Miller KJ164358 Owner's manual

OM-1586

155

318P

June

1998

Processes

~

MIG

(GMAW)

Welding

Pulsed

MIG

(GMAW-P)

Flux

Cored

(FCAW)

Welding

SS-64M

SwingarcTM

Miller

The

Power

ofBlue.

Description

Wire

Feeder

(Use

with

CC/CV

Power

Sources)

D~

Visit

our

website

at

www.MillerWetdz.com

12

and

16

Foot

OWNERS

MANUAL

U

From

Miller

to

You

I

Thank

you

and

congratulations

on

choosing

Miller.

Nowi

you

can

get

the

job

done

and

get

it

done

right.

We

know

you

dont

have

time

to

do

it

any

other

way.

Thats

why

when

Niels

Miller

first

started

building

arc

welders

in

1929,

he

made

sure

his

products

offered

long-lasting

value

and

superior

quality.

Like

you,

his

customers

couldnt

afford

anything

less.

Miller

products

had

to

be

more

than

the

best

they

could

be.

They

had

to

be

the

best

you

could

buy.

Today,

the

people

that

build

and

sell

Miller

products

continue

the

tradition.

Theyre

just

as

committed

to

providing

equipment

and

service

that

meets

the

high

standards

of

quality

and

value

established

in

1929.

This

Owners

Manual

is

designed

to

help

you

get

the

most

out

of

your

Miller

products.

Please

take

time

to

read

the

Safety

precautions.

They

will

help

you

protect

yourself

against

potential

hazards

on

the

worksite.

Weve

¶~f~Jfl1i1J1fl1~

iIh(iUIIIW

REGISTERED

QUALITY

SYSTEM

Miller

is

the

first

welding

equipment

manufacturer

in

the

U.S.A.

to

be

registered

to

the

ISO

9001

Quality

System

Standard.

Working

as

bard

asyoudo

.

power

source

Tram

MlltB~

Is

backed

by

the

must

hassle-tree

wepranty

in

the

blIsIlIesS:

made

installation

and

operation

quick

and

easy.

With

Miller

you

can

count

on

years

of

reliable

service

with

proper

maintenance.

And

if

for

some

reason

the

unit

needs

repair,

theres

a

Troubleshooting

section

that

will

help

you

figure

out

what

the

problem

is.

The

parts

list

will

then

help

you

to

decide

which

exact

part

you

may

need

to

fix

the

problem.

Warranty

and

service

information

for

your

particular

model

are

also

provided.

~

Miller

Electric

manufactures

a

full

line

of

welders

and

welding

For

information

on

other

quality

Miller

products,

contact

your

local

Miller

distributor

to

receive

the

latest

full

line

catalog

or

individual

catalog

sheets.

To

locate

your

nearest

distributor

call

1-800-4-A-Miller.

Miller

offers

a

Technical

Manual

which

provides

more

detailed

service

and

parts

information

for

your

unit

To

obtain

a

Technical

Manual,

contact

your

local

distributor

Your

distributor

can

also

supply

you

with

Welding

Process

Manuals

such

as

SMAW,

GTAW.

GMAW,

and

GMAW-P,

L

OM-1

586P

TABLE

OF

CONTENTS

SECTION

1

-

SAFETY

PRECAUTIONS

-

READ

BEFORE

USING

1

1-1.

Symbol

Usage

1

-2.

Arc

Welding

Hazards

1

1-3.

Additional

Symbols

for

Installation,

Operation,

and

Maintenance

3

1-4.

Principal

Safety

Standards

3

1-5.

EMF

Information

4

SECTION

1

-

CONSIGNES

DE

SECURITE

-

LIRE

AVANT

UTILISATION

5

1-1.

Signification

des

symboles

5

1-2.

Dangers

relatifs

au

soudage

a

arc

5

1-3.

Dangers

supplØmentaires

en

relation

avec

Iinstallation,

le

fonctionnement

et

Ia

maintenance

7

1-4.

Principales

normes

de

sØcuritØ

8

1-5.

Information

sur

les

champs

ØlectromagnØtiques

8

SECTION

2

-

INTRODUCTION

9

2-1.

Specifications

9

SECTION

3

-

INSTALLATION

9

3-1.

Installing

Swivel

Into

Pipe

Post

9

3-2.

Installing

Boom

And

Reel

Support

10

3-3.

Installing

Wire

Guide

Extension

10

3-4.

Adjusting

Control

Tilt

Bracket

10

3-5.

Equipment

Connection

Diagrarrt

11

3-6.

Connecting

Weld

Cables

And

Gas

Hoses

12

3-7.

Control

Box

Connections

13

3-8.

14-Pin

Plug

Information

13

3-9.

Motor

Start

Control

14

3-10.

Removing

Safety

Collar

And

Adjusting

Boom

14

3-11.

Gun

Recommendation

Table

15

3-12.

Wire

Type,

Size,

And

Feed

Speed

Capability

Table

15

3-13.

Installing

And

Threading

Welding

Wire

16

SECTION

4

-

OPERATION

17

4-1.

Operational

Terms

17

4-2.

Pulse

Welding

Terms

17

4-3.

Front

Panel

Controls

18

4-4.

Side

And

Rear

Panel

Controls

18

SECTION

5

-

SETFING

SEQUENCE

PARAMETERS

19

5-1.

Sequence

Parameters

In

A

Program

19

SECTION

6-

SETFING

DUAL

SCHEDULE

PARAMETERS

20

6-1.

Selecting

Dual

Schedule

Pair

20

6-2.

Dual

Schedule

Switch

Diagrams

21

SECTION

7

-

USING

THE

OPTIONAL

DATA

CARU

22

7-1.

Data

Card

Terms

22

7-2.

Installing

Data

Card

22

7-3.

Card

Displays

23

SECTION

8-

SYSTEM

SETUP

24

8-1.

System

Setup

Display

Parameters

24

SECTION

9-

STANDARD

PULSE

WELDING

PROGRAMS

25

9-1.

Program

1

-

Steel

25

9-2.

Program

2

-

Steel

25

9-3.

Program

3

-

Steel

25

9-4.

Program

4

-

Steel

25

9-5.

Program

5

-

Stainless

26

9-6.

Program

6

-

Stainless

26

9-7.

Program

7

-

Nickel

Alloy

26

9-8.

Program

8

-

Silicon

Bronze

26

SECTION

10-

TEACH

POINTS

27

10-1.

Teach

Using

15

Points

27

10-2.

Teach

Using

4

Points

28

10-3.

Redefining

Teach

Points

29

SECTION

11

-

MAINTENANCE

AND

TROUBLESHOOTING

31

11-1.

Routine

Maintenance

31

11-2.

Error

Displays

32

11-3.

Troubleshooting

33

SECTION

12

-

ELECTRICAL

DIAGRAM

34

SECTION

13-

PARTS

LIST

.36

OPTIONS

AND

ACCESSORIES

WARRANTY

SECTION

1

-

SAFETY

PRECAUTIONS

-

READ

BEFORE

USING

som

nd_5/97

1-1.

Symbol

Usage

a

A

Marks

a

special

safety

message.

lET

Means

Note~

not

safety

related.

1-2

Arc

Welding

Hazards

A

The

symbols

shown

below

are

used

throughout

this

manual

to

call

attention

to

and

identify

possible

hazards.

When

you

see

the

symbol,

watch

out,

and

followthe

to

avoid

the

hazard.

The

safety

information

given

below

is

only

a

summary

of

the

more

complete

safety

information

found

in

the

Safety

Standards

listed

in

Section

1

-4.

Read

and

follow

all

Safety

Standards.

