Chicago Electric 95629, 95424 manual Operating Instructions, Before You Begin Welding

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OPERATING INSTRUCTIONS

Before You Begin Welding

Good welding requires a high degree of skill and experience. You should practice a few sample welds on scrap metal before you begin welding your first project. Ad- ditional practice periods are recommended whenever you weld a different thickness of material, wire, or weld a different type of connection.

Understanding Duty Cycle (Duration of Use)

1.CAUTION! Avoid damage to the Welder by not leaving the unit on for more than the prescribed duty cycle time.

100% Duration of use	30% Duration of use
at 125 Amp Setting	at 250 Amp Setting

	Continuous	3 minutes in use
	Continuous	followed by
		followed by
	use	at least
	use	7 minutes OFF
		in a single 10 minute period

Other settings fall between these two ranges.

FIGURE H

2.The duty cycle defines the number of minutes, within a 10 minute period, during which a given Welder can safely produce a particular welding current. For example, this Welder, with a 30% duty cycle at 250 Amps must be allowed to rest for at least 7 minutes after every 3 minutes of continuous weld at 250 Amps. (See Figure H.)

3.Failure to carefully observe duty cycle limitations can easily over-stress a Welder’s power generation system, contributing to premature Welder failure.

4.This Welder is equipped with an internal thermal protection system to help prevent over stressing the unit. When the unit overheats, it automatically shuts down, then automatically returns to service when it cools down.

Note: Once the unit returns to service, follow a more conservative duty cycle routine to help prevent excess wear to the Welder. (See Figure H.)

	SKU 95424, 95629	For technical questions, please call 1-800-444-3353;	Page 20
		Troubleshooting section at end of manual.

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Contents Assembly And Operation Instructions For technical questions or replacement parts, please callContents Save this Manual SpecificationsPlease Note Work Area General Safety RulesElectrical Safety Personal Safety Tool USE and CareIndustrial applications must follow Osha guidelines ServiceSpecific Safety Rules Page Inhalation Hazard Welding Produces toxic fumes and gassesCylinders can explode when damaged Extension Cords SymbologyGrounding Assembly Instructions UnpackingAttaching the Wheels Stationary MobileSee , above right See , above left For use with a 11 Spool Installing a Wire SpoolFor use with a 7 Spool Routing the Wire Figure B Exercise Extreme Caution Risk of Fire AND/OR Electric Shock Changing Wire Settings Attaching the Ground Cable with ClampAttaching the Electrode Cable Arc Welder Only See Figure FSetting Polarity for Welding Type See illustration, top right initial SetupSet for Electrode Negative Dcen for gasless flux core wire See illustration, bottom rightInstalling a Gas Cylinder Figure GOther settings fall between these two ranges Operating InstructionsBefore You Begin Welding Understanding Duty Cycle Duration of UseSetting Up the Weld Voltage Selector Knob 5CMIG Welding Set Up Arc Stick Welding Set Up for Model 95424 OnlySee Figures K & J See Figure KMIG Weld Settings Chart Figure JArc Stick Welding Set Up , for Model 95424 Only Starting a weld arc for stick arc welding onlyWhen the Weld is Completed See Figure L MIG welding onlyINSPECTION, MAINTENANCE, and Cleaning Nozzle Inspection, Cleaning, and Replacement MIG OnlyContactTip Inspection, Cleaning, and Replacement MIG Only Or more for .030Tips .067 or more for .045TipsWarranty Replacing the Welding Torch Liner MIG OnlyParts Lists and Diagrams Parts List aAssembly Diagrams Assembly Diagrams Power Block #32AFront Panel #23A Figure NWire Drive Assembly #16A Figure OGun SB 25 #20A Figure PMIG/Arc Welder 95424 Electrical Schematic ControllerBlock BCN-4UMIG Dual Welder 95629 Electrical Schematic Page Troubleshooting Welder does not function when switched onWeak arc strength Welding arc not stableWire feeds, but arc does not ignite MIG welding only TroubleshootingWire feed motor does not run MIG welding only Nozzle PluggedRegulator or cylinder valve closed Gas line blocked