Miller KF834925 Owner's manual

Millerﬁ

OWNERS

MANUAL

SWINGARCTM

DS-1

2

And

DS-1

6



Read

and

follow

these

instructions

and

all



Give

this

manual

to

the

operator.

safety

blocks

carefully.

0



Have

only

trained

and

qualified

persons

install,

operate,

or

service

this

unit.



Call

your

distributor

if

you

do

not

understand

the

directions.

-



For

help,

call

your

distributor



or:

MILLER

Electric

Mfg.

Co.,

P.O.

Box

1079,

Appleton,

WI

54912

414-734-9821

May1995

Form:

OM-1584F

Effective

With

Serial

No.

KF834925

I



24

Volts,

10

Amperes,

50/60

Hertz

Boom

Mounted

Wire

Feeder



For

Use

With

CV/DC

Welding

Power

Source

With

Contactor



For

GMAW

And

FCAW

Welding



Rated

At

100

Volts,

750

Amperes,

100%

Duty

Cycle



Wire

Feed

Speed

Range:

50

To

780

ipm

(1.3

To

19.8

mpm)



Wire

Diameter

Range:

.023

To

1/8

in

(0.6

To

3.2

mm)



Vertical

Lift

Of

Boom:

Horizontal

To

60

Above

Honzontal



See

Rear

Cover

For

Options

And

Accessones

cover

5/94



ST-i

42

595-B

'

1995

MILLER

Electric

Mfg.

co.

PRINTED

IN

USA

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

Effective

January

1,1995

(Equipment

with

a

serial

number

preface

of

lCD

or

newer)

This

limited

wsrranty

supersedes

eli

wsrranties

end

is

exclusive

with

no

other

gusrsntees

or

warranties

expressed

or

implied.

LIMITED

WARRANTY



Subject

tothe

terms

end

conditions

below,

MILLER

Electric

Mfg.

Co.,

Appleton,

Wisconsin,

warrants

to

its

original

retell

purchaser

that

new

MILLER

equipment

sold

after

the

effective

date

of

this

limited

warranty

is

free

of

de

fects

in

material

and

workmanship

at

the

time

it

is

shipped

by

MILLER.

THIS

WAR

RANTY

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTHER

WARRANTIES,

EXPRESS

OR

IMPLIED,

INCLUDING

THE

WARRANTIES

OF

MERCHANTABILITY

AND

FIT

NESS.

Within

the

warranty

periods

listed

below,

MILLER

will

repair

or

replace

any

war-

rented

parts

or

components

that

fail

due

to

such

defects

in

material

or

workmanship.

MILLER

must

be

notified

in

writing

within

thirty

(30)

days

of

such

defect

or

failure,

at

which

time

MILLER

will

provide

instructions

on

the

warranty

claim

procedures

to

be

followed.

MILLER

shall

honor

warranty

claims

on

warmnted

equipment

listed

below

in

the

event

of

such

a

failure

within

the

wsnenty

time

periods.

All

warranty

time

periods

stan

on

the

date

that

the

equipment

was

delivered

to

the

original

retail

purchaser,

or

one

year

after

the

equipment

is

sent

to

a

North

American

distributor

or

eighteen

months

after

the

equipment

is

sent

to

an

International

distributor.

1.

SYeeraParts3Yeam

Labor

*

Original

main

power

rectifiers

2.

3

Years



Parts

and

Labor

*

Trensformer/Rectifier

Power

Sources



Plasma

Arc

Cutting

Power

Sources

*

Semi-Automatic

and

Automatic

Wire

Feedere

Robots

3.

2

Yeam



Parts

and

Labor



Engine

Driven

Welding

Generatore

(NOTE:

Engines

are

warranted

separately

by

the

engine

manufacturer.)

*

Air

Compressors

4.

1

Year

Parts

and

Labor



Motor

Driven

Guns



Process

Controllers

-

IHPS

Power

Sources



Water

Coolant

Systems

HF

Units



Grids



Spot

Weldem



Load

Banks



SDX

Transformers



Running

Gearllmilem

*

Plasma

Cutting

Torches

(except

APT,

ZIPCUT

&

PLAZCUT

Models)



Tecumaeh

Engines



Deutz

Engines

(outside

North

America)

*

Field

Options

(NOTE:

Field

options

are

covered

underTrue

BtueTM

for

the

remaining

warranty

period

of

the

product

they

are

installed

in,

or

for

a

minimum

of

one

year



whichever

is

greater.)

5.

6

Months



Batteries

al

fi.

go

Days



Parts

and

Labor

MIG

Guna/TIG

Torches

APT,

Z1PCUT

&

PLAZCUT

Model

Plasma

Cutting

Torches



Remote

Controls



Accessory

Kits



Replacement

Parts

MILLERS

True

BIueTM

Umited

Warranty

shall

not

apply

to:

1.

Items

furnished

by

MILLER,

but

manufactured

by

othem,

such

as

engines

or

trade

accessories.

Theae

items

are

covered

bythe

manufacturers

warranty,

if

any.

2.

Consumable

components;

such

as

contact

tips,

cutting

nozzles,

contactore

and

relays

or

parts

that

fail

due

to

normal

wear.

3.

Equipment

that

has

been

modified

by

any

party

other

than

MILLER,

or

equip

ment

that

has

been

improperly

installed,

improperly

operated

or

misused

based

upon

industry

standards,

or

equipment

which

has

not

had

reasonable

and

necessary

maintenance,

or

equipment

which

has

been

used

for

operation

outside

of

the

specifications

for

the

equipment.

MILLER

PRODUCTS

ARE

INTENDED

FOR

PURCHASE

AND

USE

BY

COMMER

CIAIJINDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

IN

THE

USE

AND

MAINTENANCE

OF

WELDING

EOUIPMENT.

In

the

event

of

a

warranty

claim

covered

by

this

warranty,

the

exclusive

remedies

shall

be,

at

MILLERS

option:

(1)

repair~

or

(2)

replacement;

or,

where

authorized

in

writing

by

MILLER

inappropriate

cases,

(3)

the

reasonable

coat

of

repair

or

replace

ment

at

an

authorized

MILLER

service

station;

or(4)

payment

of

or

credit

forthe

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

return

of

the

goods

at

customers

risk

and

expense.

MILLERS

option

of

repair

or

replacement

wilt

be

FOB.,

Factoryat

Appleton,

Wisconsin,

or

FOB.

at

a

MILLER

authorized

ser

vice

facility

as

determined

by

MILLER.

Therefore

no

compensation

or

reimburse

ment

for

transportation

costa

of

any

kind

will

be

allowed.

TO

THE

EXTENT

PERMuTED

BY

LAW,

THE

REMEDIES PROVIDED

HEREIN

ARE

THE

SOLE

AND

EXCLUSIVE

REMEDIES.

IN

NO

EVENT

SHALL

MILLER

BE

LIABLE

FOR

DIRECT,

INDIRECT,

SPECIAL,

INCIDENTALOR

CONSEQUENTIAL

DAMAGES

(INCLUDING

LOSS

OF

PROFIT),

WHETHER

BASED

ON

CON

TRACT,

TORT

OR

ANY

OTHER

LEGAL

THEORY.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WAR

RANTY,

GUARANTY

OR

REPRESENTATION

AS

TO

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

OF

CONTRACT

TORT

OR

ANY

OTHER

LEGAL

ThEORY

WHICH,

BUT

FOR

THIS

PROVISION,

MIGHTARISE

BY

IMPLICATION,

OPERATiON

OF

LAW,

CUSTOM

OF

TRADE

OR

COURSE

OF

DEALING,

IN

CLUDING

ANY

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OR

FITNESS

FOR

PARTICULAR

PURPOSE,

WITh

RESPECT

TO

ANY

AND

ALL

EQUIPMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

AND

DISCLAIMED

BY

MILLER.

Some

states

in

the

U.S.A.

do

not

allow

limitations

of

how

long

an

implied

warranty

lasts,

or

the

exclusion

of

incidental,

indirect,

special

or

consequential

damages,

so

the

above

limitation

or

exclusion

may

not

apply

to

you.

This

warranty

provides

ape

cif

ic

legal

tights,

and

other

rights

may

be

available,

but

may

vary

from

state

to

state.

