Miller DS-64M Swingarc Owner's manual

Miller.

June

1995

Form:

OM-1588B

Effective

With

Serial

No.

KF91

4926

1

OWNERS

MANUAL



~

c~~'

~F'L

DS-64M

(12)

And

(16)

Foot

Boom

Mounted

Wire

Feeder

S



Read

and

follow

these

instructions

safety

blocks

carefully.

Have

only

trained

and

qualified

install,

operate,

or

service

this

unit.

and

all

persons

~-

~

~i1~A



Give

this

manual

to

the

operator.



For

help,

call

your

distributor

S

Call

your

distributor

if

you

do

not

understand

I~J



or:

MILLER

Electric

Mfg.

Co.,

P.O.

Box

1079,

the

directions.

Appleton,

WI

54912

414-734-9821



Boom-Mounted

Microprocessor

Controlled

Constant

Speed

Dual

Wire

Feeder

S

Multi-Power

Source

Compatible



For

GMAW,

GMAW-P,

And

FCAW

Welding



For

.023

To

1/8

in

(0.6

To

3.2

mm)

Wires



Standard

Wire

Feed

Speed

Of

50

To

780

ipm

(1.3

To

19.8

mpm)



Programmable

Pulse

Weld

Parameters



For

Options

And

Accessories,

See

Rear

Cover

cover

5/94



ST-800

172

'

1995

MILLER

Electric

MIg.

Co.

PRINTED

IN

USA

l

I

J

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

Effective

January

1,1995

(Equipment

with

a

serial

number

preface

of

KD

or

newer)

This

limited

warranty

supersedes

sli

warranties

and

is

exclusive

with

no

other

guarantees

or

warranties

expressed

or

implied.

L

LIMITED

WARRANTY



Subiect

to

the

terms

and

conditions

below,

MILLER

Electric

MIg.

Co.,

Appleton,

Wisconsin,

warrants

to

its

original

retsil

purchaser

that

new

MILLER

equipment

sold

after

the

effective

date

of

this

limited

warranty

is

free

of

de

tects

in

material

and

workmanship

at

the

time

it

is

shipped

by

MILLER.

THIS

WAR

RANTY

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTHER

WARRANTIES,

EXPRESS

OR

IMPLIED,

INCLUDING

THE

WARRANTIES

OF

MERCHANTABILITY

AND

FIT

NESS.

Within

the

warranty

periods

listed

below,

MILLER

wilt

repair

or

replace

any

war

ranted

parts

or

components

that

fail

due

to

such

defects

in

material

or

workmanship.

MILLER

must

be

notified

in

writing

within

thirty

(30)

days

of

such

defect

or

failure,

at

which

time

MILLER

will

provide

instructions

on

the

warranty

claim

procedures

to

be

lollowed.

MILLER

shall

honor

warranty

claims

on

warranted

equipment

listed

below

in

the

event

of

Such

a

failure

within

the

warranty

time

periods.

All

warranty

time

periods

start

on

the

date

that

the

equipment

was

delivered

to

the

original

retail

purchaser,

or

one

year

after

the

equipment

is

sent

to

a

North

American

distributor

or

eighteen

months

after

the

equipment

is

sent

to

an

International

distributor.

5

Years

Parts

3

Years

Labor

Original

main

power

rectifiers

Inverters

(input

and

output

rectifiers

only)

2.

3

Years



Parts

and

Labor

Transformer/Rectifier

Power

Sources



Plasma

Arc

Cutting

Power

Sources

Semi-Automatic

and

Automatic

Wire

Feeders



Inverter

Power

Supplies



Intellitigs



Robots

3.

2

Years



Parts

and

Labor

Engine

Driven

Welding

Generators

(NOTE:

Engines

are

warranted

separately

by

the

engine

manufacturer.)

Air

Compressors

4.

1

Year



Parts

and

Labor



Motor

Driven

Guns



Process

Controllers

IHP5

Power

Sources

Water

Coolant

Systems



HF

Units



Grids



Spot

Welders



Load

Banks

SDX

Transformers



Running

Gear/Trailers

Plasma

Cutting

Torches

(except

APT,

ZIPCUT

&

PLAZCUT

Models)



Tecurnseh

Engines



Deutz

Engines

(outside

North

America)



Field

Options

(NOTE:

Field

options

are

covered

under

True

BIueTM

for

the

remaining

warranty

period

of

the

product

they

are

installed

in,

or

for

a

minimum

of

one

year



whichever

is

greater.)

6

Months

Batteries

6.

90

Days



Parts

and

Labor



MIG

Gufls/TIG

Torches



APT,

ZIPCUT

&

PLAZCUT

Model

Plasma

Cutting

Torches



Remote

Controls

Accessory

Kits



Replacement

Parts

MILLERS

True

BIueTM

Limited

Warranty

shall

not

apply

to:

1.

Items

furnished

by

MILLER,

but

manufactured

by

others,

such

as

engines

or

trade

accessories.

These

items

are

covered

by

the

manulacturers

warranty,

if

any.

2.

Consumable

components;

such

as

contact

tips,

cutting

nozzles,

contactors

and

relays

or

parts

that

fail

due

to

normal

wear.

3.

Equipment

that

has

been

modified

by

any

party

other

than

MILLER.

or

equip

ment

that

has

been

improperly

installed,

improperly

operated

or

misused

based

upon

industry

standards,

or

equipment

which

has

not

had

reasonable

and

necessary

maintenance,

or

equipment

which

has

been

used

for

operation

outside

of

the

specifications

for

the

equipment.

MILLER

PRODUCTS

ARE

INTENDED

FOR

PURCHASE

AND

USE

BY

COMMER

CIAL/INDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

IN

THE

USE

AND

MAINTENANCE

OF

WELDING

EQUIPMENT.

In

the

event

of

a

warranty

claim

covered

by

this

warranty,

the

exclusive

remedies

shall

be,

at

MILLERS

option:

(1)

repair;

or

(2)

replacement;

or,

where

authorized

in

writing

by

MILLER

in

appropriate

cases,

(3)

the

reasonable

cost

of

repair

or

replace

ment

Stan

authorized

MILLER

service

station;

or

(4)

payment

of

orcredit

for

the

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

return

of

the

goods

at

customers

risk

and

expense.

MILLERS

option

of

repair

or

replacement

will

be

F.O.B.,

Factory

at

Appleton.

Wisconsin,

or

FOB,

ala

MILLER

authorized

ser

vice

facility

as

determined

by

MILLER.

Therefore

no

compensation

or

reimburse

ment

for

transportation

costs

of

any

kind

will

be

allowed.

TO THE EXTENT

PERMITTED

BY

LAW,

THE

REMEDIES

PROVIDED

HEREIN

ARE

THE

SOLE

AND

EXCLUSIVE

REMEDIES.

IN

NO

EVENT

SHALL

MILLER

BE

LIABLE

FOR

DIRECT,

INDIRECT,

SPECIAL,

INCIDENTAL

OR

CONSEQUENTIAL

DAMAGES

(INCLUDING

LOSS

OF

PROFIT),

WHETHER

BASED

ON

CON

TRACT,

TORT

OR

ANY

OTHER

LEGAL

THEORY,

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WAR

RANTj,

GUARANTY

OR

REPRESENTATION

AS

TO

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

OF

CONTRACT

TORT

OR

ANY

OTHER

LEGAL

THEORY

WHICH,

BUT

FOR

THIS

PROVISION,

MIGHT

ARISE

BY

IMPLICATION,

OPERATION

OF

LAW,

CUSTOM

OF

TRADE

OR COURSE

OF

DEALING,

IN

CLUDING

ANY

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OR

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

TO

ANY

AND

ALL

EQUIPMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

AND

DISCLAIMED

BY

MILLER.

Some

states

in

the

U.S.A.

do

not

allow

limitations

of

how

long

an

implied

warranty

lasts,

or

the

exclusion

of

incidental,

indirect,

special

or

consequential

damages,

so

the

above

limitation

or

exclusion

may

not

apply

to

you.

This

warranty

provides

spe

cific

legal

rights,

and

other

rights

may

be

available,

but

may

vary

from

state

to

state.

In

Canada,

legislation

in

some

provinces

provides

for

certain

additional

warranties

or

remedies

other

than

as

stated

herein,

and

to

the

extent

that

they

may

not

be

waived,

the

limitations

and

exclusions

set

ouf

above

may

not

apply.

This

Limited

Warranty

provides

specific

legal

rights,

and

Other

rights

may

be

available,

but

may

province

to

province.

1.

RECEIVING-HANDLING

Before

unpacking

equipment,

check

carton

for

any

damage

that

may

have

occurred

during

shipment.

File

any

claims

for

loss

or

damage

with

the

delivering

carrier.

Assistance

for

filing

or

settling

claims

may

be

obtained

from

distributor

and/or

equipment

manufacturers

Transportation

Department.

