Miller KF759252 Owner's manual

Miller

December1994

Form:

OM-1582F

Effective

With

Serial

No.

KF759252

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.

~

U

Give

this

manual

to

the

operator.

~i~i]



For

help,

call

your

distributor



or:

MILLER

Electric

Mfg.

Co.,

P.O.

Box

1079,

Appleton,

WI

54912

414-734-9821

D-62

And

D-64



24

Volts

AC,

10

Amperes,

50/60

Hertz

Wire

Feeder



For

Use

With

CV/DC

Welding

Power

Source

With

Contactor



For

GMAW

And

FCAW

Welding



Rated

At

100

Volts,

750

Amperes,

100%

Duty

Cycle



Circuit

Breaker

CB1

Protects

Unit

From

Overload



Wire

Feed

Speed

Range:

50

To

780

ipm

(1.3

To

20

mpm)



Wire

Diameter

Range:

.023

To

1/8

in

(0.6

To

3.2

mm)



For

Options

And

Accessories,

See

Rear

Cover

cover

5/94



ST-143

327-A

'

1994

MILLER

Electric

MIg.

co.

PRINTED

IN

USA

Within

the

warranty

periods

listed

below,

MILLER

will

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,

et

which

lime

MILLER

will

provide

instructions

on

the

warranty

claim

procedures

to

be

followed.

MILLER

shall

honor

warranty

claims

on

warranted

equipment

listed

below

in

the

event

of

such

a

failure

within

the

warranty

lime

periods.

All

warranty

lime

periods

start

on

the

dale

that

the

equipment

was

delivered

to

the

original

retail

purchaser,

or

one

year

aher

the

equipment

is

sent

to

a

North

American

distributor

or

eighteen

months

after

the

equipment

is

sent

to

an

Intemationat

distributor.

1.

5

Years

Parts

3

Years

Labor



Original

main

power

rectifiers

2.

3

Years



Parts

and

Labor



Transformer/Rectifier

Power

Sources

*

Plasma

Arc

Cutting

Power

Sources



Semi-Automatic

and

Automatic

Wire

Feeders



Robots

3.

2 Years



Pans

and

Labor



Engine

Driven

Welding

Generators

(NOTE:

Engines

are

warranted

separately

by

the

engine

manufacturer

for

a

period

of

two

years.)



Air

Compressors

4.

1

Year



Pans

and

Labor



Motor

Driven

Guns



Process

Controllers



Water

Coolant

Systems



HF

Units



Grids



Spot

Welders



Load

Banks



SDX

Transformers



Running

Gear/Trailers



Plasma

CuBing

Torches

(escept

APT,

ZIPCUT

&

PLAZCUT

Models)



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.)

5.

6

Months



Batteries

6.

90

Days



Pans

and

Labor



MIG

Guns/TIG

Torches



APT,

ZIPCUT

&

PLAZCUT

Model

Plasma

Cusing

Torches

1.

Items

furnished

by

MILLER,

but

manufactured

by

others,

such

as

engines

or

trade

accessories.

These

items

are

covered

by

the

manufacturers

warranty,

if

any.

2.

Consumable

components;

such

as

contact

tips,

cuBing

nozzles,

costactors

and

relays

or

pans

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

EGUIPMENT.

In

the

event

of

a

warranty

claim

covered

by

this

warranty,

the

esclusive

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

or

credit

for

the

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

retum

of

the

goods

af

customers

risk

and

expense.

MILLERS

option

of

repair

or

replacement

will

be

FOB.,

Factory

at

Appleton,

Wisconsin,

or

FOB.

eta

MILLER

authorized

ser

vice

facilily

es

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

CONSEOUENTIAL

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

RANTY,

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

EOUIPMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

AND

DISCLAIMED

BY

MILLER.

Some

states

in

the

U.S.A.

do

not

allow

limitations

of

how

tong

an

implied

warranty

lasts,

or

the

esclusion

of

incidental,

indirect,

special

or

consequential

damages,

so

the

above

limitation

or

esclusion

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

staled

herein,

and

to

the

estent

that

they

may

not

be

waived,

the

limitations

and

esclusions

set

out

above

may

not

apply.

This

Limited

Warranty

provides

specific

legal

rights,

and

other

rights

may

be

available,

but

may

~!Y.irom

province

to

province.

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

Effective

January

1,

1995

(Equipment

with

a

serial

number

preface

of

KC

or

newer)

This

limited

warranty

supersedes

all

warranties

and

is

exclusive

with

no

other

guarantees

or

warranties

espressed

or

implied.

LIMITED

WARRANTY



Sub(ect

to

the

terms

snd

conditions

below,

MILLER

Electric



Remote

Controls

Mfg.

Co.,

Appleton,

Wisconsin.

warrants

to

its

original

retail

purchaser

that

new

Accessory

Kits

MILLER

equipment

sold

after

the

effective

date

of

this

limited

warranty

Is

free

of

de-



R

I

m

nf

P

n

facts

in

material

and

workmanship

at

the

time

it

is

shipped

by

MILLER.

THIS

WAR-

ep

ace

e

5

RANTY

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTHER

WARRANTIES,

EXPRESS

OR

.

TM

IMPLIED,

INCLUDING

THE

WARRANTIES

OF

MERCHANTABfLITY

AND

FIT-

MILLERS

True

Blue

Limited

Warranty

shall

not

apply

to:

NESS.

s.f

.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

11/94

ERRATA

SHEET

January

3,

1995

FORM:

OM-1582F

Use

above

FORM

number

when

ordering

extra

manuals.

After

this

manual

was

printec.~

refinements

in

equipment

design

occurred.

This

sheet

lists

exceptions

to

data

appearing

later

in

this

manual.

CHANGES

TO

SECTION

7-

PARTS

LIST

Change

Parts

List

as

follows:

Dia.

Part

**

Mkgs.

No.

Replaced

With

Description

Quantity

45-

..

P040...

158

409

...