In

Canada,

legislation

in

some

provinces

provides

for

certain

additional

warranties

or

remedies

other

than

as

stated

herein,

and

to

the

extent

that

they

may

not

be

waived,

the

limitations

and

exclusions

set

out

above

may

not

apply.

This

Umited

Warranty

provides

specific

legal

rights,

and

other

rights

may

be

available,

but

may

vary

from

province

to

province.

Before

Unpacking

equipment,

check

carton

for

any

damage

that

may

have

occurred

during

shipment.

Fi(e

any

claims

for

loss

or

damage

with

the

delivering

carrier.

Assistance

for

filing

or

settling

claims

may

be

obtained

from

distributor

and/or

equipment

manufacturers

Transportation

Department.

When

requesting

information

about

this

equipment,

always

provide

Model

Designation

and

Serial

or

Style

Number.

Use

the

following

spaces

to

record

Model

Designation

and

Serial

or

Style

Number

of

your

unit.

The

information

is

located

on

the

rating

label

or

nameplate,

Model

__________

Serial

or

Style

No.

Date

of

Purchase

I

J

?t)

LI

RECEIVING-HANDLING

miller

4/95

ARC

WELDING

SAFETY

PRECAUTIONS

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

orautomatic

wire

welding,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live.

Incorrectly

installed

or

improperly

grounded

equipment

is

a

hazard.

1.

Do

not

touch

live

electrical

parts.

2.

Wear

dry,

hole-free

insulating

gloves

and

body

protection.

3.

Insulate

yourself

from

work and

ground

using

dry

insulating

mats

or

covers

big

enough

to

prevent

any

physical

contact

with

the

work

or

ground.

4.

Disconnect

input

power

or

stop

engine

before

installing

or

servicing

this

equipment.

Lockout/tagout

input

poweraccording

to

OSHA

29

CFR

1910.147

(see

Safety

Standards).

5.

Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual

and

national,

state,

and

local

codes.

6.

Always

verify

the

supply

ground



check

and

be

sure

that

input

power

cord

ground

wire

is

properly

connected

to

ground

ARC

WELDING

can

be

hazardous.

terminal

in

disconnect

box

or

that

cord

plug

is

connected

to

a

properly

grounded

receptacle

outlet.

7.

When

making

input

connections,

attach

proper

grounding

conductor

first



double-check

connections.

8.

Frequently

inspect

input

power

cord

for

damage

or

bare

wiring



replace

cord

immediately

if

damaged



bare

wiring

can

kill.

9.

Turn

oft

all

equipment

when

not

in

use.

10.

Do

not

use

wom,

damaged,

undersized,

or

poorly

spliced

cables.

11.

Do

not

drape

cables

over

your

body.

12.

If

earth

grounding

of

the

workpiece

is

required,

ground

it

directly

with

a

separate

cable



do

not

use

work

clamp

or

work

cable.

13.

Do

not

touch

electrode

if

you

are

in

contact

with

the

work,

ground,

or

another

electrode

from

a

difterent

machine.

14.

Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

Maintain

unit

according

to

manual.

15.

Wear

a

safety

harness

if

working

above

floor

level.

16.

Keep

all

panels

and

covers

securely

in

place.

17.

clamp

work

cable

with

good

metal-to-metal

contact

to

workpiece

or

worktable

as

near

the

weld

as

practical.

£~

WARNING

PROTECT

YOURSELF

AND

OTHERS

FROM

POSSIBLE

SERIOUS

INJURY

OR

DEATH.

KEEP

CHILDREN

AWAY.

PACEMAKER

WEARERS

KEEP

AWAY

UNTIL

CONSULTING

YOUR

DOCTOR.

In

welding,

as

in

most

jobs,

exposure

to

certain

hazards

occurs.

Welding

is

safe

when

precautions

are

taken.

The

safety

information

given

below

is

only

a

summary

of

the

more

complete

safety

information

that

will

be

found

in

the

Safety

Standards

listed

on

the

Read

and

follow

all

Safety

Standards.

HAVE

ALL

INSTALLATION,

OPERATION,

MAINTENANCE,

AND

REPAIR

WORK

PERFORMED

ONLY

BY

QUALIFIED

PEOPLE.

ARC

RAYS

can

burn

eyes

and

skin;

ARC

RAYS

NOISE

can

damage

hearing;

FLYING

(,~

SLAG

OR

SPARKS

can

injure

eyes.

2.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

to

protect

yourface

and

eyes

when

welding

orwatching

(see

ANSI

Arc

rays

from

the

welding

process

produce

intense

Z49.1

and

Z87.1

listed

in

Safety

Standards).

visible

and

invisible

(ultravioletand

infrared)

rays

that

3.

Wear

approved

safety

glasses

with

side

shields.

can

burn

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

Chipping,

grinding,

and

welds

4.

Use

protective

screens

or

barriers

to

protect

others

from

flash

cooling

throw

oft

pieces

of

metal

or

slag.

and

glare;

warn

others

not

to

watch

the

arc.

NOISE

5.

Wear

protective

clothing

made

from

durable,

flame-resistant

1.

Use

approved

ear

plugs

or

ear

mufts

if

noise

level

is

high.

material

(wool

and

leather)

and

foot

protection.

to

your

health.

wearing

an

air-supplied

respirator.

Always

have

a

trained

r

FUMES

AND

GASES

can

be

hazardous

5.

Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

Welding

produces

fumes

and

gases.

Breathing

watchperson

nearby.

Welding

fumes

and

gases

can

displace

these

fumes

and

gases

can

be

hazardous

to

your

air

and

lower

the

oxygen

level

causing

injury

or

death.

Be

sure

health.

the

breathing

air

is

safe.

.-s

6.

Do

not

weld

in

locations

near

degreasing,

cleaning,

or

spraying

1.

Keep

your

head

out

of

the

fumes.

Do

not

breathe

the

fumes.

operations.

The

heat

and

rays

of

the

arc

can

react

with

vapors

to

2.

If

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

form

highly

toxic

and

irritating

gases.

remove

welding

fumes

and

gases.

7.

Do

not

weld

on

coated

metals,

such

as

galvanized,

lead,

or

3.

If

ventilation

is

poor,

use

an

approved

air-supplied

respirator.

cadmium

plated

steel,

unless

the

coating

is

removed

from

the

4.

Read

the

Material

Safety

Data

Sheets

(MSDSs)

and

the

weld

area,

the

area

is

well

ventilated,

and

if

necessary,

while

manufacturers

instruction

for

metals,

consumables,

coatings,

wearing

an

air-supplied

respirator.

The

coatings

and

any

metals

cleaners,

and

degreasers.

containing

these

elements

can

give

oft

toxic

fumes

if

welded.

CYLINDERS

can

explode

if

damaged.

4.

Never

drape

a

welding

torch

over

a

gas

cylinder.

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.

5.

6.

7.

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.

1.

Protect

compressed

gas

cylinders

from

excessive

heat,

8.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

mechanical

shocks,

slag,

open

flames,

sparks,

and

arcs.

9.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

2.

Install

cylinders

in

an

upright

position

by

securing

to

a

stationary

in

use

or

connected

for

use.

support

or

cylinder

rack

to

prevent

falling

or

tipping.

io.

Read

and

follow

instructions

on

compressed

gas

cylinders,

3.

Keep

cylinders

away

from

any

welding

or

other

electrical

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

circuits.

Standards.

srl.1.1

2/94

WELDING

can

cause

fire

or

explosion.

Welding

on

closed

containers,

such

as

tanks,

drums,

or

pipes,

can

cause

them

to

blow

up.

Sparks

can

fly

oft

from

the

welding

arc.

The

flying

sparks,

hot

workpiece,

and

hot

equipment

can

cause

fires

and

burns.

Accidental

contact

of

electrode

to

metal

objects

can

cause

sparks,

explosion,

overheating,

or

fire.

Check

and

be

sure

the

area

is

safe

before

doing

any

welding.

1.

Protect

yourself

and

others

from

flying

sparks

and

hot

metal.

2.

Do

not

weld

where

flying

sparks

can

strike

flammable

material.

3.

