Miller DS-64M Swingarc Owner's manual

Processes

Miller

The

Power

ofBlue.

Pulsed

MIG

(GMAW-P)

~

MIG(GMAW)

Flux

Cored

(FCAW)

(Gas-

and

Self-Shielded)

Description

r-~iI

I

Wire

Feeder

(Use

with

CC/CV

Power

Sources)

OM-1

5880

February

1997

Effective

with

Serial

Number

KH339697

OWNERS

MANUAL

TM

Thank

you

and

congratulations

on

choosing

Miller.

Now

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

Neils

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

conmiitted

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

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.

From

to

You

lIk(IIllhIiI

p

REGISTERED

QUALITY

SYSTEM

Miller

is

the

first

welding

equipment

manufacturer

in

the

U.S.A.

to

be

registered

to

ihe

ISO

9001

Quality

System

Standard.

.

~1~Jftft31Wfl~ﬁ

~

Working

as

hard

as

you

do



every

power

source

from

Miller

Is

backed

by

the

most

hassle-free

warranty

in

the

business.

f//A

Miller

The

Power

ofBb~e.

Call

1

-800-4-A-MILLER

for

your

local

Miller

distributor.

Your

distributor

gives

you

Service

You

always

get

the

fast,

reliable

response

you

need.

Most

replacement

parts

can

be

in

your

hands

in

24

hours.

Support

Need

fast

answers

to

the

tough

welding

questions?

Contact

your

distributor.

The

expertise

of

the

distributor

and

Miller

is

there

to

help

you,

every

step

of

the

way.

Pulsed

MIG

(GMAW-P)

MIG

(GMAW)

Flux

Cored

(FCAW)

(Gas-

and

Self-Shielded)

Miller

offers

a

Technical

Manual

7

which

provides

more

detailed

service

and

parts

information

for

7

your

unit.

To

obtain

a

Technical

Manual,

contact

your

local

16

distributor.

Your

distributor

can

also

supply

you

with

Welding

Process

19

Manuals

such

as

SMAW,

GTAW,

GMAW,

and

GMAW-P

Options

and

Accessories

Description

LI.

E;4j~jJ

~

~A

n

TM

Front

Panel

Features



2-line

by

16-character

backlit

LCD



Single

push-button

parameter

select

control



Single

knob

parameter

adjustment



Trigger

hold

control

for

making

extended

welds

without

holding

gun

trigger



Wire

jog

control

feeds

wire

without

energizing

the

contactor



Gas

purge

control

purges

line

without

energizing

feeder

Side

Panel

Features



4-line

by

20-character

backlit

LCD

for

parameter

and

mode

displays



Push-button

programming

controls

for

process,

sequence,

dual

schedule,

and

data

card

modes



Parameter

select

push

button



Parameter

increase/decrease

push

buttons

Processes

Put

the

benefits

of

technology

to

work

on

the

production

line.

The

DS-64M

represents

a

major

advancement

in

wire

feed

technology,

and

delivers

the

ultimate

in

versatility,

simplicity,

programmability

and

performance.

The

DS-64M

feeder

includes

special

features

for

pulsed

MIG

(GMAW-P)

welding

that

requires

the

use

of

inverter-type

power

sources.

However

the

DS-64M

retains

the

versatility

that

makes

it

perfectly

suited

to

conventional

MIG

processes

using

a

variety

of Miller

CV

or

CC/CV

machines.

For

pulsed

MIG

welding,

the

DS-64M

features

built-in

memory

with

eight,

factory-set

synergic

pulse

programs.

Each

program

is

specific

for

a

wire

type,

wire

size

and

gas

mixture.

Any

of

these

programs

can

be

modified

for

the

specific

requirements

of

your

welding

application.

This

dual

wire

model

operates

one

gun

at

a

time,

and

provides

efficiency

in

applications

that

alternately

require

wires

of

two

different

sizes

or

types.

Its

also

ideal

in

situations

where

a

standby

gun

is

needed.

This

dual-wire

model

can

be

programmed

to

run

the

identical

process

on

both

sides,

orto

have

one

side

run

conventional

MIG

while

the

other

is

set

for

pulsed

MIG

welding.

Table

of

Contents

Section

1.

Safety

Precautions

1.

Consignes

de

SØcuritØ

pour

le

Soudage

a

Larc

2.

Introduction

3.

Installation

4.

Operation

5.

Setting

Sequence

Parameters

6.

Setting

Dual

Schedule

Parameters

7.

Using

the

Optional

Data

Card

8.

System

Setup

9.

Standard

Pulse

Welding

Programs

10.

Teach

Points

11.

Maintenance

and

Troubleshooting

12.

Electrical

Diagram

13.

Parts

List

Page

1

4

20

21

23

24

26

30

34

36

Warranty

.

1.

Safety

Precautions



Read

Before

Using

I

~1

Symbol

Usage

4A

Means

Warning!

Watch

Out!

There

are

possible

hazards

with

this

procedure!

The

possible

hazards

are

shown

in

the

adjoining

symbols.

A

Marks

a

special

safety

message.

~

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

follow

the

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

1.3.

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

bums.

The

electrode

and

work

circuit

is

electrically

live

whenever

the

output

is

on.

The

input

power

circuit

and

machine

internal

circuits

are

also

live

when

power

is

on.

In

semiautomatic

or

automatic

wire

welding,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live.

Incorrectly

installed

or

improperly

grounded

equipment

is

a

hazard.



Do

not

touch

live

electrical

parts.



Wear

dry,

hole-free

insulating

gloves

and

body

protection.



Insulate

yourself

from

work

and

ground

using

dry

insulating

mats

or

covers

big

enough

to

prevent

any

physical

contact

with

the

work

or

ground.



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.



If

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.

Repairor

replace

damaged

parts

at

once.

Maintain

unit

according

to

manual.