171

608

...

CIRCUIT

CARD,

control

voltage

digital

(Eff

w/KF784030)

...

1

**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

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

orautomatic

wire

welding,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

touchin9

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

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

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

burn

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

Chipping,

grinding,

and

welds

cooling

throw

off

pieces

of

metal

or

slag.

ear

plugs

or

ear

muffs

if

noise

level

is

high

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

(MSDSS)

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.

Install

cylinders

in

an

upright

position

by

securing

to

a

stationary

support

or

cylinder

rack

to

prevent

falling

or

tipping.

3.

Keep

cylinders

away

from

any

welding

or

other

electrical

circuits.

ARC

WELDING

can

be

hazardous.

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.

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

harness

if

working

above

floor

level.

Keep

all

panels

and

covers

securely

in

place.

Clamp

work

cable

with

good

metal-to-metal

contact

to

workpiece

or

worktable

as

near

the

weld

as

practical

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.i

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;

warn

others

not

to

watch

the

arc.

5.

Wear

protective

clothing

made

from

durable,

flame-resistant

material

(wool

and

leather)

and

toot

protection.

5.

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.

6.

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.

7.

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

it

necessary,

while

wearing

an

air-supplied

respirator.

The

coatings

and

any

metals

containing

these

elements

can

give

off

toxic

fumes

if

welded.

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.

8.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

9.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

in

use

or

connected

for

use.

10.

Read

and

follow

instructions

on

compressed

gas

cylinders.

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

Standards.

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.

16.

17.

ARC

RAYS

2.

NOISE

4.

5.

6.

7.

Sri

.1.1

2194

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

to

AWS

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.

Wear

oil-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.

ENGINE

FUEL

can

cause

fire

or

r

~

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

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

engine

before

installing

or

connecting

unit

SPARKS

can

cause

BATTERY

GASES

TO

EXPLODE;

BATTERY

ACID

can

burn

eyes

and

skin.

Batteries

contain

acid

and

generate

explosive

gases.

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.

1.

Always

wear

a

face

shield

when

working

on

a

battery.

2.

Stop

engine

before

disconnecting

or

connecting

battery

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.

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

Haza

rdous

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.

srl.l.1

2/94

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

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.

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.

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.

CONSIGNES

DE

SECURITE

POUR

LE

SOUDAGE

A

LARC

UN

CHOC

ELECTRIQUE

peut

tuer.

Un

simple

contact

avec

des

piŁces

electnques

peut

provoquer

une

Olectrocution

ou

des

blessures

graves.

LØtectrode

et

Ia

circuit

de

soudage

sont

sous

tension

des

que

lappareil

est

sur

ON.

Le

circuit

dentrØe

et

los

circuits

internes

do

lappareil

sont

egalernent

sous

tension

a

ce

moment-l.

En

soudage

semi-automatique

ou

automatique,

10

fil,

le

dØvidoir,

le

logement

des

galets

dentraTnernentet

las

piŁces

mØtalliques

en

contact

avoc

Ia

I

il

do

soudage

sont

sous

tension.

Des

matØnels

mal

installŁs

ou

mal

mis

a

Ia

terre

prØsentent

un

danger.

1.

Ne

jarnais

toucher

les

piŁces

Oloctnques

sous

tension.

2.

Porter

des

gants

et

des

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autres

moyens

isolants

suffisamment

grands

pour

empØcher

le

contact

physique

Øventuel

avec

Ia

piŁce

ou

Ia

terre.

4.

Couper

lalimentation

ou

arrOter

le

moteur

avant

do

procØder

a

tinstallation,

a

Ia

reparation

ou

a

lentretien

do

lappareil.

DØverrouillerlalimentation

salon

Ia

norme

OSHA

29

CFR

1910.147

(voir

normos

de

sŁcuntØ).

5.

Installer

et

mettre

a

Ia

terre

correcternent

cet

appareil

conformØment

a

son

manuel

dutilisation

et

au

codes

nationaux,

provinciaux

et

municipaux.

6.

Toujours

verifier

Ia

terre

du

cordon

datimentation



Verifier

et

sassuror

ouo

Ia

fil

de

terre

du

cordon

dalimentation

est

bien

raccordØ

a

Ia

borne

do

terre

du

sectionneur

ou

qua

Ia

fiche

du

cordon

est

raccordØe

a

une

prise

corroctement

mise

a

Ia

terre.

7.

En

otfectuant

les

raccordements

dentrØe

fixer

dabord

le

conductour

do

mise

a

Ia

terre

appropri

at

contre-vŁrifier

los

connexions.

8.

Verifier

frequernment

le

cordon

dalimentation

pour

you

sil

nest

pas

endommage

ou

dOnudŁ



remplacer

le

cordon

immØdiatement

sil

est

endommage



un

cable

dØnudØ

pout

provoquer

une

electrocution.

9.

Mettre

lappareil

hors

tension

quand

on ne

Iutilise

pas.

10.

Ne

pas

utiliser

des

cables

uses,

endommages,

do

grosseur

insulfisante

ou

mal

ØpissOs.

11.

Ne

pas

enrouler

les

cables

autour

du

corps.

12.

Si

Ia

piŁce

soudØe

doit

Øtre

mise

a

Ia

terre

Ia

faire

directement

avec

un

cable

distinct



no

pas

utiliser

to

connecteur

de

piŁce

ou

le

cable

do

rotour.

13.

Ne

pas

toucher

lØlectrodo

quand

on

est

en

contact

avec

Ia

piŁce,

ta

terre

ou

une

electrode

provonant

dune

autre

machine.

14.

Nutiliser

quun

matØrial

en

bon

Øtat.

RØparer

ou

remplacor

sur-le-champ

los

piŁces

endommagØes.

Entretenir

lappareil

conformŁment

a

ce

manuel.

15.

Porter

un

harnais

do

sOcuritØ

quand

on

travaille

en

hauteur.

16.