A

Only

qualified

persons

should

install,

operate,

maintain,

and

repair

this

unit.

A

During

operation,

keep

everybody,

especially

children,

away.

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.



Do

not

touch

live

electrical

parts.



Wear

dry,

hole-free

insulating

gloves

and

body

protection.



Insulate

yourself

from

work

and

ground

using

dry

insulating

mats

or

covers

big

enough

to

prevent

any

physical

contact

with

the

work

or

ground.



Do

not

use

AC

output

in

damp

areas,

if

movement

is

confined,

or

if

there

is

a

danger

of

falling.



Use

AC

output

ONLY

if

required

for

the

welding

process.



If

AC

output

is

required,

use

remote

output

control

if

present

on

unit.



Disconnect

input

power

or

stop

engine

before

installing

or

servicing

this

equipment.

Lockout/tagout

input

power

according

to

OSHA

29

CFR

191

0.147

(see

Safety

Standards).



Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual

and

national,

state,

and

local

codes.



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.



When

making

input

connections,

attach

proper

grounding

conductor

first

-

double-check

connections.



Frequently

inspect

input

power

cord

for

damage

or

bare

wiring

-

replace

cord

immediately

if

damaged

-

bare

wiring

can

kill.



Turn

off

all

equipment

when

not

in

use.

Do

not

use

worn,

damaged,

undersized,

or

poorly

spliced

cables.

Do

not

drape

cables

over

your

body.

This

group

of

symbols

means

Warning!

Watch

Out!

possible

ELECTRIC

SHOCK,

MOVING

PARTS,

and

HOT

PARTS

hazards.

Consult

symbols

and

below

for

necessary

actions

to

avoid

the

hazards.



It

earth

grounding

of

the

workpiece

is

required,

ground

it

directly

with

a

separate

cable

-

do

not

use

work

clamp

or

work

cable.



Do

not

touch

electrode

if

you

are

in

contact

with

the

work,

ground,

or

another

electrode

from

a

different

machine.



Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

Maintain

unit

according

to

manual.



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.



Insulate

work

clamp

when

not

connected

to

workpiece

to

prevent

contact

with

any

metal

object.



Do

not

connect

more

than

one

electrode

or

work

cable

to

any

single

weld

output

terminal.

SIGNIFICANT

DC

VOLTAGE

exists

after

removal

of

input

power

on

inverters.



Turn

Off

inverter,

disconnect

input

power,

and

discharge

input

capacitors

according

to

instructions

in

Maintenance

Section

before

touching

any

parts.

FUMES

AND

GASES

can

be hazardous

L_.

IIV

Welding

produces

fumes

and

gases.

Breathing

-~-~

~

these

fumes

and

gases

can

be

hazardous

to

your

health.



Keep

your

head

out

of

the

fumes.

Do

not

breathe

the

fumes.



If

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

remove

welding

fumes

and

gases.



If

ventilation

is

poor,

use

an

approved

air-supplied

respirator.



Read

the

Material

Safety

Data

Sheets

(MSDSs)

and

the

manufacturers

instructions

for

metals,

consumables,

coatings,

cleaners,

and

degreasers.



Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

wearing

an

air-supplied

respirator.

Always

have

a

trained

watch-

person

nearby.

Welding

fumes

and

gases

can

displace

air

and

lower

the

oxygen

level

causing

injury

or

death.

Be

sure

the

breathing

air

is

safe.



Do

not

weld

in

locations

near

degreasing,

cleaning,

or

spraying

operations.

The

heat

and

rays

of

the

arc

can

react

with

vapors

to

form

highly

toxic

and

irritating

gases.



Do

not

weld

on

coated

metals,

such

as

galvanized,

lead,

or

cadmium

plated

steel,

unless

the

coating

is

removed

from

the

weld

area,

the

area

is

well

ventilated,

and

if

necessary,

while

wearing

an

air-supplied

respirator.

The

coatings

and

any

metals

containing

these

elements

can

give

off

toxic

fumes

if

welded.

Means

Warning!

Watch

Out!

There

are

possible

hazards

with

this

procedure!

The

possible

hazards

are

shown

in

the

adjoining

symbols.

.

OM-1586

Page

1

Arc

rays

from

the

welding

process

produce

intense

visible

and

invisible

(ultraviolet

and

infrared)

rays

that

can

burn

eyes

and

skin.

Sparks

fly

off

from

the

weld.



Wear

awelding

helmet

fitted

with

a

proper

shade

offilterto

protect

your

face

and

eyes

when

welding

or

watching

(see

ANSI

249.1

and

Z87.1

listed

in

Safety

Standards).



Wear

approved

safety

glasses

with

side

shields

under

your

helmet.



Use

protective

screens

or

barriers

to

protect

others

from

flash

and

glare;

warn

others

not

to

watch

the

arc.



Wear

protective

clothing

made

from

durable,

flame-resistant

material

(leather

and

wool)

and

foot

protection.

WELDING

can

caUsefireorexplosion.

Welding

on

closed

containers,

such

as

tanks,

drums,

or

pipes,

can

causethem

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

surethe

area

is

safe

before

doing

any

welding.



Protect

yourself

and

others

from

flying

sparks

and

hot

metal.



Do

not

weld

where

flying

sparks

can

strike

flammable

material.



Remove

all

flammables

within

35

ft

(10.7

m)

of

the

welding

arc.

If

this

is

not

possible,

tightly

cover

them

with

approved

covers.



Be

alert

that

welding

sparks

and

hot

materials

from

welding

can

easily

go

through

small

cracks

and

openings

to

adjacent

areas.



Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.



Be

aware

that

welding

on a

ceiling,

floor,

bulkhead,

or

partition

can

cause

fire

on

the

hidden

side.



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).



Connect

work

cable

to

the

work

as

close

to

the

welding

area

as

practical

to

prevent

welding

current

from

traveling

long,

possibly

unknown

paths

and

causing

electric

shock

and

fire

hazards.



Do

not

use

welder

to

thaw

frozen

pipes.



Remove

stick

electrode

from

holder

or

cut

off

welding

wire

at

contact

tip

when

not

in

use.



Wear

oil-free

protective

garments

such

as

leather

gloves,

heavy

shirt,

cuffless

trousers,

high

shoes,

and

a

cap.



Remove

any

combustibles,

such

as

a

butane

lighter

or

matches,

from

your

person

before

doing

any

welding.

FLYING

METAL

can

injure

eyes.



Welding,

chipping,

wire

brushing,

and

grinding

cause

sparks

and

flying

metal.

As

welds

cool,

they

can

throw

off

slag.



Wear

approved

safety

glasses

with

side

shields

even

under

your

welding

helmet.

BUILDUP

OF

GAS

can

injure

or

kill



Shut

off

shielding

gas

supply

when

not

in

use.



Always

ventilate

confined

spaces

or

use

approved

air-supplied

respirator.

HOT.

PARTS

can

cause

severe

burns.



Do

not

touch

hot

parts

bare

handed.



Allow

cooling

period

before

working

on

gun

or

torch.

MAGNETIC

FIELDS

can

affect

pacemakers.



Pacemaker

wearers

keep

away.



Wearers

should

consult

their

doctor

before

going

near

arc

welding,

gouging,

or

spot

welding

operations.

NOISE

can

damage

hearing.

Noise

from

some

processes

or

equipment

can

damage

hearing.



Wear

approved

ear

protection

if

noise

level

is

high.

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.



Protect

compressed

gas

cylinders

from

excessive

heat,

mechanical

shocks,

slag,

open

flames,

sparks,

and

arcs.