Wear

a

safety

harness

if

working

above

floor

level.

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.



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.

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.

ARC

RAYS

can

burn

eyes

and

skin.

Arc

rays

from

the

welding

process

produce

intense

,t..

/

visible

and

invisible

(ultraviolet

and

infrared)

rays

that

can

bum

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

Chipping,

grinding,

and

welds

cooling

throw

off

pieces

of

metal

or

slag.



Weara

welding

helmetfitted

with

a

propershade

of

filterto

protect

your

face

and

eyes

when

welding

or

watching

(see

ANSI

Z49.1

and

Z87.1

listed

in

Safety

Standards).



Wear

approved

safety

glasses

with

side

shields.



Use

protective

screens

or

bamers

to

protect

others

from

flash

and

glare;

warn

others

not

to

watch

the

arc.



Wear

protective

clothing

made

from

durable,

flame-resistant

material

(wool

and

leather)

and

foot

protection.

FUMES

AND

GASES

cm

be

hazardous.

I

~,,

.......:.~

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.

OM-1588D

-

2/97,

safety_som

11/96

OM-1

588

1

CYLINDERS

can

explode

If

damaged

Shielding

gas

cylinders

contain

gas

under

high

pressure.

If

damaged,

a

cylinder

can

explode.

Since

gas

cylinders

are

normally

part

of

the

welding

process,

be

sure

to

treat

them

carefully.



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.

WELDING

can

cause

fire

orexplosion.

Welding

on

closed

containers,

such

as

tanks,

drums,

or

pipes,

can

cause

them

to

blow

up.

Sparks

can

fly

off

from

the

welding

arc.

The

flying

sparks,

hot

workpiece,

and

hot

equipment

can

cause

fires

and

burns.

Accidental

contact

of

electrode

to

metal

objects

can

cause

sparks,

explosion,

overheating,

or

fire.

Check

and

be

sure

the

area

is

safe

before

doing

any

welding.



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

rn)

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

oft

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

Chipping

and

grinding

cause

flying

metal.

As

welds

cool,

they

can

throw

off

pieces

of

metal

or

slag.



Wear

a

face

shield

to

protect

eyes

and

skin.

H.F.RADIATION

can

caajse

interference



High-frequency

(H.F.)

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.

FIRE

OR

EXPLOSION

hazard.



Do

not

install

or

place

unit

on,

over,

or

near

combustible

surfaces.



Do

not

locate

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.

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.

MAGNETIC

FIELDS

can

affect

pacemakers.



Pacemaker

wearers

keep

away.



Wearers

should

consult

their

doctor

before

going

near

arc

welding,

gouging,

or

spot

welding

operations.

HOT

PARTS

can

caUse

severe

burns.



Do

not

touch

hot

parts

bare

handed.



Allow

cooling

period

before

working

on

gun

or

torch.

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.

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.

2

OM-1

588

NOISE

can

damage

hearing

Noise

from

some

processes

or

equipment

can

damage

hearing.



Wear

approved

ear

protection

if

noise

level

is

high.

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.

1

3

Principal

Safety

Standards

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.1,

from

Amencan

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

Electrical

Code,

NFPA

Standard

70,

from

National

Fire

Protection

Association,

Batteryrnarch

Park,

Quincy,

MA

02269.

FLYING

METALorDiRlcaninjureeyes



Wear

safety

glasses

with

side

shields

or

face

shield.

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

unit.



If

using

lift

forks

to

move

unit,

be

sure

forks

are

long

enough

to

extend

beyond

opposite

side

of

unit.

BUILDUP

OF

GAS

can

injure

or

kill



Shut

oft

shielding

gas

supply

when

not

in

use.

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.

1.4

EMF

Information

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

cellular

level

and

from

studies

with

animals

and

people

which

clearly

establish

that

low

frequency

magnetic

fields

can

interact

with,

and

produce

changes

in,

biological

systems.

While

most

of

this

work

is

of

very

high

quality,

the

results

are

complex.

Current

scientific

understanding

does

not

yet

allow

us

to

in

terpret

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

from

opera

tor

as

practical.

5.

Connect

work

clamp

to

workpiece

as

close

to

the

weld

as

possible.

AbOUt

Pacemakers:

The

above

procedures

are

also

recommended

for

pacemaker

wearers.

Consult

your

doctor

for

complete

information.

OM-1588

3

1.

Consignes

de

SecuritØ

pour

le

Soudage

a

larc

1

2

Dangers

du

soudage

a

Iarc

a

MISE

EN

GARDE

UN

CHOC

ELECTRIQUE

peut

tuer.

Un

simple

contact

avec

des

piŁces

Ølectriques

peut

pro

voquer

une

electrocution

ou

des

blessures

graves.

LØ

!ectrode

et

le

circuit

de

soudage

sont

sous

tension

des

que

lappareil

est

sur

ON.

Le

circuit

dentrØe

et

!es

cir

cuits

intemes

de

lappareil

sont

egalement

sous

tension

a

ce

moment-l.

En

soudage

semi-automatique

ou

automatique,

le

fil,

!e

dØvidoir,

!e

logement

des

galets

dentralnement

et

!es

piŁces

meta!!iques

en

contact

avec

!e

fil

de

soudage

sont

sous

tension.

Des

matØne!s

mat

installØs

ou

ma!

mis

a

Ia

terre

prØsentent

un

danger.

1.

Ne

jamais

toucher

!es

piŁces

e!ectriques

sous

tension.

2.

Porter

des

gants

et

des

vŒtements

de

protection

secs

ne

compor

tant

pas

de

trous.

3.

Siso!er

de

!a

piŁce

et

de

Ia

terre

au

moyen

de

tapis

ou

dautres

moyens

iso!ants

suffisamment

grands

pour

empØcher

!e

contact

physique

Øventuel

avec

Ia

piŁce

ou

!a

terre.