Maintenir

solidement

en

place

tous

los

panneaux

at

capots.

17.

Fixer

le

cable

de

rotour

de

facon

a

obtenir

un

bon

contact

mØtal-mØtal

avec

Ia

piŁce

a

souder

ou

Ia

table

do

travail,

Is

plus

prØs

possible

de

Ia

soudure.

MISE

EN

GARDE

LE

SOUDAGE

A

LARC

peut

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APPROCHER

DU

POSTE

DE

SOUDAGE,

A

MOINS

DAVOIR

CONSULTE

UN

MEDECIN.

Le

soudage,

comme

Ia

plupart

des

travaux,

prØsente

certains

dangers.

Par

contre,

le

soudage

pout

Œtro

offoctuO

en

toute

sŁcuritØ

quand

on

prend

les

mosures

qui

simposent.

Les

consignos

do

sŁcuritØ

donnŁes

ci-aprŁs

ne

font

quo

rØsumer

lintormation

contenuo

dans

los

normes

do

sØcuntO

ØnumØrØes

a

Ia

page

suivante.

Lire

et

respecter

toutos

ces

norrnes

do

sØcuritØ.

LINSTALLATION,

LUTILISATION,

LENTRETIEN

ET

LES

REPARATIONS

NE

DOIVENT

ETRE

CONFIES

ouA

DES

PERSONNES

QUALIFIEES

LE

RAYONNEMENT

DE

LARC

peut

br~er

les

RAYONNEMENT

DE

LARC

yeux

et

Ia

peau.

Le

BRUIT

peut

endommager

~

IouIe;

les

PROJECTIONS

DE

LAITIER

OU

LES

ETINCELLES

peuvent

blesser

les

yeux.

2.

Porter

un

masque

a

sorre-tŒte

muni

dun

verre

tiltrant

do

nuance

appropriee

pour

proteger

Is

visage

et

los

yeux

quand

on

soude

ou

Larc

de

soudage

produit

des

rayons

visibles

et

invisibles

observe

Ia

travail

do

soudage

(voir

les

normes

ANSI

Z49.

1

ot

Z87.

1

intenses

(ultraviolets

St

infrarouges)

qui

peuvent

brler

donnŁes

sous

Ia

rubrique

Principales

normes

do

sØcuritØ).

les

yeux

at

Ia

peau.

La

bruit

produit

par

certains

procØdOs

pout

endommager

louIe.

Des

projections

de

metal

ou

do

3.

Porter

des

lunettes

do

sOcuntO

approuvØos

avec

crans

latØraux.

laitier

sont

produites

par

le

piquage,

Ia

meulage

ou

le

ref

roidissement

des

soudures.

4.

titiliser

des

paravents

ou

dos

barriŁres

do

protection

pour

proteger

los

porsonnes

a

proximitO

contra

los

coups

darc

at

lOblouissement;

BRUIT

avortir

les

autres

personnes

de

ne

pas

regarder

Iarc.

1.

Utiliser

des

boucho-oreilles

ou

des

serre-tŒte

antibruit

approuvØs

si

5.

Porter

dos

vØtements

do

protection

en

tissu

ignifuge

durable

(lame

et

0

niveau

do

bruit

est

OlevØ.

cuir)

at

des

chaussures

do

sØcuritØ.

dangereuses

pour

Ia

sante.

portantunapparoilrespiratoireadductiondairpur.

Demanderun

~

LES

VAPEURS

ET

LES

FUMEES

peuvent

Œtre

5.

Ne

travailler

dans

un

espace

confine

quo

siI

est

bien

ventilØ,

ou en

obseivateur

ayant

recu

Ia

bonne

formation

de

toujours

so

tenir

a

Lo

soudage

produit

des

vapeurs

at

des

fumØes

quil

est

proximitØ.

Los

vapeurs

at

fumOes

do

soudage

peuvent

dŁplacer

lair

dangereux

do

respirar.

et

abaisserlo

niveau

doxygone

et

causerdos

blessuros

graves

voire

mortelles.

Sassurer

que

lair

est

propre

a

Ia

respiration.

1.

Garder

Ia

tŒte

a

lextØneur

dos

vapeurs

at

des

fumØes

et

ne

pas

los

6.

Ne

pas

souder

a

proximitØ

dopØrations

de

dOgraissage.

de

respirer.

nettoyage

ou

do

pulverisation.

La

chalour

atlas

rayons

de

Iarc

peuvent

reagir

avec

les

vapeurs

pour

former

des

gaz

hautement

2.

A

IintOrieur,

ventiler

le

poste

do

travail

ou

utiliser

un

dispositif

place

au

niveau

do

Iarc

pour

Øvacuer

los

vapeurs

ot

fumØos

do

soudage.

toxiques

at

irritants.

7.

Na

pas

souder

sur

des

mØtaux

revØtus

comme

lacier

galvanisØ,

au

3.

Si

Ia

ventilation

est

mauvaise,

utiliser

un

appareil

respiratoire

a

p10mb

ou

cadmi

a

moms

que

Ia

piŁce

nait

Łte

entiŁrement

dŁcapØe,

adduction

dair

pur

approuvØ.

quo

le

poste

de

travail

soit

bien

ventilØ.

SiI

y

a

lieu,

porter

un

appareil

4.

Consulter

las

fiches

signalØtiques

at

los

consignes

du

fabncant

rospiratoire

a

adduction

dair

pur.

Los

revŁtements

at

los

mØtaux

qui

relatives

au

mØtaux,

produits

dapport.

rovŒtements,

nettoyants

at

contiennent

do

tals

ØlOments

pouvent

degager

des

vapeurs

toxiques

degraissants.

lors

du

soudago.

LES

BOUTEILLES

peuvent

exploser

si

elles

4.

Ne

jamais

poser

un

chalumeau

soudeur

sur

une

bouteillo

do

gaz.

Les

bouteilles

contenant

dos

gaz

do

protection

sont

a

6.