Remove

all

flammables

within

35

ft

(10.7

m)

of

the

welding

arc.

If

this

is

not

possible,

tightly

cover

them

with

approved

covers.

4.

Be

alert

that

welding

sparks

and

hot

materials

from

welding

can

easily

go

through

small

cracks

and

openings

to

adjacent

areas.

5.

Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.

6.

Be

aware

that

welding

on

a

ceiling,

floor,

bulkhead,

or

partition

can

cause

fire

on

the

hidden

side.

7.

Do

not

weld

on

closed

containers

such

as

tanks,

drums,

or

pipes,

unless

they

are

properly

prepared

according

to

AWS

F4.1

(see

Safety

Standards).

8.

Connect

work

cable

to

the

work

as

close

to

the

welding

area

as

practical

to

prevent

welding

current

from

traveling

long,

possibly

unknown

paths

and

causing

electric

shock

and

fire

hazards.

9.

Do

not

use

welder

to

thaw

frozen

pipes.

10.

Remove

stick

electrode

from

holder

or

cut

off

welding

wire

at

contact

tip

when

not

in

use.

11.

Wear

oil-free

protective

garments

such

as

leather

gloves,

heavy

shirt,

cuffless

trousers,

high

shoes,

and

a

cap.

12.

Remove

any

combustibles,

such

as

a

butane

lighter

or

matches,

from

your

person

before

doing

any

welding.

ENGINE

EXHAUST

GASES

can

kill.

MOVING

PARTS

can

cause

injury.

Moving

parts,

such

as

fans,

rotors,

and

belts

can

cut

fingers

and

hands

and

catch loose

clothing.

Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

Stop

engine

before

installing

or

connecting

unit

SPARKS

can

cause

BAT1ERY

GASES

TO

EXPLODE;

BAT1ERY

ACID

can

burn

eyes

and

skin.

Batteries

contain

acid

and

generate

explosive

gases.

STEAM

AND

PRESSURIZED

HOT

COOLANT

can

burn

face,

eyes,

and

skin.

It

is

best

to

check

coolant

level

when

engine

is

cold

to

avoid

scalding.

ENGINES

can

be

hazardous.

3.

Have

only

qualified

people

remove

guards

or

covers

for

maintenance

and

troubleshooting

as

necessary.

4.

To

prevent

accidental

starting

during

servicing,

disconnect

negative

()

battery

cable

from

battery.

5.

Keep

hands,

hair,

loose

clothing,

and

tools

away

from

moving

parts.

6.

Reinstall

panels

or

guards

and

close

doors

when

servicing

is

finished

and

before

starting

engine.

1.

Always

wear

a

face

shield

when

working

on

a

battery.

2.

Stop

engine

before

disconnecting

or

connecting

battery

cables.

3.

Do

not

allow

tools

to

cause

sparks

when

working

on a

battery.

4.

Do

not

use

welder

to

charge

batteries

or

jump

start

vehicles.

5.

Observe

correct

polarity

(+

and

)

on

batteries.

1.

If

the

engine

is

warm

and

checking

is

needed,

follow

steps

2

and

3.

2.

Wear

safety

glasses

and

gloves

and

put

a

rag

over

cap.

3.

Turn

cap

slightly

and

let

pressure

escape

slowly

before

completely

removing

cap.

PRINCIPAL

SAFETY

STANDARDS

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.

1,

from

American

Welding

Society,

550

N.W.

LeJeune

Rd,

Miami

FL

33126

Safety

and

Health

Standards,

OSHA

29

CFR

1910,

from

Superinten

dent

of

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

Recommended

Safe

Practices

for

the

Preparation

for

Welding

and

Cutting

of

Containers

That

Have

Held

Hazardous

Substances,

Ameri

can

Welding

Society

Standard

AWS

F4.1

from

American

Welding

So

ciety,

550

N.W.

LeJeune

Rd, Miami,

FL

33126

National

Electrical

Code,

NFPA

Standard

70,

from

National

Fire

Pro

tection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

P-i,

from

Compressed

Gas

Association,

1235

Jefferson

Davis

High

way,

Suite

501,

Arlington,

VA

22202.

Code

for

Safety

in

Welding

and

Cutting,

CSA

Standard

Wi

17.2,

from

Canadian

Standards

Association,

Standards

Sales,

178

Rexdale

Bou

levard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

Safe

Practices

ForOccupation

And

Educational

Eye

And

Face

Protec

tion,

ANSI

Standard

Z87.i,

from

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

Cutting

And

Welding

Processes,

NFPA

Standard

51

B,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

a

WARNING

1.

Use

equipment

outside

in

open,

well-ventilated

areas.

Engines

produce

harmful

exhaust

gases.

2.

If

used

in

a

closed

area,

vent

engine

exhaust

outside

and

away

from

any

building

air

intakes.

ENGINE

FUEL

can

cause

fire

or

explosion.

Engine

fuel

is

highly

flammable.

3.

4.

Do

not

overfill

tan

Do

not

spill

fuel.

engine.

k



all

If

fuel

ow

room

fo

is

spilled,

r

fuel

to

expand.

clean

up

before

starting

1.

Stop

engine

and

let

it

cool

oft

before

checking

or

adding

fuel.

2.

Do

not

add

fuel

while

smoking

or

if

unit

is

near

any

sparks

or

open

flames.

srl.1.1

2/94

CONSIGNES

DE

SECURITE

POUR

LE

SOUDAGE

A

LARC

UN

CHOC

ELECTRIQUE

peut

tuer.

(in

simple

contact

avec

des

piŁces

Olectriques

pout

provoquer

une

electrocution

ou

des

blessures

graves.

LØlectrode

et

le

circuit

do

soudage

sont

sous

tension

des

quo

lappareil

est

sur

ON.

Le

circuit

dentrØe

et

los

circuits

intemes

do

Iappareil

sont

egalement

sous

tension

a

ce

moment-l.

En

soudage

semi-automatique

ou

automatique,

le

fil,

le

dØvidoir,

0

logement

des

galets

dentraInementet

los

piŁces

mØtalliques

en

contact

avec

le

fil

do

soudage

sont

sous

tension.

Des

matŁriels

mal

installØs

ou

mal

mis

a

Ia

terre

presentent

un

danger.

1.

No

jamais

toucher

les

piŁces

electriques

sous

tension.

2.

Porter

des

gants

et

des

vOtemonts

do

protection

secs

no

comportant

pas

do

trous.

3.

Sisoler

do

Ia

piŁce

et

de

Ia

terre

au

moyen

de

tapis

ou

dautres

moyens

isolants

suffisamment

grands

pour

empŁcher

le

contact

physique

Øventuel

avec

Ia

piŁce

ou

Ia

terre.

4.

Couper

lalimentation

ou

arrŒter

le

moteur

avant

do

procedor

a

linstallation,

a

Ia

reparation

ou

a

lentretien

do

lappareil.

DØverrouiller

lalimentation

solon

Ia

norme

OSHA

29

CFR

1910.147

(voir

normes

do

secuntO).

5.

Installeret

mettre

ala

terre

correctement

cot

appareil

conformØment

a

son

manuel

dutilisation

et

au

codes

nationaux,

provinciaux

et

municipaux.

6.

Toujours

vŁnfier

Ia

terre

du

cordon

dalimentation



Verifier

et

sassurer

Quo

0

fil

do

terre

du

cordon

dalimentation

est

bien

raccordØ

ala

borne

do

terre

du

sectionneur

ou

quo

Ia

fiche

du

cordon

est

raccordOe

a

une

priso

correctoment

mise

a

Ia

terre.

7.

En

effoctuant

los

raccordomentsdentrØefixerdabordleconductour

do

mise

a

Ia

terre

appropn

ot

contra-verifier

los

connexions.

8.

Verifier

frequemment

le

cordon

dalimontation

pourvoirsiI

nest

pas

endommage

ou

dOnudØ



romplacor

10

cordon

immØdiatoment

sil

est

endommage



un

cable

dOnudŁ

peut

provoquer

une

electrocution.

9.

Mettre

lappareil

hors

tension

quand

on

no

Iutilise

pas.

10.

Ne

pas

utiliser

des

cables

uses,

endommages,

do

grossour

insuffisante

ou

mal

ØpissŁs.

