Miller KD497659 Owner's manual

Millerﬁ

October

1993

Form:

OM-1586D

Effective

With

Serial

No.

KD497659

OWNERS

MANUAL



Read

and

follow

these

instructions

and

all

safety

blocks

carefully.



Have

only

trained

and

qualified

persons

install,

operate,

or

service

this

unit.



Call

your

distributor

if

you

do

not

understand

the

directions.

SS-64M

(12)

And

(16)

Foot

Boom

Mounted

Wire

Feeder



Microprocessor

Controlled

Constant

Speed

Wire

Feeder



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



Circuit

Breaker

Protected



Give

this

manual

to

the

operator.



For

help,

call

your

distributor



or:

MILLER

Electric

Mfg.

Co.,

P.O.

Box

1079,

Appleton,

WI

54912

414-734-9821

cover

7/93



ST.157

388

'

1993

MILLER

Electric

Mlg

Co.

PRINTED

IN

USA

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

Effective

January

1,

1992

(Equipment

with

a

sariai

number

preface

of

KC

or

newer)

This

limited

werrenty

supersedes

eli

werrenties

end

is

exclusive

with

no

other

guarantees

or

werrenties

expressed

or

implied.

LIMITED

WARRANTY



Subject

to

the

terms

and

conditions

below,

MILLER

Electric

MI

g.

Co.,

Appleton.

Wisconsin.

warrants

to

its

original

retell

purchaser

that

new

MILLER

aquipmant

sold

after

the

effective

date

of

this

limited

warranty

is

free

of

de

fects

in

material

and

workmanship

at

the

tima

it

is

shipped

by

MtLLER.

TIllS

WAR

RANT?

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,

MtLLER

will

repair

or

raplaca

any

war

ranted

parts

or

components

that

tail

due

to

such

detects

in

malarial

or

workmanship.

MILLER

must

be

notified

in

writing

within

thirty

(30)

days

of

such

defect

or

tailura,

at

which

time

MILLER

will

provide

instructions

on

the

warranty

claim

procedures

to

ba

followed.

MILLER

shall

honor

warranty

claims

on

warranted

equipment

listed

below

in

the

avant

of

such

a

failure

within

the

warranty

lime

pariods.

All

warranty

time

periods

start

on

the

data

that

the

equipment

was

delivered

to

the

original

retail

purchaser,

or

one

year

after

the

equipment

is

sant

to

the

distributor.

3.

2

Years



Parts

and

Labor

*

Engine

Driven

Welding

Ganarstors

(NOTE:

Engines

era

warranted

separately

by

the

angina

manufacturer.)



Air

Compressors

4.

1

Yasr



Psrts

end

Labor

*

Motor

Driven

Guns

*

Process

Controllers



Water

Coolant

Syatams

*

HF

Units



Grids

*

Spot

Welders



Load

Banks



SDX

Transformers



Running

Gear/Trailers

*

Field

Options

(NOTE:

Field

options

era

covarad

undar

True

Blue

TN

for

the

remaining

warranty

period

ol

tha

producl

Ihey

era

installed

in,

or

for

a

minimum

of

one

year



whichavar

is

graalar.(

6

Months



Batteries

g~

Days



Parts

and

Labor



MIG

Guns/TIG

Torchas



Plasma

Cutting

Torches

U,.



Remote

Controls

*

Accessory

Kits

*

Rapiscamant

Parts

MILLERS

True

BIuaT_

Limited

Warranty

shall

not

apply

to:

1.

Items

furnished

by

MILLER.

but

manutacturad

by

others,

such

as

engines

or

trade

accessories.

These

items

era

covarad

by

the

manufacturers

warranty,

if

any.

2.

Consumable

componants:

such

as

contact

tips,

cutting

nozzles.

contactors

and

relays

or

parts

that

fail

due

to

normal

wear.

3.

Equipment

that

has

bean

modified

by

any

party

other

than

MILLER,

or

aquip

mant

that

has

bean

improperly

installed,

improperly

oparstad

or

misused

based

upon

industry

stsndsrds,

or

equipment

which

has

not

had

reasonable

end

nacasssry

mairttansnca,

or

aquipmant

which

has

baan

used

tor

oparstion

outside

of

the

specifications

for

the

equipment.

MILLER

PRODUCTS

ARE

IHTEHDED

FOR

PURCHASE

AND

USE

BY

COMMER

CIALIINDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

IN

THE

USE

AND

MAIHTENANCE

OF

WELDING

EQUIPMENT

In

the

avant

of

a

wsrrsnty

claim

covered

by

this

warranty,

the

exclusive

remedies

shall

be.

at

MILLERS

option:

)t)

repair:

or

(2)

rapiacamant;

or.

where

authorized

in

writing

by

MILLER

in

appropriate

cases,

13)

the

reasonable

cost

of

repair

or

replace-

mantel

an

authorizad

MILLER

sarvica

station:

or

(4)

payment

of

or

credit

for

tha

pur

chase

price

(lass

reasonable

dapracistion

based

upon

actual

use)

upon

return

ot

the

goods

at

customers

risk

and

aspansa.

MILLERS

option

of

repair

or

replacement

will

be

FOB..

Factory

atApplaton.

Wisconsin,

or

F.O.B.

ala

MILLER

authorized

ser

vice

facility

as

determined

by

MILLER.

Therefore

no

compansstion

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

CDN

TRACt

TORT

OR

ANY

OTHER

LEGAL

THEORY.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WAR

RANTY,

GUARANTY

DR

REPRESENTATION

AS TO

PERFDRMANCE,

AND

ANY

REMEDY

FOR

BREACH

OF

CONTRACT

TORT

DR

ANY

OTHER

LEGAL

THEORY

WHICH,

BUT

FOR

THIS

PROVISION.

MIGHT

ARISE

BY

IMPLICATION.

OPERATIDN

DF

LAW,

CUSTOM

DF

TRADE

DR

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

slates

in

Iha

U.S.A.

do

not

allow

limitations

of

how

long

an

implied

warrsnty

lasts,

or

tha

asclusion

of

incidantal,

indiract,

special

or

consequential

damsgas.

so

Iha

above

iimitstion

or

asciusion

may

not

apply

to

you.

This

warranty

provides

spe

cific

lagal

rights,

and

other

rights

may

ba

available,

but

may

vary

from

stats

to

stats.