Install

cylinders

in

an

upright

position

by

securing

to

a

stationary

support

or

cylinder

rack

to

prevent

falling

or

tipping.



Keep

cylinders

away

from

any

welding

or

other

electrical

circuits.



Never

drape

a

welding

torch

over

a

gas

cylinder.



Never

allow

a

welding

electrode

to

touch

any

cylinder.



Never

weld

on

a

pressurized

cylinder

-

explosion

will

result.



Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

in

good

condition.



Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.



Keep

protective

cap

in

place

overvalve

except

when

cylinder

is

in

use

or

connected

for

use.



Read

and

follow

instructions

on

compressed

gas

cylinders,

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

Standards.

ARC

RAYS

can

burn

eyes

and

skin

CYLINDERS

can

explode

if

damaged.

.

OM-1586

Page

2

FIRE

OR

EXPLOSION

hazard.



Do

not

install

or

place

unit

on,

over,

or

near

combustible

surfaces.



Do

not

install

unit

near

flammables.



Do

not

overload

building

wiring

-

be

sure

power

supply

system

is

properly

sized,

rated,

and

protected

to

handle

this

unit.

FALLiNG

UNIT

can

cause

injury



Use

lifting

eye

to

lift

unit

only,

NOT

running

gear,

gas

cylinders,

or

any

other

accessories.



Use

equipment

of

adequate

capacity

to

lift

and

support

unit.



If

using

lift

forks

to

move

unit,

be

sure

forks

are

long

enough

to

extend

beyond

opposite

side

of

unit.

OVERUSE

can

cause

OVERHEATING



Allow

cooling

period;

follow

rated

duty

cycle.



Reduce

current

or

reduce

duty

cycle

before

starting

to

weld

again.



Do

not

block

or

filter

airflow

to

unit.

STATIC

(ESD)

can

damage

PC

boards



Put

on

grounded

wrist

strap

BEFORE

handling

boards

or

parts.



Use

proper

static-proof

bags

and

boxes

to

store,

move,

or

ship

PC

boards.

MOVING

PARTS

can

cause

injury



Keep

away

from

moving

parts.



Keep

away

from

pinch

points

such

as

drive

rolls.

WELDING

WIRE

can

cause

injury.



Do

not

press

gun

trigger

until

instructed

to

do

so.



Do

not

point

gun

toward

any

part

of

the

body,

other

people,

or

any

metal

when

threading

welding

wire.

1-4.

Principal

Safety

Standards

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.1,from

American

Welding

Society,

550

N.W.

LeJeune

Rd,

Miami

FL

33126

Safety

and

Health

Standards,

OSHA

29

CFR

1910,

from

Superinten

dent

of

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

Recommended

Safe

Practices

for

the

Preparation

for

Welding

and

Cutting

of

Containers

That

Have

Held

Hazardous

Substances,

American

Welding

Society

Standard

AWS

F4.1,

from

American

Welding

Society,

550

N.W.

LeJeune

Rd,

Miami,

FL

33126

National

Electncal

Code,

NFPA

Standard

70,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

MOVING

PARTS

can

cause

injury



Keep

away

from

moving

parts

such

as

fans.



Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

HF.

RADIATION

can

causeinterference.



High-frequency

(HF.)

can

interfere

with

radio

navigation,

safety

services,

computers,

and

communications

equipment.



Have

only

qualified

persons

familiar

with

electronic

equipment

perform

this

installation.



The

user

is

responsible

for

having

a

qualified

electrician

promptly

correct

any

interference

problem

resulting

from

the

installation.



If

notified

by

the

FCC

about

interference,

stop

using

the

equipment

at

once.



Have

the

installation

regularly

checked

and

maintained.



Keep

high-frequency

source

doors

and

panels

tightly

shut,

keep

spark

gaps

at

correct

setting,

and

use

grounding

and

shielding

to

minimize

the

possibility

of

interference.

ARC

WELDING

can

cause

interference



Electromagnetic

energy

can

interfere

with

sensitive

electronic

equipment

such

as

computers

and

computer-driven

equipment

such

as

robots.



Be

sure

all

equipment

in

the

welding

area

is

electromagnetically

compatible.



To

reduce

possible

interference,

keep

weld

cables

as

short

as

possible,

close

together,

and

down

low,

such

as

on

the

floor.



Locate

welding

operation

100

meters

from

any

sensitive

elec

tronic

equipment.



Be

sure

this

welding

machine

is

installed

and

grounded

according

to

this

manual.



If

interference

still

occurs,

the

user

must

take

extra

measures

such

as

moving

the

welding

machine,

using

shielded

cables,

using

line

filters,

or

shielding

the

work

area.

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

P-i,

from

Compressed

Gas

Association,

1235

Jefferson

Davis

Highway,

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

Boulevard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

Protection,

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.

1

-3~

Additional

Symbols

For

Installation,

Operation,

And

Maintenance

OM-1586

Page

3

1-5

EMF

Information

Considerations

About

Welding

And The

Effects

Of

Low

Frequency

Electric

And

Magnetic

Fields

Welding

current,

as

it

flows

through

welding

cables,

will

cause

electro

magnetic

fields.

There

has

been

and

still

is

some

concern

about

such

fields.

However,

after

examining

more

than

500

studies

spanning

17

years

of

research,

a

special

blue

ribbon

committee

of

the

National

Research

Council

concluded

that:

The

body

of

evidence,

in

the

committees

judgment,

has

not

demonstrated

that

exposure

to

power-

frequency

electric

and

magnetic

fields

is

a

human-health

hazard.

However,

studies

are

still

going

forth

and

evidence

continues

to

be

examined.

Until

the

final

conclusions

of

the

research

are

reached,

you

may

wish

to

minimize

your

exposure

to

electromagnetic

fields

when

welding

or

cutting.

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

your

body.

4.

Keep

welding

power

source

and

cables

as

far

away

from

opera

tor

as

practical.

5.

Connect

work

clamp

to

workpiece

as

close

to

the

weld

as

possible.

About

Pacemakers:

Pacemaker

wearers

consult

your

doctor

first,

If

cleared

by

your

doctor,

then

following

the

above

procedures

is

recommended.

OM-1586

Page

4

SECTION

1

-

CONSIGNES

DE

SECURITE

-

LIRE

AVANT

UTI

LISATION

Signification

des

symboles

Signifie

Mise

en

garde!

Soyez

vigilant!

Cette

procedure

prØsente

des

risques

de

danger!

Ceux-ci

sont

identifies

par

des

symboles

adjacents

aux

directives.

1-2.

DangersrØlatifs

au

soudage

a

Iarc

A

Les

symboles

prØsentØs

ci-aprŁs

sont

utilisØs

tout

au

long

du

present

manuel

pour

attirer

votre

attention

et

identifier

les

risques

de

danger.

Lorsque

vous

voyez

un

symbole,

soyez

vigilant

et

suivez

les

directives

mentionnØes

afin

dØviter

tout

danger.

Les

consignes

de

sØcuritØ

prØsentØes

ci-aprŁs

ne

font

que

rØsumer

linformation

contenue

dans

les

normes

de

sØcuritØ

ØnumØrØes

a

Ia

section

1-4

Veuillez

lire

et

respecter

toutes

ces

normes

de

sØcuritØ.

A

Linstallation,

lutilisation,

lentretien

et

les

reparations

ne

dol

vent

Łtre

confiØs

qu

des

personnes

qualifiØes.

A

Au

coursde

lutilisation,

tenirtoute

personne

a

lØcartet

plus

par

ticuliŁrement

les

enfants.