When

requesting

information

about

this

equipment,

always

provide

Model

Designation

and

Serial

or

Style

Number.

Use

the

following

spaces

to

record

Model

Designation

and

Serial

or

Style

Number

of

your

unit.

The

information

is

located

on

the

rating

label

or

nameplate.

Model

_________

Serial

or

Style

No.

Date

of

Purchase

miller

6/95

ERRATA

SHEET

September

22,

1995

FORM:

OM-1588B

Use

above

FORM

number

when

ordering

extra

manuals.

L

After

this

manual

was

printed,

refinements

in

equipment

design

occurred.

This

sheet

lists

exceptions

to

data

appearing

later

in

this

manual.

CHANGES

TO

SECTION

16

PARTS

LIST

Change

Parts

List

as

follows:

Part

Replaced

**

No.

With

Description

Quantity

89-2....

010910

....

010910

..

WASHER,

(qtychg)

(Effw/KF970957)

6

89-3....

139

590

....

079

621

..

PULLEY,

V

sgl

grv

(Eff

w/KF970957)

1

89-

Added

....

079

622

..

WASHER,

shld

.318

ID

x

.750

OD

x

.254thk

(Eff

w/KF970957)

....

4

**First

digit

represents

page

no



digits

following

dash

represent

item

no.

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

ARC

WELDING

SAFETY

PRECAUTIONS

ELECTRIC

SHOCK

can

kill.

Touching

live

electrical

parts

can

cause

fatal

shocks

or

severe

bums.

The

electrode

and

work

circuit

is

electrically

live

whenever

the

output

is

on.

The

input

power

circuit

and

machine

internal

circuits

are

also

live

when

power

is

on.

In

semiautomatic

or

automatic

wire

welding,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live.

Incorrectly

installed

or

improperly

grounded

equipment

is

a

hazard.

Do

not

touch

live

electrical

parts.

Wear

dry,

hole-free

insulating

gloves

and

body

protection.

Insulate

yourself

from

work

and

ground

using

dry

insulating

mats

or

covers

big

enough

to

prevent

any

physical

contact

with

the

work

or

ground.

4.

Disconnect

input

power

or

stop

engine

before

installing

or

servicing

this

equipment.

Lockout/tagout

input

power

according

to

OSHA

29

CFR

1910.147

(see

Safety

Standards).

5.

Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual and

national,

state,

and

local

codes.

6.

Always

verify

the

supply

ground



check

and

be

sure

that

input

power

cord

ground

wire

is

properly

connected

to

ground

terminal

in

disconnect

box

or

that

cord

plug

is

connected

to

a

properly

grounded

receptacle

outlet.

7.

When

making

input

connections,

attach

proper

grounding

conductor

first



double-check

connections.

8.

Frequently

inspect

input

power

cord

for

damage

or

bare

wiring



replace

cord

immediately

if

damaged



bare

wiring

can

kill.

9.

Turn

off

all

equipment

when

not

in

use.

Clamp

wonc

cable

with

good

metal-to-metal

contact

to

workpiece

or

worktable

as

near

the

weld

as

oractical.

a

WARNING

ARC

WELDING

can

be

hazardous.

PROTECT

YOURSELF

AND

OTHERS

FROM

POSSIBLE

SERIOUS

INJURY

OR

DEATH.

KEEP

CHILDREN

AWAY.

PACEMAKER

WEARERS

KEEP

AWAY

UNTIL

CONSULTING

YOUR

DOCTOR.

Inwelding,

as

in

most

jobs,

exposure

to

certain

hazards

occurs.

Welding

is

safe

when

precautions

are

taken.

The

safety

information

given

below

is

only

a

summary

of

the

more

complete

safety

information

that

will

be

found

in

the

Safety

Standards

listed

on

the

Read

and

follow

all

Safety

Standards.

HAVE

ALL

INSTALLATION,

OPERATION,

MAINTENANCE,

AND

REPAIR

WORK

PERFORMED

ONLY

BY

QUALIFIED

PEOPLE.

1.

2.

3.

10.

Do

not

use

worn,

damaged,

undersized,

or

poorly

spliced

cables.

11.

Do

not

drape

cables

over

your

body.

12.

If

earth

grounding

of

the

workpiece

is

required,

ground

it

directly

with

a

separate

cable



do

not

use

work

clamp

or

work

cable.

13.

Do

not

touch

electrode

if

you

are

in

contact

with

the

work,

ground,

or

another

electrode

from

a

different

machine.

14.

Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

Maintain

unit

according

to

manual.

15.

Wear

a

safety

hamess

if

working

above

floor

level.

16.

Keep

all

panels

and

covers

securely

in

place.

17.

ARC

RAYS

can

burn

eyes

and

skin;

NOISE

can

damage

hearing;

FLYING

~

SLAG

OR

SPARKS

can

injure

eyes.

Arc

rays

from

the

welding

process

produce

intense

visible

and

invisible

(ultraviolet

and

infrared)

rays

that

can

bum

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

Chipping,

grinding,

and

welds



cooling

throw

off

pieces

of

metal

or

slag.

NOISE

1.

Use

approved

ear

plugs

or

ear

muffs

if

noise

level

is

high.

ARC

RAYS

2.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

to

protect

your

face

and

eyes

when

welding

or

watching

(see

ANSI

Z49.1

and

Z87.1

listed

in

Safety

Standards).

3.

Wear

approved

safety

glasses

with

side

shields.

4.

Use

protective

screens

or

barriers

to

protect

others

from

flash

and

glare;

wam

others

not

to

watch

the

arc.

5.

Wear

protective

clothing

made

from

durable,

flame-resistant

material

(wool

and

leather)

and

foot

protection.

r

FUMES

AND

GASES

can

be

hazardous

to

your

health.

Welding

produces

fumes

and

gases.

Breathing

these

fumes and

gases

can

be

hazardous

to

your

health.

.

£~

1.

Keep

your

head

out

of

the

fumes.

Do

not

breathe

the

fumes.

2.

If

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

remove

welding

fumes

and

gases.

3.

If

ventilation

is

poor,

use

an

approved

air-supplied

respirator.

4.

Read

the

Material

Safety

Data

Sheets

(MSDS5)

and

the

manufacturers

instruction

for

metals,

consumables,

coatings,

cleaners,

and

degreasers.

CYLINDERS

can

explode

if

damaged.

Shielding

gas

cylinders

contain

gas

under

high

pressure.

If

damaged,

a

cylinder

can

explode.

Since

gas

cylinders

are

normally

part

of

the

welding

process,

be

sure

to

treat

them

carefully.

1.

Protect

compressed

gas

cylinders

from

excessive

heat.

mechanical

shocks,

slag,

open

flames,

sparks,

and

arcs.

2.

Installcylindersinanuprightpositionbysecuringtoastationary

support

or

cylinder

rack

to

prevent

falling

or

tipping.

3.

Keep

cylinders

away

from

any

welding

or

other

electrical

circuits.

5.

6.

7.

Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

wearing

an

air-supplied

respirator.

Always

have

a

trained

watchperson

nearby.

Welding

fumes

and

gases

can

displace

air

and

lower

the

oxygen

level

causing

injury

or

death.

Be

sure

the

breathing

air

is

safe.

Do

not

weld

in

locations

near

degreasing,

cleaning,

or

spraying

operations.

The

heat

and

rays

of

the

arc

can

react

with

vapors

to

form

highly

toxic

and

irritating

gases.

Do

not

weld

on

coated

metals,

such

as

galvanized,

lead,

or

cadmium

plated

steel,

unless

the

coating

is

removed

from

the

weld

area,

the

area

is

well

ventilated,

and

if

necessary,

while

wearingan

air-supplied

respirator.

The

coatings

and

any

metals

containing

these

elements

can

give

off

toxic

fumes

if

welded.

4.

5.

6.

7.

8.

9.

10.

Never

drape

a

welding

torch

over a

gas

cylinder.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

Never

weld

on

a

pressurized

cylinder



explosion

will

result.

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

in

good

condition.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

in

use

orconnected

for

use.

Read

and

follow

instructions

on

compressed

gas

cylinders,

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

Standards.

5:1.1.1

2194

ENGINE

FUEL

can

cause

fire

or

explosion.

Engine

fuel

is

highly

flammable.

1.

Stop

engine

and

let

it

cool

off

before

checking

or

adding

fuel.

2.

Do

not

add

fuel

while

smoking

or

if

unit

is

near

any

sparks

or

open

flames.

3.

Have

only

qualified

people

remove

guards

or

covers

for

maintenance

and

troubleshooting

as

necessary.

4.

To

prevent

accidental

starting

during

servicing,

disconnect

negative

()

battery

cable

from

battery.

5.

Keep

hands,

hair,

loose

clothing,

and

tools

away

from

moving

parts.

