M200250 owners - updated - BLUESHIELD

1 08/01 owner S MANUALKEEP THIS MANUALThe technical specifications and the wiring diagrams contained in this owner s manual are valid only for the model that has the part number indicated 200 - M 250M 200:ALW-M120500383M 250:ALW-M120500384 Air Liquide Welding is a trademark of L Air Liquide OF CONTENTS1 SAFETY PRECAUTIONS - READ BEFORE OF EQUIPMENT .. PROTECTION .. AND EXPLOSION PREVENTION .. FUME HAZARDS .. THE POWER SOURCE .. FIELDS CAN AFFECT PACEMAKERS .. RADIATION CAN CAUSE INJURY .. WELDING CAN CAUSE INTERFERENCE .. AND THE EFFECTS OF LOW FREQUENCY AND MAGNETIC FIELDS .. SAFETY STANDARDS ..52 SPECIFICATIONS AND DESCRIPTION .. COMPLETE WITH .. CYCLE AND OVERHEATING .. CURVES .. THE EQUIPMENT TO THE MAIN SUPPLY.

2 INPUT VOLTAGE .. A LOCATION .. POLARITY .. GAS HOSE AND REGULATOR .. THE WIRE SPOOL AND ADJUSTING HUB TENSION .. THE WIRE INTO THE WELDING GUN .. THE SG 300 SPOOL GUN ..114 OPERATION PANEL CONTROLS .. PANEL CONTROLS ..125 MAINTENANCE AND MAINTENANCE .. FEEDER MAINTENANCE ..136M 200 ELECTRICAL DIAGRAM ..147M 250 ELECTRICAL DIAGRAM ..158M 200 SPARE PARTS LIST ..169M 250 SPARE PARTS LIST ..1810 M 200 M 250 COMMON SPARE PARTS LIST ..2011 AL2 AIR-COOLED MIG WELDING GUN ..22 The use of welding equipment can causeinjury to the operator. The reading and understandingof the safety standards mentioned below is compulso-ry prior to connecting, preparing, using or transportingwelding INSTALLATION OF EQUIPMENT Compliance with the following standards is fundamental to and maintenance of equipment mustbe performed in compliance with local inspect the welder plug,receptacle and wiring.

3 If damaged, replaceimmediately with approved electrical connec-tions and adequately sized the welding ground as near as possibleto the operating not pass welding equipment cables throughor near lifting chains, crane cables or any elec-trical earth grounding of the workpiece is required,ground it directly with a separate not touch the electrode if you are in contactwith the work, ground or another electrode froma different welding only well-maintained equipment. Repair orreplace damaged parts immediately. Maintainwelding equipment according to owner s use welding equipment near water. Donot spray water or other liquids on the direct contact between wet garments andmetal parts that are electrically wear gloves and rubber-soled shoeswhen working in wet areas or standing on turn off welding equipment that is notbeing used.

4 Do not leave welding DC VOLTAGE exists after removal ofinput power or inverters. Always discharge input capacitors before touch-ing any parts. Service work should be complet-ed by qualified personnel PERSONAL operations produce radiation, noise,heat and noxious fumes. Suitable safety pre-cautions must be taken to minimize the fire resistant work gloves, longsleeve shirts, pants, safety shoes, cap and weld-ing helmet to protect the skin from radiation andmetal sparks. wear ear SAFETY PRECAUTIONS - READ BEFORE USINGWARNINGRead and understand this entire owner s Manual before installing, operating or servicing this equipment. While theinformation contained in this owner s manual represents our best judgment, Air Liquide assumes no liability for of this work, in whole or part, without written permission of the publisher is rights publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by anyerror or omission in the Air Liquide M 200 M 250 owner s Manual, whether such error results from negligence,accident or any other wear eye protection with side a fire resistant screen around the weld-ing area to protect bystanders from radiation,sparks and gas cylindersare potentially dangerous.