Na

jarnais

souder

sur

una

boutoillo

sous

pression

:

0110

axplosorait.

sont

endommagees.

5.

Ne

jamais

Iaissor

une

electrode

do

soudage

toucher

une

bouteille.

~.

haute

pres~ion.

Uno

bouteillo

endommagee

pout

7.

Nutiliser

quo

dos

bouteillos

de

gaz

do

protection,

des

dŁtendeurs,

~-

exploser.

Etant

donnØ

quo

les

bouteilles

do

gaz

fonl

des

tuyaux

souples

ot

des

raccords

appropriOs

concus

pour

normalement

partie

du

materiel

do

soudage,

los

traitor

Iapplication

particuliŁre;

conserver

ces

matØriels

at

leurs

piŁces

en

avac

le

plus

grand

soin.

bon

Øtat.

1.

ProtØger

los

bouteilles

do

gaz

comprimØ

contra

Ia

chaleur

intense,

8.

Eloigner

10

visage

do

Ia

sortio

du

robinet

do

Ia

bouteille

quand

on

los

chocs,

le

laitier,

los

flammos

flues,

los

Øtincellos

at

larc.

louvro.

2.

Placer

las

boutailles

ala

verticalo

an

las

fixant

a

un

support

fixe

ou

~

9.

Replacer

le

chapoau

sur

Ia

boutaille

aprØs

utilisation.

un

chariot

pour

Øvitor

quellos

no

tombent

ou

no

basculent.

10.

Lire

at

suivre

las

consignes

relatives

aux

boutaillos

de

gaz

comprimO,

3.

Tenir

los

bouteilles

a

lecart

du

posto

do

soudaga

ou

dautres

circuits

au

matØrial

connexe

ainsi

quo

Ia

publication

P-i

do

Ia

CGA

donnOo

Oloctriquas.

sous

Ia

rubrique

Principales

normes

do

sØcuritØ.

srl.1.1

2/94

LE

SOUDAGE

peut

causer

un

incendle

ou

une

explosion.

No

pas

souder

sur

des

recipients

fermOs

comme

des

reservoirs,

des

fQts

ou

dos

tuyaux:

us

pouvent

exploser.

Larc

do

soudage

pout

produire

dos

Øtincelles.

Des

Łtincelles,

une

piŁce

chaude

01

Un

materiel

chaud

peuvont

provoquer

des

incendies

et

des

blessures.

Le

contact

accidentel

de

lOlectrode

sur

des

objets

metalliques

pout

produiro

des

Øtincelles,

lexplosion,

Ia

surchauffe

ou

un

incondie.

Sassurer

quo

10

lieu

no

prOsento

pas

de

danger

avant

detfectuer

10

soudage.

1.

Se

protØgeretprotØger

les

porsonnos

a

proximitØ

dos

Øtincelles

otdu

metal

chaud.

2.

Ne

pas

souder

dans

un

endroit

o~

los

Øtincelles

peuvent

attoindro

des

matØriaux

inflammables.

3.

Enlevortoutes

los

matiŁres

inflammables

dans

un

rayon

do

mains do

10

m

do

larc.

Si

cola

nest

pas

possible,

bien

los

recouvrir

on

utilisant

des

bches

approuvŁos.

4.

Prendre

garde

quo

los

Øtincelles

01

los

projections

ne

penØtrent

dans

des

zones

adjacontes

en

sinfiltrant

dans

des

petites

fissures

ot

ouvortures.

5.

Prondro

garde

aux

incondies

01

toujours

avoir

un

oxtincteur

a

proximitØ.

6.

Se

rappelerque

si

Ion

soude

sur

un

plafond,

un

plancher,

une

cloison

ou

autre,

le

feu

pout

prondre

do

Iautre

ctO.

7.

No

pas

souder

sur

des

recipients

fermØs

comme

des

reservoirs,

des

fOts

ou

des

tuyaux

a

moms

quils

ne

soient

prepares

do

facon

appropnOe

conformŁment

ala

normo

F4.1

de

IAWS

(voir

Ia

rubrique

Principales

nomies

do

sØcuritO).

8.

Raccordor

10

cable

do

retour

a

Ia

piece,

le

plus

prŁs

possible

do

Ia

zone

do

soudage,

pour

empŒcher

quo

le

courant

do

soudago

no

suivo

uno

trajectoire

longue

et

Øventuellement

inconnue

ot

quil

no

provoque

dos

tisques

dOlectrocution

01

dincendie.

9.

Ne

pas

utiliser

10

chalumeau

soudour

pour

dØgelor

dos

tuyaux.

10.

Enlevor

lØloctrode

enrobØe

du

porte-electrode

ou

couper

10

fil

do

soudage

au

ras

du bec

contact

quand

on ne

lutilise

pas.

11.

Porter

des

vŒtements

do

protection

non

huileux

comme

des

gants

en

cuir,

une

chemise

Opaisso,

dos

pantalons

sans

rovers,

des

chaussures

montantes

01

un

casque.

12.

No

pas

porter

des

matiŁres

combustibles

sur

sol

commo

un

bnquot

a

gaz

ou

des

allumettes

quand

on

soudo.

LE

CARBURANT

peut

provoquer

un

Incendie

r

ou une

explosion.

Le

carburant

est

hautomont

inflammable.

1.

ArrØter

10

moteur

0110

laissor

rofroidir

avant

do

verifier

10

nivoau

de

carburant

ou

do

refaire

le

plein.

LES

PIECES

EN

MOUVEMENT

peuvent

causer

des

blessures.

Los

piŁces

on

mouvement

comme

los

ventilateurs,

los

rotors

ot

los

courroles

peuvent

couper

los

doigts

etles

mains

01

happor

los

vŁtements

amples.

1.

Sassurer

quo

los

portos,

los

panneaux,

les

capots

et

los

protoctours

sont

bien

formØs

ot

bien

a

lour

place.

2.