11.

Ne

pas

enroulor

los

cables

autour

du

corps.

12.

Si

Ia

piŁce

soudØe

doit

Otre

mise

ala

terre,

le

faire

diroctement

avec

un

cable

distinct



no

pas

utiliser

10

connoctour

do

piŁce

ou

10

cable

do

retour.

13.

Ne

pas

toucher

lŁlectrode

quand

on

ost

en

contact

avec

a

piŁce,

Ia

terre

ou une

electrode

provenant

dune

autre

machine.

14.

Nutiliser

quun

materiel

en

bon

Øtat.

Reparor

ou

remplacer

sur-le-champ

les

piŁces

ondommagees.

Entretenir

lappareil

conformement

ace

manuel.

15.

Porter

un

hamais

do

sØcuntØ

quand

on

travaillo

on

hauteur.

16.

Maintonir

solidement

en

place

tousles

panneaux

ot

capots.

17.

Fixer

10

cable

do

rotourde

facon

a

obtenir

un

bon

contact

mOtal-mOtal

avec

Ia

piŁce

~

soudorou

latable

do

travail,

le

plus

prØs

possible

do

Ia

soudure.

a

MISE

EN

GARDE

LE

SOUDAGE

A

LARC

peut

Œtre

darigereux.

SE

PROTEGER

ET

PROTEGER

LES

AUTRES

CONTRE

LES

BLESSURES

GRAVES

VOIRE

MORTELLES.

TENIR

LES

ENFANTS

A

LECART.

LES

PERSONNES

GUI

PORTENT

UN

STIMULATEUR

CARDIAQUE

NE

DOIVENT

PAS

NON

PLUS

SAPPROCHER

DU

POSTE

DE

SOUDAGE,

A

MOINS

DAVOIR

CONSULTE

UN

MEDEC~N.

Le

soudage,

comme

Ia

plupart

des

travaux,

presente

certains

dangers.

Par

contre,

0

soudage

peut

Otre

effectuØ

en

toute

sOcuritØ

quand

on

prend

les

mesures

qul

simposent.

Los

consignes

de

sØcuntØ

donnees

ci-apres

ne

font

quo

rØsumer

information

contenue

dans

es

normes

de

sOcuritØ

ØnumØrØes

a

Ia

page

suivante.

Lire

et

respecter

toutes

ces

norrnes

do

sØcuritØ.

LINSTALLATION,

LUTILISATION,

LENTRETIEN

ET LES

REPARATIONS

NE

DOIVENT

ETRE

CONFIES

QUA

DES

PERSONNES

QUALIFIEES

LE

RAYONNEMENT

DE

LARC

peut

brler

les

RAYONNEMENT

DE

LARC

yeux

et

Ia

peau.

Le

BRUIT

peut

endommager

IouIe;

les

PROJECTIONS

DE

LAITIER

OU

LES

appropriee

pour

protOger

10

visage

et

les

yeux

quand

on

soude

ou

/p~

ETINCELLES

peuvent

blesser

les

yeux.

2.

Porter

un

masque

a

serre-tŒte

muni

dun

verre

filtrant

de

nuance

Larc

do

soudage

produit

des

rayons

visibles

et

invisibles

observe

Ia

travail

do

soudage

(voir

los

normes

ANSI

Z49.

1

et

Z87.1

intenses

(ultraviolots

et

infrarougos)

qui

pouvont

brler

donnØos

sous

Ia

rubflque

Pnncipales

normes

do

sØcuntO).

les

yeux

et

Ia

peau.

Le

bruit

produit

par

certains

procOdØs

peut

endommager

louie.

Des

protections

de

metal

ou

do

3.

Porter

des

lunettes

de

sŁcuntO

approuvØes

avoc

Øcrans

latØraux.

laitier

sont

produites

par

10

piquage,

le

meulage

ou

le

refroidissement

dos

soudures.

4.

Utiliser

des

paravents

ou

des

barriŁres

de

protection

pour

proteger

los

personnes

a

proximite

contra

los

coups

darc

et

IOblouissemont;

BRUIT

avertir

los

autros

personnes

do

ne

pas

regarder

larc.

1.

Utiliser

des

bouche-oroilles

ou

des

serre-tOte

antibruit

approuvØs

si

5.

Porter

des

vØtements

do

protection

en

tissu

ignifuge

durable

(lamb

et

le

niveau

de

bruit

est

ØlevØ.

cuir)

et

des

chaussures

do

sØcufltO.



I

LES

VAPEURS

ET

LES

FUMEES

peuvent

Œtre

5.

Ne

travailler

dans

un

espace

confine

quo

sil

est

bien

ventilØ,

ou

en

dangereuses

pour

Ia

sante.

portantunappareilrespiratoireaadductiondairpur.

Demanderun

observatour

ayant

reu

Ia

bonne

formation

do

toujours

se

tenir

a

t

,__~,.

Le

soudage

produit

des

vapeurs

ot

des

fumŁes

quil

est

proximitŁ.

Los

vapeurs

et

fumOes

do

soudage

pouvent

deplacer

lair

dangereux

do

respirer.

et

abaisser

le

niveau

doxygene

et

causerdos

blessures

graves

voiro

mortelles.

Sassurer

quo

lair

est

propre

a

Ia

respiration.

1.

Garder

Ia

tŒte

a

IextØrieur

des

vapeurs

et

des

fumØes

et

no

pas

los

6.

Ne

pas

souder

a

proximite

dopØrations

do

dØgraissage,

do

respirer.

nettoyage

ou

do

pulvensation.

La

chaleur

et

les

rayons

do

Iarc

2.

A

IintØneur,

ventiler

lo

poste

do

travail

ou

utiliser

un

dispositif

place

peuvont

reagir

avec

los

vapours

pour

former

des

gaz

haubement

toxiquos

et

irritants.

au

niveau

do

larc

pour

evacuer

los

vapeurs

et

fumØes

do

soudage.

7.

Ne

pas

souder

sur

des

mØtaux

revŒtus

comme

lacier

galvanisO,

au

3.

Si

Ia

ventilation

ost

mauvaiso,

utiliser

un

appareil

respiratoiro

a

p10mb

ou

cadmiØ

a

moms

quo

Ia

piŁce

nait

ØtØ

entiŁrement

dØcapØo,

adduction

dair

pur

approuve.

quo

le

poste

de

travail

soit

bien

ventilØ.

Sil

y

a

lieu,

porter

un

apparoil

4.

Consulter

los

fiches

signalOtiques

ot

los

consignes

du

fabricant

rospiratoireaadductiondairpur.

LesrevOtementsotlesmŁtauxqui

relatives

au

mOtaux,

produits

dapport,

revØtements,

nettoyants

ot

contiennent

do

tels

ØlØments

peuvent

dØgager

des

vapeurs

toxiques

degraissants.

lors

du

soudago.

.J

LES BOUTEILLES

peuvent

exploser

Si

elles

4.

Ne

jamais

poser

un

chalumeau

soudeur

sur

une

bouteille

do

gaz.

~.

sont

endommagees.

5.

Ne

jamais

laisser

une

electrode

de

soudage

toucher

uno

bouteillo.

;~-

Les

bouteilles

contenant

des

gaz

do

protection

sont

a

6.

Ne

jamais

soudor

sur

une

bouteillo

sous

pression

:

0110

exploserait.

~.

haute

prassion.

Une

bouteillo

endommagee

pout

7.

Nutilisor

quo

des

boubeilles

de

g~

do

protection,

dos

dØtendeurs,

explosor.

Etant

donnØ

que

los

bouteilles

do

gaz

font

des

tuyaux

souplos

et

des

raccords

appropriØs

concus

pour

normalement

partie

du

materiel

do

soudago,

les

traitor

Iapplication

particuliŁre;

conserver

ces

matØrlels

ot

ours

piŁces

on

avec

le

plus

grand

SO~fl.

bon

Łtat.

1.

Protegor

les

bouteilles

do

gaz

comprime

contra

Ia

chalour

intense,

8.

Eloignor

le

visage

do

Ia

sortie

du

robinet

do

Ia

boutoille

quand

on

los

chocs,

0

laitier,

los

flammes

nues,

les

Łtincellos

et

larc.

louvre.