6.

Reinstall

panels

or

guards

and

close

doors

when

servicing

is

finished

and

before

starting

engine.

SPARKS

can

cause

BATTERY

GASES

1.

Always

wear

a

face

shield

when

working

on

a

battery.

TO

EXPLODE;

BATTERY

ACID

can

2.

Stop

engine

before

disconnecting

or

connecting

battery

burn

eyes

and

skin,

cables.

3.

Do

not

allow

tools

to

cause

sparks

when

working

on

a

battery.

4.

Do

not

use

welder

to

charge

batteries

or

jump

start

vehicles.

5.

Observe

correct

polarity

(+

and

)

on

batteries.

STEAM

AND

PRESSURIZED

HOT

1.

If

the

engine

is

warm

and

checking

is

needed,

follow

steps

2

COOLANT

can

burn

face,

eyes,

and

3.

skIn.

2.

Wear

safety

glasses

and

gloves

and

put

a

rag

over

cap.

It

is

best

to

check

coolant

level

when

engine

is

cold

3.

Turn

cap

slightly

and

let

pressure

escape

slowly

before

to

avoid

scalding.

completely

removing

cap.

PRINCIPAL

SAFETY

STANDARDS

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.

1,

from

American

Welding

Society,

550

N.W.

LeJeune

Rd,

Miami

FL

33126

Safety

and

Health

Standards,

OSHA

29

CFR

1910,

from

Superinten

dent

of

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

Recommended

Safe

Practices

for

the

Preparation

for

Welding

and

Cutting

of

Containers

That

Have

Held

Hazardous

Substances,

Ameri

can

Welding

Society

Standard

AWS

F4.

1,

from

American

Welding

So

ciety,

550

N.W.

LeJeune

Ad,

Miami,

FL

33126

National

Electrical

Code,

NFPA

Standard

70,

from

National

Fire

Pro

tection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

srl.1.1

V94

Safe

Handling

of

Compressed

Gases

in

Cylinders.

CGA

Pamphlet

P-1,from

Compressed

Gas

Association,

1235

Jefferson

Davis

High

way,

Suite

501,

Arlington,

VA

22202.

Code

for

Safety

in

Welding

and

Cutting,

GSA

Standard

Wi

17.2.

from

Canadian

Standards

Association.

Standards

Sales.

178 Rexdale

Bou

levard.

Rexdale.

Ontario,

Canada

M9W

1

R3.

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

Protec

tion,

ANSI

Standard

Z87.

1,

from

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

Cutting

And

Welding

Processes,

NFPA

Standard

51

B,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

WELDING

can

cause

fire

or

explosion.

Welding

on

closed

containers,

such

as

tanks,

drums,

or

pipes,

can

cause

them

to

blow

up.

Sparks

can

fly

off

from

the

welding

arc.

The

flying

sparks,

hot

workpiece,

and

hot

equipment

can

cause

fires

and

burns.

Accidental

contact

of

electrode

to

metal

objects

can

cause

sparks,

explosion,

overheating,

or

fire.

Check

and

be

sure

the

area

is

safe

before

doing

any

welding.

1.

Protect

yourself

and

others

from

flying

sparks

and

hot

metal.

2.

Do

not

weld

where

flying

sparks

can

strike

flammable

material.

3.

Remove

all

flammables

within

35

ft

(10.7

m)

of

the

welding

arc,

If

this

is

not

possible,

tightly

cover

them

with

approved

covers.

4.

Be

alert

that

welding

sparks

and

hot

materials

from

welding

can

easily

go

through

small

cracks

and

openings

to

adjacent

areas.

5.

Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.

6.

Be

aware

that

welding

on

a

ceiling,

floor,

bulkhead,

or

partition

can

cause

fire

on

the

hidden

side.

7.

Do

not

weld

on

closed

containers

such

as

tanks,

drums,

or

pipes,

unless

they

are

properly

prepared

according

toAWS

F4.1

(see

Safety

Standards).

8.

Connect

work

cable

to

the

work

as

close

to

the

welding

area

as

practical

to

prevent

welding

current

from

traveling

long,

possibly

unknown

paths

and

causing

electric

shock

and

fire

hazards.

9.

Do

not

use

welder

to

thaw

frozen

pipes.

10.

Remove

stick

electrode

from

holder

or

cut

off

welding

wire

at

contact

tip

when

not

in

use.

11.

Wearoil-free

protective

garments

such

as

leather

gloves,

heavy

shirt,

cuffless

trousers,

high

shoes,

and

a

cap.

12.

Remove

any

combustibles,

such

as

a

butane

lighter

or

matches,

from

your

person

before

doing

any

welding.

a

WARNING

ENGINES

can

be

hazardous.

ENGINE

EXHAUST

GASES

can

kill:

1.

Use

equipment

outside

in

open,

well-ventilated

areas.

Engines

produce

harmful

exhaust

gases.

2.

If

used

in

a

closed

area,

vent

engine

exhaust

outside

and

away

from

any

building

air

intakes.

3.

Do

not

overfill

tank



allow

room

for

fuel

to

expand.

4.

Do

not

spill

fuel.

If

fuel

is

spilled,

clean

up

before

starting

engine.

MOVING

PARTS

can

cause

Injury.

Moving

parts,

such

as

fans,

rotors,

and

belts

can

cut

fingers

and

hands

and

catch

loose

clothing.

1.

Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

2.

Stop

eng

ne

before

installing

or

connecting

unit.

Batteries

contain

acid

and

generate

explosive

iases.

CONSIGNES

DE

SECURITE

POUR

LE

SOUDAGE

A

LARC

UN

CHOC

ELEcTRIQUE

pout

tuer.

Un

simple

contact

avec

des

piŁces

Ølectnques

pout

provoquer

une

Olectrocution

ou

des

blessures

graves.

LØlectrode

et

to

circuit

de

soudago

sont

sous

tension

des

que

Iapparoil

est

surON.

Le

circuit

dentrØe

et

les

circuits

intemos

de

Iappareit

sont

egalement

sous

tension

a

ce

moment-l.

En

soudage

semi-automatique

ou

automatique,

le

fit,

le

dØvidoir.

to

logement

dos

galets

dentrainemont

ot

los

piŁces

mØtalliques

en

contact

avec

to

fit

do

soudago

sont

sous

tension.

Des

matØnels

ma!

installØs

ou

mat

mis

a

Ia

terre

prØsentont

un

danger.

1.

Ne

Jamais

toucher

los

piŁces

etectnques

sous

tension.

2.

Porter

des

gants

et

dos

vØtements

do

protection

secs

no

comportant

pas

de

trous.

3.

Sisoler

do

Ia

piŁce

et

de

Ia

terre

au

moyen

de

tapis

ou

dautros

moyens

isolants

suffisamment

grands

pour

empecher

le

contact

physique

Øventuel

avec

Ia

piŁce

ou

Ia

terre.

4.

Couper

Iatimentation

ou

arrŒtor

le

moteur

avant

do

procØdor

a

linstatlation,

a

Ia

reparation

ou

a

lentretien

do

tapparoil.

DØverrouiller

latimontation

selon

Ia

norme

OSHA

29

CFR

1910.147

(voir

normes

do

sØcuntØ).

5.

Installer

et

mettre

a

Ia

terre

correctoment

cet

appareit

confomiØment

a

son

manuel

dulilisation

et

au

codes

nationaux,

provinciaux

et

municipaux.

6.

Toujours

vØnfior

Ia

terre

du

cordon

datimentation



Verifier

et

sassurer

Quo

10

fit

do

terre

du

cordon

dalimontation

est

bien

raccordO

a

Ia

borne

do

terre

du

sectionnour

ou

quo

Ia

fiche

du

cordon

est

raccordŁe

a

uno

pnso

correctoment

mise

a

Ia

terre.

7.

En

offectuant

los

raccordemonts

dontrØe

fixer

dabord

10

conducteur

do

mise

a

Ia

terre

appropnØ

01

contro-vŁnfier

les

connexions.

8.

Verifier

frØquomment

to

cordon

datimentation

pour

voir

sit

nest

pas

endommage

ou

dØnudØ



romplacer

le

cordon

immØdiatoment

sit

est

endommagØ



un

cable

dOnudØ

pout

provoquer

uno

electrocution.

9.

Mettre

lappareil

hors

tension

quand

on

ne

lutilise

pas.

10.

No

pas

utiliser

des

cables

uses,

endommagØs.

do

grosseur

insuffisante

ou

mal

ØpissOs.

11.

Ne

pas

enrouler

les

cables

autour

du

corps.

12.

Si

Ia

piŁce

soudØe

doit

Œtre

miso

ala

terre,

le

faire

directement

avec

un

cable

distinct



no

pas

utiliser

to

connecteur

do

piŁce

ou

10

cØble

do

retour.