4.

Couper

Ia!imentation

ou

arrŒter

!e

moteur

avant

de

procØder

a

linsta!!ation,

a

!a

reparation

ou

a

!entretien

de

lapparei!.

DØver

roui!ler

Ialimentation

selon

Ia

norme

OSHA

29

CFR

1910.147

(voir

normes

de

sØcuntØ).

5.

Installer

et

mettre

a

!a

terre

correctement

cot

appareil

conformØ

ment

a

son

manue!

duti!isation

et

au

codes

nationaux,

provin

ciaux

et

municipaux.

6.

ToujoursvØnfierla

terre

du

cordon

dalimentation

VØrifieretsas

surer

que

!e

fi!

de

terre

du

cordon

dalimentation

est

bien

raccordØ

a

bome

de

terre

du

sectionneur

ou

que

Ia

fiche

du

cordon

est

raccordØe

a

une

prise

correctement

mise a

Ia

terre.

7.

En

effectuant

es

raccordements

dentrØe

fixer

dabord

le

conduc

teur

demise

a

!a

terre

appropne

et

contre-vØnfier

!es

connexions.

8.

VØnfier

frØquemment

!e

cordon

dalimentation

pour

voir

siI

nest

pas

endommage

ou

dØnudØ



remplacer

le

cordon

immediate

ment

siI

est

endommage



un

cb!e

dØnudØ

peut

provoquer

une

Ø!ectrocution.

9.

Mettre

!appareil

hors

tension

quand

on ne

lutilise

pas.

10.

Ne

pas

utiliser

des

cables

uses,

endommages,

de

grosseur

insuf

fisante

ou

ma!

ØpissØs.

11.

Ne

pas

enrouler

les

cables

autour

du

corps..

12.Si

!a

piŁce

soudØe

doit

Œtre

mise

a

!a

terre,

!e

faire

directement

avec

un

cable

distinct



ne

pas

uti!iser

le

connecteurde

piŁce

ou

!e

cable

de

retour.

1

3.Ne

pas

toucher

lØlectrode

quand

on

est

en

contact

avec

Ia

piŁce,

!a

terre

ou

une

electrode

provenant

dune

autre

machine.

1

4.Nutiliserquun

matØnel

en

bon

Øtat.

Reparer

ou

remplacersur-!e

champ

!es

piŁces

endommagees.

Entretenir

lapparei!

conformØ

ment

a

ce

manuel.

15.Porter

un

hamais de

sØcuntØ

quand

on

travaille

en

hauteur.

16.Maintenir

solidement

en

place

tousles

panneaux

et

capots.

17.

Fixer

!e

cable

de

retour

de

facon

a

obtenir

un

bon

contact

metal

avec

Ia

piŁce

a

souder

ou

Ia

table

de

travail,

le

plus

prŁs

possible

de

!a

soudure.

BRUIT

LE

RAVONNEMENT

DE

LARC

peut

brler

les

yeux

et

Ia

peau.

Le

BRUIT

peut

endommager

IouIe;

les

PROJECTIONS

DE

LAITIER

OU

LES

ETINCELLES

peuvent

blesser

les

yeux.

Larc

de

soudage

produit

des

rayons

visibles

et

invi

sibles

intenses

(ultravio!ets

et

infrarouges)

qui

peuv

ent

brUler

les

yeux

et

Ia

peau.

Le

bruit

produit

par

cer

tains

procØdes

peut

endommager

Iouie.

Des

projec

tions

de

metal

ou

de

laitier

sont

produites

par

le

piquage,

le

meulage

ou

le

refroidissement

des

sou

dures.

1.

UtHiser

des

bouche-oreilles

ou

des

serre-tŒte

antibruit

approuvØs

si

le

niveau

de

bruit

est

ØlevØ.

RAYONNEMENT

DE

LARC

2.

Porter

un

masque

a

serre-tŒte

muni

dun

verre

filtrant

de

nuance

appropnØe

pour

protØger

le

visage

et

les

yeux

quand

on

soude

ou

observe

Ia

travail

de

soudage

(voir

es

normes

ANSI

Z49.

1

et

Z87.1

donnØes

sous

Ia

rubnque

Principales

normes

de

sØcu

ntØ).

3.

Porter

des

lunettes

de

sØcuritØ

approuvØes

avec

Øcrans

late

raux.

4.

Utiliser

des

paravents

ou

des

barnØres

de

protection

pour

protØger

les

personnes

a

proximite

centre

les

coups

darc

et

Ieblouissement;

avertir

les

autres

personnes

de

ne

pas

regarder

arc.

5.

Porter

des

vŁtements

de

protection

en

tissu

ignifuge

durable

(lame

et

cuir)

et

des

chaussures

de

sØcuritØ.

11

Signification

des

symboles

OM-1

588D/cfr



2/97

4A

Signifie

Mise

en

garde!

Attention!

Ce

mode

opØratoire

peut

A

Indique

un

message

de

sØcuritØ

special.

prØsenterdes

dangers!

Les

dangers

possibles

sont

indiquØs

par

!es

divers

symboles.

f~

Signifie

NOTA;

pas

lie

a

Ia

sØcuritØ

Ce

groupe

de

symboles

signifie

Mise

en

garde!

Attention!,

risque

de

CHOCS

ELECTR!QUES

~

dangers

presentes

par

!es

PI¨CES

MOBILES

et

!es

P!ECES

CHAUDES.

Voir

les

symbo!es

et

les

consignes

associØes

ci-aprŁs

pour

prendre

les

mesures

nØcessaires

afin

de

se

premunir

contre

!es

dangers.

safety_som_cfr

2/97

Les

symboles

donnØs

ci-aprŁs

sont

utilisØs

dans

tout

le

manuel

pour

attirer

Iattention

sur

les

dangers

possibles

et

pour

indiquer

le

type

de

danger

dont

ii

sagit.