5 Consult the supplierfor correct handling procedures. Always protectcompressed gas cylinders from the sun s rays,flames and sudden temperature changes. FIRE AND EXPLOSION PREVENTIONHot slag and sparks cancause fire. The risk of fire and explosion can beminimized by removing all flammable materialfrom the welding perform welding operation with and tubes that have been emptiedand thoroughly cleaned still represent a poten-tial perform welding operations or cut aclosed container or perform welding operations on open con-tainers or pipes that may have been contami-nated with substances that could explode orreact when exposed to heat or a preventative measure, keep fire extinguish-ers near the welding METAL FUME HAZARDSW elding fumes and gases may be haz-ardous if a ventilation system in the welding a forced air system when welding lead,beryllium, cadmium, zinc, zinc-coated or paint-ed material.

6 Always wear a protective the ventilation system is inadequate, use anair of gas leaks. Shielding gases such asargon are heavier than air and when used insmall spaces, will replace the the event that a welding operation occurs in aconfined place, the operator should be accom-panied by another keep gas cylinders in a well-ventilatedarea. Close the main gas valve when cylinder isnot in not perform welding operations near chlori-nated hydrocarbon vapors produced bydegreasing or painting. The heat generated byarc rays can react to form phosgene, a highlytoxic of the eyes, nose and throat are symp-toms of inadequate ventilation. Take immediatesteps to improve ventilation.

7 Do not continuewelding if symptoms TRANSPORTING THE POWER welding machine may be carried by disconnect the power source and acces-sories from the main supply before lifting orhandling the welding not drag, pull or lift welding equipment bythe weld MAGNETIC FIELDS CAN pacemaker wearers away fromwelding wearers should consult with aphysician prior to being exposed to any weldingor cutting RADIATION CAN CAUSE frequency (HF) emissions caninterfere with radio navigation, safety devices,computers and communication of welding equipment should beperformed by a qualified operator is responsible for having a quali-fied electrician correct any interference problemresulting from the welding equipment notified by the FCC about interference, stopusing the welding equipment the welding equipment installationchecked and maintained on a regular high-frequency source doors and panelstightly shut.

8 Keep spark gaps at the correct set-ting and use grounding to minimize the possi-bility of ARC WELDING CAN energy can interferewith sensitive electronic equipment such ascomputers and computer-driven equipment sure that all equipment in the welding areais electro-magnetically reduce possible interference, keep weldcables as short as possible, close together anddown welding operations at least 100 meters(350 feet) away from any sensitive sure welding equipment is installed andgrounded according to this interference still occurs, the operator musttake extra measures such as moving the weld-ing machine, using shielded cables, using linefilters or shielding the work WELDING AND THE EFFECTS OF LOWFREQUENCY AND MAGNETIC FIELDSAs welding current flows through welding cables, itcan cause electromagnetic fields.

9 To reduce mag-netic fields, use the following procedures:1 Keep cables close together by twisting or cables to one side and away from not coil or drape coils around welding power source and cables as faraway from the operator as practically work clamp to workpiece as close tothe weld as PRINCIPAL SAFETY STANDARDSS afety in Welding and Cutting,ANSI from the American Welding Society, Lejeune Rd., Miami, FL and Health Standards,OSHA 29 CFR1910, from the Superintendent of Documents, Government Printing Office, Washington, Safe Practices for the Preparationfor Welding and Cutting of Containers That HaveHeld Hazardous Substances,American WeldingSociety Standard AWS , from the AmericanWelding Society, 550 Lejeune Rd.

10 , Miami, Electrical Code,NFPA Standard 70, fromthe National Fire Protection Association,Batterymarch Park, Quincy, MA Handling of Compressed Gases in Cylinders,CGA Pamphlet P-1, from the Compressed GasAssociation, 1235 Jefferson Davis Highway, Suite501, Arlington, VA for Safety in Welding and Cutting,CSAS tandard , from the Canadian StandardsAssociation, Standard Sales, 178 RexdaleBoulevard, Rexdale, Ontario M9W Practices For Occupation And EducationalEye And Face Protection,ANSI Standards the American National Standards Institute,1430 Broadway, New York, NY And Welding Processes,NFPA Standards51B, from the National Fire Protection Association,6 EQUIPMENT INSTALLATION AND MAINTENANCE MUST BE PERFORMED IN COMPLIANCE WITH LOCAL SAFETY STANDARDS.