In

Csnsds,

Iagislslion

in

soma

provincas

provides

for

certain

additional

warranties

or

remedies

other

than

as

slslad

herein.

and

to

the

aslanl

thaI

they

may

not

be

waived,

the

limitations

and

exclusions

sat

out

above

may

nol

apply.

This

Limited

Warranty

provides

specific

legal

rights,

and

other

rights

may

be

available,

but

may

vary

hom

province

to

province.

1.

5

Yaars

Parts



3

Years

Labor

*

Original

main

power

rectifiers

2.

3

Years



Parts

and

Labor



Transformar/Ractifiar

Powar

Sources



Plasma

Arc

Cutting

Power

Sources



Semi-Automatic

and

Automatic

Wira

Feeders

Robots

5.

B.

I

RECEIVING-HANDLING

Before

unpacking

equipment,

check

carton

for

any

dama9e

that

may

have

occurred

during

Shipment.

File

any

claims

for

loss

or

damage

with

the

deiivering

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

5/93s

ERRATA

SHEET

June

2,

1994

FORM:

OM-1586D

Use

above

FORM

number

when

ordering

extra

manuals.

CHANGES

TO

SECTION

3

INSTALLATION

Replace

Section

3-11B.

Welding

Wire

Installation:

Installation

Of

Optional

Wire

Reel

And

Reel

Type

Wire

Figure

3-14.

Installation

Of

Optional

Wire

Reel

And

Reel

Type

Wire

CHANGES

TO

SECTION

15

ELECTRICAL

DIAGRAMS

Replace

Figure

15-1.

Circuit

Diagram

For

Wire

Feeder

(see

Pages

2

and

3

on

this

Errata

Sheet)

Replace

Figure

15-2.

Wiring

Diagram

For

Wire

Feeder

Effective

With

Serial

No.

KD497659

And

Following

(see

Pages

4

and

5

on

this

Errata

Sheet)

After

this

manual

was

printed,

refinements

in

equipment

design

occurred.

This

sheet

lists

exceptions

to

data

appearing

later

in

this

manual.

8

5

4

2

.1

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.

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.

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478~A

/

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463

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KD497659

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OM-1586D

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CHANGES

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SECTION

16-

PARTS

LIST

Change

Parts

List

as

follows:

**First

digit

represents

page

no



digits

following

dash

represent

item

no.

+When

ordering

a

component

originally

displaying

a

precautionary

label,

the

label

should

also

be

ordered.

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

**

Dia.

Mkgs.

Part

No.

Replaced

With

Description

Quantity

.

79-7

124

905

...

+168

104

..

RETAINER,

spool

support

(Eft

wIKE621826)

(consisting

of)

1

166

594

.

..

LABEL,

caution

falling

wire

reel

can

cause

damage

1

.

79-8

124904

168

103

..

NUT,

spanner

retaining

(Effw/KE621826)

1

.

81-2

164

842

164

842

..

METER,

(qty

chg)

(used

on

front

meter

only)

1

.

81-2

164842

155

024

..

LENS,

clear

anti

glare

(used

on

side

meter

only)

...

1

.

81-10

.

. .

.

PC1O

....

164713

161

781

..

CIRCUITCARD,processorw/prom

1

.

82-34

...

PLG1O3

...

135

635

Deleted

..

Eff

w/KE593886

.

82-43

154

932

167

698

..

PANEL,

front

(Eff

w/KE623992)

1

.

82-44

157

113

010291

..

WASHER,

flat

.625

ID

nylafil

(Effw/KE623992)

....

1

.

82-45

097

924

167700

..

KNOB,

pointer

(Eff

w/KE623992)

1

. .

82-

Added

..

.

167

633

..

WASHER,

shldr

.612

ID

(Eff

w/KE623992)

1

.

82-

Added

. .

.

159

264

..

RING,

rtng

ext

.625

shaft

grv

x

.045

thk

E

style

(Eff

w/KE623992)

1

.

83-15

83-20

133

603

...

154031

.

165

934

..

167

387

..

SPRING,

cprsn

.573

OD

x

.088

wire

x

1.062

lg

(Eff

w/KE644333)

SPACER,

locating

(Eff

w/KE552693)

2

.

83-

Added

165

799

..

WASHER,

flat

.257

ID

stl

(Eff

w/KE644333)

2

. .

83-

Added

165

798

..

SPRING,

pressure

arm

retaining

(Eff

w/KE644333)

.

2

. .

83-

Added

163

282

..

NUT,

.250-28

stl

(Eff

w/KE644333)

2

.

85-1

057

357

010 493

..

BUSHING,

snap-in

nyl

.625

ID

x

.875mtg

hole

1

OM-1

586D

Page

6

ARC

WELDING

SAFETY

PRECAUTIONS

ELECTRIC

SHOCK

can

kill.

Touching

live

electrical

parts

can

cause

fatal

shocks

or

severe

burns.

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.

1.

Do

not

touch

live

electrical

parts.

2.

Wear

dry.

hole-free

insulating

gloves

and

body

protection.

3.

Insulate

yourself

from

work

and

ground

using

dry

insulating

mats

or

covers.

4.

Disconnect

input

power

or

stop

engine

before

installing

or

servicing

this

equipment.

WELDING

can

cause

fire

or

explosion.

Sparks

and

spatter

fly

off

from

the

welding

arc.

The

flying

sparks

and

hot

metal,

weld

spatter,

hot

workpiece,

and

hot

equipment

can

cause

fires

and

burns.

Accidental

contact

of

electrode

orwelding

wire

to

metal

objects

can

cause

sparks,

overheating,

or

fire.

Protect

yourself

and

others

from

flying

sparks

and

hot

metal.

Do

not

weld

where

flying

sparks

can

strike

flammable

material.

Remove

all

flammables

within

35

ft

(10.7

m)

of

the

welding

arc.

If

this

is

not

possible,

tightly

cover

them

with

approved

covers.

Be

alert

that

welding

sparks

and

hot

materials

from

welding

can

through

small

cracks

and

openings

to

adjacent

areas

FLYING

SPARKS

AND

HOT

METAL

can

cause

injury.

Chipping

and

grinding

cause

flying

metal.

As

welds

cool,

they

can

throw

off

slag.

ARC

WELDING

can

be

hazardous.

5.

Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual

and

national,

state,

and

local

codes.

6.

When

making

input

connections,

attach

proper

grounding

conductor

first.

7.

Turn

off

all

equipment

when

not

in

use.

8.

Do

not

use

worn,

damaged,

undersized,

or

poorly

spliced

cables.

