Full Product Manual

20
Section 2 Setup Guide
General Product and Use Information
CONNECTING THE GAS TO THE CYLINDER:
To safely connect the regulator to the cylinder, rst make sure the cylinder is properly chained and secured. Then,
before connecting the regulator and while standing to the side of the discharge (not in front of the discharge), briefly
crack the valve and allow a 1 to 2 second blast of gas to clear any dirt or contamination from the valve seat. Then con-
nect the regulator and screw the tting clockwise until nger tight and nish tightening with one 1 1/8” wrench. Do not
use a pair of pliers or other grip/lock devices. Use a large adjustable wrench if no other wrench is available. Make sure
the connection is tight. Slowly open the valve to check the connection for leaks with luke-warm soapy water (or ap-
proved leak detector solution) applied to the ttings at the valve.
To connect the hose to the rear of the unit, screw the 5/8” gas tting into the gas inlet on the rear of the unit, rotating
clockwise until nger tight. Then use two (2) 3/4” wrenches to complete the tightening process. One wrench should
be placed on the female gas inlet nut and should be held tightly to while the other wrench is used to nish tightening
the male tting. Always tighten the connection at the welder using one wrench to hold the welder inlet tting and an-
other wrench to tighten the regulator hose tting. Using only one wrench may result in damage to the ttings. Check
all ttings and connections for leaks once again. See illustration next page for proper connection arrangements.
Do not use thread tape or sealant on threads of the unit, regulator or cylinder. Plugging and sticking of the gas sole-
noid valves, regulator or torches may occur if thread sealants are used. The compression ttings used will tighten up
once proper pressure has been achieved. If the cylinder will not seal, the threads may be worn on the valve. If hoses
show sign of leaks, tighten the clamps with a pair of side cutters or end nippers. Gently squeeze the clamp tight until
the leak stops or add an additional clamp only if absolutely necessary. If the regulator leaks, remove it from service.
NOTICE:
The Lightning MTS 275 uses two gas connections. One connection is for MIG operation and the other is for TIG oper-
ation. Two cylinders may be connected at the same time. Only one regulator is supplied, but an additional regulator
may be purchased. If only one cylinder is used, or no connections are being used, the open tting(s) should be
plugged or covered to prevent dirt and debris from entering the ttings. Use a rubber cork, or hydraulic tting cap to
keep the tting covered. Failure or sticking of the gas solenoids is typically caused by dirt or debris entering the sys-
tem. Although the solenoid may be disassembled and cleaned to restore normal operation in most cases, extreme dirt
and contamination will damage the solenoid(s), necessitating replacement.
WARNING!
Never attempt to repair a damaged regulator yourself. The parts are under pressure. Serious injury or death may occur.
Do not open the cylinder valve quickly or damage can occur to the regulator.
REGULATOR ADJUSTMENT
The Ball valve will float briefly once the main cylinder valve is opened and will then settle down and stop floating after
4 to 5 seconds. Fully open the cylinder when in use to prevent valve leaks. If the valve continues to float, you have a
leak. Stop and check. To adjust the gas flow rate, the welder must be turned on. Select MIG or TIG and set post flow
to maximum. Gas flow is actuated by quickly tapping the trigger on the torch (or pedal). The small knob on top of the
down tube that connects to the hose adjusts gas flow rate. Screw the knob counter-clockwise to increase flow. This
meter will work with both Argon and Argon/CO2 mixes. The flow rate is calibrated in Cubic Feet per Hour (CFH).
(Markets outside of North America may be calibrated in Liters per Minute (LPM)). The pressure gauge only registers
the pressure inside of the gas cylinder. The clear plastic tube determines actual flow rate. As the cylinder looses
pressure near the end of its contents, flow rate may need to be readjusted. This is normal. Read the flow rate of the
gas at the middle of the floating ball.