User's Guide Manual

230 AMP AC/140 AMP DO

ARC WELDER

U.S.A. January 1999 Form No. 811-517-000

English
INTRODUCTION ..................................................................................... 3
OPERATION ........................................................................................... 4
DUTY CYCLE ....................................................................................... 4
SELECTING AC OR DC WELDING ..................................................... 4
ALTERNATING CURRENT WELDING ............................................... 4
DIRECT CURRENT WELDING .......................................................... 4
SETTING THE AMPERAGE CONTROL ............................................... 5
WIRING DIAGRAM ................................................................................ 6
REPLACEMENT PARTS LIST ............................................................... 7
LIMITED WARRANTY ............................................................................ 8
This User's Guide manual provides DO NOT ATTEMPT TO OPERATE
specific welder information for the 230 THIS WELDER until you have read and
amp ac/140 amp dc arc welder. This understand both manuals. Make certain
manual contains information such as the you have removed all documentation
specific assembly information, welder from the shipping carton.
duty cycle, welder open circuit voltage,
Additional information on your welder is
heat control adjustments, recommended
available through the place of purchase
electrodes, etc. that are related to this or from the manufacturer.
welder only. Table 1 lists the welder
Read SAFETY SUMMARY in the
specifications.
WELDER'S INSTRUCTION MANUAL,
General welder information such as
ARC WELDERS before unpacking the
safety information, general installation or welder and before proceeding with any
assembly instructions, preparation for procedures or making any attempts to
welding, general operation instructions do any welding.
and welding techniques, etc are in the
WELDER'S INSTRUCTION MANUAL,
ARC WELDERS.

Table 1. Welder Specifications

230 amp ac/140 amp dc

DESCRIPTION:
Arc Welder

INPUT: 230 Vac, 48 amp, 60 Hz, 10

ac High Output: 60-230 amps

ac Low Output: minimum-180 amps

dc Straight/Reverse 20-140 amps

MAX O. C. VOLTS: 72

DUTY CYCLE: 20% @ max. rated amperage

MODEL: 110-114
DUTY CYCLE Most ac welding operations will be
performed using the LOW AMPERAGE
The duty cycle rating of a welder defines jack. This output tap, because it has a
how long the operator can weld and higher open circuit voltage (OCV),
how long the welder must be rested and provides a deep penetrating arc for
cooled. Duty cycle is expressed as a welding rusty or thicker metals.
percentage of 10 minutes and American Welding Society (AWS) rated
represents the maximum welding time rods 6011 and 7018 type are formulated
allowed. The balance of the 10 minute
to work well with the higher OCV of the
cycle is required for cooling. Your new LOW AMPERAGE jack.
welder has a duty cycle rating of 20% at
maximum rated output at either output The HIGH AMPERAGE jack is better
tap. suited for welding thinner pieces
because the OCV at this tap is much
SELECTING AC OR DC lower. This tap delivers a shallow
penetrating arc and smooth, non-stick
WELDING
welding, preferred for welding thinner
The proper type of welding current is metals. AWS rated 6013 and 7014 type
determined by the work that needs to be rods work well at this tap, since they do
done. not require a very high open circuit
ALTERNATING CURRENT voltage to start.

WELDING a. LOW/180 amp. jack = Approx.

71.60CV
• Alternating current (ac) welding is
performed when the welding cables b. HIGH/230 amp. jack = Approx.
are connected to the AC OUTPUT 44.70CV
jacks. This kind of welding current is DIRECT CURRENT WELDING
ideal for Heavy Plate (flat position)
welding. Direct current (dc) welding is performed
when the welding cables are connected
This welder has three plug in AC to the DC OUTPUT receptacles. The
OUTPUTS and two DC OUTPUTS, on welder has two dc welding options,
the front of the welder. The ac jacks are straight polarity and reverse polarity
marked HIGH AMPERAGE, LOW welding.
AMPERAGE, and GROUND. The dc
jacks are marked, POS and NEG.
Connect the electrode output cable to
the HIGH AMPERAGE jack for high
current (230 amp maximum), low
voltage ac operation or to the LOW
AMPERAGE jack for low current (180
amp maximum), high voltage ac
operation.
StraightPolarity To weld with reverse polarity dc, place
the electrode cable in the plug marked
Straight polarity dc current flows from
POS (positive) and the ground cable in
the welding rod (negative) into the work
the plug marked NEG (negative).
piece (positive). Straight polarity dc
welding is ideal for: As you can see, most of the dc current
welding is done in the dc reverse
• Cutting Steel,
polarity mode of operation.
• Hardfacing work,
SETTING THE AMPERAGE
• Single Carbon Brazing, CONTROL
• and Build up work for heavy deposits. This welder has a unique OUTPUT
AMPERAGE SELECTION (current)
To weld with straight polarity dc, place
control lever for faster, more efficient
the electrode cable in the plug marked
heat adjustments than plug in style,
NEG (negative) and the ground cable in
clicker switch, and crank type designs
the plug marked POS (positive.).
commonly used in other welders. The
Reverse Polarity OUTPUT AMPERAGE SELECTION

Reverse polarity dc current flows from control provides amperage control

the work piece (negative) to the (current adjustment) for both, ac and dc
welding operations.
electrode (positive). Reverse polarity dc
welding is ideal for: To reduce the amperage: Squeeze
the OUTPUT AMPERAGE SELECTION
Overhead welding.
control lever (on the front of the welder),
Vertical Welding, push in lightly, and push the lever
downward.
Cast iron Welding,
To raise the amperage: Squeeze the
Heavy Aluminum Welding. OUTPUT AMPERAGE SELECTION
control lever (on the front of the welder),
Rivet Welding, pull out lightly, and move the lever
upward.
Sheet Metal Welding,

Low Hydrogen Rod Welding,

and Arc Bronze Rod Welding.