Quand

on

voit

le

symbole,

prendre

garde

et

suivre

les

directives

correspondantes

pour

Øviter

le

danger.

Les

consignes

de

sØcuritØ

donnØes

ci-aprŁs

ne

font

que

rØsumer

Iinformation

contenue

dans

les

normes

de

sØcuritØ

ØnumØrØes

a

Ia

section

1-4.

Lire

et

respecter

toutes

ces

normes

de

sØcuritØ.

Linstallation,

Iutilisation,

lentretien

et

les

reparations

ne

doivent

Œtre

conflØs

qu

des

personnes

qualifiØes.

Aucune

personne,

et

particuliŁrement

les

enfants,

ne

doit

se

trouver

a

proximitØ

du

poste

de

soudage

4

OM-1588

I

LES

VAPEURS

ET

LES

FUMEES

peuvent

Œtre

dangereuses

pour

Ia

sante.

Le

soudage

produit

des

vapeurs

et

des

fumØes

quit

est

dangereux

de

respirer.

1.

Garder

Ia

tŒte

a

lextØneur

des

vapeurs

et

des

fumØes

et

ne

pas

es

respirer.

2.

A

lintØrieur,

ventiler

le

paste

de

travail

ou

utiliser

un

dispositif

place

au

niveau

de

larc

pour

Øvacuer

es

vapeurs

et

fumØes

de

soudage.

3.

Si

Ia

ventilation

est

mauvaise,

utiliser

un

appareil

respiratoire

a

adduction

dair

pur

approuvØ.

4.

Consulter

les

fiches

signaletiques

et

les

consignes

du

fabncant

relatives

au

mØtaux,

produits

dapport,

revŒtements,

nettoyants

et

LES

BOUTEILLES

peuvent

exploser

Si

elles

sont

endornmagØes.

Les

bouteilles

contenant

des

gaz

de

protection

sont

a

haute

prepsion.

Une

bouteille

endommagØe

peut

exploser.

Etant

donnØ

que

es

bouteilles

de

gaz

font

normalement

partie

du

matØnel

de

soudage,

les

traiter

avec

le

plus

grand

soin.

1.

Proteger

les

bouteilles

de

gaz

comprime

contre

a

chaleur

intense,

les

chocs,

le

laitier,

es

flammes

flues,

les

Øtincelles

et

larc.

2.

Placer

les

bouteilles

ala

verticale

en

les

fixant

a

un

support

fixe

ou

a

un

chariot

pour

Øviter

quelles

ne

tombent

ou

ne

basculent.

3.

Tenir

es

bouteilles

a

lØcart

du

poste

de

soudage

ou

dautres

circuits

~ues

LE

SOUDAGE

peut

causer

un

incendieou

une

explosion.

Ne

pas

souder

sur

des

recipients

fermØs

comme

des

reservoirs,

des

Wits

ou

des

tuyaux:

ils

peuvent

exploser.

Larc

de

soudage

peut

produire

des

Øtincelles.

Des

Øtincelles,

une

piŁce

chaude

et

un

materiel

chaud

peuvent

provoquer

des

incendies

et

des

blessures.

Le

contact

accidentel

de

lØlectrode

sur

des

objets

metalliques

peut

produire

des

Øtincelles,

lexplosion,

Ia

surchauffe

ou

un

incendie.

Sassurer

que

le

lieu

ne

presente

pas

de

danger

avant

deffectuer

le

soudage.

1.

Se

proteger

et

protØger

les

personnes

a

proximitØ

des

Øtincelles

et

du

metal

chaud.

2.

Ne

pas

souder

dans

un

endroit

ou

les

Øtincelles

peuvent

atteindre

des

matØnaux

inflammables.

3.

Enlevertoutes

les

matiŁres

inflammables

dans

un

rayon

de

mains

de

10

m

de

larc.

Si

cela

nest

pas

possible,

bien

les

recouvnr

en

utilisant

des

bches

approuvees.

4.

Prendre

garde

que

les

Øtincelles

et

les

projections

ne

penetrent

dans

des

zones

adjacentes

en

sinfiltrant

dans

des

petites

UN

INCENDIE

OU

UNE

EXPLOSION

peut

Œtre

cause

par

un

appareil

place

au

contact,

au-dessus

ou

a

ctØ

de

surfa

ces

combustibles.

1.

Ne

pas

placer

Iappareil

au

contact,

au-dessus,

ou

a

ctØ

dune

surface

combustible.

2.

Ne

pas

installer

Iappareil

a

ctØ

dun

objet

ou

dun

produit

inflammable.

EN

TOMBANT,

LE

MATERIEL

peut

sen

dommager

ou

causer

des

blessures

graves.

1.

Nutiliser

Ianneau

de

levage

que

pour

soulever

Iappareil;

NE

PAS

lutiliser

pour

soulever

les

cha

riots,

les

bouteilles

de

gaz

ou

autres

accessoires.

2.

Pour

soulever

Ia

source

de

courant,

utiliser

des

appareils

de

puissance

suffisante.

3.

Si

Ion

utilise

un

ØlØvateur

a

fourthe

pour

dØplacer

Iappareil,

sassurer

que

Ia

fourche

est

suffisamment

et

dØpasse

de

Iautre

ctØ

de

Iappareil.

5.

Ne

travaillerdans

un

espace

confine

que

sil

est

bien

ventilØ,

ou

en

portant

un

appareil

respiratoire

a

adduction

dair

pur.

Demander

a

un

observateur

ayant

recu

Ia

bonne

formation

de

toujours

se

tenir

a

proximite.

Les

vapeurs

et

fumØes

de

soudage

peuvent

dØplacer

lair

et

abaisser

le

niveau

doxygŁne

et

causer

des

blessures

graves

voire

mortelles.