13.

Ne

pas

toucher

lØlectrodo

quand

on

est

en

contact

avec

Ia

piŁce.

Ia

terre

ou

une

electrode

provenant

dune

autre

machine.

14.

Nutiliser

quun

materiel

en

bon

Øtat.

RØparer

ou

remplacer

sur-le-champ

les

piŁces

endommagØes.

Entretenir

lappareil

conformØment

a

ce

manuel.

15.

Porter

un

hamais

de

sŁcuntØ

quand

on

travaille

en

hauteur.

16.

Maintenir

solidement

en

place

tous

los

panneaux

at

capots.

17.

Fixer

le

cable

do

retour

do

faon

~

obtonir

un

bon

contact

mØtal-mØtal

avec

Ia

piŁce

a

souderou

Ia

table

do

travail,

le

plus

pres

possible

de

Ia

soudure.

a

MISE

EN

GARDE

LE

SOUDAGE

A

LARC

pout

Œtre

dangereux.

SE

PROTEGER

ET

PROTEGER

LES

AUTRES

CONTRE

LES

BLESSURES

GRAVES

VOIRE

MORTELLES.

TENIR

LES

ENFANTS

A

LECART.

LES

PERSONNES

QUI

PORTENT

UN

STIMULATEUR

CARDIAQUE

NE

DOIVENT

PAS

NON

PLUS

SAPPROCIIER

DU

POSTEDE

SOUDAGE

A

MOINS

DAVOIR

CONSULTE

UN

MEDECIN.

Le

soudage,

comme

Ia

plupart

des

travaux,

prØsente

certains

dangers.

Par

contre,

to

soudage

peut

Øtre

ettectuØ

en

toute

sØcuntØ

quand

on

prend

los

mesures

qui

simposent.

Los

consignes

de

sØcuntØ

donnŁes

ci-aprŁs

ne

font

quo

rØsumor

linformation

contonue

dans

los

normes

do

sØcuntØ

OnumOrØes

a

Ia

page

suivante.

Lire

et

respecter

toutes

ces

normes

do

sØcuntO.

LINSTALLATION,

LUTILISATION,

LENTRETIEN

El

LES

REPARATIONS

NE

DOIVENT

ETRE

CONFIES

QuA

DES

PERSONNES

OUALIFIEES

.

LE

RAYONNEMENT

DE

LARC

pout

brler

les

RAVONNEMENT

DE

LARC

yeux

et

Ia

peau.

Le

BRUIT

pout

endommager

~

IouIe;

les

PROJECTIONS

DE

LAITIER

OU

LES

ETINCELLES

peuvent

blesser

les

yeux.

2.

Porter

un

masque

a

serre-tØte

muni

dun

vorre

filtrant

do

nuance

appropnee

pour

proteger

Ia

visage

et

los

yeux

quand

on

soudo

ou

Larc

do

soudage

produit

des

rayons

visibles

et

invisiblos

observe

Ia

travail

do

soudago

(voir

los

normes

ANSI

Z49.

1

01

Z87.

I

-

.

intenses

(ultraviolots

et

infrarougos)

qui

pouvent

brlor

donnØes

sous

Ia

rubrique

Principales

norrnes

de

sØcurite).

los

yeux

et

Ia

peau.

Le

bruit

produit

par

certains

procŁdŁs

pout

endommagor

IouIe.

Des

projections

de

metal

ou

de

3.

Porter

des

lunettes

do

sØcuntŁ

approuvØos

avoc

Øcrans

latOraux.

laitier

sont

produites

par

le

piquago,

le

meulage

ou

le

refroidissemont

dos

soudures.

4.

Utitiser

des

paravents

ou

des

barriŁres

do

protection

pour

proteger

los

personnes

a

proximitØ

contre

les

coups

darc

et

lØblouissement;

BRUIT

avertir

los

autres

personnes

do

ne

pas

regarder

larc.

1.

Utiliser

des

boucho-oroittes

ou

des

serre-tOto

antibruit

approuvØs

si

5.

Porter

dos

vŒtomenls

do

protection

en

tissu

ignifugo

durable

(tame

ot

to

niveau

de

bruit

est

ØlovØ.

cuir)

et

des

chaussures

do

sOcuntØ.

LES

VAPEURS

ET

LES

FUMEES

peuvent

ºtre

5.

Ne

travailler

dans

un

espace

confine

que

sit

est

bien

ventilØ,

ou

en

dangereuses

pour

Ia

sante.

portant

un

appareit

respiratoire

a

adduction

dairpur.

Demander

a

un

observateur

ayant

recu

Ia

bonne

formation

do

toujours

so

lenir

a

I

mortelles.

Sassurer

que

lair

est

propre

a

Ia

respiration.

~Q

Le

soudage

produit

des

vapeurs

et

des

fumOes

quit

est

proximitØ.

Los

vapeurs

et

fumØes

de

soudage

peuvent

doplacer

lair

V

dangereux

do

respirer.

et

abaisser

le

niveau

do~gene

et

causer

dos

blessures

graves

voire

1.

Garder

Ia

tŒte

a

lextrieur

des

vapeurs

et

des

fumŁos

et

no

pas

les

6.

No

pas

souder

a

proximitO

dopOrations

de

dOgraissage,

de

respirer.

nettoyage

ou

de

pulvØnsation.

La

chateur

et

los

rayons

do

larc

peuvent

reagir

avec

los

vapours

pour

former

des

gaz

hautement

2.

A

linlØnour,

ventiler

le

posto

de

travail

ou

utiliser

un

dispositif

place

au

niveau

do

Iarc

pour

Øvacuer

los

vapeurs

et

fumŁes

de

soudage.

toxiques

et

irritants.

7.

Ne

pas

souder

sur

des

mØtaux

revŒtus

comme

lacier

galvanisŁ,

au

3.

Si

Ia

ventilation

ost

mauvaiso,

utiliser

un

appareil

respiratoire

a

p10mb

ou

cadmiØ

a

moms

quota

piŁce

nait

ØtØ

ontiŁrement

dØcapOe.

adduction

dair

pur

approuvØ.

quote

posto

do

travail

soit

bion

vontilØ.

Sit

y

a

lieu,

porter

un

appareil

4.

Consulter

los

fichos

signafetiques

et

les

consignes

du

fabncant

respiratoire

a

adduction

dair

pur.

Les

revØtements

et

los

mŁtaux

qui

relatives

au

mØtaux,

produits

dapport.

revŒtements.

nettoyants

et

contiennont

do

tels

ŁlŁments

pouvont

dogager

des

vapeurs

toxiquos

degraissants.

lors

du

soudage.

LES

BOUTEILLES

peuvent

exploser

sI

elles

4.

Ne

jamais

poser

un

chatumeau

soudeur

sur

une

bouteille

do

gaz.

~

sont

endommagØes.

5.

Ne

jamais

laisser

une

electrode

do

soudago

toucher

une

bouteille.

Los

bouteillos

contenant

des

gaz

do

protection

sont

a

6.

No

jamais

souder

sur

une

bouteille

sous

pression

:

elte

oxploserait.

.z~.

haute

pression.

Une

bouteillo

endommagee

pout

7.

Nutilisor

quo

dos

boutoilles

do

gaz

de

protection,

des

dØtendeurs,

exploser.

Etant

donnØ

que

los

bouloilles

do

gaz

font

des

tuyaux

souplos

ot

dos

raccords

appropriŁs

concus

pour

norrnalement

partie

du

materiel

de

soudage.

les

traitor

application

particuliŁre;

consorvor

ces

matØriels

at

leurs

piŁces

en

avec

le

plus

grand

soin.

bon

Łtat.

1.

ProtØgor

los

bouteillos

do

gaz

comprimØ

contre

Ia

chaleur

intense,

8.

Eloigner

10

visage

de

Ia

sortie

du

robinet

do

Ia

bouteille

quand

on

les

chocs,

te

tail

ier,

les

flammes

nues.

les

Øtincetles

el

larc.

louvre.

2.

Placer

los

bouteiltes

a

Ia

vorticale

en

les

fixant

a

un

support

fixe

ou

a

9.

Replacer

to

chapeau

sur

Ia

bouteille

aprŁs

utilisation.

un

chariot

pour

Øviter

quelles

ne

tombent

ou

no

bascuient.

10.

Lire

at

suivre

los

consignes

relatives

aux

bouteitles

do

gaz

compnme,

3.

Tenir

les

bouteitles

a

IØcart

du

poste

de

soudage

ou

dautres

circuits

au

materiel

connexe

ainsi

quo

Ia

publication

P-l

de

Ia

CGA

donnØe

electriques.

sous

Ia

rubnque

Pnncipales

normes

de

scuritØ.

srl.I,1

2/94

LE

SOUDAGE

peut

causer

un

Incendle

ou une

explosion.