9.

Do

not

wrap

cables

around

your

body.

10.

Ground

the

workpiece

to

a

good

electrical

(earth)

ground.

11.

Do

not

touch

electrode

if

in

contact

with

the

work

or

ground.

12.

Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

13.

Wear

a

safety

harness

if

working

above

floor

level.

14.

Keep

all

panels

and

covers

securely

in

place.

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

or

drums.

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.

Do

not

use

welder

to

thaw

frozen

pipes.

Remove

stick

electrode

from

holder

or

cut

off

welding

wire

at

contact

tip

when

not

in

use.

11.

Wear

oil-free

protective

garments

such

as

leather

gloves,

heavy

shirt,

cuffless

trousers,

high

shoes,

and

a

cap.

1.

Wear

approved

face

shield

or

safety

goggles.

Side

shields

recommended.

2.

Wear

proper

body

protection

to

protect

skin.

a

WARNING

PROTECT

YOURSELF

AND

OTHERS

FROM

POSSIBLE

SERIOUS

INJURY

OR

DEATH.

KEEP

CHILDREN

AWAY.

PACEMAKER

WEARERS

KEEP

AWAY

UNTIL

CONSULTING

YOUR

DOCTOR.

In

welding,

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.

ARC

RAYS

can

burn

eyes

and

skin;

ARC

RAYS

~

NOISE

can

damage

hearing.

2.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

(see

ANSI

Z49.

I

listed

in

Safety

Standards)

to

protect

your

face

and

Arc

rays

from

the

welding

process

produce

intense

eyes

when

welding

or

watching.

heat

and

strong

ultraviolet

rays

that

can

burn

eyes

3.

Wear

approved

safety

glasses.

Side

shields

recommended.

and

skin.

Noise

from

some

processes

can

damage

hearing.

~

Use

protective

screens

or

barriers

to

protect

others

from

flash

and

glare;

warn

others

not

to

watch

the

arc.

NOISE

5.

Wear

protective

clothing

made

from

durable,

flame-resiŒtant

1.

Use

approved

ear

plugs

or

ear

muffs

if

noise

level

is

high.

material

(wool

and

leather)

and

foot

protection.

FUMES

AND

GASES

can

be

hazardous

5.

Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

~~:

.~

to

your

health.

wearing

an

air-supplied

respirator.

Shielding

gases

used

for

~

Weldingproducesfumesandgases.

Breathingthese

welding

can

displace

air

causing

injury

or

death.

Be

sure

the

fumes

and

gases

can

be

hazardous

to

your

health.

breathing

air

is

safe.

6.

Do

not

weld

in

locations

near

degreasing,

cleaning,

or

spraying

operations.

The

heat

and

rays

of

the

arc

can

react

with

vapors

to

1.

Keep

your

head

out

of

the

fumes.

Do

not

breathe

the

fumes.

form

highly

toxic

and

irritating

gases.

2.

If

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

remove

welding

fumes

and

gases.

7.

Do

not

weld

on

coated

metals,

such

,as

galvanized,

lead,

or

3.

If

ventilation

is

poor,

use

an

approved

air-supplied

respirator.

cadmium

plated

steel,

unless

the

coating

is

removed

from

the

4.

Read

the

Material

Safety

Data

Sheets

(MSDS5)

and

the

weld

area,

the

area

is

well

ventilated,

and

if

necessary,

while

manufacturers

instruction

for

metals,

consumables,

coatings,

wearing

an

air-supplied

respirator.

The

coatings

and

any

metals

and

cleaners,

containing

these

elements

can

give

off

toxic

fumes

if

welded.

1.

2.

3.

4.

9.

10.

srI

9/92

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,

and

arcs.

2.

Install

and

secure

cylinders

in

an

upright

position

by

chaining

them

to

a

stationary

support

or

equipment

cylinder

rack

to

prevent

falling

or

tipping.

a

WARNING

3.

Keep

cylinders

away

from

any

welding

or

other

electrical

circuits.

4.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

5.

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

in

good

condition.

6.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

7.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

in

use

or

connected

for

use.

8.

Read

and

follow

instructions

on

compressed

gas

cylinders,

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

Standards.

PRINCIPAL

SAFETY

STANDARDS

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.i,

from

American

Welding

Society,

550

N.W.

Le.Jeune

Rd,

Miami

FL

33126

Safetyand

Health

Standards,

OSHA29

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

Rd,

Miami,

FL

33126

National

Electrical

Code,

NFPA

Standard

70,

from

National

Fire

Pro

tection

Association,

Batterymarch

Park.

Quincy,

MA

02269.

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

P-i,

from

Compressed

Gas

Association,

1235

Jefferson

Davis

High

way,

Suite

501,

Arlington,

VA

22202.

Code

for

Safety

in

Welding

and

Cutting,

CSA

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

EyeAnd

Face

Protec

tion,

ANSI

Standard

Z87.i,

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.

ENGINE

EXHAUST

GASES

can

kill.

1.

Use

equipment

outside

in

open,

well-ventilated

areas.

ENGINES

can

be

hazardous.

2.

If

used

in

a

closed

area,

vent

engine

exhaust

outside

and

Engines

produce

harmful

exhaust

gases.

away

fr

om

any

building

air

intakes.

ENGINE

FUEL

can

cause

fire

or

1.

Stop

engine

before

checking

or

adding

fuel.

4



explosion.

Engine

fuel

is

highly

flammable.

2.

3.

4.

5.

Do

not

add

fuel

while

smoking

or

if

unit

is

near

any

sparks

or

open

flames.

Allow

engine

to

cool

before

fueling.

If

possible,

check

and add

fuel

to

cold

engine

before

beginning

job.

Do

not

overfill

tank



allow

room

for

fuel

to

expand.

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,

3.

4.

Have

only

qualified

people

remove

guards

or

covers

for

maintenance

and

troubleshooting

as

necessary.

To

prevent

accidental

starting

during

servicing,

disconnect

negative

(.)

battery

cable

from

battery.

1.

Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

5.

6.

Keep

hands,

hair,

loose

clothing,

and

toots

away

from

moving

parts.

Reinstall

panels

or

guards

and

close

doors

when

servicing

is

2.

Stop

eng

ne

before

installing

or

connecting

unit,

finished

and

before

starting

engine.

SPARKS

can

cause

BATTE

TO

EXPLODE;

BATTERY

RY

GASES

ACID

can

1.

2.