Sassurer

que

lair

est

propre

a

Ia

respiration.

6.

Ne

pas

souder

a

proximitØ

dopØrations

de

degraissage,

de

nettoyage

ou

de

pulvensation.

La

chaleur

et

les

rayons

de

larc

peuvent

reagir

avec

les

vapeurs

pour

former

des

gaz

hautement

toxiques

et

irritants.

7.

Ne

pas

souder

sur

des

mØtaux

revŒtus

comme

lacier

galvanise,

au

p10mb

ou

cadmiØ

a

moms

que

Ia

piŁce

nait

ØtØ

entiŁrement

dØcapØe,

que

le

poste

de

travail

soit

bien

venlilØ.

Sil

y

a

lieu,

porter

un

appareil

respiratoire

a

adduction

dair

pur.

Les

revŒtements

et

les

mØtaux

qui

contiennent

de

tels

ØlØments

peuvent

degager

des

vapeurs

toxiques

lors

du

soudage.

4.

Ne

jamais

poser

un

chalumeau

soudeur

sur

une

bouteille

de

gaz.

5.

Ne

jamais

laisser

une

electrode

de

soudage

toucher

une

bouteille.

6.

Nejamais

soudersur

une

bouteille

sous

pression

:

elle

exploserait.

7.

Nutiliser

que

des

bouteilles

de

gaz

de

protection,

des

dØtendeurs,

des

tuyaux

souples

et

des

raccords

appropnØs

concus

pour

lapplication

particuliŁre;

conserver

ces

matØriels

et

leurs

piŁces

en

ban

Øtat.

8.

Eloigner

le

visage

de

Ia

sortie

du

robinet

de

Ia

bouteille

quand

on

louvre.

9.

Replacer

le

chapeau

sur

Ia

bouteille

aprŁs

utilisation.

10.Lire

et

suivre

les

consignes

relatives

aux

bouteilles

de

gaz

compnmØ,

au

matØnel

connexe

ainsi

que

Ia

publication

P-i

de

Ia

CGA

donnØe

sous

Ia

rubrique

Principales

normes

de

sØcuritØ.

5.

Prendre

garde

aux

incendies

et

toujours

avoir

un

extincteur

a

proximitØ.

6.

Se

rappeler

que

si

Ion

soude

sur

un

plafond,

un

plancher,

une

cloison

ou

autre,

le

feu

peut

prendre

de

lautre

cotØ.

7.

Ne

pas

souder

sur

des

recipients

fermØs

comme

des

reservoirs,

des

fts

ou

des

tuyaux

a

mains

quils

ne

soient

prØparØs

de

faon

appropriØe

conformØment

a

Ia

norrne

F4.1

de

lAWS

(voir

Ia

rubrique

Pnncipales

normes

de

sØcuntØ).

8.

Raccorder

le

cable

de

retour

ala

piŁce,

le

plus

prØs

possible

de

Ia

zone

de

soudage,

pour

empŒcher

que

le

courant

de

soudage

ne

suive

une

trajectoire

longue

et

Øventuellement

inconnue

et

quit

ne

provoque

des

risques

dØlectrocution

et

dincendie.

9.

Ne

pas

utiliser

le

chalumeau

soudeur

pour

degeler

des

tuyaux.

10.

Enlever

lØlectrode

enrobØe

du

porte-electrode

ou

couper

le

fil

de

soudage

au

ras

du bec

contact

quand

on

ne

lutilise

pas.

11.

Porter

des

vŒtements

de

protection

non

huileux

comme

des

gants

en

cuir,

une

chemise

Øpaisse,

des

pantalons

sans

revers,

des

chaussures

montantes

et

un

casque.

12.Ne

pas

porter

des

matiŁres

combustibles

sur

soi

comme

un

bnauet

a

aaz

ou

des

allumettes

quand

on

soude

LES

PI¨CES

CHAUDES

peuvent

provo

quer

des

brlures

graves.

1.

Ne

pas

toucher

les

piŁces

chaudes

les

mains

flues.

2.

Laisser

une

periode

de

ref

roidissement

avant

de

toucher

Ie

pistolet

ou

Ia

torche.

LES

PI¨CES

MOBILES

peuvent

causer

des

blessures.

1.

Se

tenir

a

IØcart

des

piŁces

en

mouvement

cam-

me

les

ventilateurs.

2.

Sassurer

que

tous

Ies

capots,

panneaux,

portes

et

protecteurs

sont

bien

fermØs

et

fermement

maintenus.

LES

ECLATS

DE

METAL

ou

LES

SALE

TES

peuvent

provoquer

des

lØs

ions

aux

yeux.

1.

Porter

des

lunettes

de

sØcuntØ

avec

Øcrans

late

raux

ou

Øcran

facial.

1.3

Autres

dangers

relatifs

a

Iinstallation,

Iutilisation

et

Ientretien

OM-1

588

5

LES

CHAMPS

MAGNETIQUES

PRO

DUITS

PAR

LES

COU

RANTS

ELEVES

peuvent

nuire

au

fonctionnement

du

sti

mulateur

cardiaque

1.

Lespersonnesqui

portentunslimulateurcardiaque

doivent

se

tenir

eloignØes

du

poste

de

soudage.

2.

Les

personnes

qui

portent

un

stimulateur

cardiaque

devraient

consulter

leur

mØdecin

avant

de

sapprocher

dun

poste

de

soudage

ou

de

gougeage

a

larc

ou

de

soudage

par

points.

LES

PI¨CES

MOBILES

peuvent

provo

quer

des

blessures.

1.

Se

tenir

a

IØcart

des

piŁces

mobiles.

2.

Se

tenir

a

lØcart

des

points

de

pincement,

ex.

alets

dentrainement.

LE

AL

DE

SOUDAGE

peut

percer

Ia

peau.

1.

Attendre

les

instructions

avant

dappuyer

sur

Ia

gachette.

