...

Page 17: ...ng at the top of a weld joint and pulling the gun down toward the bottom However in the event that puddle control becomes difficult such as the puddle wanting to run downward starting a vertical weld at the bottom of a weld joint and pushing the gun up toward the top will help to overcome this problem 2 TRAVEL SPEED is the rate at which the gun is being pushed or pulled along the weld joint For a ...

Page 18: ...p prevent the weld puddle from running downward while still allowing slow enough travel speed to achieve good penetration A good starting point for angle B is about 30 degrees DOWN from being perpendicular to the work piece Figure 13 Horizontal Position Weld The VERTICAL POSITION Figure 14 is the next most difficult position Pulling the gun from top to bottom may be easier for many people but in s...

Page 19: ...gure 15 Triple Pass V Butt Joint Most fillet weld joints on metals of moderate to heavy thickness will require multiple pass welds to produce a strong joint The illustrations in Figure 16 show the sequence of laying multiple pass beads into a T fillet joint and a lap fillet joint Lap Joint Welded In Three Passes Figure 16 Triple Pass Lap And T Weld Joint SPECIAL WELDING METHODS SPOT WELDING The pu...

Page 20: ...lding the same thickness material with a continuous bead 3 The LAP SPOT METHOD directs the welding arc to penetrate the bottom and top pieces at the same time right along each side of the lap joint seam Select the heat setting as if you were welding the same thickness material with a continuous bead SPOT WELDING INSTRUCTIONS Select the heat setting recommended above for the method of spot welding ...

Page 21: ...the nozzle in a timely fashion WILL CAUSE DAMAGE TO THE FRONT END OF THE GUN ASSEMBLY which is NOT REPLACEABLE The results of the inaction will REQUIRE THE REPLACEMENT OF THE ENTIRE GUN ASSEMBLY 1 Stop welding and clean any accumulated slag or spatter from the nozzle every 5 to 10 minutes of welding time 2 When welding overhead if any molten metal drips from the weld puddle and falls into the nozz...

Page 22: ...ecommended for your welder TROUBLESHOOTING The following TROUBLESHOOTING information is provided as a guide to help resolve some of the more common problems that could be encountered Table 4 is a troubleshooting table provided to help you determine a possible remedy when you are having a problem with your welder This table does not provide all possible solutions only those possibilities considered...

Page 23: ...4 Liner is stretched or is too long 1 Gun liner is worn or damaged 2 Liner stretched or is too long 3 Wrong size contact tip 4 contact tip clogged or damaged Bad connection from cable to clamp Slag buildup inside nozzle or nozzle is shorted 1 Check ground and connections tighten as necessary 2 Check connection to gun or replace gun 1 Replace wire speed circuit board 2 Adjust the drive tension 3 Re...

Page 24: ...Feed Motor Wire Feed Drive Black Gun Leads Power Cord White Black Blacl_ White White Welding Gun Yellow Red Wire Speed Control Low Off High Min 1 Max 2 Switch Ground Calmp Back View Of Switch Transformer 24 ...

Page 25: ...1117 o711 ...

Page 26: ...Y THE IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THIS EXPRESS WARRANTY AFTER 1 2 5 YEARS AS APPLICABLE FROM DATE OF PURCHASE ALL RISK OF LOSS FROM WHATEVER REASON SHALL BE PUT UPON THE PURCHASER THE MANUFACTURER SHALL NOT BE LIABLE FOR INCIDENTAL AND CONSEQUENTIAL DAMAGES UNDER ANY CIRCUMSTANCES THE MANUFACTURER S LIABILITY IF ANY SHALL NE...

Page 27: ...311 000 246 404 000 880 395 000 880 391 000 312 076 666 Description Main weld transformer Thermal breaker assy Base Drive deck Wire tensioner kit Fan motor bracket Hood Drive motor gearbox assy Gun assy Black trigger for 238 490 Red trigger for 238 542 3 position switch 0 030 Contact Tips KP45 40 15 KP1937 1 334 228 000 Model 117 071 Rated Output 80 amp Primary Input Input Plug 120V 15 amp 15a Ste...