Always

wear

Stop

engine

a

face

s

before

hietd

when

working

on

a

battery.

disconnecting

or

connecting

battery

burn

eyes

and

skin,

cables.

3.

Batteries

contain

acid

and

generate

explosive

4.

Do

not

allow

tools

to

cause

sparks

when

working

on

a

battery.

Do

not

use

welder

to

charge

batteries

or

jump

start

vehicles.

gases.

5.

Observe

correct

polarity

(+

and

)

on

batteries.

.

.

~-

/

STEAM

AND

COOLANT

can

skin.

The

coolant

in

the

under

pressure.

PRESSURIZED

burn

face,

eyes,

radiator

can

be

very

ho

HOT

and

t

and

i.

2.

3.

Donotremoveradiatorcapwhenengineishot.Allowengine

to

cool.

Wear

gloves

and

put

a

rag

over

cap

area

when

removing

cap.

Allow

pressure

to

escape

before

completely

removing

cap.

Sri

9/92

PRECAUTIONS

DE

SECURITE

EN

SOUDAGE

A

LARC

DESSAI.

LELECTROCUTION

peut

Œtre

mortelle.

Une

dØcharge

Ølectrique

peut

vous

tuer

ou

vous

brler

gravement.

LØlectrode

et

le

circuit

de

soudage

sont

sous

tension

au

demarrage.

Le

circuit

dentrØe

et

les

circuits

internes

des

matØriels

sont

aussi

sous

tension

des

Ia

mise

en

marche.

En

soudage

ou

semi-automatique

avec

til,

ce

dernier,

le

support

de

roquette,

le

logement

des

galets

dentraInement

et

toutes

les

piŁces

metalliques

en

contact

avec

le

fil

de

soudage

sont

sous

tension.

Des

matØriels

mal

installØs

ou

mal

mis

a

terre

sont

dangereux.

1.

Ne

touchez

pas

a

des

piŁces

sous

tension.

2.

Portez

des

gants

et

des

vØtements

isolants,

secs

et

non

trouŁs.

3.

lsolez-vous

de

Ia

tle

a

souder

et

de

Ia

mise

ala

terre

au

moyen

de

petits

tapis

isolants

ou

autres.

4.

DØconnectez

Ia

prise

dentrØe

des

matØriels

ou

arrŒtez

leur

moteur

avant

de

les

installer

ou

den

faire

Ientretien.

C~

Le

RAYONNEMENT

DE

LARC

peut

brUler

(es

yeux

et

Ia

peau;

le

BRUIT

peut

endommager

IouIe.

Larc

de

soudage

produit

une

chaleur

et

des

rayons

ultraviolets

intenses,

susceptibles

de

brler

les

yeux

et

a

peau.

Le

bruit

cause

par

certains

procŁdes

peut

endommager

louIe.

1.

Portez

un

casque

de

soudeur

avec

Øcran

filtrant

de

teinte

appropriØe

(consultez

Ia

norme

ANSI

Z49

indiquee

ci-apres),

pour

vous

protØger

le

visage

et

les

yeux

Iorsque

vous

soudez

ou



I

Les

VAPEURS

ET

LES

FUMEES

sont

~

dangereuses

pour

Ia

sante.

U

Le

soudage

degage

des

vapeurs

et

des

fumØes

quil

=9..

est

dangereux

de

respirer.

1.

Ecartez

le

visage

pour

Øviter

de

respirer

les

tumØes.

2.

A

lintØrieur,

assurez-vous

que

laire

de

soudage

est

bien

ventilØe

ou

que

es

fumØes

et

les

vapeurs

sont

aspirees

a

arc.

3.

Si

Ia

ventilation

est

mauvaise,

portez

un

respirateur

a

adduction

dair

approuvØ.

4.

Lisez

les

fiches

signaletiques

et

les

consignes

du

fabricant

relatives

aux

mØtaux,

aux

produits

consummables,

aux

revŒtements

et

aux

produits

nettoyants.

~

~

Le

SOUDAGE

peut

causer

un

incendie

(~

~

ou

une

explosion.

Larc

produit

des

Øtincelles

et

des

projections.

Avec

Ia

chaleur

intense

dØgagee

par

Ia

tle

et

les

matØriels,

elles

peuvent

causer

un

incendie

et

des

brlures.

Le

contact

accidentel

de

lelectrode

avec

un

objet

mØtallique

peut

provoquer

des

Øtincelles,

un

Øchauffement

ou

un

incendie.

1.

Protegez-vous,

ainsi

que

les

autres,

contre

les

Łtincelles

et

les

projections.

2.

Ne

soudez

pas

dans

un

endroit

o

des

Øtincelles

peuvent

atteindre

des

matØriaux

inflammables.

3.

Enlevez

toutes

es

matiŁres

inflammables

dans

un

rayon

de

10,7

metres

autour

de

larc,

ou

couvrez-les

soigneusement

avec

des

bÆches

approuvees.

4.

MØfiez-vous

des

Øtincelles

et

des

Øclats

brUlants,

susceptibles

de

pØnØtrerdans

des

aires

adjacentes

parde

petites

ouvertures

ou

fissures.

LE

SOUDAGE

A

LARC

est

dangereux.

5.

Veillez

a

installer

ces

matØriels

eta

les

mettre

ala

terre

selon

le

manuel

dutilisation

et

les

codes

nationaux,

provinciaux

et

locaux

applicables.

6.

ArrŒtez

tous

es

matØriels

apres

utilisation.

7.

Nutilisez

pas

de

cables

uses,

endommagØs,

mal

ŁpissØs

ou

de

calibre

trop

petits.

8.

Nenroulez

pas

de

cables

autour

de

votre

corps.

9.

Mettez

ala

terre

Ia

tle

a

souder

au

moyen

dune

bonne

prise

de

terre.

10.

Ne

touchez

pas

a

IØlectrode

Si

vous

Øtes

en

contact

avec

le

circuit

de

Soudage

(terre).

11.

Nutilisez

que

des

matØriels

en

bon

Øtat.

RØparez

ou

remplacez

sur-le-champ

les

piŁces

endommagees.

12.

Portez

un

harnais

de

sØcuritØ

si

vous

travaillez

en

hauteur.

13.

Fermez

solidement

tous

les

panneaux

et

les

capots.

que

vous

observez

lexØcution

dune

soudure.

2.

PortezdeslunettesdesØcuritØapprouvØes.

Des

Øcran~

latØraux

sont

recommandees.