Ne

pas

pointer

le

pistolet

sur

une

partie

du

corps,

sur

dautres

personnes,

ou

sur

une

piŁce

metal

lique

lorsquon

enfile

le

fil

de

soudage.

UNE

UTILISATION

EXCESSIVE

peut

se

traduire

par

une

SURCHAUFFE

DU

MA

TERIEL.

1.

Laisser

une

pØnode

de

refroidissement.

2.

RØduire

le

courant

ou

le

facteur

de

marche

avant

de

recommencer

a

souder.

3.

Utiliser

le

facteur

de

marche

nominal.

LACCUMULATION

DE

GAZ

DE

PRO

TECTION

peut

Œtre

nuisibte

a

Ia

sante

voire

mortel.

1.

Quand

on

nutilise

pas

le

gaz

de

protection,

fermer

le

robinet

de

Ia

bouteille.

LELECTRICITE

STATIQUE

peutendom

mager

les

piŁces

des

circuits

imprimØs.

1.

Mettre

un

bracelet

antistatique

AVANT

de

mani

puler

les

cartes

de

circuits

impnmØs

ou

les

piŁces.

2.

Utiliser

des

sacs

et

boites

antistatiques

adequats

pour

ranger,

dØplacer

ou

expedier

les

cartes

de

circuits

imprimes.

LA

HAUTE

FREQUENCE

peut

crØer

des

interferences

dans

les

systŁmes

de

ra

dionavigation,

les

services

de

sØcuritØ,

les

ordinateurs

et

le

materiel

de

tØlØ

communications.

1.

Ne

confier

cette

installation

qu

un

personnel

qualifiØ

et

connaissant

bien

lequipement

Ølectro

nique.

2.

Lutilisateur

a

Ia

responsabilitØ

de

faire

corriger

rapidement

par

un

Ølectncien

qualifie

les

problŁmes

dintrfØrences

resultant

de

linstalla

tion.

3.

Dans

le

cas

dun

avertissement

dinterfØrence

donnØ

par

le

Conseil

fØdØral

des

communications,

arrŒter

dutiliser

immØdiatement

Iequipement.

4.

Faire

vØnfier

et

entretenir

regulierement

installa

tion.

5.

Tenir

es

portes

et

panneaux

de

Ia

source

de

haute

frequence

bien

fermØs,

maintenir

les

Øclateurs

au

bon

reglage

et

utiliser

une

mise

a

Ia

terre

et

un

Øcran

de

protection

afin

de

rØduire

au

minimum

Ia

possibilitØ

dinterfØrences.

UNE

TENSION

C.C.

IMPORTANTE

est

prØsente

sur

les

onduleurs

aprŁs

que

Ion

ait

coupØ

Ialimentation.

1.

Avant

de

toucher

les

piŁces,

mettre

Ionduleur

hors

tension,

couper

lalimentation

et

dØcharger

les

condensateurs

dentrØe

conformØment

aux

directives

de

Ia

section

Entretien.

2.

..Q=HF))

)J

I

U

IA

Principalesnormesde!securite

-

Safely

in

Welding

and

Cutting,

norrne

ANSI

Z49.1,

de

American

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

Welding

Society,

550

N.W.

Lejeune

Rd,

Miami

FL 33126

P-i,

de

Ia

Compressed

Gas

Association,

1235

Jefferson

Davis

Safely

and

Health

Sandards,

OSHA

29

CFR

1910,

du

Highway,

Suite

501,

Arlington,

VA

22202.

Superintendent

of

Documents,

U.S.

Govemment

Printing

Office,

Regles

de

sØcuritØ

en

soudage,

coupage

et

procedØs

connexes,

Washington,

D.C.

20402.

norme

CSA

Wi

17.2,

de

lAssociation

canadienne

de

normalisation,

vente

de

normes,

178

Rexdale

Boulevard,

Rexdale

(Ontario)

Recommended

Safe

Practice

for

the

Preparation

for

Welding

and

Canada

M9W

1

R3.

Cutting

of

Containers

That

Have

Held

Hazardous

Substances,

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

norme

AWS

F4.

1,

de

American

Welding

Society,

550

N.W.

Lejeune

Protection,

norme

ANSI

Z87.1,

de

IAmencan

National

Standards

Rd,

Miami

FL

33126

Institute,

1430

Broadway,

New

York,

NY

10018.

National

Electrical

Code,

NFPA

Standard

70,

de

Ia

National

Fire

Cutting

and

Welding

Processes,

norme

NFPA

51

B,

de

Ia

National

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

1.5

Informatins

surlescharnpseiectromagnetiques

1:1:

NOTA

DonnØes

sur

le

soudage

et

sur

les

effets

des

champs

Ølectn-

Pour

reduire

lintensitØ

des

champs

magneliques

au

poste

de

travail:

ques

et

magnØtiques

basse

frequence.

1.

Grouper

solidement

les

cables

en

les

entrelaant

ou en

les

Voici

une

dtation

tiree

des

conclusions

generales

du

document

Biolo

serrant

avec

un

ruban

adhØsif.

gical

Effects

of

Power

Frequency

Electric

&

Magnetic

Fields

-

Back

ground

Paper

(Effets

biologiques

des

champs

electriques

et

magnØti-

2.

Disposer

les

cables

sur

un

seul

ctØ

et

a

IØcart

de

Iopera

ques

aux

frequences

dutilisation

-

Document

de

base),

OTABP

teur.

-E-53

(Washington,

DC:

U.S

Govemment

Printing

Office,

mai

1989)

publiØ

par

IOffice

of

Technology

Assessment

(Congres

des

Etats-

3.

Eviter

denrouler

les

cables

ou

de

les

poser

sur

Iepaule.

