Miller KF785422 Owner's manual

M~IIer

March

1995

Form:

OM-1584E

Effective

With

Serial

No.

KF785422

OWNERS

MANUAL



U

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.



Give

this

manual

to

the

operator.

1I~fl

U

For

help,

call

your

distributor

U

or:

MILLER

Electric

Mfg.

Co.,

P0.

Box

1079,

Appleton,

WI

54912

414-734-9821

SWINGARCTM

DS-12

And

DS-16



24

Volts,

10

Amperes,

50/60

Hertz

Boom

Mounted

Wire

Feeder

U

For

Use

With

C

V/DC

Welding

Power

Source

With

Contactor



For

GMAW

And

FCAW

Welding



Rated

At

100

Volts,

750

Amperes,

100%

Duty

Cycle



Wire

Feed

Speed

Range:

50

To

780

ipm

(1.3

To

19.8

mpm)



Wire

Diameter

Range:

.023

To

1/8

in

(0.6

To

3.2

mm)



Vertical

Lift

Of

Boom:

Honzontal

To

60

Above

Horizontal



See

Rear

Cover

For

Options

And

Accessones

cover

5/94



ST-142 595-B

'

1995

MILLER

Electric

Mfg.

Co.

PRINTED

IN

USA

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

Effective

January

1,

1995

(Equipment

with

a

serial

number

preface

of

KD

or

newer)

This

limited

wsrrsnty

supersedes

eli

warranties

snd

is

exclusive

with

no

other

gusrsntees

or

wsrranties

expressed

or

implied.

LIMITED

WARRANTY

Subject

to

the

terms

end

conditions

below,

MILLER

Electric

Mtg.

Co.,

Appleton,

Wisconsin,

warrants

to

its

original

retell

purcheser

thst

new

MILLER

equipment

sold

after

the

effective

date

ot

this

limited

warranty

is

tree

of

de

tects

in

material

end

workmanship

at

the

time

it

is

shipped by

MILLER.

THIS

WAR

RANTY

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTHER

WARRANTIES,

EXPRESS

OR

IMPUED,

INCLUDING

THE

WARRANTIES

OF

MERCHANTABILITY

AND

FIT

NESS.

Within

the

warranty

periods

listed

below,

MILLER

will

repair

or

replace

eny

war

ranted

pans

orcomponents

that

tail

due

to

such

detects

in

materiel

orwortcmanahip.

MILLER

must

be

notitied

in

writing

within

thirty

(30)

days

ct

such

detect

or

tailure,

at

which

time

MILLER

will

provide

instructions

on

the

warranty

claim

procedures

to

be

tollowed.

MILLER

shall

honor

warranty

claims

on

warranted

equipment

listed

below

in

the

event

ot

such

a

tailure

within

the

warranty

time

periods.

All

warranty

time

periods

start

on

the

dete

thet

the

equipment

was

delivered

to

the

original

retail

purchaser,

or

one

year

after

the

equipment

is

sent

to

a

North

American

distributor

or

eighteen

months

eher

the

equipment

is

sent

to

en

Intemational

distributor.

5

Years

Pans

3

Years

Labor

Original

main

power

rectiffem

2.

3

Years



Parts

and

Labor



TmnstormerfRectitier

Power

Sources

*

Plasma

Arc

CuBing

Power

Sources

*

Semi-Automatic

end

Automatic

Wire

Feeders

*

Robots

3.

2

Years



Pans

and

Labor



Engine

Driven

Welding

Generators

(NOTE:

Engines

are

warranted

separately

by

the

engine

manutacturer.)

*

Air

Compressors

4.

1

Year



Pens

and

Labor

Motor

Driven

Guns

Process

Controllers

Water

Coolant

Systems

HF

Units

Grids

Spot

Welders

Load

Banks

SDX

Tmnatormem

Running

Gear/Trailers

Plasma

Cutting

Torches

(except

APT,

ZIPCUT

&

PLAZCUT

Models)

Tecumaeh

Engines

Deutz

Engines

(outside

North

America)

Field

Options

(NOTE:

Field

options

are

covered

under

True

BIueTM

tor

the

remaining

warranty

period

ot

the

product

they

are

installed

in,

or

tor

a

minimum

ot

one

year



whichever

is

greater.)