2.

Placer

los

bouteilles

ala

vorticale

en

los

fixant

a

un

support

fixe

ou

a

9.

Replacer

Ia

chapoau

sur

Ia

bouteille

apres

utilisation.

un

chariot

pour

Øviter

quolles

no

tombent

ou

no

basculent.

10.

Lire

ot

suivre

los

consignes

relatives

aux

bouteilles

do

gaz

compnme,

3.

Tenir

los

bouteillos

a

lecart

du

poste

do

soudage

ou

dautres

circuits

au

materiel

connexe

ainsi

que

Ia

publication

P-i

do

Ia

CGA

donnØe

electriques.

sous

Ia

rubnquo

Principales

norrnes

de

sŁcuntŁ.

sri

.1.1

2/94

LE

SOUDAGE

peut

causer

un

incendie

ou

une

explosion.

Ne

pas

souder

sur

des

recipients

fermØs

comme

des

reservoirs,

des

Wits

ou

des

tuyaux:

us

peuvent

oxploser.

Larc de

soudage

peut

produire

dos

Øtincelles.

Des

Øtincelles,

une

piŁce

chaudo

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,

explosion,

Ia

surchauffe

ou

un

incendie.

Sassurer

que

le

lieu

ne

prØsente

pas

de

danger

avant

deffectuer

le

soudage.

1.

Se

protØgeret

proteger

lespersonnes

a

proximitØ

des

Øtincelles

et

du

metal

chaud.

2.

Ne

pas

souder

dans

un

endroit

00

les

Øtincelles

peuvent

atteindre

des

matOrlaux

inflammables.

3.

Enlevertoutes

les

matiŁres

inflammables

dans

un

rayon

de

moms

de

10

m

de

larc.

Si

cela

nest

pas

possible,

bien

les

recouvriren

utilisant

des

baches

approuvØes.

4.

Prendre

garde

que

los

Øtincelles

et

les

projections

ne

penetrent

dans

des

zones

adjacentes

en

sinfiltrant

dans

des

potites

fissures

et

ouvertures.

5.

Prendre

garde

aux

incendies

et

toujours

avoir

un

extincteur

a

proximite.

6.

Se

rappelerque

si

on

soude

sur

un

plafond,

un

plancher,

une

cloison

ou

autre,

le

feu

peut

prendre

de

lautre

ctØ.

7.

Ne

pas

souder

sur

des

recipients

fermØs

commo

des

reservoirs,

des

fOts

ou

des

tuyaux

a

moms

quils

ne

solent

prepares

de

tacon

appropriee

confom,Øment

ala

norme

F4.

1

de

lAWS

(voir

Ia

rubrique

Principales

normos

de

securitO).

8.

Raccorder

le

cable

de

retour

a

Ia

piece,

le

plus

pres

possible

de

Ia

zone

de

soudage,

pour

ompecher

que

le

courant

de

soudage

no

suive

une

trajectoire

longue

et

Øventuellement

inconnue

et

quil

ne

provoque

des

nsques

dOlectrocution

et

dincendie.

9.

Ne

pas

utiliser

le

chalumeau

soudeur

pour

degeler

des

tuyaux.

10.

Enlever

electrode

enrobØe

du

porte-electrode

ou

couper

le

fil

de

soudage

au

ras

du bec

contact

quand

on

ne

lutilise

pas.

ii.

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

briquet

a

gaz

ou

des

allumettes

quand

on

soude.

LES

GAZ

DECHAPPEMENT

DES

MOTEURS

1.

Utiliser

le

materiel

a

lextØrieur,

dans

des

lieux

ouverts

et

bien

peuvent

Œtre

mortels.

ventilØs.

Les

moteurs

produisent

des

gaz

dOchapp

ement

nocifs.

2.

Si

on

utilise

un

moteur

dans

un

local

fermØ,

dechappement

a

lextØnour

et

loin

des

pnses

dai

Øvacuer

les

gaz

r

du

btiment.

Ne

pas

fumer

en

faisant

le

plein

ou

si

lappareil

se

trouve

a

proximitØ

dØtincelles

ou

de

flammos

nues.

3.

Ne

pas

remplir

le

reservoir

a

ras

bord

:

prevoir

de

lespace

pour

Ia

dilatation

du

combustible.

4.

Ne

pas

renverser

du

carburant.

Si

on

renverse

du

carburant,

nettoyor

les

lieux

avant

do

faire

dØmarrer

le

moteur.

3.

Soules

des

personnes

qualifiees

doivent

dØmonter

les

protecteurs

ou

les

capots

pour

faire

lentrotien

ou

les

reparations

nØcossaires.

4.

Pour

empØchor

un

demarrage

accidentel

dun

systŁme

pendant

lentretion

ou

los

reparations,

dObrancher

le

cable

negatif

()

do

Ia

batterie.

5.

Eloigner

los

mains,

los

cheveux,

los

vŒtements

amples

et

les

outils

des

piŁces

en

mouvement.

6.

Replacerles

capots

ou

les

protecteurs

et

reformer

los

portes

uno

fois

Ientretien

et

les

reparations

termmnØs

et

avant

de

faire

dOmarrer

le

moteur.

2.

ArrØter

le

moteur

avant

do

branchor

ou

do

dØbrancher

los

cables

de

Ia

batterie.

3.

Ne

pas

faire

des

Øtincolles

avec

es

outils

quand

on

travaille

sur

une

battone.

4.

Ne

pas

utiliser Ia

source

do

courant

do

soudage

pour

charger

los

batteries

ou

pour

faire

dØmarrer

un

vŁhicule.

5.

Ne

pas

intervortir

Ia

polarite

des

batteries.

2.

PRINCIPALES

NORMES

DE

SECURITE

Safety

in

Welding

and

Cutting,

normeANSlZ49.i,

dolAmerican

Welding

Society,

550

N.W.

Lojouno

Ad,

Miami

FL

33126

Safety

and

Health

Sandards,

OSHA

29

CFR

1910,

du

Superintendent

of

Documents,

U.S.

Govemment

Printing

Office,

Washington,

D.C.

20402.

Recommended

Safe

Practice

for

the

Preparation

for

Welding

and

Cutting

of

Containers

That

Have

Held

Hazardous

Substances,

norme

AWS

F4.

1,

do

lAmoncan

Welding

Society,

550

N.W.

Lojeune

Ad,

Miami

FL 33126

National

ElectricalCode,

NFPA

Standard

70,

de

Ia

National

Fire

Protection

Association,

Batlerymarch

Park,

Qumncy,

MA

02269.

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

P-i,

do

Ia

Compressed

Gas

Association,

1235

Jefferson

Davis

Highway,

Suite

501,

Arlington,

VA

22202.

Regles

de

sØcuætØ

en

soudage,

coupage

et

procØdds

connexes,

norme

CSA

Wi

17.2,

do

Association

canadionne do

normalisation,

vente

do

norrnos,

i78

Roxdale

Boulovard,

Roxdale

(Ontario)

Canada

M9W

1

R3.

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

Protection,

norme

ANSI

Z87.1,

de

IAmorican

National

Standards

Institute,

1430

Broadway,

Now

York,

NY

10018.

Cutting

and

Welding

Processes,

nomie

NFPA

51

B,

do

Ia

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

a

MISE

EN

GARDE

LES

MOTEURS

peuvent

presenter

un

danger.

LE

CARBURANT

peut

provoquer

un

incendie

r

ou

une

explosion.

Le

carburant

est

hautoment

inflammable.

1.

ArrOter

le

moteur

et

le

laisser

refroidir

avant

de

verifier

le

niveau

de

carburant

ou

de

refaire

le

plein.

LES

PI¨CES

EN

MOUVEMENT

peuvent

causer

des

blessures.

Les

piŁces

en

mouvement

comme

los

ventilateurs,

les

rotors

et.

les

courroies

peuvent

couper

les

doigts

et

les

mains

et

happer

les

vŒtements

amples.

1.

Sassurerque

los

portes,

es

panneaux,

los

capots

et

les

protectours

sont

bien

fermØs

ot

bien

a

lour

place.

2.