Unis):

...

des

experiences

au

niveau

cellulaire

et

des

etudes

sur

Ihomme

et

lanimal

nous

ont

apportØ

une

foule

de

renseignements

:

1

4.

Eloigner

le

plus

possible

Ia

source

de

courant

et

les

cables

est

maintenant

clair

que

les

champs

magnetiques

basse

frØquence

de

soudage.

peuvent

infiuer

sur

les

systŁmes

biologiques

et

les

modifier.

Ces

tra

vaux

sont

gØneralement

dexcellente

qualite,

mais

les

rØsultats

obte-

5.

Raccorder

le

connecteur

de

piŁce

a

Ia

piŁce

a

souder,

le

plus

nus

sont

complexes.

Dans

IØtat

actuel

de

nos

connaissances

dans

le

prŁs

possible

de

Ia

soudure.

domaine

scientifique,

nous

ne

sommes

pas

en

mesure

dinterpreter

nos

observations

a

Ia

lumiŁre

dune

thØone

gØnerale.

Et,

Ce

qui

est

Stimulateurs

cardiaques:

encore

plus

regrettable,

nous

ne

pouvons

nen

affirmer

de

dØfinitif

au

Les

recommandations

ci-avant

sadressent

aussi,

normalement,

sujet

des

nsques

Øventuels,

ni

proposer

des

mØthodes

scientifiques

aux

personnes

qui

utilisent

un

stimulateur

cardiaque.

Pour

de

plus

precises

pour

rØduire

ces

nsques

ou

pour

les

Øviter.~

amples

renseignements,

consultez

votre

mØdecin.

.

6

OM-1

588

2.

Introduction

21

Specifications

Wire

Feed

Speed

Range

Wire

Diameter

Range

Welding

Circuit

Weight

Rating

3.

Installation

3.1

Installing

Swivel

into

Pipe

Post

.

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

A

Do

not

remove

until

instructed

to.

ST-152

382

Tools

Needed:

~

3/4in

Type

of

Input

Power

Welding

Power

Source

Type

24

Volts

AC

Constant

Voltage

(CV)

Standard:

50

To

780

.023

To

1/8

in

(0.6

100

Volts,

12

ft

(3.7

m):

Single-Phase

DC

For

GMAW

Or

pm

(1.3

To

19.8

mpm)

To

3.2

mm)

750

Amperes,

207

lb

(94

kg)

10

Amperes

Constant

Voltage

(CV)

/

100%

Duty

Cycle

50/60

Hertz

Constant

Current

(CC)

DC

For

GMAW-P

All

Need

14-Pin

And

Contactor

Control

Optional

High

Speed:

92

To

1435

ipm

(2.3

To

36.5

mpm)

Max

Spool

Weight:

60

lb

(27

kg)

16

ft

(4.9

m):

280

lb

(127

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

Honzontal

to

60

Above

Horizontal

5

4

3

2

OM-1

588

7

1

Weld

Control

2

Bracket

3

Screw

Bracket

and

screws

are

installed

onto

bottom

of

control

at

factory.

4

Swivel

Loosen

screws.

Place

control

on

swivel

and

slide

forward.

Tighten

screws.

5

Tilt

Bracket

6

Rear

Pivot

Screw

7

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.

3~3

Installing

Boom

and

Reel

Support

1

Swivel

Plates

2

Yoke

Remove

hardware

from

swivel

plates

and

yoke.

3

Boom

Set

boom

into

swivel

as

shown.

4

Yoke

Install

through

yoke.

Install

cot

ter

and

spread

ends.

5

Bolt

Install

bolt,

washers,

and

nut.

Tighten

hardware,

and

back

bolt

off

one

half

turn.

6

Locking

Knob

Install

locking

knob

but

do

not

tighten.

7

Reel

Support

Install

reel

support.

32

Installing

Control

Box

and

Adjusting

Tilt

ST-BOO

174

I

ST-801

278

2,

.6

3~

3

4

Tools

Needed:

ST-153

170

7

Tools

Needed:

~

3/8,314in

2

.

8

OM-1

588

34

tnstallung

Wire

Guide

Extension

1

Wire

Guide

Fitting

2

Bolt

3

Monocoil

Liner

4

Wire

Guide

Extension

Tighten

bolt

to

secure

liner

in

wire

guide

fitting.

Do

not

overtighten

bolt

and

crush

liner.

Repeat

procedure

for

opposite

side.

4

ST-152

383

Tools

Needed:

c-~:I:~::::~=~iJ

3/8

in

9

OM-1

588

3.5

Equipment

Connection

Diagram

1

300/400

Ampere

Model

CCICV

Inverter

Welding

Power

Source

U7

Use

settings

shown

for

both

pulse

MIG

welding

and

MIG

welding.

2

450

Ampere

Model

CV

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

7

Workpiece

Voltage

Sensing

Lead

(Optional

Use)

8

Gun

Be

sure

gun

is

rated

for

peak

am

perage

if

pulse

welding.

Install

ac

cording

to

its

Owners

Manual.

9

Wire

Feeder

For

connections

see

Section

3.7.

10

Shielding

Gas

Supply

11

Supplied

V

Adapter

12

Gas

Hose

From

Boom

1

.

ST-801

806/Ref.

ST-175

086/Ref.

ST-i

80

311-B

PANEL

0

REMOTE

INDUCTANCE/DIG

V/A

CONTROL

9

12

10

OM-1

588

36

Connecting

Weld

CabLes

And

Gas

Hoses

The

weld

cables

and

shielding

gas

hoses

extend

10

ft

(3

m)

from

the

boom.

Route

weld

cables

from

boom

through

reed

relays,

if

applicable.

If

the

welding

power

source

or

gas

supply

are

further

from

the

boom,

extend

cables

or

hoses

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:

~

518in

Ref.

ST-801

806

/

Ref.

ST-i

52

800-A

OM-1

588

11

37

Control

Box

Connections

rn

~

ST-800

1

77-A

/

Ref.