6

Months



Batteries

90

Days



Pans

and

Labor

MIG

GunslflG

Torches

APT,

ZIPCUT

&

PLAZCUT

Model

Plasma

Cutting

Torches

a]



Remote

Controls

*

Accessory

Kits



Replacement

Pans

MILLERS

True

BIueTM

Limited

Warranty

shall

not

apply

to:

1.

Items

tumiahed

by

MILLER,

but

manutactured

by

cthers,

such

as

engines

or

trade

accessories.

These

items

are

covered

by

the

manutacturera

warranty,

it

any.

2.

Consumable

components;

such

as

contact

tips,

cutting

nozzles,

contactors

and

relays

or

pans

that

tail

due

to

normal

wear.

3.

Equipment

that

has

been

moditied

by

any

party

other

than

MILLER,

or

equip

ment

that

has

been

improperty

installed,

improperty

operated

or

misused

based

upon

industry

standards,

or

equipment

which

has

not

had

reasonable

and

necessary

maintenance,

orequipment

which

has

been

used

tor

operation

outside

ot

the

apecitications

tor

the

equipment.

MILLER

PRODUCTS

ARE

INTENDED

FOR

PURCHASE

AND

USE

BYCOMMER

CIALIINDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

IN

THE

USE

AND

MAINTENANCE

OF

WELDING

EQUIPMENT.

In

the

event

ot

a

warranty

claim

covered

by

this

warranty,

the exclusive

remedies

shall

be,

at

MILLERS

option:

(1)

repair;

or

(2)

replacement;

or,

where

authorized

in

writing

by

MILLER

in

appropriate

cases,

(3)

the

reasonable

coat

ot

repair

or

replace

ment

at

an

authorized

MILLER

service

station;

or

(4)

payment

ot

orcmdit

torthe

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

retum

otthe

goods

at

customers

risk

and

expense.

MILLERS

option

ot

repair

or

replacement

will

be

FOB.,

Factoryat

Appleton,

Wisconsin,

or

FOB.

at

a

MILLER

authorized

ser

vice

tacility

an

determined

by

MILLER.

Theretore

no

compensation

or

reimburse

ment

for

transportation

costs

ot

any

kind

will

be

allowed.

TO

THE

EXTENT

PERMITTED

BY

LAW,

THE

REMEDIES

PROVIDED

HEREtN

ARE

THE SOLE

AND

EXCLUSIVE

REMEDIES.

IN

NO

EVENT

SHALL

MILLER

BE

UABLE

FOR

DIRECT,

INDIRECT,

SPECIAL,

INCIDENTALOR

CONSEQUENTIAL

DAMAGES

(INCLUDING

LOSS OF

PROFIT),

WHETHER

BASED

ON

CON

TRACT,

TORT

OR

ANY

OTHER

LEGAL

THEORY.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WAR

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,

MIGHTARISE

BY

IMPLICATtON,

OPERATION

OF

LAW,

CUSTOM

OF

TRADE

OR

COURSE

OF

DEALING,

IN

CLUDING

ANY

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OR

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECTTO

ANY

AND

ALL

EQUIPMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

AND

DISCLAIMED

BY

MILLER.

Some

states

in

the

U.S.A.

do

not

allow

limitations ot

how

long

an

implied

warranty

lasts,

or

the

exclusion

ot

incidental,

indirect,

special

or

consequential

damages,

so

the

above

limitation

or

exclusion

may

not

apply

to

you.

This

warranty

provides

ape

citic

legal

rights,

end

other

rights

may

be

available,

but

may

vary

trom

state

to

state.

In

Canada,

legislation

in

some

provinces

provides

tor

certain

additional

warranties

or

remedies

other

than

as

stated

herein,

and

to

the

extent

that

they

may

not

be

waived,

the

limitations

and

exclusions

set

out

above

may

not

apply.

This

Umited

Warranty

provides

specific

legal

rights,

and

other

rights

may

be

available,

but

may

vary

trom

province

to

province.

5.

6.

fu

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

Numberof

your

unit.

The

information

is

located

on

the

rating

label

or

nameplate.

Model

_________

Serial

or

Style

No.

Date

of

Purchase

miller

1/95

ERRATA

SHEET

March

29,

1995

FORM:

OM-1584E

Use

above

FORM

number

when

ordering

extra

manuals.

After

this

manual

was

printed,

refinements

in

equipment

design

occurred.