No

pas

soudor

sur

des

recipients

fermØs

comme

des

reservoirs,

dos

fts

ou

des

tuyaux:

us

pouvent

exploser.

Larc

do

soudage

pout

produire

des

Øtincelles.

Des

Øtincelles,

une

piŁce

chaudo

et

un

materiel

chaud

peuvent

provoquor

des

incendios

et

des

blossures.

Le

contact

accidentel

do

lŁlectrode

sur

des

objets

motalliques

pout

produire

dos

Øtincelles,

lexplosion,

Ia

surchaufte

ou

un

incendie.

Sassurer

quo

10

lieu

no

prØsonte

pas

do

danger

avant

deflectuer

le

soudago.

1.

So

protØgeretprotegerles

personnos

a

proximitØ

dos

Øtincelles

etdu

metal

chaud.

2.

Ne

pas

souder

dans

un

ondroit

o

los

Øtincollos

pouvent

atteindro

des

matOriaux

inflammables.

3.

Enlovertoutes

los

matiŁres

inflammablos

dans

un

rayon

do

moms

do

10

m

de

larc.

Si

cola

nest

pas

possible,

bien

los

rocouvnren

utilisant

dos

bathes

approuvees.

4.

Prendro

garde

quo

los

Øtincollos

et

los

projections

no

pØnØtront

dans

dos

zones

adjacentos

en

sinfiltrant

dans

dos

petites

fissures

et

ouverturos.

5.

Prondre

garde

aux

incendios

et

toujours

avoir

Un

extinctour

~

proximitØ.

6.

Se

rappelerquo

si

Ion

soude

sur

un

plafond,

un

planchor,

une

cloison

ou

autre,

lo

lou

peut

prendre

do

lautre

ctØ.

7.

No

pas

souder

sur

des

recipients

fermØs

commo

des

reservoirs,

des

fOts

ou

dos

tuyaux

a

moms

quils

ne

soient

prepares

do

facon

appropnee

conformØmont

ala

norme

F4.1

do

lAWS

(voir

Ia

rubnque

Pnncipalos

normes

do

sØcuntØ).

8.

Raccorder

10

cable

do

retour

a

Ia

piŁce,

lo

plus

prØs

possible

do

Ia

zone

do

soudage,

pour

empOcher

quo

le

courant

do

soudago

ne

suive

une

trajoctoiro

longue

et

Øventuollemont

inconnue

at

quil

no

provoque

dos

nsques

dØlectrocution

et

dincondio.

9.

No

pas

utiliser

le

chalumoau

soudeur

pour

degoler

dos

tuyaux.

10.

Enlever

lØlectrode

enrobØo

du

porte-electrode

ou

couper

le

fil

de

soudage

au

ras

dii

bec

contact

quand

on no

Iutilise

pas.

11.

Porter

dos

vOtoments

do

protection

non

huileux

comme

dos

gants

en

cuir,

une

chemise

Øpaisse,

dos

pantalons

sans

rovers,

dos

chaussures

montantos

of

un

casque.

12.

Ne

pas

porter

des

matiŁres

combustibles

sur

soi

comme

un

bnquet

a

gaz

ou

des

allumettes

quand

on

soude.

LE

CARBURANT

peut

provoquer

un

Incendie

r

~

ou une

explosion.

Le

carburant

est

hautemont

inflammable.

1.

ArrOter

lo

moteur

ot

10

laissor

refroidir

avant

de

verifier

lo

nivoau

de

carburant

ou

de

rofaire

le

plein.

LES

PIECES

EN

MOUVEMENT

peuvent

causer

des

blessures.

Los

piŁces

en

mouvomont

comme

los

ventilateurs,

los

rotors

et

los

courroles

peuvent

couper

los

doigts

otles

mains

ot

happer

los

vŒtements

amples.

1.

Sassurer

quo

los

portes,

los

panneaux,

los

capots

et

los

protectours

sont

bien

fermØs

ot

bion

A

leur

place.

2.

ArrŒter

10

moteur

avant

do

mettro

en

place

ou

do

raccorder

un

disoositif.

2.

Ne

pas

fumer

en

faisant

le.

plein

ou

si

lappareil

se

trouve

a

proximitØ

dØtincelles

ou

do

flammos

nues.

3.

Ne

pas

remplir

le

reservoir

a

ras

bord

prØvoir

de

lospace

pour

Ia

dilatation

du

combustible.

4.

Ne

pas

renverser

du

carburant.

Si

on

ronverso

du

carburant,

nottoyer

los

Iieux

avant

do

faire

dØmarrer

10

moteur.

3.

Seules

des

personnes

qualifiees

doivent

dØmonter

los

protoctours

ou

los

capots

pour

faire

lentretien

ou

los

reparations

nØcessairos.

4.

Pour

ompOcher

un

demarrage

accidontol

dun

systŁme

pendant

lontrotion

ou

los

reparations,

dØbranchor

lo

cable

negatif

()

do

Ia

battono.

5.

Eloigner

los

mains,

los

chevoux,

los

vŒtemonts

amplos

et

los

outils

des

piŁces

en

mouvement.

6.

Replacer

los

capots

ou

les

protecteurs

et

reformer

les

portes

uno

fois

Ientrotion

ot

los

reparations

terminØs

ot

avant

de

faire

dØmarrer

10

moteur.

a

MISE

EN

GARDE

LES

MOTEURS

peuvent

presenter

un

danger.

LES

GAZ

DECHAPPEMENT

DES

MOTEURS

1.

Utiliser

le

materiel

a

IoxtØneur,

dans

dos

lioux

ouvorts

at

bien

peuvent

tre

mortels.

ventilØs.

Les

motours

produisent

des

gaz

de

chapp

oment

focus.

2.

Si

on

utilise

in

moteur

dans

un

local

ferrnO,

Øvacuer

los

gaz

dechappement

a

lextØneur

et

loin

des

pnses

dair

du

btiment.



+

1.

Toujours

LES

ETINCELLES

peuvent

faIre

EXPLOSER

LE

2.

ArrØter

le

motour

avant

do

brancher

ou

do

dØbrancher

los

cAbles

do

GAZ

DES

BA1TER~ES;

LELECTROLYTE

peut

Ia

battene.

brler

Ia

peau

et

es

yeux.

3.

Ne

pas

faire

dos

Øtincolles

avec

los

outits

quand

on

travaille

sur

une

Los

batteries

contiennent

un

produit

acido

et

degagent

battene.

des

vapeurs

explosives.

4.

No

pas

utiliser

Ia

source

do

courant

do

soudage

pour

charger

los

batteries

ou

pour

faire

dØmarror

un

vØhicule.

~

un

Øcran

facial

quand

on

travaille

sur

une

battene.

5.

Ne

pas

intervertir

Ia

polaritØ

des

batteries.

LA

VAPEUR

ET LE

LIQUIDE

DE

1.

Si

Ion

doit

verifier

10

nivoau

quand

le

motour

est

chaud,

suivro

los

REFROIDISSEMENT

BRULANT

SOUS

Øtapos

2013.

PRESSION

peuvent

brler

Ia

peau

et

lee

yeux.

2.

Porterdoslunottesdosecuflteetdosgantsetplacorunchiffonsurle

II

vaut

mioux

verifier

10

nivoau

du

liquide

do

bouchon.

ref

roidissoment

quand

10

moteur

ost

froid

af

in

&Øviter

les

3.

Toumor

lentoment

10

bouchon

et

laissor

Ia

prossion

sechapper

brUlures.

lontement

avant

donlever

complOtoment

lo

bouchon.

PRINCIPALES

NORMES

DE

SECURITE

Safety

in

Welding

and

Cutting,

normo

ANSI

Z49.1,do

lAmoflcan

Welding

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

P-ide

Society,

550

N.W.

Lojoune

Rd,

Miami

FL

33126

Ia

Compressed

Gas

Association.

1235

Jefferson

Davis

Highway,

Suite

501,

Arlington,

VA

22202.

Safety

and

Health

Sandards,

OSHA

29

CFR

1910,

du

Supenntondonl

of

Regles

de

sØcunfØ

en

soudage.

coupage

et

procddds

connexes,

norme

Documents,

U.S.

Government

Pnnting

Office,

Washington,

D.C.

20402.

CSA

W117.2,

do

lAssociation

canadienne

do

norrnalisation,

vento

do

normes,

178

Rexdalo

Boulovard,

Roxdale

(Ontario)

Canada

M9W

1

R3.

Recommended

Safe

Practice

for

the

Preparation

for

Welding

and

Cutting

of

Containers

That

Have

Held

Hazardous

Substances,

norrne

AWS

F4.1.

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

Protection,

do

IArnoncan

Welding

Society,

550

N.W.