ST-800

175

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

14-Pin

Cord

Volt

Sense

Lead

(Optional

Use)

Gun

Trigger

Plug

From

Boom

3~8

14-Pin

Plug

Information

*The

remaining

pins

are

not

used.

Information

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

0.

H

Voltage

feedback;

0

to

+10

volts

dc,

1

volt

per

10

arc

volts.

F

Current

feedback;

0

to

+10

volts

dc,

1

volt

per

100

amperes.

M

CC/CV

Select

(+24

V

=

CV)

4

5

6

5

4

REMOTE

14

pin.

A

N

Inductance

(0-10

V)

12

OM-1

588

3.9

MotorStart

Control

,

~

ST-162

132/Ret.

55-146862-0

To

change

wire

feed

starting

speed

proceed

as

follows:

Turn

Off

wire

feeder

and

welding

power

source.

Remove

wrapper.

1

Motor

Board

PCi

2

Motor

Start

Control

Poten

tiometer

R70

Turn

potentiometerclockwiseto

in

crease

time

it

takes

the

motor

to

ramp

up

to

speed.

Remove

protec

tive

white

rubber

cap

before

mak

ing

adjustment.

Adjust

potentiome

ter

R70

using

a

small

nonconduc

tive

screwdriver.

Reinstall

wrapper.

Non-Conductive

~====-

~w===~

1III~I~j~1J

1/4

in

3.10

Removing

Safety

Collar

and

Adjusting

Boom

~

Tools

Needed:

~

1-lI8in

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

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

assembling

or

moving

boom.

Tools

Needed:

ST-142

599-B

1

3

2

Rod

j,

H:

.-~

~~2

Increasing

Spring

Decreasing

Spring

Pressure

For

A

Pressure

For

A

Heavy

Gun

Lighter

Gun

OM-1

588

13

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-40GL

Or

GA-5OGL

3.12

Wire

Type,

Size,

and

Feed

Speed

Capability

Table

Motor

Speed

Wire

Type

Optional

High

All

Speed

.023

To

5/64

in

(0.6

To

2

mm)

Feed

Speed

Capability

Wire

Size

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)

92

To

1440

ipm

(2.3

To

35.6

mpm)

14

OM-1

588



riV~d

4

~

Be

sure

that

outlet

cable

has

proper

size

liner

for

the

welding

wire

size.

When

installing

gun,

position

liner

extending

fro

moutlet

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.

fJ

For

soft

wire

or

small

diameter

stainless

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

set

ting

will

generally

give

the

best

perfor

mance

for

these

types

of

wires.

To

adjust

drive

roll

pressure,

hold

nozzle

about

2

in

(51

mm)

from

nonconductive

surface

and

press

gun

tnggerto

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.

3/16,5/64

in

~

15/16,3/8

in

313

Installing

and

Threading

Welding

Wire

ST-i

52

564-5

I

Ref.

ST-i

56

929

I

Ref.

SC-i

50 922

/

Ref.

ST-i

56

930

/

S-0627-A

Install

wire

spool.

Adjust

tension

nut

so

wire

is

taut

when

wire

feed

stops.

Install

wire

guide.

4-

Tools

Needed:

OM-1

588

15

4.

Operation

41

Operational

Terms

Note

1iLI~

See

Menu

Guide

for

detailed

programming

steps.

The

following

is

a

list

of

terms

and

their

definitions

as

they

apply

to

this

wire

feeder:

General

Terms

The

wire

feeder

automatically

regulates

pulse

frequency

to

maintain

a

constant

arc

length,

regard

less

of

change

in

welding

wire

stickout.

When

weld

amperage

is

not

present,

wire

feeds

for

about

three

seconds

at

set

wire

feed

speed.

Then

the

welding

power

source

contactor

deenergizes

and

wire

continues

to

feed

at

the

wire

jog

speed.

As

inductance

increases,

arc

on

time

increases,

and

the

weld

puddle

becomes

more

fluid.

Arc

length

adjustment

in

pulse

welding.

Increasing

trim

increases

the

actual

arc

length.

Trim

is

re

placed

by

volts

in

MIG

programs.

The

operator

programs

pulse

parameters

for

a

specific

wire

feed

speed.

The

wire

feeder

determines

the

pulse

parameters

between

these

wire

feed

speed

increments.

4.2

Pulse

Welding

Terms

1

Apk

=

Peak

Amperage

Increasing

Apk

increases

penetra

tion.

Vpk

=

Peak

Voltage

Arc

voltage

during

peak

current

phase

of

the

pulse

waveform.

This

determines

arc

length

during

adaptive

pulse

welding.

2

Abk

=

Background

Amperage

Maintains

arc

between

pulses.

3

PPS

=

Pulses

Per

Second

Increasing

PPS

increases

travel

________________ ________________

speed.

4

PWms

=

Pulse

Width

In

Milliseconds

Increasing

PWms

increases

bead

width.

Adaptive

Pulse

Welding

Cold

Wire

Jog

Inductance

Trim

Synergic

Side

Panel

Terms

Process

Mode

Sequence

Mode

Dual

Schedule

Mode

Card

Mode

Security

Mode

Is

used

to

select

the

type

of

process

to

be

used,

including

Pulse,

Adaptive

Pulse,

or

Mig.

Is

used

to

select

and

program

the

weld

sequences

which

include

weld,

crater,

bumback,

postflow,

preflow,

and

run-in.

Is

used

to

select

a

pair

of

programs

that

can

be

used

together.

Is

used

to

select

use

of

the

optional

data

card

storage

and

retrieval

capabilities.

Only

functions

with

a

data

card.

Allows

using

the

lock

feature

for

restricting

range

of

program

pa

rameter

changing.

3

p

Amps

/

I

\

k

/

Time

/

16

OM-1

588

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