 RED
POWER
WjT ,1_ N

WHITE
(#8) LGR
BLACK
(#8) [ POWER CORD

I_ FFAN
MOTOR

SLEEVED START #7 ALUMINUM

SLEEVED FINISH #7 ALUMINUM

DC OUTPUTS
TRANSFORMER

(POS)

(NEG)

#4 ALUMINUM START
AC OUTPUTS
#2 ALUMINUM FINISH

HIGH AMPS
(LOW OCV) #4 ALUMINUM FINISH
LOW AMPS
(HIGH OCV)

GROUND
#2 ALUMINUM START
Usetheinformation inthis
partslisttoorderreplacement
parts.Allservice
workshould be
performed byqualified
service
personnel.

ITEM DESCRIPTION PARTNUMBER

1 Base 410-182-730
2 Reactor 860-986-888
3 Switch 246-371-000
4 Power Cord 248-301-000
5 StrainRelief 541-019-000
6 Faceplate
(U.S.) 711-133-170
Faceplate
(Canada) 711-133-300
7 ReceptacleAssembly 312-028-100
8 insulator 512-072-000
9 HeatSinkChannel 412-433-000
10 Diode 860-476-666
11 Transient
VoltageProtector 860-189-666
12 HeatSinkAngle 412-436-000
13 ShuntAssembly 860-402-666
14 TransformerAssembly 860-431-888
15 FanMotor 216-086-666
16 FanMounting Bracket 411-072-000
17 FanBlade 316-007-666
18 Ground Strap(Canadaonly) 218-235-000
§ Cover 410-164-100
§ Ground CableW/Clamp 4018
Electrode
CableW/Holder 4017
§ NotShown
Themanufacturer warrants thatitwillrepair, atnocharge forpartsorlabor, theWelder or
Welding GunorCables, proven defective inmaterial orworkmanship, during thefollowing
timeperiod(s) afterdateoforiginal retailpurchase:
For5Years:TheWelders Transformer andRectifier
For2Years:TheEntire Welder (excluding accessories packed withthewelder)
For1Year: TheWelders MIGWelding GunorArcWelding Cables (asapplicable)
Ifafterreasonable efforts
bythemanufacturer, theWelder orWelding GunorCables is/
aredeemed unrepairable, themanufacturer will,atitsoption,refundtheoriginal purchase
priceorsupply a replacement welder, orwelding gunorcables (which everisdefective).
Thiswarranty extends totheWelder, theWelder's TransformerandRectifier, andWelding
GunorCables onlyanddoesnotapply toanyaccessory itemsincluded withtheproduct
whicharesubject towearfromusage; thereplacement orrepairofthese itemsshallbeat
theexpense oftheowner.
THETERMS OFTHEMANUFACTURER'S LIMITED WARRANTY CONSTITUTE THE
BUYER'S SOLE ANDEXCLUSIVE REMEDY. THEIMPLIED WARRANTIES OR
MERCHANTABILITY ANDFITNESS FORAPARTICULAR PURPOSE ARELIMITED IN
DURATION TOTHISEXPRESS WARRANTY. AFTER 2YEARS FROM DATE OF
PURCHASE FORTHEWELDER, 5YEARS FROM DATE OFPURCHASE FORTHE
WELDER'S TRANSFORMER ANDRECTIFIER, AND1YEAR FROM DATE OF
PURCHASE FORTHEWELDING GUNORCABLES, ALLRISK OFLOSS, FROM
WHATEVER REASON, SHALL BEUPON THEPURCHASER.
THEMANUFACTURER SHALL NOTBELIABLE FORINCIDENTAL AND
CONSEQUENTIAL DAMAGES UNDER ANYCIRCUMSTANCES: THE
MANUFACTURER'S LIABILITY, IFANY, SHALL NEVER EXCEED THEPURCHASE
PRICE OFTHISPRODUCT, REGARDLESS OFWHETHER LIABILITY ISPREDICATED
UPON BREACH OFWARRANTY (EXPRESS ORIMPLIED), NEGLIGENCE, STRICT
TORT ORANYOTHER THEORY.
Thiswarranty extends toeachperson whoacquires lawful ownershipwithintwoyears of
theoriginalretailpurchase fortheWelder, withinfiveyearsoftheoriginal retailpurchase
fortheWelder's Transformer andRectifier, andwithinoneyearoftheoriginal retail
purchase fortheWelding GunorCables, butisvoidifeither hasbeenabused, altered,
misused, orimproperly packaged anddamaged whenreturned forrepair.
Some states donotpermit thelimitation ofwarranties orlimitation
ofconsequential or
incidental
damages, sotheabove disclaimer andlimitation maynotapplytoyou.This
warranty givesyouspecific legalrights, andyoumayalsohaveotherrights whichvary
fromstatetostate.
TOOBTAIN SERVICES UNDER THISWARRANTY:
Owner paystransportation charges totheclosest servicecenter.
Owner mayavoidtransportation charges, ifhewishes, bycallingWELDER SERVICE, at
thetelephone number listed below, forfreediagnosis andimmediate shipment of
replacement parts.Theowner, inthiscase, assumes theresponsibility
forinstallationof
parts.
Welder Service
866-236-0044