ArrOter

le

moteur

avant

do

mettre

en

place

ou

do

raccorder

un

dispositif.

LES

ETINCELLES

peuventtaire

EXPLOSER

LE

GAZ

DES

BATTERIES;

LELECTROLYTE

peut

brUler

Ia

peau

et

les

yeux.

Los

batteries

contiennent

un

produit

acide

et

degagent

des

vapeurs

explosives.

orter

un

Łcran

facial

quand

on

travaille

sur

une

batteno.

LA

VAPEUR

ET

LE

LIQUIDE

DE

REFROIDISSEMENT

BRULANT

SOUS

PRESSION

peuvent

brUler

Ia

peau

et

les

yeux.

II

vaut

mieux

verifier

le

niveau

du

liquide

de

refroidissement

quand

10

moteur

est

froid

afin

dØviter

los

brOluros.

1.

Si

Ion

doit

verifier

le

niveau

quand

0

moteur

ost

chaud,

suivre

los

etapos

2

ot

3.

2.

Portordos

lunottos

de

sØcuntŁ

ot

des

gants

et

placer

un

chiffon

sur

le

bouchon.

3.

Toumor

lentement

le

bouchon

et

laissor

Ia

pression

sØchappor

lentement

avant

donlever

complŁtoment

le

bouchon.

srl.1.1

2/94

EMF

INFORMATION

TABLE

OF

CONTENTS

SECTION

1



SAFETY

INFORMATION

1

SECTION

2

SPECIFICATIONS

1

SECTION

3

INSTALLATION

3-1.

Equipment

Connection

Diagrams

3-2.

Installing

Swivel

Into

Pipe

Post

3-3.

Installing

Control

Box

Onto

Swivel

3-4.

Installing

Boom

And

Reel

Support

3-5.

Installing

Wire

Guide

Extension

3-6.

Wire

Guide

And

Drive

Roll

Installation

3-7.

Welding

Gun

Connections

3-8.

Wire

Feed

Motor

And

Gas

Valve

Control

Connections

3-9.

14-Pin

Plug

Connection

3-10.

Shielding

Gas

And

Weld

Cable

Connections

3-11.

Voltage

Sensing

Lead

(Optional)

3-12.

Removing

Safety

Collar

And

Adjusting

Boom

3-13.

Welding

Wire

Installation

3-14.

Motor

Start

Control

3-15.

DIP

Switches

Options

3-16.

Changing

Optional

Digital

Voltage

Control

For

Use

With

A

MILLER

Inverter-Type

Power

Source

3-17.

Threading

Welding

Wire

SECTION4-OPERATION

18

SECTION

5

MAINTENANCE

&

TROUBLESHOOTING

24

5-1.

Routine

Maintenance

24

5-2.

Overload

Protection

25

5-3.

Troubleshooting

25

OM-1584F

-

5/95

NOTE

D~

I

Considerations

About

Welding

And

The

Effects

Of

Low

Frequency

Electric

And

]

Magnetic

Fields

The

following

isa

quotation

from

the

Generat

Conclusions

Section

of

the

U.S.

Congress,

Office

of

Technology

Assessment,

Biological

Effects

of

Power

Frequency

Electric

&

Magnetic

Fields



Background

Paper,

OTA-BP-E-53

(Washington,

DC:

U.S.

Government

Printing

Office,

May

1989):.

. .

there

is

now

a

very

large

volume

of

scientific

findings

based

on

experiments

at

the

cellularlevel

and

from

studies

with

animals

and

people

which

clearly

establish

that

low

frequency

magnetic

fields

can

interact

with,

and

produce

changes

in,

biological

systems.

While

most

of

this

work

is

of

very

high

quality,

the

results

are

complex.

Current

scientific

understanding

does

not

yet

allow

us

to

interpret

the

evidence

in

a

single

coherent

framework.

Even

more

frustrating,

it

does

not

yet

allow

us

to

draw

definite

conclusions

about

questions

of

possible

risk

or

to

offer

clear

science-based

advice

on

strategies

to

minimize

or

avoid

potential

risks.

To

reduce

magnetic

fields

in

the

workplace,

use

the

following

procedures:

1.

Keep

cables

close

together

by

twisting

or

taping

them.

2.

Arrange

cables

to

one

side

and

away

from

the

operator.

3.

Do

not

coil

or

drape

cables

around

the

body.

4.

Keep

welding

power

source

and

cables

as

far

away

as

practical.

5.

Connect

work

clamp

to

workpiece

as

close

to

the

weld

as

possible.

About

Pacemakers:

The

above

procedures

are

among

those

also

normally

recommended

for

pacemaker

wearers.

Consult

your

doctor

for

complete

information.

modlO

1

4/93

2

3

4

5

6

7

8

9

11

12

15

16

SECTION

6

ELECTRICAL

DIAGRAMS

27

SECTION

7

PARTS

LIST

30

Figure

7-1.

Main

Assembly

30

Figure

7-2.

Support,

Hub

&

Reel

32

Figure

7-3.

Control

Box

33

Figure

7-4.

Panel,

Front

w/Components

35

Figure

7-5.

Boom

Assembly

36

Figure

7-6.

Drive

Assembly,

Wire

38

Figure

7-7.

Control

Panel

40

Table

7-1.

Drive

Roll

And

Wire

Guide

Kits

43

SECTION

1

-

SAFETY

INFORMATION

Figure

1-1.

Safety

Information

modl.1

2193

1

Safety

Alert

Symbol

2

Signal

Word

WARNING

means

possible

death

or

serious

injury

can

happen.

CAUTION

means

possible

minor

injury

or

equipment

damage

can

happen.

3

Statement

Of

Hazard

And

Result

4

Safety

Instructions

To

Avoid

Hazard

5

Hazard

Symbol

(If

Available)

6

Safety

Banner

Read

safety

blocks

for

each

sym

bol

shown.

7

NOTE

Special

instructions

for

best

oper

ation



not

safety.

SECTION

2-

SPECIFICATIONS

Table

2-1.

Wire

Feeder

Specification

Description

Type

Of

Input

Power

From

Welding

Power

Source

Single-Phase

24

Volts

AC,

10

Amperes,

50/60

Hertz.

(If

115

Volts

AC

Is

The

Only

Power

Available,

Use

Optional

Power

Supply

Adapter

Model

PSA-2.)

Maximum

Weld

Circuit

Rating

100

Volts,

750

Amperes,

100%

Duty

Cycle

Welding

Power

Source

Type

Constant

Voltage

(CV)

DC,

With

Contactor

Wire

Feed

Speed

Range

50

To

780

ipm

(1.3

To

19.8

mpm);

Standard

Motor

90

To

1400

ipm

(2.3

To

35.6

mpm);

High

Speed

Motor

Wire

Diameter

Range

.023

Thru

1/8

in

(0.6

To

3.2

mm)

Welding

Processes

Gas

Metal

Arc

(GMAW)

And

Flux

Cored

Arc

Welding

(FCAW)

Input

Power

Cord

Maximum

Height

With

4

ft

(1.2

m)

Post

10

ft

(3.1

m)

12

ft

(3.7

m)

Boom

16

ft

(4.9

m)

Boom

17

ft

(5.2

m)

21

ft

(6.4

m)

Weight

Net:

207

lb

(94

kg)

Ship:

318

lb

(144

kg)

Net:

280

lb

(127

kg)

Ship:

411

lb

(186

kg)

Vertical

Lift

Of

Boom

Horizontal

To

60

Above

Horizontal

To

600

Above

Horizontal



Read

all

safety

messages

throughout

this

manual.



Obey

all

safety

messages

to

avoid

injury.



Learn

the

meaning

of

WARNING

and

CAUTION.

2

a

WARNING

2

a

CAUTION

MOVING

PARTS

can

injure



Keep

away

from

moving

parts.~

L

:

ELECTRIC

SHOCK

can

kiIIJ~



Do

not

touch

live

electncal

parts

S

Keep

all

panels

and

covers

closed



Disconnect

input

power

before

when

operating.

inatalling

or

servicing.

/

5

,

READ

SAFETY

BLOCKS

at

start

of

I

Section

3-1

before

proceeding.