ArrØter

to

moteur

avant

do

mettre

en

place

ou

do

raccordor

un

LES

ETINCELLES

peuvent,faire

EXPLOSER

LE

GAZ

DES

BATTERIES;

LELECTROLYTE

pout

brler

Ia

peau

et

les

yeux.

Los

batteries

contiennent

un

produit

acide

ot

degagont

dos

vapeurs

explosives.

orter

un

Ocran

facial

quand

on

travaille

sur

une

batterie.

2.

Ne

pas

turner

en

faisant

10

plein

OU

si

Iappareil

so

trouve

a

proximitŁ

dOtincollos

ou

do

flammes

flues.

3.

Ne

pas

romplir

10

reservoir

a

ras

bord

:

prŁvoir

do

Iospace

pour

Ia

dilatation

du

combustible.

4.

No

pas

renverser

du

carburant.

Si

on

renverse

du

carburant,

nettoyer

los

Iieux

avant

do

faire

dØmarror

10

moteur.

3.

Seulos

des

personnes

qualifiØes

doivent

dŁmonter

los

protecteurs

ou

los

capots

pour

faire

Iontrotien

ou

los

reparations

nØcessaires.

4.

Pour

empØchor

un

demarrage

accidentel

dun

systŁme

pendant

lentrotion

ou

los

reparations,

dObrancher

le

cable

negatif

()

do

a

batterie.

5.

Eloigner

los

mains,

les

cheveux,

los

vŒtomonts

amplos

ot

es

outils

des

piŁces

en

mouvoment.

6.

Replacer

les

capots

ou

los

protecteurs

01

rofermer

es

portes

une

fois

Iontrotien

01

les

reparations

torminØs

et

avant

do

faire

dØmarrer

le

motour.

ArrOter

le

moteur

avant

do

branchor

ou

do

dObrancher

los

cables

do

Ia

battorie.

No

pas

faire

des

Łtincellos

avoc

los

outils

quand

on

travaille

sur

une

batlerie.

No

pas

utiliser

Ia

source

do

courant

do

soudage

pour

charger

los

batteries

ou

pour

faire

dOmarrer

un

vØhicule.

No

pas

intervertir

Ia

polaritØ

dos

batteries.

a

MISE

EN

GARDE

LES

MOTELJRS

peuvent

presenter

un

danger.

LES

GAZ

DECHAPPEMENT

DES

MOTEURS

1.

Utiliser

le

matŁnel

a

lextØrieur,

dans

des

lieux

ouverts

01

bien

peuvent

Øtre

mortels.

ventilØs.

Los

motours

produisent

dos

gaz

dØ

chapp

ement

nocits.

2.

Si

on

utiliso

un

motour

dans

un

local

formØ,

dOchappement

a

lextOrieur

01

loin

dos

pnses

dai

Łvacuor

los

gaz

r

du

btiment.

1.

Toujoursi

2.

3.

4.

5.

~,?~k~jJ

~

~j~IJJ

~4

(~

~.

~

~

LA

VAPEUR

El

LE

LIQUIDE

DE

REFROIDISSEMENT

BRULANT

SOUS

PRESSION

peuvent

brtiler

Ia

peau

et

les

yeux.

II

vaut

mieux

verifier

10

niveau

du

liquide

do

rot

roidissement

quand

lo

moteur

est

froid

af

in

dØvitor

los

brOlures.

1.

2.

3.

Si

Ion

doit

verifier

le

niveau

quand

le

moteur

est

chaud,

suivre

los

Øtapes

2

et

3.

PortordoslunettesdesØcuritØetdesgantsetplacerunchiffonsurlo

bouchon.

Tourner

lentement

10

bouchon

et

laisser

Ia

pression

sØchapper

lentement

avant

denlevor

complØtement

le

bouchon.

PRINCIPALES

NORMES

DE

SECURITE

Safety

in

Welding

and

Cutting.

norme

ANSI

Z49.1,

de

IAmencan

Welding

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

P.1,

do

Society,

550

NW.

Lejeune

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

Superintendent

of

Regles

do

securitØ

en

soudage.

coupage

et

procØdØs

connexes,

norme

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

CSA

W117.2,

do

IAssociation

canadienne

de

normalisation,

vente

do

normes,

178

Roxdale

Boulovard,

Rexdalo

(Ontario)

Canada

M9W

1

R3.

Recommended

Safe

Practice

for

the

Preparation

for

Welding

and

Cutting

of

Containers

That

Have

Held

Hazardous

Substances,

norme

AWS

F4.

1.

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

Protection,

de

IAmorican

Welding

Society,

550

N.W.

Lejeuno

Rd.

Miami

FL

33126

normo

ANSI

Z87.1,

do

IAmerican

National

Standards

Instituto.

1430

Broadway,

New

York,

NY

10018.

National

Electrical

Code,

NFPA

Standard

70,

do

Ia

National

Fire

Protection

Cutting

and

Welding

Processes,

norme

NFPA

51

B,

de

Ia

National

Fire

Association,

Batterymarch

Park,

Qumncy,

MA

02269.

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

srl.1.1

2/94

EMF

INFORMATION

TABLE

OF

CONTENTS

SECTION

1



SAFETY

INFORMATION

1

SECTION

2-

SPECIFICATIONS

1

SECTION

3INSTALLATION

3-1.

Site

Selection

3-2.

Equipment

Connection

Diagrams

3-3.

Wire

Guide

And

Drive

Roll

Installation

3-4.

Welding

Gun

Connections

3-5.

Motor

Start

Control

3-6.

Dip

Switches

Options

3-7.

Changing

Optional

Digital

Voltage

Control

For

Use

With

A

MILLER

Inverter-Type

Power

Source

3-8.

14-Pin

Plug

Connection

3-9.

Shielding

Gas

And

Weld

Cable

Connections

3-10.

Voltage

Sensing

Lead

(Optional)

3-11.

Welding

Wire

Installation

3-12.

