Miller KG217318 Owner's manual

Miller

September

1996

Form:

OM-1

587E

Effective

With

Serial

No.

KG21

7318

OWNERS

MANUAL

D-64M

Wire

Feeder

For

GMAW-P,

GMAW,

And

FCAW

Welding

CE

Type

of

Input

Power

Welding

Power

Source

Type

Wire

Feed

Speed

Range

Wire

Diameter

Range

Welding

Circuit

Rating

IP

Rating

Overall

Dimensions

Weight

24

Volts

AC

Single-Phase

10

Amperes

50/60

Hertz

Constant

Voltage

(CV)

DC

For

GMAW

Or

Constant

Voltage(CV)

/

Constant

Current

(CC)

DC

For

GMAW-P

All

Need

14-Pin

And

Contactor

Control

Standard:

50

To

780

1pm

(1.3

To

19.8

mpm)

Optional

High

Speed:

92

To

1435

ipm

(2.3

To

36.5

mpm)

.023

To

1/8

in

(0.6

To

3.2

mm)

Max

Spool

Weight:

60

lb

(27

kg)

100

Volts,

750

Amperes,

100%

Duty

Cycle

23

Length:

32

in

(812

mm)

Width:

18

in

(457

mm)

Height:

14

in

(356

mm)

78

lb

(35

kg)

cover_om

4/95



ST-800

179

'

1996

MILLER

Eleclnc

Mfg.

Co.

PRINTED

IN

USA

a

I

u-f

MILLERS

TRUE

BLUEﬁ

LIMITED

WARRANTY

Effective

February

7,

1996

(Equipment

with

a

serial

number

preface

of

KD

or

newer)

This

limited

werrsnty

supersedes

all

werrenties

end

is

exclusive

with

no

other

guarantees

or

warranties

expressed

or

implied.

LIMITED

WARRANTY



Subject

to

the

terms

end

conditions

below,

MILLER

Electric

Mfg.

Co.,

Appleton,

Wisconsin,

warrants

to

its

original

retell

purchaser

thst

new

MILLER

equipment

sold

efter

the

effective

date

ot

this

limited

warranty

is

free

of

de

fects

in

material

end

workmanship

et

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

warrenty

periods

listed

below,

MILLER

will

repair

or

replace

any

war

ranted

psrts

orcomponents

mat

feil

due

to

such

defects

in

materiel

or

workmenship.

MILLER

must

be

notified

in

writing

within

thirty

(30)

deys

of

such

defect

or

failure,

at

which

time

MILLER

will

provide

instructions

on

the

warranty

claim

procedures

to

be

followed.

MILLER

shell

honor

warranty

claims

on

warrenfed

equipment

listed

below

in

the

event

of

such

a

failure

within

the

warranty

time

penods.

All

warranty

time

periods

start

on

the

date

that

the

equipment

was

delivered

to

the

original

retail

purchaser,

or

one

year

after

the

equipment

is

sent

to

a

North

Amencan

distributor

or

eighteen

months

after

the

equipment

is

sent

to

en

International

distnbutor.

1.

5YearaParts3YesrsLsbor



Original

main

power

rectifiers



Inverters

(input

and

output

rectifiers

only)

2.

3

Years



Parts

and

Labor

-

Trsnsfom,er/Rectiflar

Power

Sources

-

Plasma

Arc

Cutting

Power

Sources

-

Semi-Automatic

end

Automatic

Wire

Feeders

-

Inverter

Power

Supplies



Intellitig



Robots

(1

year

laborj

3.

2

Years



Parts

end

Labor



Engine

Driven

Welding

Generators

(NOTE:

Engines

are

warranted

sepersrely

by

the

engine

manufacturer.)



Air

Compressors

4.

1

Year



Parts

end

Labor

-

Motor

Driven

Guns

-

Process

Controllers

IHPS

Power

Sources

-

Water

Coolant

Systems

-

HF

Units

-

Gnda



Spot

Welders

-

Load

Banks

-

SDX

Transformers



Miller

Cyclomatic

Equipment



Running

Gear/Trailers

-

Plasma

Cutting

Torches

(except

APT,

ZIPCUT

&

PLAZCUT

Models)

-

Tecumaeh

Engines



Deutz

Engines

(outside

North

America)

-

Field

Options

(NOTE:

Field

options

are

covered

under

True

Blueﬁ

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

6.