This

sheet

lists

exceptions

to

data

appearing

later

in

this

manual.

CHANGES

TO

SECTION

6

ELECTRICAL

DIAGRAMS

Replace

Figure

6-2.

Circuit

Diagram

For

Wire

Feeder

With

Optional

Equipment

(See

Pages

2

and

3

on

this

Errata

Sheet)

Figure

6-2.

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Diagram

For

Wire

Feeder

With

Optional

Equipment

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Page

3

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

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

poweraccording

to

OSHA

29

CFR

1910.147

(see

Safety

Standards).

5.

Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual

and

national,

state,

and

local

codes.

6.

Always

verify

the

supply

ground



check

and

be

sure

that

input

power

cord

ground

wire

is

properly

connected

to

ground

terminal

in

disconnect

box

or

that

cord

plug

is

connected

to

a

properly

grounded

receptacle

outlet.

7.

When

making

input

connections,

attach

proper

grounding

conductor

first



double-check

connections.

8.

Frequently

inspect

input

powercord

fordamage

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.

16.

Keep

all

panels

and

covers

securely

in

place.

17.

Clamp

work

cable

with

good

metal-to-metal

contact

to

workpiece

or

worktable

as

near

the

weld

as

practical.

a

WARNING

ARC

WELDING

can

be

hazardous.

PROTECT

YOURSELF

AND

OTHERS

FROM

POSSIBLE

SERIOUS

INJURY

OR

DEATH.

KEEP

CHILDREN

AWAY.

PACEMAKER

WEARERS

KEEP

AWAY

UNTIL

CONSULTING

YOUR

DOCTOR.

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;

FLYING

f/~

SLAG

OR

SPARKS

can

injure

eyes.

2.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

to

protect

yourface

and

eyes

when

welding

orwatching

(see

ANSI

Arc

rays

from

the

welding

process

produce

intense

Z49.1

and

Z87.1

listed

in

Safety

Standards).

visible

and

invisible

(ultraviolet

and

infrared)

rays

that

3.

Wear

approved

safety

glasses

with

side

shields.

can

bum

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

Chipping,

grinding,

and

welds

4.

Use

protective

screens

or

barriers

to

protect

others

from

flash

cooling

throw

off

pieces

of

metal

or

slag.

and

glare;

warn

others

not

to

watch

the

arc.

NOISE

5.

Wear

protective

clothing

made

from

durable,

flame-resistant

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.

Always

have

a

trained

Welding

produces

fumes

and

gases.

Breathing

watchperson

nearby.

Welding

fumes

and

gases

can

displace

these

fumes

and

gases

can

be

hazardous

to

your

air

and

lower

the

oxygen

level

causing

injury

or

death.

Be

sure

health.

the

breathing

air

is

safe.

6.

Do

not

weld

in

locations

near

degreasing,

cleaning,

or

spraying

1.

Keep

your

head

out

of

the

fumes.

Do

not

breathe

the

fumes.

operations.

The

heat

and

rays

of

the

arc

can

react

with

vapors

to

2.

If

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

form

highly

toxic

and

irritating

gases.

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

(MSDSs)

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

cleaners,

and

degreasers.

containing

these

elements

can

give

off

toxic

fumes

if

welded.

I

CYLINDERS

can

explode

if

damaged.

4.

Never

drape

a

welding

torch

over

a

gas

cylinder.

Shielding

gas

cylinders

contain

gas

under

high

5.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

pressure.

If

damaged,

a

cylinder

can

explode.

Since

6.

Never

weld

on a

pressurized

cylinder



explosion

will

result.

process,

be

sure

to

treat

them

carefully.

fittings

designed

for

the

specific

application;

maintain

them

and

I

gas

cylinders

are

normally

part

of

the

welding

~

Useonlycorrectshieldinggascylinders,

regulators,hoses,and

associated

parts

in

good

condition.

1.

Protect

compressed

gas

cylinders

from

excessive

heat,

8.

Tum

face

away

from

valve

outlet

when

opening

cylinder

valve.

mechanical

shocks,

slag,

open

flames,

sparks,

and

arcs.

9.

Keepprotectivecapinplaceovervalveexceptwhencylindoris

2.

lnstallcylindersinanuprightpositionbysecuringtoastationary

in

use

or

connected

for

use.

support

or

cylinder

rack

to

prevent

falling

or

tipping.

io.