Threading

Welding

Wire

With

Drive

Assembly

Horizontal

3-13.

Rotating

The

Drive

Assembly

And

Threading

Welding

Wire

SECTION

4OPERATION

SECTION

5

MAINTENANCE

&

TROUBLESHOOTING

5-1.

Routine

Maintenance

5-2.

Replacing

The

Hub

Assembly

5-3.

Overload

Protection

5-4.

Troubleshooting

SECTION

6

ELECTRICAL

DIAGRAMS

SECTION

7

PARTS

LIST

38

Figure

7-1.

Main

Assembly

38

Figure

7-2.

Control

Box

40

Figure

7-3.

Control

Panel

43

Figure

7-4.

Panel,

Front

w/Components

44

Table

7-1.

Wire

Drive

Assembly

Kits

46

Figure

7-5.

Drive

Assembly,

Wire

(4

Drive

Roll

Assembly

Illustrated)

46

Table

7-2.

Drive

Roll

And

Wire

Guide

Kits

48

OM-1582F

-

12194

MOTE

L~

~

Considerations

About

Welding

And

The

Effects

Of

Low

Frequency

Electric

And

I

Magnetic

Fields

The

following

is

a

quotation

from

the

General

Conclusions

Section

of

the

U.S.

Congress,

Office

of

Technology

Assessment,

Biological

Effects

of

Power

Frequency

Electric

&

Magnetic

Fields



Backg

round

Papei

OTA-BP-E-53

(Washington,

DC:

U.S.

Government

Printing

Office,

May

1989):.

. .

there

is

now

a

very

large

volume

of

scientific

findings

based

on

experiments

at

the

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

single

coherent

framework.

Even

more

frustrating,

it

does

not

yet

allow

us

to

draw

definite

conclusions

about

questions

of

possible

risk

or

to

offer

clear

science-based

advice

on

strategies

to

minimize

or

avoid

potential

risks.

To

reduce

magnetic

fields

in

the

workplace,

use

the

following

procedures:

1.

Keep

cables

close

together

by

twisting

or

taping

them.

2.

Arrange

cables

to

one

side

and

away

from

the

operator.

3.

Do

not

coil

or

drape

cables

around

the

body.

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.

About

Pacemakers:

The

above

procedures

are

among

those

also

normally

recommended

for

pacemaker

wearers.

Consult

your

doctor

for

complete

information.

modlo,1

4/93

3

4

6

7

8

9

12

13

14

15

16

18

20

22

28

29

30

33

SECTION

1

-

SAFETY

INFORMATION



Read

all

safety

messages

throughout

this

manual.

a

Obey

all

safety

messages

to

avoid

injury.



Learn

the

meaning

of

WARNING

and

CAUTION.

Figure

1-1.

Safety

Information

SECTION

2-

SPECIFICATIONS

Table

2-1.

Wire

Feeder

modl.l

2/93

1

2

a

CAUTION

/

5

ELECTRIC

SHOCK

can

kill

~



MOVING

PARTS

can

Injure.

II

~

I



Do

not

touch

live

electflcal

parts.

~

S

Keep

away

from

movIng

p~.

I



Disconnect

input

power

before



Keep

all

panels

and

covers

closed

I

installlrt9

or

setvicing.

when

operating.

6

a

WARNING

1

Safety

Alert

Symbol

2

SignalWord

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.

READ

SAFETY

BLOCKS

at start

of

SectIon

3-1

before

proceedIng.

NOTE

~

Turn

Off

switch

when

using

high

frequency.

SpecifIcation

Type

Of

Input

Power

From

Welding

Power

Source

Maximum

Weld

Circuit

Rating

Welding

Power

Source

Type

Wire

Feed

Speed

Range

Description

Welding

Processes

Input

Power

Cord

Overall

Dimensions

Weight

Single-Phase

24

Volts

AC,

10

Amperes,

50/60

Hertz

(If

115

Volts

AC

is

The

Only

Power

Available,

Use

Optional

Power

Supply

Adapter

Model

PSA-2.)

100

Volts,

750

Amperes,

100%

Duty

Cycle

Constant

Voltage

(CV)

DC,

With

Contactor

Standard

Motor:

50

To

780

1pm

(1.3

To 20

mpm)

High

Speed

Motor:

90

To

1400

1pm

(2.3

To

35.6

mpm)

Gas

Metal

Arc

(GMAW),

Flux

Cored

Arc

Welding

(FCAW)

lOft(3.1

m)

Length:

32

in

(812mm);

Width:

18

in

(457

mm);

Height:

14

in

(356

mm)

Shipping:

82

lb

(37.2

kg);

Net:

74

lb

(33.6

kg)

Add

4

lb

(1.8

kg)

For

4-Drive

Roll

Models

OM-1

582

Page

1

Table

2-2.

Options

The

table

below

should

be

used

to

determine

the

options

that

can

be

used

together

on

a

wire

feeder.

Use

the

column

on

the

left

side

of

the

table

to

choose

the

desired

option

and

follow

the

line

across

to

see

which

options

are

compatible.

Desired

Option

Burn-

back

Control

4-in-i

Control

Digital

Meter(s)

Tach

Feed-

back

Digital

Voltage

Control

Voltage

Control

Run-In

Control

Digital

Dual

Scheduie

Dual

Schedule

Control

Remote

Pendant

Control

Cord

#137

552

(For

RCSP-45)

Burnback

Control



No

Yes

Yes Yes Yes Yes Yes Yes

4-In-i

Control

(In-

ciudes

prof

low/post

flow,

spotlburnback,

and

trigger

hold

con

trol)

No



Yes

Digital

Meter(s)/Tach

Feedback

(one

ortwo

meter

option)

Yes Yes



Yes

Yes Yes

No

Yes

Digital

Voltage

Control

(DVC)

Yes

Reqd



No

Yes Yes

No

Yes

Voltage

Control

Yes

Yes Yes

No



Yes

No

Yes

Run-in

Control

(Option

interface

Required)

Yes Yes

Yes



Yes

Yes Yes

Yes

Digital

Dual

Schedule

(Option

Interface

Re-

quired)

Yes

Reqd Reqd

No

Yes



No No No

Dual

Schedule

Control

(Option

Interface

Re-

quired)

Yes

No

Yes

No



No

Remote

Pendant

Con

trol

(Option

Interface

Required)

Yes

No

Yes

No No



No

Cord

#137

552

(For

RCSP-45)

(Option

In-

terface

Required)

Yes

Yes Yes

Yes

Yes Yes

No



OM-i

582

Page

2

3-1.