UN

CHOC

ELECTRIQUE

peut

tuer

Un

simple

contact

avec

des

piŁces

Ølectriques

peut

provoquer

une

electrocution

ou

des

blessures

graves.

LØlectrode

et

le

circuit

de

soudage

sont

sous

tension

des

que

lappareil

est

sur

ON.

Le

circuit

dentrŁe

et

les

circuits

internes

de

lappareil

sont

egalement

sous

tension

a

ce

moment-l.

En

soudage

semi-automatique

ou

automatique,

le

f

ii,

le

dØvidoir,

le

logement

des

galets

dentrainement

et

es

piŁces

mØtalliques

en

contact

avec

le

fil

de

soudage

sont

sous

tension.

Des

matŁriels

mal

installŁs

ou

mal

mis

a

Ia

terre

prŁsentent

un

danger.



Ne

jamais

toucher

es

piŁces

Łlectriques

sous

tension.



Porter

des

gants

et

des

vŒtements

de

protection

secs ne

comportant

pas

de

trous.



Sisoler

de

Ia

piŁce

et

de

Ia

terre

au

moyen

de

tapis

ou

dautres

moyens

isolants

suffisamment

grands

pour

empŁcher

le

contact

phy

sique

Łventuel

avec

Ia

piŁce

ou

a

terre.



Ne

pas

se

servir

de

source

Łlectrique

courant

electrique

dans

les

zones

humides,

dans

les

endroits

confines

ou

l

ou on

risque

de

tomber.



Se

servir

dune

source

electnque

courant

Łlectrique

UNIQUEMENT

Si

le

procŁdØ

de

soudage

le

demande.



Si

Iutilisation

dune

source

Łlectrique

courant

Łlectrique

savŁre

nØces

saire,

se

servir

de

Ia

fonction

de

tØlØcommande

Si

Iappareil

en

est

ŁquipØ.



Couperlalimentation

ou

arrŒter

le

moteuravantde

procŁder

linstal

lation,

a

Ia

reparation

ou

a

lentretien

de

lappareil.

DØverrouiller

Ialimentation

selon

Ia

norme

OSHA

29

CFR

191

0.147

(voir

normes

de

sØcuritŁ).



Installeretmettrelaterre

correctement

cet

appareil

conformŁment

son

manuel

dutilisation

et

aux

codes

nationaux,

provinciaux

et

municipaux.



Toujours

verifier

Ia

terre

du

cordon

datimentation

-

Verifier

et

sassu

rer

que

le

fll

de

terre

du

cordon

dalimentation

est

bien

raccordŁ

a

Ia

borne

deterre

du

sectionneur

ou

que

Ia

fiche

du

cordon

est

raccordØe

a

une

prise

correctement

mise

a

Ia

terre.



En

effectuant

les

raccordements

dentrØe

fixer

dabord

le

conducteur

de

mise

a

Ia

terre

appropriŁ

et

contre-vØrifier

les

connexions.



Verifier

frequemment

le

cordon

dalimentation

pour

voir

siI

nest

pas

endommagŁ

ou

dŁnudŁ

-

remplacer

le

cordon

immŁdiatement

sil

est

endommage

-

un

cable

dŁnudØ

peut

provoquer

une

electrocution.



Mettre

lappareil

hors

tension

quand

on

ne

Iutilise

pas.



Ne

pas

utiliser

des

cables

uses,

endommages,

de

grosseur

insuffi

sante

ou

mal

ŁpissØs.



Ne

pas

enrouler

les

cables

autour

du

corps.



Si

Ia

piŁce

soudØedoitŒtre

mise

a

laterre,

lefairedirectementavec

un

cable

distinct

-

ne

pas

utiliser

le

connecteur

de

piŁce

ou

le

cable

de

retour.

scm

ndfre

5/97

Ce

groupe

de

symboles

signifie

Mise

en

garde

!

Soyez

vigilant

lIy

a

des

risques

de

danger

relies

aux

CHOCS

ELECTRIQUES,

aux

PIECES

EN

MOUVEMENTetaux

PIECESCHAUDES.

Reportez-vousauxsymboles

etauxdirectivesci-dessous

afin

de

connaitre

les

mesures

a

prendre

pour

Øviter

tout

danger.



Ne

pas

toucher

lŁlectrode

quand

on

est

en

contact

avec

Ia

piŁce,

Ia

terre

ou

une

electrode

provenant

dune

autre

machine.



Nutiliser

quun

materiel

en

bon

Łtat.

RØparer

ou

remplacer

sur-le

champ

es

piŁcesendommagŁes.

Entretenir

lappareilconformØment

a

ce

manuel.



Porter

un

harnais

de

sŁcuritŁ

quand

on

travaille

en

hauteur.



Maintenir

solidement

en

place

tous

les

panneaux

et

capots.



Fixer

Ie

cable

de

retour

de

facon

a

obtenir

un

bon

contact

mŁtal-mØtal

avec

Ia

piŁce

a

souderou

a

table

detravail,

le

plus

prŁs

possible

de

Ia

soudure.



solar

Ia

pince

de

masse

quand

pas

mis

a

Ia

piŁce

pour

Øviter

le

contact

avec

tout

objet

metallique.

ily

a

DU

COU

RANT

CONTINU

IMPORTANT

dans

les

convertisseurs

aprŁs

Ia

suppression

de

Ialimenta

tion

Ølectrique.



ArrŒter

Ies

convertisseurs,

dŁbrancher

le

courant

electrique,

et

dŁ

charger

les

condensateurs

dalimentation

selon

Ies

instructions

indiquŁes

dons

Ia

partie

entretien

avant

de

toucher

Ies

piŁces.

LES

FUMEES

ET

LES

GAZ

peuvent

Œtredangereux.

Le

soudage

genere

des

fumŁes

et

des

gaz.

Leur

W

inhalation

peut

Œtre

dangereux

pour

votre

sante.

_____________



Eloigner

votre

tŒte

des

fumŁes.

Ne

pas

respirer

Ies

fumŁes.



A

IintØrieur,

ventiler

Ia

zone

et/ou

utiliser

un

Łchappement

au

ni

veau

de

Iarc

pour

IØvacuation

des

fumŁes

et

des

gaz

de

soudage.



Si

Ia

ventilation

est

insuffisante,

utiliser

un

respirateur

a

alimenta

tion

dair

homologuŁ.



Ure

Iesspecificationsde

sŁcuritØ

des

matØriaux

(MSDSs)

et

les

ins

tructions

du

fabricant

concernant

Ies

mŁtaux,

les

consommables,

les

revØtements,

les

nettoyants

et

les

dØgraisseurs.



Travailler

dans

un

espace

fermØ

seulement

siI

est

bien

ventilØ

ou

en

portant

un

respirateur

a

alimentation

dair.

Demander

toujours

a

un

surveillant

dment

formØ

de

se

tenir

a

proximitØ.

Des

fumØes

et

des

gaz

de

soudage

peuvent

dØplacer

lair

et

abaisser

le

niveau

doxygene

provoquant

des

blessures

ou

des

accidents

mortels.

Sassurer

que

lair

de

respiration

ne

prØsente

aucun

danger.



Ne

pas

souder

dansdes

endroits

situØs

a

proximitØ

dopØrations

de

degraissage,

de

nettoyage

ou

de

pulvØnsation.

La

chaleur

et

les

rayons

de

Iarc

peuvent

rØagir

en

presence

de

vapeurs

et

former

des

gaz

hautement

toxiques

et

irritants.