3.

Entourez

laire

de

soudage

de

rideaux

ou

de

cloisons

de

protection

contre

les

coups

darc

ou

lØblouissement;

avertissez

les

observateurs

de

ne

pas

regarder

larc.

4.

Portez

des

vŒtements

en

tissus

ignifuge

durable

(lame

et

cuir)

et

des

chaussures

de

sØcuritØ.

5.

Portez

un

casque

antibruit

ou

des

bouchons

doreille

approuvØs

si

le

niveau

de

bruit

est

ØlevØ.

5.

Ne

travaillez

dans

un

espace

confine

que

siI

est

bien

ventilØ;

sinon,

portez

un

respirateura

adduction

dair.

Les

gaz

protecteurs

de

soudage

peuvent

dØplacer

loxygene

de

lair

et

causer

des

blessures

ou

Ia

mort.

Assurez-vous

que

lair

eSt

propre

a

Ia

respiration.

6.

Ne

soudez

pas

a

proximite

dopØrations

de

degraissage,

de

nettoyage

ou

de

pulvØrisation.

La

chaleur

et

les

rayons

de

larc

peuvent

rØagir

avec

des

vapeurs

et

former

des

gaz

hautement

toxiques

et

irritants.

7.

Ne

soudez

pas

de

tles

galvanisØesou

plaquees

en

p10mb

ou

en

cadmium

sans

les

avoir

grattØes

a

fond,

car

ces

mØtaux,

et

tout

revŒtement

qui

en

contient,

peuvent

alors

dØgager

des

fumees

toxiques.

Assurez-vous

dune

bonne

ventilation

et

portez

un

respirateur

a

adduction

dair

si

cest

nØcessaire.

5.

MØfiez-vous

des

incendies

et

gardez

un

extincteur

a

portØe

de

Ia

main.

6.

Noubliez

pas

quune

soudure

sur

un

plafond,

un

plancher,

une

cloison

ou

une

paroi

peut

en

entlammer

Iautre

ctØ.

7.

Ne

soudez

pas

un

recipient

fermØ,

comme

un

reservoir

ou

un

tonneau.

8.

Connectez

le

cable

de

soudage

le

plus

prŁs

possible

de

Ia

tle

de

soudage

pour

empØcher

le

courant

de

suivre

un

parcours

long

et

inconnu,

et

prØvenir

ainsi

les

risques

dØlectrocution

et

dincendie.

9.

Ne

faites

pas

degeler

des

tuyaux

avec

un

chalumeau.

10.

Videz

votre

carquois

porte-electrodes

ou

coupez

le

fil

au

tube-

contact

aprŁs

le

soudage.

11.

Portez

des

vØtements

protecteurs

non

huileux,

tels

des

gants

en

cuir,

une

chemise

Øpaisse,

un

pantalon

sans

revers,

des

chaussures

montantes

et

un

casque.

MISE

EN

GARDE

PROTEGEZ-VOUS,

AINSI

OUE

LES

AUTRES,

CONTRE

LES

BLESSURES

GRAVES

POSSIBLES

OU

LA

MORT.

NE

LAISSEZ

PAS

LES

ENFANTS

SAPPROCHER,

NI

LES

PORTEURS

DE

STIMULATEUR

CARDIAQUE

(A

MOINS

QUILS

NAIENT

CONSULTE

UN

MEDECIN).

Le

soudage,

comme

Ia

plupart

des

activitØs

industrielles,

expose

a

certains

risques.

Le

soudage

nest

pas

dangereux

lorsquon

prend

des

precautions.

Les

consignes

de

sØcuritØ

suivantes

ne

font

que

rØsumer

information

contenue

dans

les

normes

ØnumØrŁes

ci-apres.

Lisez

et

respectez

toutes

ces

normes.

SEULES

DES

PERSONNES

QUALIFIEES

DOIVENT

FAIRE

DES

TRAVAUX

DINSTALLATION,

DE

REPARATION,

DENTRETIEN

ET

d

Les

BOUTEILLES

endommagees

peuvent

exploser.

Les

bouteilles

contiennent

des

gaz

protecteurs

sous

haute

pression.

Des

bouteilles

endommagees

peuvent

exploser.

Comme

les

bouteilles

font

normalement

partie

du

procedØ

de

soudage,

traitez-les

avec

soin.

1.

Les

bouteilles

doivent

Œtre

protOgØes

contre

les

sources

de

chaleur

intense,

les

chocs

et

les

arcs

de

soudage.

2.

EnchaInez

verticalement

les

bouteilles

a

un

support

ou

a

un

cadre

fixe

pour

les

empŒcher

de tomber

ou

dŒtre

renversØes.

3.

Eloignez

les

bouteilles

de

tout

circuit

Ølectrique

ou

de

soudage.

MISE

EN

GARDE

Le

CARBURANT

peut

causer

un

incendie

ou

une

explosion.

Le

carburant

est

hautement

inflammable.

I

~

ArrŒtez

le

moteur

avant

de

verifier

le

niveau

de

carburant

ou

do

faire

le

plein.

2.

Ne

faites

pas

le

plein

en

fumant

ou

proche

dune

source

Des

PIECES

EN

MOUVEMENT

peuvent

causer

des

blessures.

Des

piŁces

en

mouvement,

telles

des

ventilateurs,

des

rotors

et

des

courroies

peuvent

couper

es

doigts

et

les

mains,

ou

accrocher

des

vŒtements

amples.

1.

Assurez-vous

que

es

portes,

los

panneaux,

les

capots

et

los

protecteurs

sont

bien

fermØs.

2.

Avant

dinstaller

ou

do

connecter

un

systeme,

arrŒtez-en

le

moteur.

3.

Seules

des

personnes

qualifiØes

doivent

dØmonter

des

4.

EmpŒchez

tout

contact

entre

une

bouteille

et

une

electrode.

5.

Nutilisez

que

des

bouteilles

de

gaz

protecteur,

des

dØtendeurs,

des

flexibles

et

des

raccords

concus

pour

chaque

application

spØcifique;

ces

matØriels

et

les

piŁces

connexes

doivent

Øtro

en

bon

Łtat.

6.

Ne

mettez

pas

le

visage

devant

le

robinet

de

bouteille

en

louvrant.

7.

Remettez

le

chapeau

de

bouteille

apres

utilisation.

8.