Read

and

follow

instructions

on

compressed

gas

cylinders,

3.

Keep

cylinders

away

from

any

welding

or

other

electrical

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

circuits.

Standards.

Sri

.1.1

2/94

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

lire.

Check

and

be

sure

the

area

is

sate

betore

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.

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.

SPARKS

can

cause

BA11ERY

GASES

TO

EXPLODE;

BATTERY

ACID

can

burn

eyes

and

skin.

3.

Do

not

allow

tools

to

cause

sparks

when

working

on

a

battery.

Do

not

use

welder

to

charge

batteries

or

jump

start

vehicles.

Observe

correct

polarity

(+

and

)

on

batteries.

STEAM

AND

PRESSURIZED

HOT

1.

If

the

engine

is

warm

and

checking

is

needed,

follow

steps

2

COOLANT

can

burn

face,

eyes,

and

3.

skin.

2.

Wear

safety

glasses

and

gloves

and

put

a

rag

over

cap.

It

is

best

to

check

coolant

level

when

engine

is

cold

3.

Turn

cap

slightly

and

let

pressure

escape

slowly

before

to

avoid

scalding.

completely

removing

cap.

PRINCIPAL

SAFETY

STANDARDS

Safely

in

Welding

and

Cutting,

ANSI

Standard

Z49.

1,

from

American

Welding

Society,

550

NW.

LeJeune

Rd,

Miami

FL

33126

Safety

and

Health

Standards,

OSHA

29

CFR

1910,

from

Superinten

dent

of

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

Recommended

Safe

Practices

for

the

Preparation

for

Welding

and

Cutting

of

Containers

That

Have

Held

Hazardous

Substances,

Ameri

can

Welding

Society

Standard

AWS

F4.1

,from

American

Welding

So

ciety,

550

NW.

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

Safely

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

ForOccupation

And

Educational

EyeAndFace

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.

A~

WARNING

I~

~

ENGINE

FUEL

can

cause

fire

or

3.

Do

not

overfill

tank



allow

room

for

fuel

to

expand.

explosion.

-

Engine

fuel

is

highly

flammable,

4.

Do

not

spill

fuel.

engine.

If

fuel

is

spilled,

clean

up

before

starting

1.

Stop

engine

and

let

it

cool

off

before

checking

or

adding

fuel.

2.

Do

not

add

fuel

while

smoking

or

if

unit

is

near

any

sparks

or

open

flames.

MOVING PARTS

can

cause

injury.

3.

Have

only

qualified

people

remove

guards

or

covers

for

maintenance

and

troubleshooting

as

necessary.

Moving

parts,

such

as

fans,

rotors,

and

belts

can

cut

fingers

and

hands

and

catch loose

clothing,

4.

To

prevent

accidental

starting

during

servicing,

disconnect

negative

()

battery

cable

from

battery.

5.

Keep

hands,

hair,

loose

clothing,

and

tools

away

from

moving

1.

Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

6.

parts.

Reinstall

panels

or

guards

and

close

doors

when

servicing

is

2.

Stop

engine

before

installing

or

connecting

unit.

finished

and

before

starting

engine.

1.

2.

Battenes

contain

acid

and

generate

explosive

iases.

Always

wear

a

face

shield

when

working

on

a

battery.

Stop

engine

before

disconnecting

or

connecting

battery

cables.

4.

5.

Sri

.1.1

2/94

EMF

INFORMATION

TABLE

OF

CONTENTS

SECTION

1



SAFETY

INFORMATION

1

SECTION

2

SPECIFICATIONS

1

SECTION

3INSTALLATION

3-1.

Equipment

Connection

Diagrams

3-2.

Installing

Swivel

Into

Pipe

Post

3-3.

Installing

Control

Box

Onto

Swivel

3-4.

Installing

Boom

And

Reel

Support

3-5.

Installing

Wire

Guide

Extension

3-6.

Wire

Guide

And

Drive

Roll Installation

3-7.

Welding

Gun

Connections

3-8.

Wire

Feed

Motor

And

Gas

Valve

Control

Connections

3-9.

14-Pin

Plug

Connection

3-10.

Shielding

Gas

And

Weld

Cable

Connections

3-11.

Voltage

Sensing

Lead

(Optional)

3-12.

Removing

Safety

Collar

And

Adjusting

Boom

3-13.