Ne

pas

souder

des

mØtaux

munis

dun

revØtement,

tels

que

lacier

galvanise,

plaque

en

p10mb

ou au

cadmium

a

moms

que

le

revŒte

ment

nait

Łte

enlevØ

dans

Ia

zone

de

soudure,

que

lendroit

soit

bien

ventilØ,

et

Si

nØcessaire,

en

portant

un

respirateur

a

alimenta

tion

dair.

Les

revØtements

et

tous

les

mØtaux

renfermant

ces

Ł!Ø~

ments

peuvent

dØgager

des

fumØes

toxiques

en

cas

de

soudage.

~1.

A

Identifie

un

message

de

sØcuritØ

particulier.

lET

Signifie

NOTA

nest

pas

relatif

a

a

sØcuritØ.

OM-1586

Page

5

LES

RAVONS

DE

LARCpeuventpro-.

voquer

des

bri~Iures

dans

les

yeux

et

sur

Ia

P~U

1..

Le

rayonnement

de

arc

du

procØdØ

de

soudage

gØnŁre

des

rayons

visibles

et

invisibles

intenses

(ultraviolets

et

infrarouges)

susceptibles

de

provoquer

des

brfilures

dans

les

yeux

et

sur

Ia

peau.

Des

Øtincettes

sont

projetØes

pendant

le

soudage.



Porter

un

casque

de

soudage

muni

dun

Øcran

de

filtre

appropriØ

pour

protØger

votre

visage

et

vos

yeux

pendant

te

soudage

ou

pour

regar

der

(voir

ANSI

Z49.

1

et

Z87.

1

ØnumØrØ

dans

les

normes

de

sØcuritØ).



Porter

des

protections

approuvØs

pour

les

oreilles

si

le

niveau

sondre

est

trop

ØlevØ.



Utiliser

des

Øcrans

ou

des

barriŁres

pour

protØger

des

tiers

de

IØclair

et

de

lØblouissement;

demander

aux

autres

personnes

de

ne

pas

re

garder

larc.



Porter

des

vŒtements

de

protection

constituØ

dans

une

matiŁre

dura

ble,

resistant

au

feu

(cuir

ou

lame)

et

une

protection

des

pieds.

LE

SOUDAGE

peut

provbquer

Un

I

incendie

ou

une

explosion.

Le

souda~e

effectuØ

sur

des

conteneurs

fermØs

tels

que

des

reservoirs,

tambours

ou

des

conduites

peut

provo9uerleurØclatement.

DesØtincellespeuventŒtre

projetees

de

larc

de

soudure.

La

projection

dØtincel

les,

des

piŁces

chaudes

et

des

Øquipements

chauds

peut

provoquer

des

incendies

et

des

brlures.

Le

contact

accidentel

de

IŁlectrode

avec

des

objets

mØtalliques

peut

provoquer

des

Øtincelles,

une

explosion,

un

surchauffement

ou

un

incendie.

Avant

de

commencer

le

soudage,

verifier

et

sassurer

que

lendroit

ne

prØsente

pas

de

danger.



Se

protØger

et

dautres

personnes

de

Ia

projection

dØtincelles

et

de

metal

chaud.



Ne

pas

souder

dans

un

endroit

l

o

des

Øtincelles

peuvent

tomber

sur

des

substances

inflammables.



DŁplacertoutes

les

substances

inflammables

a

une

distance

del

0,7

m

de

larc

de

soudage.

En

cas

dimpossibilitØ

es

recouvrirsoigneuse

ment

avec

des

protections

homologues.



Des

Łtincelles

et

des

matØriaux

chauds

du

soudage

peuvent

facile

ment

passer

dans

dautres

zones

en

traversant

de

petites

fissures

et

des

ouvertures.



SurveillertoutdØctenchementdincendieettenirunextincteuraproxi

mite.



Le

soudage

effectuŁ

sur

un

plafond,

plancher,

paroi

Cu

separation

peut

dØclencher

un

incendie

de

lautre

ctØ.



Ne

pas

effectuer

le

soudage

sur

des

conteneurs

fermØs

tels

que

des

reservoirs,

tambours,

ou

conduites,

a

moms

quils

naient

ØtØ

prØpa

rØs

correctement

conformØment

a

AWS

F4.1

(voir

es

normes

de

sØcurite).



Brancher

le

cable

sur

Ia

piŁce

le

plus

prŁs

possible

de

Ia

zone

de

sou

dage

pour

Øviter

le

transport

du

courant

sur

une

longue

distance

par

des

chemins

inconnus

Øventuels

en

provoquant

des

risques

dØlec

trocution

et

dincendie.



Ne

pas

utiliser

le

poste

de

soudage

pour

dØgeler

des

conduites

ge

lees.



En

cas

de

non

utilisation,

enlever

Ia

baguette

dØlectrode

du

porte

electrode

ou

couper

le

fil

a

Ia

pointe

de

contact.



Porter

des

vŒtements

de

protection

dØpourvus

dhuile

tels

que

des

gants

en

cuir,

une

chemise

en

matØriau

lourd,

des

pantalons

sans

re

vers,

des

chaussures

hautes

et

un

couvre

chef.



Avant

de

souder,

retirer

toute

substance

combustible

de

vos

poches

telles

quun

allumeur

au

butane

ou

des

allumettes.

DES

PARTJCULES

VOLANTES

~

peuvent

blesser

les

yeux~.:



Le

soudage,

lŁcaillement,

le

passage

de

Ia

piŁce

a

Ia

brosse

en

fil

de

fer,

et

le

meulage

gŁnerent

desØtincellesetdes

particules

mØtalliquesvolan

tes.

Pendant

Ia

pØriode

de

refroidissement

des

soudures,

elles

risquent

de

projeter

du

laitier.



Porter

des

lunettes

de

sØcuritŁ

avec

Øcrans

latØraux

ou

un

Øcran

facial.

LES

ACCUMU

ATIONSDE

GAZ

ris~

quent

de

provoquer

des

blessures

o

mŒme

Ia

mart.



Fermer

lalimentation

du

gaz

protecteur

en

cas

de

non

utilisation.



Veiller

toujours

a

bien

aØrer

las

espaces

confines

ou

se

servir

dun

respi

rateur

dadduction

dair

homotoguŁ.

DES

PI¨CES

CHAUDES

peuvent

pro

voquer

des:brlures

graves.



Ne

pas

toucher

des

parties

chaudes

a

mains

nues



PrŁvoir

une

pŁriode

de

refroidissement

avant

dutiliser

le

pistolet

ou

Ia

torche.

LES

CHAMPS

MAGNETIQUES

peuvent

affecter

les

stimulateurs

cardiaques.



Porteurs

de

stimutateur

cardiaque,

restez

a

distance.



Les

porteurs

dun

stimutateur

cardiaque

doivent

dabord

consulter

leur

mØdecin

avant

de

sapprocher

des

operations

de

soudage

a

larc,

de

gougeage

ou

de

soudage

par

points.

LE

BRUIT

peut

affecter

louIe.

Le

bruit

des

processus

et

des

Øquipements

peut

affecter

IouIe.



Porter

des

protections

approuves

pour

les

oreilles

si

le

niveau

sondre

est

trop

ØlevØ.

Si

des

BOIJTEILLES

sont

endomma

gØes,

elles

purront

exploser.

Des

bouteilles

de

gaz

protecteur

contiennent

du

gaz

sous

haute

pression.

Si

une

bouteille

est

endomma

gee,

ella

peutexploser.

Du

faitque

les

bouteillesde

gaz

font

normalement

partie

du

procØdØ

de

soudage,

les

manipuler

avec

precaution.



ProtØger

les

bouteilles

de

gaz

comprimØ

dune

chaleur

excessive,

des

chocs

mecaniques,

du

laitier,

des

flammes

ouvertes,

des

Øtin

celles

et

des

arcs.