Lisez

et

respectez

les

consignes

relatives

aux

bouteilles

de

gaz

comprimØ

et

aux

matØriels

connexes,

ainsi

que

Ia

publication

P-i

de

Ia

CGA,

ØnumŁrØes

dans

les

normes

ci-dessous.

Les

MOTEURS

peuvent

Œtre

dangereux.

dØtincelles

ou

dune

flamme

flue.

3.

Si

cest

possible,

laissez

le

moteur

refroidir

avant

de

faire

le

plein

do

carburant

ou

den

verifier

le

niveau

au

debut

du

soudage.

4.

Ne

faites

pas

le

plein

do

carburant

a

ras

bord

:

prØvoyez

do

espace

pour

son

expansion.

--

5.

Faites

attention

done

pas

renverser

do

carburant.

Nettoyez

tout

carburant

renversØ

avant

do

faire

dØmarrer

le

moteur.

protecteurs

ou

des

capots

pour

faire

lentretien

ou

le

depannage

nŁcessaire.

4.

Pour

empŒcher

un

dØmarrage

accidentel

dun

systŁme

pendant

lentretien,

dŁbranchez

le

cable

daccumulateur

a

borne

negative.

5.

Napprochez

pas

los

mains

ou

los

cheveux

de

piŁces

en

mouvemont;

elles

peuvent

aussi

accrocher

des

vŒtements

amplos

et

des

outils.

6.

RØinstallez

los

capots

ou

los

protecteurs

et

fermez

los

portes

apres

des

travaux

dentretien

of

avant

de

faire

dØmarrer

le

moteur.

Safety

in

Welding

and

Cutting

norme

ANSI

Z49.

1,

American

Welding

Society,

550,

N.W.

LeJeune

Rd.,

Miami

FL

33128.

Safety

and

Health

Standards

OSHA

29

CFR

1910,

Superintendent

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

norme

AWS

F4.1,

American

Welding

Society,

550,

N.W.

LoJoune

Rd.,

Miami

FL

33128.

Safe

Handling

of

Comoressed

Gases

in

Cylinders

document

P-i,

Compressed

Gas

Association,

1235

Jefferson

Davis

Highway,

Suite

501,

Arlington,

Va

22202.

Code

for

Safety

in

Welding

and

Cutting

norme

CSA

Wi

17.2,

Asso

ciation

canadienne

de

normalisation,

Standards

Sales,

176

Rexdale

Boulevard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

Safe

Practices

for

Occupation

and

Educational

Eve

and

Face

Protec

ti~n,

norme

ANSI

Z87.

1

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

National

Electrical

Code

norme

70

NFPA,

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

srlt

9/91

Cutting

and

Welding

Processes

norme

51B

NFPA,

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

LES

ETINCELLES

ET

LES

metal.

En

refroidissant,

Ia

soudure

peut

projeter

du

laitier.

PROJECTIONS

BRULANTES

peuvent

causer

des

blessures.

Le

piquage

et

le

meulage

produisent

des

Øclats

de

1.

2.

Portez

un

Øcran

facial

ou

des

lunettes

a

coques

approuvØes.

Des

Øcrans

latØraux

sont

recommandØs.

Portez

des

vŒtements

de

protection

individuelle

appropriØs.

-r

Les

GAZ

DECHAPPEMENT

D

ES

MOTEURS

1.

Utilisez

des

machines

a

lextØrieur

dans

des

aires

ouvertes

et

PEUVENT

ETRE

MORTELS.

bien

ventilØes.

Les

moteurs

produisent

des

gaz

nocits.

dØchappement

2.

Si

vous

utilisez

des

machines dans

un

endroit

confine,

les

fumØes

dechappement

doivent

Œtre

envoyØes

a

lextØrieur,

loin

des

prises

dair

du

btiment.

Des

ETINCELLES

peuvent

FAIRE

EXPLOSER

UNACCUMULATEUR;LELECTROLYTEDUN

ACCUMULATEUR

peut

brUter

Ia

peau

et

es

2.

~

un

accumulateur.

ArrŒtez

le

moteur

avant

de

connecter

ou

de

dØconnecter

des

cables

daccumulateur.

Nutilisoz

quo

des

outils

anti-Łtincollos

pour

travailler

sur

un

yeUX.

accumulateur.

Los

accumulateurs

contiennent

de

lØlectrolyte

et

4.

Nutilisez

pas

un

poste

do

soudage

pou(chargerun

accumulateur

degagent

dos

vapeurs

explosives.

ou

connecter

provisoirement

un

vŁhicule.

1.

Portez

toujours

un

Øcran

facial

en

travaillant

sur

5.

Utilisez

Ia

polarite

correcte

(+

et

-)

de

laccumulateur.

La

VAPEUR

ET

LE

LIQUIDE

DE

1.

Ntezpaslebouchonderadiateurtantquelemoteurnapas

REFROIDISSEMENT

BROLANT

SOUS

refroidi.

PRESSION

peuvent

brUler

Ia

peau

et

es

Øux

-

Le

liquide

do

refroidissement

dun

radiateur

peut

etre

2.

3.

Mettezdesgantsetposezuntorchonsurlebouchonpourloter.

Laissez

Ia

pression

sØchapper

avant

doter

complŁtement

le

bouchon.

.

brlant

et

sous

pression.

PRINCIPALES

NORMES

DE

SECURITE

EMF

INFORMATION

N

OTE

~

Considerations

About

Welding

And

The

Effects

Of

Low

Frequency

Electric

And

_____________________

Magnetic

Fields

The

following

is

a

quotation

from

the

General

Conclusions

Section

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



1.

Keep

cables

close

together

by

twisting

or

taping

them.

Background

Paper,

OTA-BP-E-53

(Washington,

DC:

U.S.

Government

Printing

Office,

May

1989):

.

. .

there

is

now

a

very

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

4.

Keep

welding

power

source

and

cables

as

far

away

as

establish

that

low

frequency

magnetic

fields

can

interact

with,

and

nractical

produce

changes

in,

biological

systems.

While

most

of

this

work

is

of

very

high

quality,

the

results

are

complex.

Current

scientific

5.

Connect

work

clamp

to

workpiece

as

close

to

the

weld

as

understanding

does

not

yet

allow

us

to

interpret

the

evidence

in

a

possible.

single

coherent

framework.

Even

more

frustrating,

it

does

not

yet

About

Pacemakers:

allow

us

to

draw

definite

conclusions

about

questions

of

possible

The

above

procedures

are

among

those

also

normally

risk

or

to

offer

clear

science-based

advice

on

strategies

to

minimize

recommended

for

pacemaker

wearers.