Site

Selection

SECTION

3-INSTALLATION

a

WARNING

t_*

I

WARNING:

FALLING

WIRE

FEEDER

can

cause

serious

personal

injury

and

equipment

damage.



Do

not

put

wire

feeder

where

it

will

tip

or

fall.



Put

all

four

rubber

feet

solidly

on

a

flat

surface.

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,

or

other

stationary

support.

ELECTRIC

SHOCK

can

kIll.



Do

not

touch

live

electrical

parts.

The

welding

wire,

drive

rolls,

drive

assembly,

and

all

metal

paris

touching

the

welding

wire

are

electrically

live

when

welding

or

feeding

wire

using

gun

trigger.

wfwam7.1

9/91

Do

not

put

feeder

where

welding

wire

hits

cylinder.

5

1

Wire

Feeder

2

Lifting

Eye

3

Rubber

Feet

4

Installation

Slots

When

installing

wire

feeder

over

a

lifting

eye

on

a

welding

power

source,

select

the

slot

that

will

al

low

all

four

rubber

feet

on

base

of

feeder

to

sit

securely

on

top

of

welding

power

source.

5

Wire

Spool/Reel

6

Gas

Cylinder

(Customer

Supplied)

7

Welding

Power

Source

Position

wire

feeder

on

welding

power

source

so

that

welding

wire,

or

wire

spool/reel,

does

not

touch

gas

cylinder.

3

sT152

586

/

ST-152

568

Figure

3-1.

Installing

Wire

Feeder

Over

A

Lifting

Eye

OM-1582

Page

3

3-2.

Equipment

Connection

Diagrams

£~

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,

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.



Tum

Off

wire

feeder

and

welding

power

source,

and

disconnect

input

power

before

making

connections.

Stop

engine

on

welding

generator.

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.

Figure

3-2.

Connections

With

A

Constant

Voltage

(CV)

Or

Constant

Voltage/Constant

Current

(CV/CC)

Welding

Power

Source

Having

A

14-Socket

Receptacle

And

24

VAC

Supply

NOTE

~

If

using

wire

feeder

with

an

engine-driven

power

source,

place

engine

control

____________________

switch

in

Run

(high

speed)

position.

Some

wire

feeders

may

work

with

switch

in

Run/Idle

position.

wfwamg.1

2193

1

CV

Or

CC/CV

Welding

Power

Source

Supplying

24

VAC

To

Feeder

2

14-Pin

Plug

PLG1O

And

Inter

connecting

Cord

3

Positive

(+)

Weld

Cable

4

Negative

()

Weld

Cable

5

Workpiece

6

Voltage

Sensing

Lead

7

Gun

8

Wire

Feeder

9

Y

Adapter

Gas

Hose

10

Gas

Cylinder

ST-152

616

OM-1582

Page

4

CV

Welding

Power

Source

2

PSA-2

Interconnecting

Cord

(Supplied

With

PSA-2

Con

trol)

Positive

(+)

Weld

Cable

Negative

()

Weld

Cable

Workpiece

Voltage

Sensing

Lead

Gun

Figure

3-3.

Connections

With

A

Constant

Voltage

(CV)

Welding

Power

Source

Having

Only

115

VAC

Available

3

4

5

6

7

8

9

Wire

Feeder

14-Pin

Plug

PLG1O

And

Inter

connecting

Cord.

10

PSA-2

Control

(Optional)

11

V

Adapter

Gas

Hose

12

Gas

Cylinder

2

4

5-

8

9

11

ST-152

320

OM-1582

Page

5

3-3.

Wire

Guide

And

Drive

Roll

Installation

4~

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,

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.



Tum

Off

wire

feederand

welding

powersource,

and

disconnect

input

power

before

making

connections.

Stop

engine

on

welding

generator.

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

A.

Wire

Guide

Installation

Figure

3-4.

Wire

Guide

Installation

When

changing

wire

size

or

type,

check

guide

size

(see

Table

7-2).

1

Drive

Rolls

Remove

drive

rolls

before

installing

wire

guides

(see

Figure

3-5).

2

Wire

Guide

Securing

Screws

Loosen

wire

guide

screws.

3

Antiwear

Guide

4

Inlet

Wire

Guide

Install

inlet

wire

guide

into

antiwear

guide.

Install

inlet

guide

so

wire

guide

screw

is

centered

in

groove

in

guide.

5

Intermediate

Wire

Guide

Insert

intermediate

guide

until

flange

on

guide

rests

against

cast

ing,

and

secure

with

guide

screw.

Install

drive

rolls

(see

Figure

3-5).

Repeat

procedure

for

opposite

side

of

wire

feeder.

)

5/64

in

ST-153

125-B

/

ST.137

317-D

Tools

Needed:

1

OM-1

582

Page

6

B.

Drive

Roll

Installation

Figure

3-5.

Drive

Roll

Installation

(Four-Drive

Roll

Model

Shown)

3-4.

Welding

Gun

Connections

£~

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.

Stop

engine

on

welding

generator.

wfwarnl.1

2/93

Figure

3-6.

Gun

And

Trigger

Lead

Connections

When

changing

wire

size

or

type,

check

drive

roll

size

(see

Table

7-2).

1

Spring

Shaft

Carrier

Close

spring

shaft

carrier.