H

NOTE

~

Turn

Off

switch

when

using

high

frequency

-]

OM-1

584

Page

1

SECTION

3-INSTALLATION

3-1.

Equipment

Connection

Diagrams

A~

WARNING

CYLINDERS

can

explode

if

damaged.



Keep

cylinders

away

from

welding

and

other

electrical

circuits.



Never

touch

cylinder

with

welding

electrode.



Always

secure

cylinder

to

running

gear,

wall,

or

other

stationary

support.

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

wire

feeder

and

welding

powersource,

and

disconnect

input

power

before

making

connections.

Stop

engine

on

welding

generator.

The

welding

wire,

drive

rolls,

drive

assembly,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live

when

welding

or

feeding

wire

using

gun

trigger.

HOT

SURF

ACES

can

burn

skin.



Allow

gun

to

cool

before

touching.

Have

only

qualified

persons

install

this

unit.

wfwam9.1

2)93

2.

1

Welding

Power

Source

2

Remote

14

Connection

3

Negative

()

Weld

Output

Cable

4

Positive

(+)

Weld

Output

Cable

5

Workpiece

6

Voltage

Sensing

Clamp

7

Weld

Control

8

Boom

9

Gun

10

Swivel

11

Pipe

Post

And

Base

12

Gas

Hose

13

Gas

Supply

12

ST-i

53

176-A

10

9

Figure

3-1.

Typical

System

Connections

OM.1584

Page

2

3-2.

Installing

Swivel

Into

Pipe

Post

a

WARNING

RELEASE

OF

SPRING

PRESSURE

WITHOUT

BOOM

ATTACHED

can

cause

serious

personal

injury.



Do

not

remove

safety

collar

until

instructed

to

do

so.

FALLING

BOOM

can

cause

serious

personal

injury

and

equipment

damage.



Securely

mount

pipe

post

to

base

that

can

support

weight

of

unit

with

boom

in

horizontal

position.



Use

proper

equipment

for

lifting

swivel

and

boom

into

place.

5

4

1

Swingpak

Base

or

CBC

Cart

2

Pipe

Post With

Base

3

Steel

Bolt

Secure

as

shown

using

as

a

mini

mum

1/2

in

diameter

SAE

grade

5

steel

bolts.

4

Swivel

Assembly

Insert

into

pipe

post.

Lubricate

swivel.

5

Safety

Collar

Do

not

remove

until

instructed

to.

Tools

Needed:

~

3/4

in

ST-i

52

382

Figure

3-2.

Swivel

Installation

3-3.

Installing

Control

Box

Onto

Swivel

2

4

Tools

Needed:

3

cI::::::z:1===11

3/8

in

1

Weld

Control

2

Bracket

3

Screws

Bracket

and

screws

are

installed

onto

bottom

of

control

at

factory.

4

Swivel

Loosen

screws.

Place

control

on

swivel

and

slide

forward.

Tighten

screws.

ST-153

174

Figure

3-3.

Control

Box

Installation

OM-1

584

Page

3

3-4.

Installing

Boom

And

Reel

Support

3-5.

Installing

Wire

Guide

Extension

READ

SAFETY

BLOCKS

at

start

of

Section

3-2

before

proceeding.

1

Swivel

Plates

2

Yoke

Remove

hardware

from

swivel

plates

and

yoke.

3

Boom

Set

boom

into

swivel

as

shown.

4

Yoke

Install

through

yoke.

Install

cot

ter

and

spread

ends.

6

5

Bolt

7

Install

bolt,

tighten

hardware,

and

back

bolt

oft

one

half

turn.

6

Locking

Knob

Install

locking

knob

but

do

nottight

en.

7

Reel

Support

Install

reel

support.

Tools

Needed:

~

3/4,

3/8

in

Ref.

ST-153

170

Figure

3-4.

Boom

Installation

4

Tools

Needed:

3/8in

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.

ST-152

383

Figure

3-5.

Wire

Guide

Extension

Installation

OM-1584

Page

4

3-6.

Wire

Guide

And

Drive

Roll

Installation

READ

SAFETY

BLOCKS

at

start

of

Section

3-1

before

proceeding.

A.

Wire

Guide

Installation

When

changing

wire

size

or

type,

check

guide

size.

See

Table

7.1.

1

Drive

Rolls

Remove

drive

rolls

before

install

ing

wire

guides

(see

Figure

3-7).

2

Wire

Guide

Securing

Screws

Loosen

wire

guide

screws.

3

lnletWire

Guide

4

Intermediate

Wire

Guide

Insert

intermediate

guide

until

flange

on

guide

rests

against

cast

ing,

and

secure

with

guide

screw.

Install

drive

rolls

(see

Figure

3-7).

Repeat

procedure

for

opposite

side

of

wire

feeder.

Tools

Needed:

~==~

1

ST-137

391-F

I

ST-142

597-A

Figure

3-6.

Wire

Guide

Installation

B.

Drive

Roll

Installation

When

changing

wire

size

or

type,

check

drive

roll

size.

See

Table

7-1.

1

Spring

Shaft

Carrier

Close

spring

shaft

carrier.

2

Drive

Roll

Nut

3

Drive

Roll

Carrier

Turn

all

nuts

one

click

until

lobes

of

nut

line

up

with

lobes

of

drive

roll

carrier.

Open

spring

shaft

carrier.

4

Drive

Roll

Slide drive

rolls

onto

drive

roll

carri

ers.

Close

spring

shaft

carrier.

Turn

nut

one

click.

5

Drive

Assembly

Cover

Close

cover.

Repeat

procedure

for

opposite

side

of

wire

feeder.

ST-142

597-A

Figure

3-7.

Drive

Roll

Installation

OM-1

584

Page

5

3-7.

Welding

Gun

Connections

wfwami.i

2193

1

Drive

Assembly

Cover

2

Gun

Securing

Knob

3

Gun

Connector

Loosen

securing

knob.

Insert

gun

connector,

and

position

as

close

as

possible

to

drive

rolls

without

touching.

lighten

knob.

4

Gun

Trigger

Plug

5

Gun

Trigger

Receptacle

Insert

plug

into

free-hanging

re

ceptacle

and

tighten

threaded

col

lar.

6

Trigger

Cord

7

Trigger

Plug

8

Weld

Control

Trigger

Recep

tacle

Insert

plug

into

receptacle

and

tighten

threaded

collar.

Repeat

procedure

forgun

on

oppo

site

drive

assembly.

A~

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

wire

feeder

and

welding

power

source,

and

disconnect

input

power

before

inspecting

or

installing.

4

Figure

3-8.

Gun

And

Trigger

Lead

Connections

ST-i

53 072

/

Ref.

ST-153

172/

Ref.

ST-142

598-C

OM-1

584

Page

6

3-8.

Wire

Feed

Motor

And

Gas

Valve

Control

Connections

3-9.

14-Pin

Plug

Connection

Figure

3-10.

14-Pin

Plug

With

Information

1

Wire

Feed

Motor

And

Gas

Valve

Control

Receptacle

2

Plug

From

Boom

3

Cord

From

Boom

Insert

plug

from

boom

cord

it-ito

re

ceptacle

on

rear

of

control,

and

tighten

threaded

collar.

Repeat

procedure

for

opposite

side

of

weld

control.

Ref.

ST-142

598-c

Figure

3-9.

Boom

Connections

3

1

2

1

Plug

PLG1O

2

Keyway

3

Threaded

Collar

Connect

14-pin

plug

PLG1O

to

matching

receptacle

on

welding

powersource

as

follows:

align

key-

way,

insert

plug,

and

tighten

threaded

collar.

Information:

A,

B

Contact

closure

completes

the

24

volts

ac

contactor

control

circuit.

C

Command

signal:

+10

volts

dc.

D

Control

circuit

common.

E

Remote

power

source

voltage

command

signal

from

feeder(potentiometerwiperoro-1

0

volts

do

source);

0

to

+10

volts

dc.

F

Current

feedback;

0-10

volts

dc,

1

volt

per

100

amperes.

G

Circuit

common

for

24

volts

ac

circuit.

H

Voltage

feedback;

0-10

volts

dc,

1

volt

per

10

arc

volts.

The

remaining

pins

in

the

plug

are

not

used

by

the

feeder.

Ref.