9ODaysFsrtsendLsbor



MIG

Guns/TIG

Torches

-

APT,

ZIPCUT

&

PLAZCUT

Model

Plasma

Cutting

Torches



Remote

Controls

-

Accessory

Kits



Replacement

Parts

MILLERS

True

Blueﬁ

Limited

Warranty

shell

not

apply

to:

1.

Iteme

fumished

by

MILLER.

but

manufactured

by

others,

such

as

engines

or

trade

accessories.

These

items

em

covered

by

the

menufacturars

warranty,

if

any.

2.

Consumable

components:

such

as

contact

tips,

cutting

nozztes,

contectors

end

relays

or

pens

that

fsil

due

to

normal

wear.

3.

Equipment

thst

has

been

modifIed

by

any

party

other

then

MILLER,

or

equip

ment

that

has

been

improperiy

installed,

improperiy

operated

or

misused

based

upon

industry

standards,

or

equipment

which

hss

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

PURCHASEAND

USE

BY

COMMER

CIAIJINDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

IN

THE

USE

AND

MAINTENANCE

OF

WELDING

EGUIPMENT.

In

the

event

of

a

warranty

claim

covered

by

this

warranty,

the

exclusive

remedies

shatl

be,

at

MILLERS

option:

(1)

rspeir~

or

(2)

replacement;

or,

where

authorized

in

writing

by

MILLER

in

appropnate

csses,

(3)

the

reasonable

cost

of

mparror

replace

ment

at

an

authorized

MILLER

service

station;

or

(4)

payment

of

orcredit forthe

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

mtum

of

the

goods

at

customers

risk

and

expense.

MILLERS

option

of

repair

or

replacement

will

be

FOB.,

Factory

at

Appleton.

Wisconsin,

or

FOB.

ate

MILLER

euthorised

ser

vice

facility

as

determined

by

MILLER.

Therefore

no

compensation

or

reimburse

ment

for

transportation

costs

of

any

kind

will

be

allowed.

TO

THE

EXTENT

PERMITTED

BY

LAW,

THE

REMEDIES

PROVtDED

HEREIN

ARE

THE

SOLE

AND

EXCLUSIVE

REMEDIES.

IN

NO

EVENTSHALL

MILLER

BE

UABLE

FOR

DIRECT,

INDIRECT,

SPECIAL,

tNCIDENTALOR

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

IMPLtED

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,

MIGHT

ARISE

BY

IMPLtCATtON,

OPERATION

OF

LAW,

CUSTOM

OF

TRADE

OR

COURSE

OF

DEAUNG,

IN

CLUDING

ANY

IMPUED

WARRANTY

OF

MERCHANTABILITY

OR

FITNESS

FOR

PARTICULAR

PURPOSE.

WITH

RESPECTTO

ANY

AND

ALL

EQUIPMENT

FURNISHED

BY

MILLER

5

EXCLUDED

AND

DISCLAIMED

BY

MILLER.

Some

states

in

the

U.S.A.

do

nor

allow

limitations

of

how

long

an

implied

warranty

lasts,

or

the

exclusion

of

incidentsl.

indirect,

speciel

or

consequential

damages,

so

the

above

limitation

or

exclusion

may

not

apply

to

you.

This

warranty

provides

ape

cit

ic

legal

righta,

and

other

rights

may

be

available,

but

may

vary

from

state

to state.

In

Ceneda,

legislation

in

some

provinces

provides

for

certain

additional

warranties

or

remedies

other

than

as

stated

herein,

end

to

the

extent

that

they

may

not

be

waived,

the

limitations

end

exclusions

set

out

above

may

not

apply.

This

Limited

Warranty

provides

specific

Iegsl

rights,

and

other

rights

may

be

available,

but

may

vary

from

province

to

province.

WHO

DO

I

CONTACT?

For

help,



contact

your

distributor

.

For

additional

information,

such

as

Technical

Manuals

(Service

And

Parts)

Engine

Manuals

Circuit

And

Wiring

Diagrams

Process

Handbooks

To

file

a

claim

for

loss

or

damage

during

shipment,

U

contact

the

delivering

carner

For

assistance

in

filing

or

settling

claims,



contact

your

distributor

and/or

equipment

manufactUrerS

Transportation

Department

7~~~jf9~

{TETIT]

Miller

Electric

Mfg.

Co.



CALL:

414-7354505

U

FAX:

800-637-2348

(in

USA),

or

414-735-4136

(outside

USA)

Users

Guides

Distributor

Directories



contact

your

distributor

.

oj

.

