Miller DS-64M Swingarc Owner's manual

Miller
Brand
Miller
Model
DS-64M Swingarc
Category
Welding System
Type
Owner's manual

This manual is also suitable for

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
related
equipment.
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
related
instructions
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
related
instructions
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
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
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
Pin
Install
pin
through
yoke.
Install
cot
ter
pin
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.
Pin
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
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
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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Miller DS-64M Swingarc Owner's manual

Miller
Brand
Miller
Model
DS-64M Swingarc
Category
Welding System
Type
Owner's manual
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