ST-143 260-Al

Ref.

S-0512

OM-1

584

Page

7

3-10.

Shielding

Gas

And

Weld

Cable

Connections

a

WARNING

CYLINDERS

can

explode

it

damaged.



Keep

cylinders

away

from

welding

and

other

electrical

circuits.



Never

touch

cylinder

with

welding

electrode.



Always

secure

cylinder

to

running

gear,

wall,

or

other

stationary

support.

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

wire

feederand

welding

powersource,

and

disconnect

input

power

before

inspecting

or

installing.

BUILDUP

OF

SHIELDING

GAS

can

harm

health

or

kill.



Shutoff

shielding

gas

supply

when

not

in

use.

The

weld

cables

and

shielding

gas

hoses

ex

tend

10

ft

(3m)

from

the

boom.

If

the

welding

power

source

or

gas

supply

are

further

from

the

boom,

extend

cables

and

hoses

as

follows:

1

Weld

Cables

2

Insulated

Sleeving

Bolt

together

weld

cables

from

welding

pow

ersource

and

boom.

Use

electrical

tape

and

insulated

sleeving

to

cover

connection.

3

Shielding

Gas

Extension

Hose

4

Boom

Shielding

Gas

Hose(s)

Connect

boom

shielding

gas

hoses

to

gas

supplies

or

extend

hoses.

The

hoses

from

the

boom

have

5/8-18

right-hand

threads.

5

Shielding

Gas

V

Adapter

Connect

single

end

fitting

of

V

adapter

to

gas

supply,

and

connect

boom

shielding

gas

hoses

to

fittings

on

V

end

of

adapter.

The

hoses

from

the

boom

have

5/8-18

right-hand

threads.

Figure

3-11.

Shielding

Gas

And

Weld

Cable

Connections

wam4.1

2/93

Tools

Needed:

~

5/8iri

Ref.

ST-153

175-B

OR

OM-1584

Page

8

3-11.

Voltage

Sensing

Lead

(Optional)

A

35

ft

(10.6

m)

voltage

sensing

lead

is

provided

with

several

options.

Connect

voltage

sensing

lead

to

workpiece

(see

Figure

3-1).

3-12.

Removing

Safety

Collar

And

Adjusting

Boom

a

WARNING

RELEASE

OF

SPRING

PRESSURE

FALLING

BOOM

can

cause

serious

WITHOUT

BOOM

ATTACHED

can

cause

serious

personal

injury.

personal

injury

and



Adjustment

rod

must

equipment

damage.

be

threaded

fully

through



Do

not

remove

safety

collar

until

instructed

to

do

so.

yoke.

1

Locking

Knob

lighten

knob

to

prevent

boom

movement.

Loosen

knob

to

allow

boom

movement.

Change

knob

position

to

limit

upward

movement.

Tools

Needed:

E

2

Increasing

Spring

Decreasing

Spring

Pressure

ForA

Pressure

ForA

I-ieavy

Gun

Light

Gun

move

safety

collar.

Boom

should

zontal

to

60

degrees

above

hori

balance

in

any

position

from

hori

2

Threaded

Rod

Pull

boom

down

slightly

and

re

zontal.

If

necessary,

adjust

boom

as

follows:

3

Jam

Nut

Loosen

jam

nut

and

turn

threaded

rod

until

boom

balances.

lighten

jam

nut.

Be

sure

several

full

vent

boom

falling.

threads

are

through

yoke

to

pro-

4

Yoke

Retain

safety

collar

for

use

in

dis

Z~

1-1/8

in

assembling

or

moving

boom.

Ret.

ST-142

599-B

/

Ref

ST-i

52

380-A

Figure

3-12.

Boom

Adjustments

3-13.

Welding

Wire

Installation

A.

Installation

Of

Spoo

I-Type

Wire

1

Retaining

Ring

2

Wire

Spool

3

Hub

Remove

retaining

ring

and

slide

spool

unto

hub.

1

4

HubPin

Turn

spool

until

hub

fits

in

spool.

Reinstall

retaining

ring.

Repeat

procedure

for

installing

spool-type

wire

on

opposite

side

of

wire

feeder.

E

ST-i

53

171

Figure

3-13.

Installation

Of

Spool-Type

Wire

OM-1

584

Page

9

B.

Installation

Of

Optional

Wire

Reel

And

Reel

Type

Wire

C.

Adjusting

Hub

Tension

Figure

3-14.

Installation

Of

Optional

Wire

Reel

And

Reel

Type

Wire

8

5

4

1

Retaining

Ring

2

Spanner

Nut

3

Lock

4

Wire

Retainer

5

Wire

Reel

6

Hub

7

Hub

8

Reel

Support

Remove

retaining

ring.

Pull

lock

and

turn.

Remove

spanner

nut,

wire

retainer,

and

wire

reel

from

hub.

Lay

wire

reel

assembly

on

flat

sur

face,

and

install

wire

as

shown.

Tighten

spanner

nut

until

lock

is

in

position

over

hole

in

wire

retainer.

Pull

lock

and

turn

to

insert

locking

into

wire

retainer.

Slide

wire

reel

assembly

onto

hub,

and

turn

assembly

until

hub

is

seated

in

hole

in

reel.

Reinstall

re

taining

ring.

ST-i

43478-A

/

sT-i

52

463

~T)

/cDDD~\

Wire

Installation

Tum

Off

wire

feeder

and

welding

power

source.

1

Hex

Nut

2

Spool

Grasp

spool

in

one

hand

and

turn

while

using

a

wrench

to

adjust

hex

nut.

When

a

slight

force

is

needed

to

turn

spool,

tension

is

set.

Repeat

procedure

to

adjust

hub

tension

on

opposite

side

of

wire

feeder.

Tools

Needed:

~

5/8in

5T-153

i73

Figure

3-15.

Adjusting

Hub

Tension

OM-1584

Page

10

3-14.

Motor

Start

Control

a

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

wire

feederand

welding

powersource,

and

disconnect

input

power

before

inspectIng

or

installing.

Figure

3-16.

Motor

Start

Control

On

Motor

Control

Board

PCi

STATIC

ELECTRICITY

can

damage

parts

on

circuit

boards.



Put

on

grounded

wrist

strap

BEFORE

handling

boards

or

parts.

wfwaml.1

2193

To

change

wire

feed

starting

speed

proceed

as

follows:

Turn

Off

wire

feeder

and

welding

power

source.

Remove

wrapper.

1

Front

Panel

Front

panel

shown

open

for

illus

tration

purposes.

2

Motor

Board

PCi

3

Motor

Start

Control

Poten

tiometer

R70

Turn

potentiometer

clockwise

to

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.

Close

and

secure

front

panel,

and

reinstall

wrapper.

Tools

Needed:

non-conductive

cII:1:::::l=::=U

1/4

in

Ref.

$T-142

710-A

/

SB-146

862-0

OM-i

584

Page

11

3-15.

DIP

Switches

Options

A~

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

wire

feederand

welding

powersource,

and

disconnect

input

power

before

inspecting

or

installing.

STATIC

ELECTRICITY

can

damage

parts

on

circuit

boards.



Put

on

grounded

wrist

strap

BEFORE

handling

boards

or

parts.

wfwaml.1

2/93

Figure

3-17.

Spot

Time

DIP

Switch

Si

Ref.

ST-142

710-A/

SA-146

866-B

A.

Spot

Time

DIP

Switch

Si

Change

DIP

switch

position

if

a

dif

ferent

range

of

Spot

Time

is

de

sired.

Turn

Off

wire

feeder

and

welding

power

source.

Rernove

wrapper.

1

Front

Panel

Remove

screw

from

upper

left

cor

ner,

and

open

hinged

front

panel.

2

4-In-i

Board

PC3O

3

Spot

Time

DIP

Switch

Si

Place

switch

(on

either

or

both

PC3O

boards)

in

desired

position:

Long

Time

for

0-5

seconds,

and

Short

Time

for

0-2.5

seconds

(see

Figure

4-11

for

control

operation).

Close

and

secure

front

panel,

and

reinstall

wrapper.

Tools

Needed:

non-conductive

c::::::::J:~n

1/4

in

OM-1

584

Page

12

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