WRITE:

Miller

Electric

Mfg.

Co.

P.O.

BOX

1079

Appleton,

WI

54912

USA

Always

provide

Model

Name

and

Serial

or

Style

Number

~~1

I

miller_wan

3/96

Declaration

of

Conformity

for

European

Community

(CE)

Products

NOTE

~

This

information

is

provided

for

units

with

CE

certification

(see

rating

label

on

unit).

Manufacturers

Name:

Miller

Electric

Mfg.

Co.

Manufacturers

Address:

1635

W.

Spencer

Street

Appleton,

WI

54914

USA

Declares

that

the

product:

D64

IVI

conforms

to

the

following

Directives

and

Standards:

Directives

Low

Voltage

Directive:

73/23/EEC

Electromagnetic

Compatibility

(EMC)

Directive:

89/336/EEC

Machinery

Directives:

89/392/EEC,

91/368/EEC,

93/C

133/04,

93/68/EEC

Standards

Arc

Welding

Equipment

Part

I:

Welding

Power

Sources:

IEC

974-1

(April

1995

Draft

Revision)

Arc

Welding

Equipment:

Wirefeed

Systems:

IEC

974-4

(May

1995



Draft

Revision)

Degrees

of

Protection

Provided

By

Enclosures

(IP

Code):

IEC

529:1989

Insulation

Coordination

For

Equipment

With

Low-Voltage

Systems:

Part

I:

Principles,

Requirements

and

Tests:

IEC

664-1:

1992

Electromagnetic

Compatibility,

(EMC):

EN

50199

European

Contact:

Mr.

Luigi

Vacchini,

Managing

Director

MILLER

Europe

S.P.A.

Via

Privata

lseo

20098

San

Giuliano

Milanese,

Italy

Telephone:

39(02)98290-1

Fax:

39(02)9828

1

-552

dec_coni

1/96

SECTION

1

-

SAFETY

PRECAUTIONS

FOR

ARC

WELDING

OM-1587

E

9/96

safety_Born

1

4/95

1-1.

Symbol

Usage

4A

Means

Warning!

Watch

Out!

There

are

possible

hazards

with

this

A

Marks

a

special

safety

message.

procedure!

The

possible

hazards

are

shown

in

the

adjoining

symbols.

~

Means

NOTE;

not

safety

related.

I

~

This

group

of

symbols

means

Warning!

Watch

Out!

possible

ELECTRIC

SHOCK,

MOVING

PARTS,

and

HOT

PARTS

hazards.

Consult

symbols

and

below

for

necessary

I

________________________________

actions

to

avoid

the

hazards.

1-2.

Arc

Welding

Hazards

4~

WARNING

The

symbols

shown

below

are

used

throughout

this

manual

to

call

attention

to

and

identify

possible

hazards.

When

you

see

the

symbol,

watch

out,

and

follow

the

to

avoid

the

hazard.

The

safety

information

given

below

is

only

a

summary

of

the

more

complete

safety

information

found

in

the

Safety

Standards

listed

in

Section

1-4.

Read

and

follow

all

Safety

Standards.

Only

qualified

persons

should

install,

operate,

maintain,

and

repair

this

unit.

During

operation,

keep

everybody,

especially

children,

away.

ELECTRIC

SHOCK

can

kill.

Touching

live

electrical

parts

cart

cause

fatal

shocks

or

severe

burns.

The

electrode

and

work

circuit

is

electrically

live

whenever

the

output

is

on.

The

input

power

circuit

and

machine

intema!

circuits

are

also

live

when

power

is

on.

In

semiautomatic

or

automatic

wire

welding,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live.

Incorrectly

installed

or

improperly

grounded

equipment

is

a

hazard.

1.

Do

not

touch

live

electrical

parts.

2.

Wear

dry,

hole-free

insulating

gloves

and

body

protection.

3.

Insulate

yourself

from

work

and

ground

using

dry

insulating

mats

or

covers

big

enough

to

prevent

any

physical

contact

with

the

work

or

ground.

4.

Disconnect

input

power

or

stop

engine

before

installing

or

servicing

this

equipment.

Lockout/tagout

input

power

according

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

nnw~r

r.nrrf

r,rntjnrf

wirp

ic

nrnnariti

r~onnpt-.torl

tn

riroiir~r1

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

off

all

equipment

when

not

in

use.

10.