Placer

les

bouteilles

debout

en

les

fixant

dans

un

support

station

naire

ou

dans

un

porte-bouteilles

pour

las

empŒcher

de

tomber

ou

de

se

renverser.



Tenir

las

bouteilles

ØtoignØes

des

circuits

de

soudage

cu

autres

cir

cuits

Ølectriques.



Ne

jamais

placer

une

torche

de

soudage

sur

une

bouteille

a

ga.z.



Une

electrode

de

soudage

ne

dolt

jamais

entrer

en

contact

avec

une

bouteille.



Ne

jamais

souder

une

bouteille

pressurisØe

-

risque

dexplosion.



Utiliser

seulement

des

bouteilles

de

gaz

protecteur,

rØgulateurs,

tuyaux

et

raccords

convenables

pour

cette

application

specifique;

les

maintenir

ainsi

que

les

ØlŁments

associØs

en

bon

Łtat.



Ne

pas

tenir

Ia

tŒte

en

face

de

Ia

sortie

en

ouvrant

Ia

soupape

de

Ia

bouteille.



Maintenir

le

chapeau

de

protection

sur

Ia

soupape,

sauf

en cas

dutilisation

ou

de

branchement

de

Ia

bouteille.



Ure

et

suivre

les

instructions

concernant

las

bouteilles

de

gaz

corn

prime,

les

Øquipements

associØs

et

les

publications

P-l

CGA

Ønu

mØrØes

dans

Ies

normes

de

sØcuritØ.

OM-1586

Page

6

LA

CHUTE

DE

LAPPAREIL

peut

blesser.



Utiliser

lanneau

de

levage

uniquement

pour

sou

lever

lappareil,

NON

PAS

les

chariot,

les

bouteil

les

de

gaz

ou

tout

autre

accessoire.



Utiliser

un

engin

dune

capacitØ

appropriØe

pour

soulever

lappareil.



En

utilisant

des

fourches

de

levage

pour

dØplacer

lunitØ,

sassurer

que

lestourches

sont

suflisamment

tongues

pour

dØpasser

du

ctØ

oppose

de

lappareil.

LEMPLOI

EXCESSIF

peut

SURCHAUFFER

LEQUIPEMENT.



PrØvoir

une

pØriode

de

ref

roidissement,

respec

ter

le

cycle

opØratoire

nominal.



RØduire

le

courantou

le

cycle

opØratoire

avantde

recommancer

le

soudage.



Ne

pas

obstruer

les

passages

dair

du

poste.

LES

CHARGES

ELECTROSTATIQUES

peuvent

endommager

tes

circuits

im

primes.



Etablir

Ia

connexion

avec

Ia

barrette

de

terre

avant

de

manipuler

des

cartes

Cu

des

piŁces.



Utiliser

des

pochettes

et

des

boItes

antistatiques

pour

stocker,

dØplacer

ou

expØdier

des

cartes

de

circuits

imprimes.

DES

ORGANES

MOBILES

peuvent

provoquer

des

blessures.



Ne

pas

sapprocher

des

organes

mobiles.



Ne

pas

sapprocher

des

points

de

coincement

tels

que

des

rouleaux

de

commande.

LES

FILS

DE

SOUDAGE

peuvent

pro

voquer

des

blessures.



Ne

pas

appuyer

sur

Ia

gachette

avant

den

avoir

recu

linstruction.



Me

pas

diriger

le

pistolet

vers

soi,

dautres

per

sonnes

ou

toute

piŁce

mØcanique

en

engageant

le

fil

de

soudage.

DES

ORGANES

MOBILES

peuvent

provoquer

des

blessures.



Rester

a

lØcart

des

organes

mobiles

comme

le

ventilateur.



Maintenir

fermØs

et

fixement

en

place

les

portes,

panneaux,

recouvrements

et

dispositifs

de

protection.

LE

RAYONNEMENT

HAUTE

FRE

QUENCE

(H.F.)

risque

de

provoquer

des

interferences.



Le

rayonnement

haute

frequence

peut

provoquer

des

interferences

avec

les

Øquipements

de

ra

dio-navigation

etde

communication,

les

services

de

sØcuritØ

et

les

ordinateurs.



Demander

seulement

a

des

personnes

qualifiØes

familiarisØes

avec

des

Øquipements

Ølectroniques

de

faire

fonctionner

linstalla

tion.



Lutilisateur

est

tenu

de

faire

corriger

rapidement

par

un

Ølectricien

qualifiŁ

es

interferences

resultant

de

linstallation.



Si

le

FCC

signale

des

interferences,

arrŒter

immØdiatement

lappa

reil.



Effectuer

reguliŁrement

le

contrle

et

lentretien

de

linstallation.



Maintenir

soigneusement

fermØs

les

portes

et

les

panneaux

des

sources

de

haute

frequence,

maintenir

les

Øclateurs

a

une

distance

correcte

et

utiliser

une

terre

et

un

blindage

pour

rØduire

les

inter

fØrences

Øventuelles.

LE

SOUDAGE

A

LARC

risque

de

provoquer

des

interferences.



LØnergie

ØlectromagnØtique

risque

de

provoquer

des

interferences

pour

lØquipement

Ølectronique

sensible

tel

que

es

ordinateurs

et

lØquipement

commandØ

par

ordinateur

tel

que

les

robots.



Veiller

ace

que

tout

lØquipement

de

Ia

zone

de

soudage

soit

com

patible

ØlectromagnØtiquement.



Pour

rŁduire

Ia

possibilitØ

dinterfØrence,

maintenir

les

cables

de

soudage

aussi

courts

que

possible,

les

grouper,

et

les

poser

aussi

bas

que

possible

(ex.

par

terre).



Veiller

a

souder

a

une

distance

de

100

metres

de

tout

equipement

Łlectronique

sensible.



Veitler

a

ce

que

ce

poste

de

soudage

soit

pose

et

mis

a

Ia

terre

conformØment

a

ce

mode

demploi.



En

cas

dinterfØrences

aprŁs

avoir

pris

les

mesures

prØcØdentes,

ii

incombe

a

lutilisateur

de

prendre

des

mesures

supplØmentaires

telles

que

le

dØplacement

du

poste,

lutilisation

de

cØbles

blindØs,

lutilisation

de

filtres

de

ligne

ou

Ia

pose

de

protecteurs

dans

Ia

zone

de

travail.

LES

CHAMPS

MAGNETIQUES

peuvent

affecter

les

stimulateurs

cardiaques.



Porteurs

de

stimulateur

cardiaque,

restez

a

dis

tance.



Les

porteurs

dun

stimulateur

cardiaque

doivent

dabord

consulter

leur

mØdecin

avant

de

sappro

cher

des

operations

de

soudage

a

larc,

de

gou

geage

Cu

de

soudage

par

points.

1-3.

Dangers

supplØmentairesen

relation

avec

linstatlation,

le

fonctionnement



et

Ia

maintenance

~

Risque

DINCENDIE

OU

~

DEXPLOSION.

A



Ne

pas

placer

lappareil

sur,

au-dessus

Cu

a

proximitØ

de

surfaces

infllammables.



Ne

pas

installer

lappareil

a

proximitØ

de

produits

inflammables



Ne

pas

surcharger

linstallation

Ølectrique

-

sassurer

que

lalimen

tation

est

correctement

dimensionnØ

et

protØgØ

avant

de

mettre

lappareil

en

service.

OM-1586

Page

7

1-4

Principales

normes

de

securitØ

Safetyin

Welding

and

Cutting,

norme

ANSI

Z49.