Welding

Wire

Installation

3-14.

Motor

Start

Control

3-15.

DIP

Switches

Options

3-16.

Changing

Optional

Digital

Voltage

Control

For

Use

With

A

MILLER

Inverter-Type

Power

Source

3-17.

Threading

Welding

Wire

SECTION

4OPERATION

18

SECTION

5-

MAINTENANCE

&

TROUBLESHOOTING

24

5-1.

Routine

Maintenance

24

5-2.

Replacing

The

Hub

Assembly

25

5-3.

Overload

Protection

25

5-4.

Troubleshooting

26

CM-i

584E

-

3/95

NOTE

~

Considerations

About

Welding

And

The

Effects

Of

Low

Frequency

Electric

And

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



Background

Paper~

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

cellularlevel

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.

modiO

i

4/93

2

3

4

5

6

7

8

9

11

12

15

16

SECTION

6

ELECTRICAL

DIAGRAMS

29

SECTION

7

PARTS

LIST

34

Figure

7-1.

Main

Assembly

34

Figure

7-2.

Support,

Hub &

Reel

37

Figure

7-3.

Control

Box

38

Figure

7-4.

Panel,

Front

w/Components

40

Figure

7-5.

Boom

Assembly

42

Figure

7-6.

Drive

Assembly,

Wire

44

Figure

7-7.

Control

Panel

46

Table

7-1.

Drive

Roll

And

Wire

Guide

Kits

49

SECTION

1

-

SAFETY

INFORMATION

Figure

1-1.

Safety

Information

modl.1

2/93

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.

SECTION

2-

SPECIFICATIONS

Table

2-1.

Wire

Feeder

12

ft

(3.7

m)

Boom

16

ft

(4.9

m)

Boom



Read

all

safety

messages

throughout

this

manual.



Obey

all

safety

messages

to

avoid

injury.



Learn

the

meaning

of

WARNING

and

CAUTION.

1

2

;1~II~e~

3

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Disconnect

input

power

before

4

installing

or

servicing.

a

CAUTION

MOVING

PARTS

can

injure.



Keep

away

from

moving

parts.



Keep

all

panels

and

covers

closed

when

operating.

/

5

READ

SAFETY

BLOCKS

at

start

of

6

Section

3-1

before

proceeding

7~NOTE

-

~

Turn

Off

switch

when

using

high

frequency.

Specification

Description

Type

Of

Input

Power

From

Welding

Power

Source

Maximum

Weld

Circuit

Rating

Welding

Power

Source

Type

Wire

Feed

Speed

Range

Wire

Diameter

Range

Welding

Processes

Input

Power

Cord

Maximum

Height

With

4

ft

(1.2

m)

Post

Weight

Vertical

Lift

Of

Boom

Single-Phase

24

Volts

AC,

10

Amperes,

50/60

Hertz.

(It

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

50

To

780

ipm

(1.31019.8

mpm);

Standard

Motor

90

To

1400

ipm

(2.3

To

35.6

mpm);

High

Speed

Motor

.023

Thru

1/8

in

(0.6

To

3.2

mm)

Gas

Metal

Arc

(GMAW)

And

Flux

Cored

Arc

Welding

(FCAW)

lOft(3.1

m)

17

ft

(5.2

m)

Net:

207

lb

(94

kg)

Ship:

318

lb

(144

kg)

Honzontal

To

60

Above

Horizontal

21

ft

(6.4

m)

Net:

280

lb

(127

kg)

Ship:

411

lb

(186

kg)

Honzontal

To

60

Above

Horizontal

OM-1

584

Page

1

SECTION

3-INSTALLATION

3-1.

Equipment

Connection

Diagrams

A~

WARNING

CYLINDERS

can

explode

if

damaged.



Keep

cylinders

away

from

welding

and

other

electrical

circuits.



Never

touch

cylinder

with

welding

electrode.



Always

secure

cylinder

to

running

gear,

wall,

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.



Turn

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.

wfwarn9.1

2/93

2

13

4

5-

1

Welding

Power

Source

2

Remote

14

Connection

3

Negative

()

Weld

Output

Cable

4

Positive

(+)

Weld

Output

Cable

5

Workpiece

6

Voltage

Sensing

Clamp

7

Weld

Control

8

Boom

9

Gun

10

Swivel

11

Pipe

Post

And

Base

12

Gas

Hose

13

Gas

Supply

12

ST-153

176-A

10

Figure

3-1

.