Consult

your

doctor

for

or

avoid

potential

risks.

complete

information.

modlo

I

4/93

TABLE

OF

CONTENTS

SECTION

1



SAFETY

INFORMATION

-

1

SECTION

2

SPECIFICATIONS

1

SECTION

3

INSTALLATION

3-1.

Equipment

Connection

Diagram

2

3-2.

Installing

Swivel

Into

Pipe

Post

3

3-3.

Installing

Boom

And

Reel

Support

3

3-4.

Installing

Wire

Guide

Extension

4

3-5.

Wire

Guide

And

Drive

Roll

Installation

4

3-6.

Welding

Gun

Connections

5

3-7.

Wire

Feed

Motor

And

Gas

Control

Connections

6

3-8.

Control

Connection

6

3-9.

Shielding

Gas

And

Weld

Cable

Connections

7

3-10.

Removing

Safety

Collar

And

Adjusting

Boom

8

3-11.

Welding

Wire

Installation

9

3-12.

Motor

Start

Control

10

3-13.

Threading

Welding

Wire

10

SECTION

4

GLOSSARY

12

SECTION

5-OPERATION

5-1.

Front

Panel

Controls

15

5-2.

Side

Panel

Controls

17

5-3.

Rear

Panel

Controls

17

5-4.

Setting

Switches

On

450

Ampere

Inverter

Model

Welding

Power

Source

18

SECTION

6

STEPPING

THROUGH

THE

MICROPROCESSOR

CONTROLS

6-1.

Front

Panel

Microprocessor

Controls

19

6-2.

Side

Panel

Microprocessor

Push

Buttons

21

SECTION

7-

STANDARD

PULSE

WELDING

PROGRAMS

24

OM.15860



10/93

SECTION

8

GETTING

STARTED

8-1.

Welding

With

Only

Front

Panel

Controls

33

8-2.

Setting

Sequence

Pulse

Welding

Parameters

On

Side

Panel

Display

34

SECTION

9-

TEACHING

A

PULSE

WELDING

PROGRAM

9-1.

Pulse

Waveform

Explained

38

9-2.

Teach

Points

Explained

39

9-3.

Teaching

A

Pulse

Welding

Program

40

9-4.

Changing

To

Adaptive

Pulse

Welding

43

SECTION

10-

TEACHING

A

MIG

WELDING

PROGRAM

44

SECTION

11



SETTING

DUAL

SCHEDULE

PARAMETERS

48

SECTION

12-

USING

THE

OPTIONAL

DATA

CARD

12-1.

Installing

Data

Card

49

12-2.

Using

The

Data

Card

49

SECTION

13SETUP

13-1.

Setup

Flow

Chart

53

13-2.

Using

Setup

Displays

54

13-3.

Selecting

Process

Capability

54

13-4.

Selecting

Welding

Power

Source

Range

55

13-5.

Selecting

Security

Lock

56

13-6.

Selecting

Or

Changing

Access

Code

57

13-7.

Selecting

Voltage

Correction

58

13-8.

Selecting

Voltage

Sensing

Method

58

13-9.

Selecting

Regular

Or

Hot

Arc

Start

59

13-10.

Selecting

Type

Of

Dual

Schedule

Switch

59

13-11.

Selecting

Trigger

Program

Select

60

13-12.

Selecting

Remote

Increase/Decrease

Capability

61

13-13.

Resetting

Arc

Time

61

13-14.

Using

Self

Test

62

13-15.

Selecting

Units

For

Wire

Feed

Speed

And

Motor

Type

63

13-16.

Selecting

Bench

Or

Boom

Model

Type

63

13-17.

Resetting

Memory

64

13-18.

Selecting

Voltage

Error

Shutdown

64

13-19.

Selecting

Program

Name

Feature

65

13-20.

Software

Version

Number

65

SECTION

14-

MAINTENANCE

&

TROUBLESHOOTING

14-1.

Routine

Maintenance

66

14-2.

Replacing

The

Hub

Assembly

67

14-3.

Overload

Protection

67

14-4.

Error

Displays

68

14-5.

Diagnostic

Indicator

LEDs

69

14-6.

Troubleshooting

70

SECTION

15

ELECTRICAL

DIAGRAMS

72

SECTION

16

PARTS

LIST

Figure

16-1.

Main

Assembly

76

Figure

16-2.

Support,

Hub

&

Reel

79

Figure

16-3.

Control

Box

80

Figure

16-4.

Wire

Drive

Assembly

83

Figure

16-5.

Boom

Assembly

84

Table

16-1.

Drive

Roll

&

Wire

Guide

Kits

86

SECTION

1



SAFETY

IN

FORMATION

Figure

1-1.

Safety

Information

SECTION

2

SPECIFICATIONS

Table

2-1.

Wire

Feeder

Specification

Description

Type

Of

Input

Power

From

Welding

Power

Source

Single-Phase

24

Volts

AC.

10

Amperes.

50/60

Hertz

Maximum

Weld

Circuit

Rating

100

Volts.

750

Amperes.

100%

Duty

Cycle

Welding

Power

Source

Type

Constant

Voltage

(CV)

DC.

With

Contactor

Wire

Feed

Speed

Range*

Standard:

50

To

780

ipm

(1.3

To

19.8

mpm)

High

Speed:

92

To

1435

1pm

(2.3

To

36.5

mpm)

Low

Speed:

13

To

213

ipm

(0.34

To

5.38

mpm)

Wire

Diameter

Range

.023

Thru

1/8

in

(0.6

To

3.2

mm)

Welding

Process

Gas

Metal

Arc

(GMAW),

Gas

Metal

Arc

-

Pulse

(GMAW-P),

Flux

Cored

Arc

Welding

(FCAW)

Input

Power

Cord

Maximum

Height

With

4

ft

(1.2

m)

Post

10

ft

(3.1

m)

12

ft

(3.7

m)

Boom

16

ft

(4.9

m)

Boom

17

ft

(5.2

m)

21

ft

(6.4

m)

Weight

Net:

160

lb

(73

kg);

Ship:

280

lb

(127

kg)

Net:

210

lb

(95

kg);

Ship:

350

lb

(159

kg)

Vertical

Lift

Of

Boom

Horizontal

To

60

Above

Horizontal

To

60

Above

Horizontal

*These

are

the

wire

feed

speed

ranges

while

GMAW

welding.