1,

de

lAmerican

Wel

ding

Society,

550

N.W.

Lejeune

Rd,

Miami

FL

33126

Safetyand

Health

Sandards,

OSHA

29

CFR

1910,

du

Superintendent

of

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

Recommended

Safe

Practice

for

the

Preparation

for

Welding

and

Cut

ting

of

Containers

That

Have

Held

Hazardous

Substances,

norme

AWS

F4.

1,

de

lAmerican

Welding

Society,

550

N.W.

Lejeune

Rd,

Mia

mi

FL

33126

National

Electrical

Code,

NFPA

Standard

70,

de

Ia

National

Fire

Pro

tection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

DonnØes

sur

le

soudage

Ølectrique

et

sur

les

effets,

pour

lorganisme,

des

champs

magnØtiques

basse

frØquence

Le

cournt

de

soudage,

pendant

son

passage

dans

les

cables

de

sou

dage,

causera

des

champs

Ølectromagnetiques.

II

y

a

eu

et

il

y

a

encore

un

certain

souci

a

propos

de

tels

champs.

Cependant,

aprŁs

avoir

examine

plus

de

500

etudes

qui

ont

ØtØ

faites

pendant

une

pe

node

de

recherche

de

17

ans,

un

comitØ

special

ruban

bleu

du

National

Research

Council

a

conclu:

Laccumulation

de

preuves,

sui

vant

le

jugement

du

comitØ,

na

pas

dØmontrØ

que

lexposition

aux

champs

magnØtiques

et

champs

Ølectriques

a

haute

frequence

reprØ

sente

un

risque

a

Ia

sante

humaine.

Toutefois,

des

etudes

sont

toujours

en

cours

et

les

preuves

continuent

a

Œtre

examinØes.

En

at

tendant

que

les

conclusions

finales

de

Ia

recherche

soient

Øtablies,

ii

vous

serait

souhaitable

de

rØduire

votre

exposition

aux

champs

Ølec

tromagnØtiques

pendant

le

soudage

ou

le

coupage.

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

P-i,

de

Ia

Compressed

Gas

Association,

1235

Jefferson

Davis

High

way,

Suite

501,

Arlington,

VA

22202.

RŁgles

de

sØcuritØ

en

soudage,

coupage

et

procØdds

connexes,

nor-

me

CSA

Wi

17.2,

de

lAssociation

canadienne

de

normalisation,

vente

de

normes,

178 Rexdale

Boulevard,

Rexdale

(Ontario)

Canada

M9W

1R3.

Safe

Practices

ForOccupationAndEducationalEyeAnd

Face

Protec

tion,

norme

ANSI

Z87.i,

de

lAmerican

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

Cutting

and

Welding

Processes,

norme

NFPA

51

B,

de

Ia

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

Afin

de

rØduire

es

champs

ØlectromagnØtiques

dans

lenvironnement

de

travail,

respecter

les

consignes

suivantes

1

Garder

les

cables

ensembles

en

les

torsadant

ou

en

les

attachant

avec

du

ruban

adhØsif.

2

Mettre

tous

les

cables

du

ctØ

oppose

de

lopØrateur.

3

Ne

pas

courber

pas

et

ne

pas

entourer

pas

les

cables

autour

de

votre

corps.

4

Garder

le

poste

de

soudage

et

les

cables

le

plus

loin

possible

de

vous.

5

Relier

Ia

pince

de

masse

le

plus

prŁs

possible

de

Ia

zone

de

soudure.

Consignes

relatives

aux

stimulateurs

cardiaques

Les

personnes

qui

portent

un

stimulateur

cardiaque

doivent

avant

tout

consulter

leur

docteur.

Si

vous

Œtes

dØclarØ

apte

par

votre

docteur,

il

est

alors

recommandØ

de

respecter

les

consignes

ci-dessus.

.

1-5.

Information

sur

les

champs

ØlectromagnØtiqes

OM-1586

Page

8

2-1.

Specifications

SECTION

2-

INTRODUCTION

Type

of

Input

Power.

Welding

Power

Source

Type

Wire

Feed

Speed

Range

Wire Diameter

Range

Welding

Circuit

Rating

Weight

24

Volts

AC

Single-Phase

10

Amperes

50/60

Hertz

Constant

Voltage

(CV)

DC

For

GMAW

Or

Constant

Voltage

(CV)

/

Constant

Current

(CC)

DC

For

GMAW-P

All

Need

14-Pin

And

Contactor

Control

Standard:

50

To

780

1pm

(1.3

To

19.8

mpm)

Optional

High

Speed:

92

To

1435

ipm

(2.3

To

36.5

mpm)

.023

To

1/8

in

(0.6

To

3.2

mm)

Max

Spool

Weight:

60

lb

(27

kg)

100

Volts,

750

Amperes,

100%

Duty

Cycle

12

ft

(3.7

m):

160

lb

(73

kg)

16

ft

(4.9

m):

210

lb

(95

kg)

12

ft

(3.7

m)

Boom

16

ft

(4.9

m)

Boom

Maximum

Height

With

4

ft

(1.2

m)

Post

17

ft

(5.2

m)

21

ft

(6.4

m)

Vertical

Lift

Of

Boom

Horizontal

to

60

Above

Horizontal

to

60

Above

Horizontal

SECTION

3-

INSTALLATION

3-1.

Installing

Swivel

Into

Pipe

Post

2

1

Swingpak

Base

or

CBC

Cart

5

2

Pipe

Post

With

Base

3

Steel

Bolt

4

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

3

A

Do

not

remove

until

instructed

to.

ST-152

268

Tools

Needed:

~

OM-1586

Page

9

6

3-4.

Adjusting

Control

Tilt

Bracket

.

4

1

Swivel

Plates

2

Yoke

Remove

hardware

from

swivel

plates

and

yoke.

5

3

Boom

Set

boom

into

swivel

as

shown.

4

Yoke

Install

through

yoke.

Install

cot

ter

and

spread

ends.

2

Tools

Needed:

~

3/8,

3/4

in

5

Bolt

Install

bolt,

tighten

hardware,

and

back

bolt

off

one

half

turn.

6

Locking

Knob

Install

locking

knob

but

do

not

tighten.

7

Reel

Support

Install

reel

support.

3-3.

Installing

Wire

Guide

Extension

ST-142

596-C

Tools

Needed:

cIII~J~==iJ

3/8

in

1

Wire

Guide

Fitting

2

Bolt

3

Monocoil

Liner

4

Wire

Guide

Extension

Tighten

bolt

to

secure

liner

in

wire

guide

fitting.

Do

not

overtighten

bolt

and

crush

liner.

ST-i

52

323

1

Tilt

Bracket

2

Rear

Pivot

Screw

3

Front

Screw

Loosen

rear

pivot

screw.

Remove

front

screw.

Pivot

control

down

ward

to

desired

viewing

angle.

Re

place

and

tighten

front

screw.

Tighten

pivot

screw.

5T-801

279

3

OM-1

586

Page

10

3-5.

Equipment

Connection

Diagram

1

300/400

Ampere

Model

CC/CV

Inverter

Welding

Power

Source

U?

Use

settings

shown

for

both

pulse

MIG

welding

and

MIG

welding.

2

450

Ampere

Model

DC

Inverter

Welding

Power

Source

3

14-Pin

Cord

4

Positive

(+)

Weld

Cable

5

Negative

(-)

Weld

Cable

Be

sure

weld

cables

are

sized

properly

for

peak

amperage

if

pulse

welding

(see

welding

power

source

Owners

Manual).