Typical

System

Connections

OM-1584

Page

2

3-2.

Installing

Swivel

Into

Pipe

Post

____

a

WARNING

1*

RELEASE

OF

SPRING

PRESSURE

WITHOUT

BOOM

ATTACHED

can

cause

serious

personal

injury.



Do

not

remove

safety

collar

until

instructed

to

do

so.

FALLING

BOOM

can

cause

serious

personal

injury

and

equipment

damage.



Securely

mount

pipe

post

to

base

that

can

support

weight

of

unit

with

boom

in

horizontal

position.



Use

proper

equipment

for

lifting

swivel

and

boom

into

place.

4

1

Swingpak

Base

or

CBC

Cart

2

Pipe

Post

With

Base

3

Steel

Bolt

Secure

as

shown

using

as

a

mini

mum

1/2

in

diameter

SAE

grade

5

steel

bolts.

4

Swivel

Assembly

Insert

into

pipe

post.

Lubricate

swivel.

5

Safety

Collar

Do

not

remove

until

instructed

to.

Tools

Needed:

~

3/4in

ST-152

382

Figure

3-2.

Swivel

Installation

3-3.

Installing

Control

Box

Onto

Swivel

2

4

Tools

Needed:

3

c~zJ==n

3/8

in

1

Weld

Control

2

Bracket

3

Screws

Bracket

and

screws

are

installed

onto

bottom

of

control

at

factory.

4

Swivel

Loosen

screws.

Place

control

on

swivel

and

slide

forward.

Tighten

screws.

ST-153

174

Figure

3-3.

Control

Box

Installation

OM-1

584

Page

3

3-4.

Installing

Boom

And

Reel

Support

3-5.

Installing

Wire

Guide

Extension

READ

SAFETY

BLOCKS

at

start

of

Section

3-2

before

proceeding.

1

Swivel

Plates

2

Yoke

Remove

hardware

from

swivel

plates

and

yoke.

3

Boom

Set

boom

into

swivel

as

shown.

4

Yoke

Install

through

yoke.

Install

cot

ter

and

spread

ends.

5

Bolt

7

Install

bolt,

tighten

hardware,

and

back

bolt

off

one

half

turn.

6

Locking

Knob

Install

locking

knob

but

do

not

tight

en.

7

Reel

Support

Install

reel

support.

Ref.

ST-i

53

170

Tools

Needed:

~

3/4,3/8

in

Figure

3-4.

Boom

Installation

4

Tools

Needed:

3/8

in

1

Wire

Guide

Fitting

2

Bolt

3

Moriocoil

Liner

4

Wire

Guide

Extension

Tighten

bolt

to

secure

liner

in

wire

guide

fitting.

Do

not

overtighten

bolt

and

crush

liner.

Repeat

procedure

for

opposite

side.

ST-152

383

Figure

3-5.

Wire

Guide

Extension

Installation

OM-1

584

Page

4

3-6.

Wire

Guide

And

Drive

Roll

Installation

READ

SAFETY

BLOCKS

at

start

of

Section

3-1

before

proceeding.

B.

Drive

Roll

Installation

Figure

3-6.

Wire

Guide

Installation

Figure

3-7.

Drive

Roll

Installation

A.

Wire

Guide

Installation

When

changing

wire

size

or

type,

check

guide

size.

See

Table

7-1.

1

Drive

Rolls

Remove

drive

rolls

before

install

ing

wire

guides

(see

Figure

3-7).

2

Wire

Guide

Securing

Screws

Loosen

wire

guide

screws.

3

InletWireGuide

4

Intermediate

Wire

Guide

Insert

intermediate

guide

until

flange

on

guide

rests

against

cast

ing,

and

secure

with

guide

screw.

Install

drive

rolls

(see

Figure

3-7).

Repeat

procedure

for

opposite

side

of

wire

feeder.

ST-i

37

391-F/

ST-142

597-A

Tools

Needed:

1

When

changing

wire

size

or

type,

check

drive

roll

size.

See

Table

7-1

-

1

Spring

Shaft

Carrier

Close

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.

Open

spring

shaft

carrier.

4

Drive

Roll

Slide

drive

rolls

onto

drive

roll

carri

ers.