Lojoune

Rd,

Miami

FL

33126

norrne

ANSI

Z87.1,

de

IArnencan

National

Standards

Institute.

1430

Broadway,

Now

York,

NY

10018.

NationalElectncal

Code,

NFPA

Standard

70,

do

Ia

National

Fire

Protection

Cutting

and

Welding

Processes,

norme

NFPA

51

B,

do

Ia

National

Fire

Association.

Batterymarch

Park,

Quincy,

MA

02269.

Protection

Association,

Batterymarch

Park,

Qumncy,

MA

02269.

srl.1.1

2/94

EMF

INFORMATION

TABLE

OF

CONTENTS

SECTION

1



SAFETY

INFORMATION

SECTION

2

SPECIFICATIONS

SECTION

3

INSTALLATION

3-1.

Equipment

Connection

Diagram

3-2.

Installing

Swivel

Into

Pipe

Post

3-3.

Installing

Control

Box

Onto

Swivel

3-4.

Installing

Boom

And

Reel

Support

3-5.

Installing

Wire

Guide

Extension

3-6.

Wire

Guide

And

Drive

Roll

Installation

3-7.

Welding

Gun

Connections

3-8.

Wire

Feed

Motor

And

Gas

Valve

Control

Connections

3-9.

Control

Connection

3-10.

Shielding

Gas

And

Weld

Cable

Connections

3-11.

Removing

Safety

Collar

And

Adjusting

Boom

3-12.

Welding

Wire

Installation

3-13.

Motor

Start

Control

3-14.

Adjusting

Control

Tilt

Bracket

3-15.

Threading

Welding

Wire

SECTION

4-

GLOSSARY

SECTION

5-

OPERATION

5-1.

Front

Panel

Controls

5-2.

Side

Panel

Controls

5-3.

Rear

Panel

Controls

5-4.

Setting

Switches

On

450

Ampere

lnverter

Model

Welding

Power

Source

SECTION

6

STEPPING

THROUGH

THE

MICROPROCESSOR

CONTROLS

6-1.

Front

Panel

Microprocessor

Controls

6-2.

Side

Panel

Microprocessor

Push

Buttons

SECTION

7

STANDARD

PULSE

WELDING

PROGRAMS

SECTION

8-

GE111NG

STARTED

35

8-1.

Welding

With

Only

Front

Panel

Controls

36

8-2.

Setting

Sequence

Pulse

Welding

Parameters

On

Side

Panel

Display

37

OM-15885

-6/95

NOTE

~

Considerations

About

Welding

Magnetic

Fields

The

following

is

a

quotation

from

the

General

Conclusions

Section

And

The

Effects

Of

Low

Frequency

Electric

And

To

reduce

magnetic

fields

in

the

workplace,

use

the

following

of

the

U.S.

Congress,

Office

of

Technology

Assessment,

Biological

procedures:

Effects

of

Power

Frequency

Electric

&

Magnetic

Fields



Background

Pape4

OTA-BP-E-53

(Washington,

DC:

U.S.

Government

Printing

Office,

May

1989):

.

. .

there

is

now

a

very

1.

Keep

cables

close

together

by

twisting

or

taping

them.

2.

Arrange

cables

to

one

side

and

away

from

the

operator.

large

volume

of

scientific

findings

based

on

experiments

at

the

3.

Do

not

coil

or

drape

cables

around

the

body.

cellular

level

and

from

studies

with

animals

and

people

which

clearly

establish

that

low

frequency

magnetic

fields

can

interact

with,

and

produce

changes

in,

biological

systems.

While

most

of

this

work

is

of

very

high

quality,

the

results

are

complex.

Current

scientific

understanding

does

not

yet

allow

us

to

interpret

the

evidence

in

a

4.

Keep

welding

power

source

and

cables

as

far

away

as

practical.

5.

Connect

work

clamp

to

workpiece

as

close

to

the

weld

as

possible.

single

coherent

framework.

Even

more

frustrating,

it

does

not

yet

About

Pacemakers:

allow

us

to

draw

definite

conclusions

about

questions

of

possible

risk

or

to

offer

clear

science-based

advice

on

strategies

to

minimize

The

above

procedures

are

among

those

also

normally

recommended

for

pacemaker

wearers.

Consult

your

doctor

for

or

avoid

potential

risks.

complete

information.

modlO.1

4/93

2

3

4

5

6

7

8

9

10

11

12

14

16

17

19

20

21

22

24

27

SECTION

9

TEACHING

A

PULSE

WELDING

PROGRAM

41

9-1.

Pulse

Waveform

Explained

41

9-2.

Teach

Points

Explained

42

9-3.

Teaching

A

Pulse

Welding

Program

43

9-4.

Changing

To

Adaptive

Pulse

Welding

46

SECTION

10TEACHING

A

MIG

WELDING

PROGRAM

47

10-1.

Changing

To

MIG

Welding

47

10-2.

Setting

Sequence

MIG

Welding

Parameters

On

Side

Panel

Display

48

SECTION

11



SETTING

DUAL

SCHEDULE

PARAMETERS

51

SECTION

12

USING

THE

OPTIONAL

DATA

CARD

53

12-1.

Installing

Data

Card

53

12-2.

Using

The

Data

Card

53

SECTION

13SETUP

57

13-1.

Setup

Flow

Chart

57

13-2.

Using

Setup

Displays

58

13-3.

Selecting

Process

Capability

58

13-4.

Selecting

Welding

Power

Source

Range

59

13-5.

Selecting

Security

Lock

60

13-6.

Selecting

Or

Changing

Access

Code

61

13-7.

Selecting

Voltage

Correction

62

13-8.

Selecting

Voltage

Sensing

Method

62

13-9.

Selecting

Regular

Or

Hot

Arc

Start

63

13-10.

Selecting

Type

Of

Dual

Schedule

Switch

63

13-11.

Selecting

Trigger

Program

Select

64

13-12.

Selecting

Remote

Increase/Decrease

Capability

65

13-13.

ResettingArcTime

65

13-14.

Using

Self

Test

66

13-15.

Selecting

Units

For

Wire

Feed

Speed

And

Motor

Type

67

13-16.

Selecting

Bench

Or

Boom

Model

Type

67

13-17.

Resetting

Memory

68

13-18.

Selecting

Arc

Start/Volt

Sense

Error

Shutdown

68

13-19.

Selecting

Program

Name

Feature

69

13-20.

Software

Version

Number

69

SECTION

14-

MAINTENANCE

&

TROUBLESHOOTING

70

14-1.

Routine

Maintenance

70

14-2.

Replacing

The

Hub

Assembly

71

14-3.

Overload

Protection

71

14-4.

Error

Displays

72

14-5.

Troubleshooting

73

SECTION

15

ELECTRICAL

DIAGRAMS

74

SECTION

16

PARTS

LIST

78

Figure

16-1.

Main

Assembly

78

Figure

16-2.

Support,

Hub

&

Reel

80

Figure

16-3.

Panel,

Front

w/Components

81

Figure

16-4.

Control

Box

82

Figure

16-5.

Drive

Assembly,

Wire

84

Figure

16-6.

Panel,

Side

w/Components

87

Figure

16-7.

Boom

Assembly

88

Table

16-1.

Drive

Roll

And

Wire

Guide

Kits

86

SECTION

1

-

SAFETY

INFORMATION

Figure

1-1.

Safety

Information

modl.1

2/93

1

Safety

Alert

Symbol

2

Signal

Word

WARNING

moans

possiblo

death

or

serious

injury

can

happen.

CAUTION

means

possible

minor

injury

or

equipment

damage

can

happen.

3

Statement

Of

Hazard

And

Result

4

Safety

Instructions

To

Avoid

Hazard

5

Hazard

Symbol

(If

Available)

6

Safety

Banner

Read

safety

blocks

for

each

sym

bol

shown.

7

NOTE

Special

instructions

for

best

oper

ation



not

safety.

SECTION

2-

SPECIFICATIONS

Table

2-1.

Wire

Feeder

*These

are

wire

feed

speed

ranges

for

GMAW.

While

Pulse

welding,

wire

feed

speed

ranges

may

be

more

limited

(see

Section

9).

OM-1588

Page

1



Read

all

safety

messages

throughout

this

manual.



Obey

all

safety

messages

to

avoid

injury.



Learn

the

meaning

of

WARNING

and

CAUTION.

1

2

;1~ll~Ie~

3

ELECTRIC

SHOCK

can

kiIi.~



Do

not

touch

live

electrical

parts.



Disconnect

input

power

before

4

installing

or

servicing.

a

CAUTION

57

~

MOVING

PARTS

can

Injure.

)~



Keep

away

from

moving

parts.



Keep

all

panels

and

covers

closed

when

operaling.

6

a

WARNING

7~{

NOTE

READ

SAFETY

BLOCKS

at start

of

Section

3-1

before

proceeding.