6

Workpiece

7

Voltage

Sensing

Lead

(Optional

Use)

8

Wire

Feeder

For

connections

see

Section

3-7.

9

Gun

Be

sure

gun

is

rated

for

peak

am

perage

if

pulse

welding.

Install

ac

cording

to

its

Owners

Manual.

10

Gas

Hose

From

Boom

11

Shielding

Gas

Supply

ST-aol

805/Ref

ST.175086/Ref

ST.180311-B

.

ri~ł~

~

0

PANEL

0

REMOTE

INDUCTANCE/DIG

V/A

CONTROL

~

6

10

OM-1

586

Page

11

3-6.

Connecting

Weld

Cables

And

Gas

Hoses

The

weld

cable

and

shielding

gas

hose

extend

10

ft

(3

m)

from

the

boom.

Route

weld

cable

from

boom

through

reed

relay,

if

applicable.

If

the

welding

power

source

or

gas

supply

are

further

from

the

boom,

extend

cable

or

hose

as

follows:

1

Weld

Cable

2

Insulated

Sleeving

Bolt

together

weld

cables

from

welding

power

source

and

boom.

Use

electrical

tape

and

insulated

sleeving

to

cover

connection.

3

Shielding

Gas

Hose

Connect

hose

to

gas

supply

or

ex

tension

hose.

The

hose

from

the

boom

has

5/8-18

right-hand

threads.

Tools

Needed:

~

5/8

in

Ref.

ST-aol

8051

Ref.

ST-152

800-A

.

OM-1586

Page

12

3-7.

Control

Box

Connections

3-8.

14-Pin

Plug

Information

*The

remaining

pins

are

not

used.

REMOTE

14

~jfl*

Information

A

24

volts

ac

with

respect

to

socket

G.

B

Contact

closure

to

A

completes

24

volts

ac

contactor

control

circuit.

G

Circuit

common

for

24

volts

AC

circuit.

C

+10

volts

dc

output

to

remote

control

with

respect

to

socket

D.

D

Remote

control

circuit

common.

E

0

to

+10

volts

dc

input

command

signal

from

remote

control

with

respect

to

socket

D.

H

Voltage

feedback;

0

to

+10

volts

dc,

1

volt

per

10

arc

volts.

F

Current

feedback;

Oto

+10

volts

dc,

1

volt

per

100

amperes.

M

CC/CV

Select

(+24

V

=

CV)

N

Inductance

(0-10

V)

1

Optional

Reed

Relay

Connection

2

Wire

Feed

Motor

And

Gas

Valve

Control

Receptacle

3

Wire

Feed

Motor

And

Gas

Valve

Control

Plug

From

Boom

4

14-Pin

Cord

5

Volt

Sense

Lead

(Optional

Use)

6

Gun

Trigger

Plug

From

Boom

=

4

ST-157

433-B

/

Ref.

ST-157

434

OM-1

586

Page

13

3-9.

Motor

Start

Control

3

Loosen

jam

nut

and

turn

threaded

rod

until

boom

baJances.

Tighten

jam

nut.

Be

sure

several

full

threads

are

through

yoke

to

pre

vent

boom

falling.

4

Yoke

.

To

change

wire

feed

starting

speed

proceed

as

follows:

Turn

Off

unit

and

welding

power

source.

Remove

wrapper.

1

Front

Panel

Remove

screw

from

upper

left

cor

ner,

and

open

hinged

front

panel.

2

Motor

Board

PCi

3

Motor

Start

Control

Potentiometer

R70

Rotate

potentiometer

clockwise

to

increase

time

it

takes

the

motor

to

ramp

up

to

speed.

Remove

protec

tive

white

rubber

cap

before

making

adjustment.

Adjust

poten

tiometer

R70

using

a

small

non-

conductive

screwdriver.

Close

and

secure

front

panel,

and

reinstall

wrapper.

Tools

Needed:

Non-Conductive

c:I:::::z:J=::::=fLJ

1/4

in

ST-i

57480-A

/

Ref.

SA-183

121-B

1

Locking

Knob

Tighten

knob

to

prevent

boom

movement.

Loosen

knob

to

allow

boom

movement.

Change

knob

position

to

limit

upward

movement.

Pull

boom

down

slightly

and

re

move

safety

collar.

Boom

should

balance

in

any

position

from

hori

zontal

to

60

degrees

above

hori

zontal.

If

necessary,

adjust

boom

as

follows:

2

Threaded

Rod

3

Jam

Nut

2

Rod

Increasing

Spring

Pressure

For

A

Heavy

Gun

Tools

Needed:

~-~-~r

1-1/8

in

E

4

Retain

safety

collar

for

use

in

disas

sembling

or

moving

boom.

2

Decreasing

Spring

Pressure

For

A

Ught

Gun

Ref.

ST-152

380-A

OM-i

586

Page

14

3-11.

Gun

Recommendation

Table

Process

Gun

GMAW-P

-

Hard

or

Cored

Wires

GW-500

Or

GW-600

GMAW

-

Hard

or

Cored

Wires

M25,

M40,

Or

GA-50C

FCAW

-

Self-Shielding

Wires

GA-4OGL

Or

GA-5OGL

3-12.

Wire

Type,

Size,

And

Feed

Speed

Capability

Table

Motor

Speed

Wire

Type

Wire

Size

Feed

Speed

Capability

Standard

All

.023

To

5/64

in

(0.6

To

2

mm)

50

To

780

ipm

(1.3

To

19.8

mpm)

Standard

All

3/32

To

7/64

in

(2.4

To

2.8

mm)

50

To

700

ipm

(1.3

To

17.8

mpm)

Standard

All

1/8

in

(3.2

mm)

50

To

300

pm

(1.3

To

7.6

mpm)

Optional

High

All

.023

To

5/64

in

(0.6102

mm)

92

To

1440

ipm

(2.3

To

35.6

mpm)

OM-1

586

Page

15

3-13.

Installing

And

Threading

Welding

Wire

-~

Tools

Needed:

~~

3/16,5/641n

~=z~

15/16,3/8

in

4-

g?

Be

sure

that

outlet

cable

has

proper

size

liner

for

the

welding

wire

size.

When

installing

gun,

position

liner

extending

from

outlet

wire

guide

as

close

as

possible

to

drive

rolls

without

touching.

Install

gun.

Lay

gun

cable

out

straight.

Cut

off

end

of wire.

Push

wire

through

guides

up

to

drive

rolls;

continue

to

hold

wire.

Press

Jog

button

to

feed

wire

out

gun.

To

adjust

drive

roll

pressure,

hold

nozzle

about

2

in

(51

mm)

from

nonconductive

surface

and

press

gun

trigger

to

feed

wire

against

surface.

Tighten

knob

so

wire

does

not

slip.

Do

not

overtighten.

If

contact

tip

is

completely

blocked,

wire

should

slip

at

the

feeder

(see

pressure

adjustment

above).

Cut

wire

off.

Close

cover.

Repeat

for

other

side.

5T-152

648.A/

Ref.

5T-157

432/

Ref.

51-137

391-A/

ST-142

597-Al

Ref.

S-0627-A/

Ref.

ST-150

922

Install

wire

spool.

Adjust

tension

nut

so

wire

is

taut

when

wire

feed

stops.

4,

Install

wire

guide.

OJ~

Forsoft

wire

orsmall

diameterstainless

steel

wire,

use

2

drive

rolls

and

set

drive

roll

pressure

from

0

to

a

maximum

of

4

on

the

pressure

indicator

scale

(so

that

only

the

inner

spring

is

compressed).

This

setting

will

generally

give

the

best

performance

for

these

types

of

wires.

OM-1586

Page

16

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