Close

spring

shaft

carrier.

Turn

nut

one

click.

5

Drive

Assembly

Cover

Close

cover.

Repeat

procedure

for

opposite

side

of

wire

feeder.

ST-142

597-A

2

3

OM-1

584

Page

5

3-7.

Welding

Gun

Connections

wfwarnl.1

2/93

1

Drive

Assembly

Cover

2

Gun

Securing

Knob

3

Gun

Connector

Loosen

securing

knob.

Insert

gun

connector,

and

position

as

close

as

possible

to

drive

rolls

without

touching.

lighten

knob.

4

Gun

Trigger

Plug

5

Gun

Trigger

Receptacle

Insert

plug

into

free-hanging

re

ceptacle

and

tighten

threaded

col

lar.

6

Trigger

Cord

7

Trigger

Plug

8

Weld

Control

Trigger

Recep

tacle

a

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Oft

wire

feeder

and

welding

power

source,

and

disconnect

input

power

before

inspecting

or

installing.

2

4

Insert

plug

into

receptacle

and

tighten

threaded

collar.

Repeat

procedure

forgun

on

oppo

site

drive

assembly.

Figure

3-8.

Gun

And

Trigger

Lead

Connections

ST-i

53

072/

Ref.

ST-153

172

/

Ref.

ST-142

598-C

OM-1

584

Page

6

3-8.

Wire

Feed

Motor

And

Gas

Valve

Control

Connections

3-9.

14-Pin

Plug

Connection

Figure

3-10.

14-Pin

Plug

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.

Repeat

procedure

for

opposite

side

of

weld

control.

Ref.

ST-142

598-C

Figure

3-9.

Boom

Connections

2

1

Plug

PLG1O

2

Keyway

3

Threaded

Collar

Connect

14-pin

plug

PLG1O

to

matching

receptacle

on

welding

powersource

as

follows:

align

key.

way,

insert

plug,

and

tighten

threaded

collar.

Information:

A,

B

Contact

closure

completes

the

24

volts

ac

contactor

control

circuit.

C

Command

signal;

+10

volts

dc.

D

Control

circuit

common.

E

Remote

power

source

voltage

command

signal

from

feeder

(potentiometerwiper

oro-1

0

volts

dc

source);

0

to

+10

volts

dc.

F

Current

feedback;

0-10

volts

dc,

1

volt

per

100

amperes.

G

Circuit

common

for

24

volts

ac

circuit.

H

Voltage

feedback;

0-10

volts

dc,

1

volt

per

10

arc

volts.

The

remaining

pins

in

the

plug

are

not

used

by

the

feeder.

Ref.

ST-143

260-A

/

Ref.

S-0512

OM-1584

Page

7

3-10.

Shielding

Gas

And

Weld

Cable

Connections

a

WARNING

CYLINDERS

can

explode

if

damaged.



Keep

cylinders

away

from

welding

and

other

electrical

circuits.



Never

touch

cylinder

with

welding

electrode.



Always

secure

cylinder

to

running

gear,

wall,

or

other

stationary

support.

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Oft

wire

feederand

welding

power

source,

and

disconnect

input

power

before

inspecting

or

installing.

BUILDUP

OF

SHIELDING

GAS

can

harm

health

or

kill.



Shut

off

shielding

gas

supply

when

not

in

use.

The

weld

cables

and

shielding

gas

hoses

ex

tend

10

ft

(3m)

from

the

boom.

If

the

welding

power

source

or

gas

supply

are

further

from

the

boom,

extend

cables

and

hoses

as

follows:

1

Weld

Cables

2

Insulated

Sleeving

Bolt

together

weld

cables

from

welding

pow

er

source

and

boom.

Use

electrical

tape

and

insulated

sleeving

to

cover

connection.

3

Shielding

Gas

Extension

Hose

4

Boom

Shielding

Gas

Hose(s)

Connect

boom

shielding

gas

hoses

to

gas

supplies

or

extend

hoses.

The

hoses

from

the

boom

have

5/8-18

right-hand

threads.

5

Shielding

Gas

Y

Adapter

Connect

single

end

fitting

of

V

adapterto

gas

supply,

and

connect

boom

shielding

gas

hoses

to

fittings

on

V

end

of

adapter.

The

hoses

from

the

boom

have

5/8-18

right-hand

threads.