Turn

Off

switch

when

using

high

frequency

Specification

Description

Type

Of

Input

Power

From

Welding

Power

Source

Maximum

Weld

Circuit

Rating

Welding

Power

Source

Type

Wire

Feed

Speed

Range

Wire Diameter

Range

Welding

Processes

input

Power

Cord

Maximum

Height

With

4

ft

(1.2

m)

Post

Weight

Vertical

Lift

Of

Boom

Single-Phase

24

Volts

AC,

10

Amperes,

50/60

Hertz

100

Volts,

750

Amperes,

100%

Duty

Cycle

Constant

Voltage

(CV)

DC,

With

Contactor

For

GMAW

Welding

Constant

Current

(CC)

DC,

With

Contactor

For

GMAW-P

Welding

Standard:

50

To

780

ipm

(1.3

To

19.8

mpm)

High

Speed:

92

To

1435

ipm

(2.3

To

36.5

mpm)

.023

To

1/8

in

(0.6

To

3.2

mm)

Gas

Metal

Arc

(GMAW),

Gas

Metal

Arc

-

Pulse

(GMAW-P),

Flux

Cored

Arc

Welding

(FCAW)

lOft(3.1

m)

12

ft

(3.7

m)

Boom

17ft(5.2

m)

Net:

207

lb

(94

kg)

Ship:

318

lb

(144

kg)

Horizontal

To

60

Above

Horizontal

16

ft

(4.9

m)

Boom

21

ft

(6.4

m)

Net:

280

lb

(127

kg)

Ship:

411

lb

(186

kg)

Horizontal

To

60

Above

Horizontal

SECTION

3-INSTALLATION

3-1.

Equipment

Connection

Diagram

£~

WARNING

CYLINDERS

can

explode

if

damaged.



Keep

cylinders

away

trom

welding

and

other

electrical

circuits.



Never

touch

cylinder

with

welding

electrode.



Always

secure

cylinder

to

running

gear,

wall,

or

other

stationary

support.

HOT

SURFACES

can

burn

skin.



Allow

gun

to

cool

before

touching.

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



TurnOffwirefeederandwelding

power

source,

and

disconnect

input

power

before

making

connections.

The

welding

wire,

drive

rolls,

drive

assembly,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live

when

welding

or

feeding

wire

using

gun

trigger.

Have

only

qualified

persons

install

this

unit.

wfwam9.1

2/93

2

4

1

Welding

Power

Source

2

Remote

14

Connections

3

Negative

()

Weld

Output

Cable

4

Positive

(+)

Weld

Output

Cable

5

Workpiece

6

Voltage

Sensing

Clamp

7

Weld

Control

8

Boom

9

Gun

10

Swivel

11

Pipe

Post

And

Base

12

Gas

Hoses

12

13

Gas

Supplies

5T-800

173

11

9

Figure

3-1.

Typical

System

Connections

OM-1588

Page

2

3-2.

Installing

Swivel

Into

Pipe

Post

a

WARNING

RELEASE

OF

SPRING

PRESSURE

WITHOUT

BOOM

ATTACHED

can

cause

serious

personal

injury.

S

Do

not

remove

satety

collar

until

instructed

to

do

so.

FALLING

BOOM

can

cause

serious

personal

injury

and

equipment

damage.



Securely

mount

pipe

post

to

base

that

can

support

weight

of

unit

with

boom

in

horizontal

position.



Use

proper

equipment

for

lifting

swivel

and

boom

into

place.

5

4

3

2

1

Swingpak

Base

or

CBC

Cart

2

Pipe

Post

With

Base

3

Steel

Bolt

Secure

as

shown

using

as

a

mini

mum

1/2

in

diameter

SAE

grade

5

steel

bolts.

4

Swivel

Assembly

Insert

into

pipe

post.

Lubricate

swivel.

5

Safety

Collar

Do

not

remove

until

instructed

to.

Tools

Needed:

~

3/4

in

5T.152

382

Figure

3-2.

Swivel

Installation

3-3.

Installing

Control

Box

Onto

Swivel

2

3~

1

Weld

Control

2

Bracket

3

Screw

Bracket

and

screws

are

installed

onto

bottom

of

control

at

factory.

4

Swivel

Loosen

screws.

Place

control

on

swivel

and

slide

forward.

Tighten

screws.

5T.800

174

Tools

Needed:

4

Figure

3-3.

Control

Box

Installation

OM-1

588

Page

3

3-4.

Installing

Boom

And

Reel

Support



READ

Sectio

SAFETY

n

3-2

bef

BLOCKS

at

start

of

ore

proceeding.

2

1

Swivel

Plates

2

Yoke

Remove

hardware

from

swivel

plates

and

yoke.

3

Boom

Set

boom

into

swivel

as

shown.

4

Yoke

Install

through

yoke.

Install

cot

ter

and

spread

ends.

5

Bolt

Install

bolt,

washers,

and

nut.

Tighten

hardware,

and

back

bolt

off

one

half

tum.

6

Locking

Knob

Install

locking

knob

but

do

not

tighten.

7

Reel

Support

Tools

Needed:

Install

reel

support.

3/8,3/4in

ST-153

170

4

1

Figure

3-4.

Boom

Installation

3-5.

Installing

Wire

Guide

Extension

1

Wire

Guide

Fitting

2

Bolt

3

Monocoil

Liner

4

Wire

Guide

Extension

Tighten

bolt

to

secure

liner

in

wire

guide

fitting.

Do

not

overtighten

bolt

and

crush

liner.

Repeat

procedure

for

opposite

side.

Tools

Needed:

~O

3/

Bin

5T-152

383

Figure

3-5.

WIre

Guide

Extension

Installation

OM-1

588

Page

4

3-6.

Wire

Guide

And

Drive

Roll

Installation

A~

WARNING

___

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

wire

feeder

and

welding

power

source,

and

disconnect

input

power

before

inspecting

or

installing.

A.

Wire

Guide

Installation

B.

Drive

Roll

Installation

Figure

3-6.

Wire

Guide

Installation

Figure

3-7.

Drive

Roll

Installation

wfwaml.1

2/93

When

changing

wire

size

or

type,

check

guide

size

(see

Table

16-1).

I

Drive

Rolls

Remove

drive

rolls

before

install

ing

wire

guides

(see

Figure

3-7).

2

Wire

Guide

Securing

Screws

Loosen

wire

guide

screws.

3

Inlet

Wire

Guide

4

Intermediate

Wire

Guide

Insert

intermediate

guide

until

flange

on

guide

rests

against

cast

ing,

and

secure

with

guide

screw.

Install

drive

rolls

(see

Figure

3-7).

Repeat

procedure

for

opposite

side

of

wire

feeder.

Ref.

ST-137

391-F

/

ST.142

597-A

1

Tools

Needed:



5

4

.---1~i



When

changing

wire

size

or

type,

check

drive

roll

size

(see

Table

16-1).

1

Spring

Shaft

Carrier

2

Drive

Roll

Nut

3

Drive

Roll

Carrier

Turn

all

nuts

one

click

until

lobes

of

nut

line

up

with

lobes

of

drive

roll

carrier.

4

Drive

Roll

Slide

drive

rolls

onto

drive

roll

carri

ers.

Turn

nut

one

click.

5

Drive

Assembly

Cover

Close

cover.

Repeat

procedure

for

opposite

side

of

wire

feeder.

ST-142

597-A

2

3

OM-1

588

Page

5

3-7.

Welding

Gun

Connections

a

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

wire

feeder

and

welding

power

source,

and

disconnect

input

power

before

inspecting

or

installing.

wfwaml.1

2/93

4

3

1

Drive

Assembly

Cover

2

Gun

Securing

Knob

3

Gun

Connector

Loosen

securing

knob.

Insert

gun

connector

until

it

bottoms

against

drive

assembly.

Tighten

knob.

4

Gun

Trigger

Plug

5

Gun

Trigger

Receptacle

Insert

plug

into

free-hanging

re

ceptacle

and

tighten

threaded

col

lar.

6

Trigger

Cord

7

Trigger

Plug

8

Weld

Control

Trigger

Receptacle

Insert

plug

into

receptacle

and

tighten

threaded

collar.

Repeat

procedure

for

gun

on

oppo

drive

assembly.

Ref.

ST-152

466

/

Ref.

ST-800

178/

Ref.

ST-800

175

Figure

3-8.

Gun

And

Trigger

Lead

Connections

3-8.

Wire

Feed

Motor

And

Gas

Valve

Control

Connections

I

Wire

Feed

Motor

And

Gas

Valve

Control

Receptacle

2

Plug

From

Boom

3

Cord

From

Boom

Insert

plug

from

boom

cord

into

re

ceptacle

on

rear

of

control,

and

tighten

threaded

collar.

Repeat

procedure

for

opposite

side

of

weld

control.