2

Drive

Roll

Nut

3

Drive

Roll

Carrier

Turn

nut

one

click

until

lobes

of

nut

line

up

with

lobes

of

drive

roll

carri

er.

Open

spring

shaft

carrier.

4

Drive

Roll

Slide

drive

roll

onto

drive

roll

carri

er.

Turn

nut

one

click.

Repeat

procedure

for

top

drive

roll.

5

Drive

Assembly

Cover

Close

cover.

Repeat

procedure

for

opposite

side

of

wire

feeder.

ST-137

377~D

4

1

GunSecunngKnob

2

Gun

Block

3

Gun

End

Loosen

gun

securing

knob.

Insert

end

into

block.

Position

as

close

as

possible

to

drive

rolls

without

touch

ing.

Tighten

knob.

4

Gun

Trigger

Plug

Insert

plug

into

receptacle,

and

tight

en

threaded

collar.

5

Gun

Trigger

Receptacle

6

Drive

Assembly

Cover

Close

cover.

Repeat

procedure

for

welding

gun

on

opposite

side

of

wire

feeder.

Ref.

$1149652/

Ref.

ST-152

466

OM-1

562

Page

7

3-5.

Motor

Start

Control

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



TurnOffwirefeederandweldingpowersource,

and

disconnect

input

power

before

inspecting

or

installing.

Stop

engine

on

welding

generator.

STATIC

ELECTRICITY

can

damage

parts

on

circuit

boards.



Put

on

grounded

wrist

strap

BEFORE

handling

boards

or

parts.

wfwaml.r

2/93

Figure

3-7.

Motor

Start

Control

On

Motor

Control

Board

PCi

To

change

wire

feed

starting

speed,

proceed

as

follows:

Turn

Off

wire

feeder

and

welding

power

source.

Remove

wrapper.

Front

panel

shown

open

for

illustra

tion

purposes.

2

Left

Side

Inner

Control

Panel

It

may

be

necessary

to

remove

panel

to

access

Motor

Start

Con

trol.

Remove

panel

only

as

far

as

required

if

options

are

attached

to

panel.

3

Motor

Board

PCi

4

Motor

Start

Control

Poten

tiometer

R70

Turn

potentiometerclockwiseto

in

crease

time

it

takes

the

motor

to

ramp

up

to

speed.

Remove

protec

tive

white

rubber

cap

before

mak

ing

adjustment.

Adjust

potentiome

ter

R70

using

a

small

nonconduc

tive

screwdriver.

Reinstall

left

side

inner

control

pan

el

if

it

was

removed.

Reinstall

wrapper.

Ref.

ST-143

259-E

/

Ref.

SB-146

862-0

£~

WARNING

1

Front

Panel

Tools

Needed:

c~~zJ=~n

1/4

in

OM-1582

Page

8

3-6.

Dip

Switches

Options

AA

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

wire

feeder

and

welding

power

source,,

disconnect

input

power

before

inspecting

installing.

Stop

engine

on

welding

generator.

STATIC

ELECTRICITY

can

damage

parts

on

circuit

boards.



Put

on

grounded

wrist

strap

BEFORE

handling

boards

or

parts.

wfwamlV

2/93

A.

SpotlTime

DIP

Switch

Si

Change

DIP

switch

position

If

a

dif

ferent

range

of

Spot/Time

Is

de

sired.

1/4

in

Ref.

ST-143

259-E

/

SA-146

868-A

Figure

3-8.

Spot/Time

DIP

Switch

Si

Turn

Off

wire

feeder

and

welding

power

source.

Remove

wrapper.

1

Front

Panel

Remove

screw

from

upper

left

cor

ner,

and

open

hinged

front

panel

if

necessary.

2

4-In-i

Board

PC3O

3

Spot/Time

D~P

Switch

SI

Place

switch

(on

either

or

both

PC3O

boards)

in

desired

position:

Long

Time

for

0-5

seconds,

and

Short

Time

for

0-2.5

seconds

(see

Figure

4-12

for

control

operation).

Close

and

secure

front

panel,

and

reinstall

wrapper.

1

Tools

Needed:

OM-1582

Page

9

B.

Digital

Meter

Functions

And

Positions

The

Digital

Meter

Board

PC6O

for

the

Two

Meter

Option

is

equipped

with

DIP

switch

S3.

This

switch

is

shipped

from

the

factory

in

the

Off

position,

and

should

not

be

changed.

Change

DIP

switch

positions

if

a

different

mode

of

operation

is

de

sired.

Turn

Off

wire

feeder

and

welding

power

source.

Remove

the

six

(6)

screws

from

front

edge

of

wrapper.

1

Front

Panel

Front

panel

shown

open

for

illustra

tion

purposes.

2

Digital

Meter

Board

PC6O

3

Meter

Functions

DIP

Switch

S2

Place

switch

in

appropriate

posi

tion

for

desired

mode

(see

Figure

4-7

for

meter

operation).

Some

units

have

a

5-position

DIP

switch

which

corresponds

to

the

bottom

five

positions

of

the

9-posi

tion

switch

shown.

Reinstall

wrapper

screws.

Figure

3-9.

Digital

Meter

Functions

DIP

Switch

S2

Ref.

ST-143

259-E

I

Ref.

5-0389-A

/

SA-135

481-K

OM-1

582

Page

10

Or

Standard

Motor

Inches/Minute

Standard

Motor

Meters/Minute

High

Speed

Motor

High

Inches/Minute

Speed

Meters/Minute

I

j:

j;

I

I I

I

Ir

~

I



(D

~

I

u

u,

Or

I

I

I~

I

I~



t~)

C~)



c~



cJ

I

N

><.-

><-

><

><-

Or

Voltage

Monitor

><~

><~-

><(D

><~n

><~

><~,

><c~

I



~jT~

~

Means

place

switch

in

this

position.

X

Means

switch

can

be

In

either

position.

~1

Tools

Needed:

c~z=n

1/4

in

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