Figure

3-11.

Shielding

Gas

And

Weld

Cable

Connections

wam4.1

2/93

Tools

Needed:

Z~

5/8

in

Ref.

ST-153

175-B

OR

OM-1

584

Page

8

3-11.

Voltage

Sensing

Lead

(Optional)

A

35

ft

(10.6

m)

voltage

sensing

lead

is

provided

with

several

options.

Connect

voltage

sensing

lead

to

workpiece

(see

Figure

3-1).

3-12.

Removing

Safety

Collar

And

Adjusting

Boom

4~

WARNING

RELEASE

OF

SPRING

PRESSURE

FALLING

BOOM

can

cause

serious

WITHOUT

BOOM

ATTACHED

can

cause

serious

personal

injury.

personal

in



Adjustment

jury

and

equipment

damage.

rod

must

be

threaded

fully

through



Do

not

remove

safety

collar

until

instructed

to

do

so.

yoke.

1

Locking

Knob

Tighten

knob

to

prevent

boom

movement.

Loosen

knob

to

allow

boom

movement.

Change

knob

position

to

limit

upward

movement.

Tools

Needed:

O

\~,/

~

~1Jfr~J

~

LI~

~

Increasing

Spring

Pressure

ForA

Heavy

Gun

\~,1

1.J

~

~j1J1~

~

1

~

2

Decreasing

Spring

Pressure

ForA

Light

Gun

Pull

boom

down

slightly

and

re

move

safety

collar.

Boom

should

balance

in

any

position

from

hori

zontal

to

60

degrees

above

hori

zontal.

If

necessary,

adjust

boom

as

follows:

2

Threaded

Rod

3

Jam

Nut

Loosen

jam

nut

and

turn

threaded

rod

until

boom

balances.

Tighten

jam

nut.

Be

sure

several

full

threads

are

through

yoke

to

pre

vent

boom

falling.

4

Yoke

.

Retain

safety

collar

for

use

in

dis

1-1/8

in

assembling

or

moving

boom.

Ref.

ST-142

599-B

/

Ref

ST-152

380-A

Figure

3-12.

Boom

Adjustments

3-13.

Welding

Wire

Installation

A.

Installation

Of

Spool-Type

Wire

3

1

Retaining

Ring

2

Wire

Spool

3

Hub

Remove

retaining

nng

and

slide

spool

unto

hub.

4

Hub

Turn

spool

until

hub

fits

in

spool.

Reinstall

retaining

ring.

Repeat

procedure

for

installing

spool-type

wire

on

opposite

side

of

wire

feeder.

E

ST-153

171

Figure

3-13.

Installation

Of

Spool-Type

Wire

OM-1

584

Page

9

B.

Installation

Of

Optional

Wire

Reel

And

Reel

Type

Wire

C.

Adjusting

Hub

Tension

Figure

3-14.

Installation

Of

Optional

Wire

Reel

And

Reel

Type

Wire

5

-4

1

Retaining

Ring

2

Spanner

Nut

3

Lock

4

Wire

Retainer

5

Wire

Reel

6

Hub

7

Hub

8 Reel

Support

Remove

retaining

ring.

Pull

lock

and

turn.

Remove

spanner

nut,

wire

retainer,

and

wire

reel

from

hub.

Lay

wire

reel

assembly

on

flat

sur

face,

and

install

wire

as

shown.

Tighten

spanner

nut

until

lock

is

in

position

over

hole

in

wire

retainer.

Pull

lock

and

turn

to

insert

locking

into

wire

retainer.

Slide

wire

reel

assembly

onto

hub,

and

turn

assembly

until

hub

is

seated

in

hole

in

reel.

Reinstall

re

taining

ring.

ST-143

478-A

/

ST-i

52463

__

4

S

/

Wire

Installation

Turn

Off

wire

feeder

and

welding

power

source.

1

Hex

Nut

2

Spool

Grasp

spool

in

one

hand

and

turn

while

using

a

wrench

to

adjust

hex

nut.

When

a

slight

force

is

needed

to

turn

spool,

tension

is

set.

Repeat

procedure

to

adjust

hub

tension

on

opposite

side

of

wire

feeder.

Tools

Needed:

I~

5/8in

ST-153

173

2

Figure

3-15.

Adjusting

Hub

Tension

OM-1

584

Page

10

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