ST-$OO

177/Ref.

ST-800

175

Figure

3-9.

Boom

Connections

OM-1

588

Page

6

3-9.

Control

Connection

Table

3-1.

Remote

17

Socket

Information

REMOTE

17

SOCket*

Socket

Information

E

1b

~

C

G

CC/CV

select;

+13

to

+24

volts

dc

is

CV,

0

volts

dc

is

CC.

Arc

control/inductance

control;

0

to

+10

volts

dc.

E

Actual

weld

current

output

signal;

+1

volt

dc

is

100

amps.

M

Actual

weld

voltage

output

signal;

+1

volt

dc

is

10

volts

dc.

F

H

Current

feedback

from

welding

power

source;

0

to

+10

volts

dc,

1

volt

per

100

amperes.

Voltage

feedback

from

welding

power

source;

0

to

+10

volts

dc,

1

volt

per

10

arc

volts.

The

remaining

sockets

are

not

used.

Table

3-2.

Remote

14-Pin

Information

REMOTE

14

~j~*

Information

A

24

volts

ac.

(3,

OUTPUT

(CONTACTOR)

B

G

Contact

closure

to

A

completes

24

volts

ac

contactor

control

circuit.

Circuit

common

for

24

volts

ac

circuits.

C

+10

volts

dc

input

to

remote

control.

a

~

AMPERAGE

~l~

VOLTAGE

0

E

Remote

control

circuit

common.

0

to

+10

volts

dc

output

command

signal

from

feeder

voltage

control.

The

remaining

pins

are

not

used.

1

17-Pin

Receptacle

(See

Table

3-1)

2

Keyway

To

connect

interconnecting

cord

to

receptacle,

align

keyway,

insert

plug,

and

tighten

threaded

collar.

3

Weld

Current

Sensor

Recep

tacle

(For

Use

With

Field

Op

tion

Only)

4

35

ft

(10.6

m)

Voltage

Sens

ing

Lead

Connect

to

workpiece

(see

Figure

3-1).

5

Threaded

Collar

6

14-Pin

Plug

(see

Table

3-2)

To

connect

plug

to

matching

recep

tacle

on

welding

power

source,

align

keyway,

insert

plug,

and

tight

en

threaded

collar.

ST-800

177

/

Ref.

S-0512

/

$-0003-A

/

S-0628

Figure

3-10.

Control

Connections

With

Information

OM-1

588

Page

7

3-10.

Shielding

Gas

And

Weld

Cable

Connections

or

wam4.1

9/91

/wfwaml.1

2/93

The

weld

cables

and

shielding

gas

hoses

ex

tend

lOft

(3m)

from

the

boom.

If

the

welding

power

source

or

gas

supply

are

further

from

the

boom,

extend

cables

and

hoses

as

follows:

1

Weld

Cables

2

Insulated

Sleeving

3

Shielding

Gas

Extension

Hose

4

Boom

Shielding

Gas

Hose(s)

5

Supplied

Shielding

Gas

Y

Adapter

Connect

single

end

filling

of

V

adapter

to

gas

supply,

and

connect

boom

shielding

gas

hoses

to

fittings

on

V

end

of

adapter.

Figure

3-11.

Shielding

Gas

And

Weld

Cable

Connections

a

WARNING

CYLINDERS

can

explode

if

damaged.



Keep

cylinders

away

from

welding

and

other

electrical

circuits.



Never

touch

cylinder

with

welding

electrode.



Always

secure

cylinder

to

running

gear,

wall,

other

stationary

support.

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



TurnOffwirefeederandwelding

powersource,and

disconnect

input

power

before

inspecting

or

installing.

BUILDUP

OF

SHIELDING

GAS

can

harm

health

or

kill.



Shut

off

shielding

gas

supply

when

not

in

use.

A.

Connecting

Weld

Cables

And

Gas

Hose

Tools

Needed:

~iI

-~

5/8in

Bolt

together

weld

cables

from

welding

pow-

Connect

boom

shielding

gas

hoses

to

gas

er

source

and

boom.

Use

electrical

tape

and

supplies

or

extension.

The

hoses

from

the

insulated

sleeving

to

cover

connection.

boom

have

5/8-18

right-hand

threads.

Ref.

ST-153

175-A

OM-1588

Page

8

B.

Shielding

Gas

Connections

To

Regulator/Flowmeter

Figure

3-12.

Typical

Regulator/Flowmeter

Installation

3-11.

Removing

Safety

Collar

And

Adjusting

Boom

a

WARNING

L_~J

Figure

3-13.

Boom

Adjustments

4

3

1

.2

6

OR

5

4

Obtain

gas

cylinder

and

chain

to

running

gear,

wall,

or

other

station

ary

support

so

cylinder

cannot

fall

and

break

off

valve.

1

Cap

2

Cylinder

Valve

Remove

cap,

stand

to

side

of

valve,

and

open

valve

slightly.

Gas

flow

blows

dust

and

dirt

from

valve.

Close

valve.

3

Cylinder

4

Regulator/Flowmeter

Install

so

face

is

vertical.

5

Gas

Hose

Connection

Fitting

has

5/8-18

right-hand

threads.

Install

gas

hose

according

to

Figure

3-11.

6

Flow

Adjust

Typical

flow

rate

is

20

cfh

(cubic

feet

per

hour).

Check

wire

manufactur

ers

recommended

flow

rate.

Make

sure

flow

adjust

is

closed

when

opening

cylinder

to

avoid

damage

to

the

flowmeter.

7

CO2

Adapter

8

0-Ring

Install

adapter

with

0-ring

between

regulator/flowmeter

and

CO2

cylinder.

~

-

5T-158

697-A

Argon

Gas

.2

Tools

Needed:

~

5/8,1-1/8

in

CO2

Gas

RELEASE

OF

SPRING

PRESSURE

FALLING

BOOM

can

cause

serIous

WITHOUT

BOOM

ATTACHED

can

cause

serious

personal

injury.

personal

injury

and



Adjustment

rod

must

equipment

damage.

be

threaded

fully

through



Do

not

remove

safety

collar

until

instructed

to

do

so.

yoke.

1

Locking

Knob

Tighten

knob

to

prevent

boom

movement.

Loosen

knob

to

allow

boom

movement.

Change

knob

position

to

limit

upward

movement.

Pull

boom

down

slightly

and

re

move

safety

collar.

Boom

should

balance

in

any

position

from

hori

zontal

to

60

degrees

above

hori

zontal.

If

necessary,

adjust

boom

as

follows:

Loosen

jam

nut

and

turn

threaded

rod

until

boom

balances.

Tighten

jam

nut.

Be

sure

several

full

threads

are

through

yoke

to

pre

vent

boom

falling.

2

4

Yoke

Tools

Needed:

~

1-1/8in

E

Q

j

Rod~

Increasing

Spring

Pressure

For

A

HeavyGun

Decreasing

Spring

Pressure

For

A

LightGun

Retain

safety

collar

for

use

in

dis

assembling

or

moving

boom.

8T-142599-B

2

Threaded

Rod

3

Jam

Nut

OM-1

588

Page

9

3-12.

Welding

Wire

Installation

A.

Installation

Of

Spool-Type

Wire

Figure

3-14.

Installation

Of

Spool-Type

Wire

B.

Installation

Of

Optional

Wire

Reel

And

Reel

Type

Wire

Figure

3-15.

Installation

Of

Optional

Wire

Reel

And

Reel

Type

Wire

4

3

1

Retaining

Ring

2

Wire

Spool

3

Hub

Remove

retaining

ring

and

slide

spool

onto

hub.

4

Hub

Turn

spool

until

hub

fits

hole

in

spool.

Reinstall

retaining

ring.

Repeat

procedure

for

opposite

side.

ST-153

171

E

2

8

4

1

Retaining

Ring

2

Spanner

Nut

3 Lock

4

Wire

Retainer

5

Wire

Reel

6

Hub

7

Hub

8

Reel

Support

Remove

retaining

ring.

Pull

lock

and

turn.

Remove

spanner

nut,

wire

retainer,

and

wire

reel

from

hub.

~1IIIiI~

.

fD~

Wire

Installation

Lay

wire

reel

assembly

on

flat

sur

face,

and

install

wire

as

shown.

Tighten

spanner

nut

until

lock

is

in

position

over

hole

in

wire

retainer.

Pull

lock

and

turn

to

insert

locking

into

wire

retainer.

Slide

wire

reel

assembly

onto

hub,

and

turn

assembly

until

hub

is

seated

in

hole

in

reel.

Reinstall

re

taining

ring.

ST-143

478-A

/

ST-152

463

OM-1

588

Page

10

Page is loading ...

Miller DS-64M Swingarc Owner's manual

This manual is also suitable for

Miller DS-64M Swingarc Owner's manual

Related papers

Other documents