While

Pulse

welding.

the

wire

feed

speed

ranges

may

be

more

limited

(see

Section

9).

1

U

Read

all

safety

messages

throughout

this

manual.

110

r~N~

U

Obey

all

safety

messages

to

avoid

injury.

~

U

Learn

the

meaning

of

WARNING

and

CAUTION.

2

\

modl.l

2/93

a

WARNING

2

3

ELECTRIC

SHOCK

can

kill.~



Do

not

touch

live

electrical

parts



Disconnect

input

power

belore

ristalling

or

servicing

/

a

CAUTION

5

I

Keep

away

Iron

moving

parts.



MOVING

PARTS

can

injure.



Keep

all

panels

and

covers

closed

wIrer

operating

6

READ

SAFETY

BLOCKS

at

start

of

I

Section

3-1

before

proceeding.

1

Safety

Alert

Symbol

2

Signal

Word

WARNING

means

possible

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.

7H

NOTE

~

Turn

Off

switch

when

using

high

frequency.

OM-1

586

Page

1

SECTION

3INSTALLATION

3-1.

Equipment

Connection

Diagram

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

HOT

SURFACES

can

burn

skin.



Allow

gun

to

cool

before

touching.

a

WARNING

or

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

wire

feeder

and

welding

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.

wfwamg.1

2/93

3

4

5.

6

12

1

Welding

Power

Source

2

Positive

(+)

Weld

Output

Cable

3

Remote

14

Connection

4

Remote

17

Connection

5

Negative

()

Weld

Output

Cable

-

6

Workpiece

7

Voltage

Sensing

Clamp

B

Weld

Control

9

Boom

10

Gun

11

Swivel

12

Gas

Hose

13

Gas

Supply

Ret.

ST-152

800-A

/

5T-152

321

11

10

FIgure

3-1.

Typical

System

Connections

OM-1586

Page

2

3-2.

Installing

Swivel

Into

Pipe

Post

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.

READ

SAFETY

BLOCKS

at

start

of

Section

3-2

before

proceeding.

a

WARNING

RELEASE

OF

SPRING

PRESSURE

WITHOUT

BOOM

ATTACHED

can

cause

serious

personal

injury.



Do

not

remove

safety

collar

until

instructed

to

do

so.

2

/3

I

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:

-

~

3/4in

ST.152

268

Figure

3-2.

Swivel

Installation

3-3.

Installing

Boom

And

Reel

Support

I

Swivel

Plates

2

Yoke

Remove

hardware

from

swivel

plates

and

yoke.

7

3

Boom

Set

boom

into

swivel

as

shown.

4

Yoke

Install

through

yoke.

Install

cot

ter

and

spread

ends.

2

5

Bolt

Install

bolt,

tighten

hardware,

and

back

bolt

off

one

half

turn.

6

Locking

Knob

Install

locking

knob

but

do

not

tighten.

7

Reel

Support

Tools

Needed:

Install

reel

support.

~

3/8,

3/4

in

5T-142596.B

4

5

Figure

3-3.

Boom

Installation

OM-1

586

Page

3

3-4.

Installing

Wire

Guide

Extension

3-5.

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.

wfwarnll

2/93

A.

Wire

Guide

Installation

When

changing

wire

size

or

type,

check

guide

size

(see

Table

16-1).

1

Drive

Rolls

Remove

drive

rolls

before

installing

wire

guides

(see

Figure

3-6).

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

3-6).

Tools

Needed:

Ref.

ST-137

39~-F

/

ST-142

597A

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.

Tools

Needed:

~EZ3lJ

3/8

in

ST-152

323

Figure

3-4.

Wire

Guide

Extension

Installation

Figure

3-5.

Wire

Guide

Installation

OM-1586

Page

4

B.

Drive

Roll

Installation

Figure

3-6.

Drive

Roll

Installation

3-6.

Welding

Gun

Connections

a

WARNING

4

I

3

6

Figure

3-7.

Gun

And

Trigger

Lead

Connections

4



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.

ST-142

597-A

2

3

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.

.

wfwarnl,1

2/93

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

recep

tacle

and

tighten

threaded

collar.

6

Trigger

Cord

7

Trigger

Plug

8

Weld

Control

Trigger

Receptacle

Insert

plug

into

receptacle

and

tighten

threaded

collar.

Ref.

STI

52

466

/

ST-I

52

321

/

Ref.

ST-I

57

434

OM-1586

Page

5

3-7.

Wire

Feed

Motor

And

Gas

Control

Connections

3-8~

Control

Connection

Figure

3-9.

Control

Connections

With

Information

1

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.

ST-157

433.A

/

Ref.

ST-157

434

Figure

3-8.

Boom

Connections

2

1

17-Pin

Receptacle

2

Keyway

0

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

3-10).

5

Threaded

Collar

2

6

14-Pin

Plug

To

connect

plug

to

matching

recep

tacle

on

welding

power

source.

align

keyway.

insert

plug,

and

tight

en

threaded

collar.

Signals

Supplied

To

Welding

Power

Source

Through

14-Pin

Plug:

Contactor

Control

A

24voltsac.

E

Remote

power

source

voltage

com

mand

signal

from

feeder

(potentiom

eter

wiper

or

0

to

+10

volts

dc).

cuit.

B

Contact

closure

to

A

completes

the

24

volts

ac

contactor

control

cir

ST-157

433-A

/

Ref.

S-0512

/

S-0003-A

/

S-0628

H

Nonfunctional

at

this

time.

Signals

Supplied

By

Welding

Power

Source:

G

Circuit

common

for

24

volts

ac

circuit.

Voltage

Control

Remote

Metering

Signals

Supplied

To

Welding

Power

Source

Through

17-Pin

Receptacle:

C

Command

signal:

#10

volts

do.

Remote

Output

Control

E

Actual

weld

current

output

signal;

+1

volt

dc

=

100

amps.

D

Control

circuit

common.

C

CC/CV

select;

+

13

thru

+24

volts

dc

=

CV,

0

volts

dc

=

CC.

M

Actual

weld

voltage

output

signal;

+

I

volt

dc

=

10

volts

dc.

Feedback

Signals

F

Current

feedback

0-10

volts

dc;

1

volt

per

100

amperes.

G

Arc

control/inductance

control;

0

to

+10

volts

dc.

H

Voltagefeedbacko-lovoltsdc;

1

volt

per

10

arc

volts.

The

remaining

pins

are

not

used.

OM-1586

Page

6

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