Do

not

use

worn,

damaged,

undersized,

or

poorly

spliced

cables.

11.

Do

not

drape

cables

over

your

body.

12.

If

earth

grounding

of

the

workpiece

is

required,

ground

it

directly

with

a

separate

cable



do

not

use

work

clamp

or

work

cable.

13.

Do

not

touch

electrode

if

you

are

in

contact

with

the

work,

ground,

or

another

electrode

from

a

different

machine.

14.

Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

Maintain

unit

according

to

manual.

15.

Wear

a

safety

hamess

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

wnrkniet-~

nr

~

~s

near

thA

weld

....

.__.__

..__.__

.._

yy,Jprstau,c



co

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

or

watching

(see

ANSI

Arc

rays

from

the

welding

process

produce

intense

Z49.i

and

Z87.1

listed

in

Safety

Standards).

-

.

visible

and

invisible

(ultraviolet

and

infrared)

rays

3.

Wear

approved

safety

glasses

with

side

shields.

that

can

bum

eyes

and

skin.

Noise

from

some

processes

can

damage

heanng.

Chipping,

4.

Use

protective

screens

or

barriers

to

protect

others

from

flash

grinding,

and

welds

cooling

throw

off

pieces

of

metal

or

slag.

and

glare;

warn

others

not

to

watch

the

arc.

NOISE

5.

Wear

protective

clothing

made

from

durable,

flame-resistant

1.

Use

approved

ear

plugs

or

ear

muffs

if

noise

level

is

high.

material

(wool

and

leather)

and

foot

protection.

-

hazardous

to

your

health.

wearing

an

air-supplied

respirator.

Always

have

a

trained

,~

FUMES

AND

GASES

can

be

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

air

-

these

fumes

and

gases

can

be

hazardous

to

your

and

lower

the

oxygen

level

causing

injury

or

death.

Be

sure

the

health,

breathing

air

is

safe.

6.

Do

not

weld

in

locations

near

degreasing,

cleaning,

or

spraying

1.

Keep

your

head

out

of

the

fumes.

Do

not

breathe

the

fumes.

operations.

The

heat

and

rays

of

the

arc

can

react

with

vapors

to

form

highly

toxic

and

irritating

gases.

2.

If

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

remove

welding

fumes

and

gases.

7.

Do

not

weld

on

coated

metals,

such

as

galvanized,

lead,

or

3.

If

ventilation

is

poor,

use

an

approved

air-supplied

respirator.

cadmium

plated

steel,

unless

the

coating

is

removed

from

the

4.

Read

the

Material

Safety

Data Sheets

(MSDSs)

and

the

weld

area,

the

area

is

well

ventilated,

and

if

necessary,

while

manufacturers

instruction

for

metals,

consumables,

coatings,

wearing

an

air-supplied

respirator.

The

coatings

and

any

metals

cleaners,

and

degreasers.

containing

these

elements

can

give

off

toxic

fumes

if

welded.

CM-i

587

Page

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.

1.

Protect

compressed

gas

cylinders

from

excessive

heat,

mechanical

shocks,

slag,

open

flames,

sparks,

and

arcs.

2.

Install

cylinders

in

an

upright

position

by

securing

to

a

stationary

support

or

cylinder

rack

to

prevent

falling

or

tipping.

3.

Keep

cylinders

away

from

any

welding

or

other

electrical

circuits.

4.

Never

drape

a

welding

torch

over

a

gas

cylinder.

5.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

6.

Never

weld

on

a

pressurized

cylinder



explosion

will

result.

7.

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

in

good

condition.

8.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

9.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

in

use

or

connected

for

use.

10.

Read

and

follow

instructions

on

compressed

gas

cylinders,

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

Standards.

WELDING

can

cause

fire

or

explosion.

Welding

on

closed

containers,

such

as

tanks,

drums,

orpipes,

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

bums.

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

lighteror

matches,

from

your

person

before

doing

any

welding.

1-3.

Additional

Installation,

Operation,

And

Maintenance

Hazards

FIRE

OR

EXPLOSION

can

result

from

placing

unit

on,

over,

or

near

combustible

surfaces.

1.

Do

not

locate

unit

on,

over,

or

near

combustible

surfaces.

FALLING

EQUIPMENT

can

cause

serious

personal

injury

and

equipment

damage.

1.

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.

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.

1.

Keep

away

from

moving

parts

such

as

fans.

2.

Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

MAGNETIC

FIELDS

FROM

HIGH

CURRENTS

can

affect

pacemaker

operation.

Pacemaker

wearers

keep

away.

Wearers

should

consult

their

doctor

before

going

near

arc

welding,

gouging,

or

spot

welding

operations.

MOVING

PARTS

can

cause

injury.

1.

Keep

away

from

moving

parts.

2.

Keep

away

from

pinch

points

such

as

drive

rolls.

FLYING

PIECES

OF

METAL

or

DIRT

can

injure

eyes.

1.

Wear

safety

glasses

with

side

shields

or

face

shield.

1.

Do

not

press

gun

trigger

until

instructed

to

do

so.

2.

Do

not

point

gun

toward

any

part

of

the

body,

other

people,

or

any

metal

when

threading

welding

wire.

HIGH-FREQUENCY

RADIATION

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.

2.

Do

not

install

unit

near

flammables.

4

WELDING

WIRE

can

cause

puncture

~

wounds.

OM-1587

Page

2

OVERUSE

can

cause

OVERHEATED

EQUIPMENT.

1.

Allow

cooling

period.

2.

Reduce

current

or

reduce

duty

cycle

before

starting

to

weld

again.

3.

Follow

rated

duty

cycle.

SIGNIFICANT

DC

VOLTAGE

exists

after

removal

of

input

power

on

Inverters.

1.

Turn

Off

inverter,

disconnect

input

power,

and

discharge

input

capacitors

according

to

instructions

in

Maintenance

Section

before

touchina

any

Darts.

BUILDUP

OF

SHIELDING

GAS

can

harm

health

or

kill.

1.

Shut

off

shielding

gas

supply

when

not

in

use.

STATIC

ELECTRICITY

can

damage

parts

on

circuit

boards.

1.

Put

on

grounded

wrist

strap

BEFORE

handling

boards

or

parts.

-

2.

Use

proper

static-proof

bags

and

boxes

to

store,

move,

or

ship

PC

boards.

1-4.

Principal

Safety

Standards

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.1,

from

American

Welding

Society,

550

N.W.

LeJeune

Rd,

Miami

FL

33126

Safety

and

Health

Standards,

OSHA

29

CFR

1910,

from

Superintendent

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,

Batterymarch

Park,

Quincy,

MA

02269.

1-5.

EMF

Information

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

W117.2,

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.

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

PapeI

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

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

also

recommended

for

pacemaker

wearers.

Consult

your

doctor

for

complete

information.

OM-1

587

Page

3

SECTION

1

-

CONSIGNES

DE

SECU

RITE

POUR

LE

SOUDAGE

A

LARC

safety_Born_cf

r

4195

1-1.

Signification

des

symboles

AA

Signifie

Mise

en

garde!

Attention!

Ce

mode

opØratoire

peut

A

Indique

un

message

de

securitC

special.

prØsenterdes

dangers!

Les

dangers

possibles

sont

indiques

par

~

signme

NOTA;

pas

lie

ala

sdcuritØ

es

divers

symboles.

I

~

I

Ce

groupe

de

symbolos

signifie

Mise

en

garde!

Attention!,

risque

de

CHOCS

ELECTRIQUES,

dan-

I

gers

prØsentØs

par

los

PI¨CES

MOBILES

et

los

PI¨CES

CHAUDES.

Voir

les

symboles

et

Ies

I

corisignes

associØes

ci-aprŁs

pour

prendre

los

mesures

nØcessaires

afiri

do

so

prØmurtir

contre

I

les

dangers.

1-2.

Dangers

du

soudage

a

Iarc

a

MISE

EN

GARDE

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

volt

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,

lutilisation,

Ientretien

et

les

reparations

ne

doivent

Œtre

confiØs

qu

des

personnes

qualifiØes.

Aucune

personne,

et

particuliŁrement

les

enfants,

ne

dolt

se

trouver

a

proximitØ

du

poste

de

soudage

UN

CHOC

ELECTRIQUE

peut

tuer.

Un

simple

contact

avec

des

piŁces

electnques

pout

provoquerune

electrocution

ou

des

blessures

graves.

LØlectrode

et

Ie

circuit

do

soudage

sont

sous

tension

des

que

lappareil

est

sur

ON.

Le

circuit

dentrØe

et

es

circuits

intemes

de

lappareil

sont

egalement

sous

tension

a

ce

moment-l.

En

soudage

somi-automati

que

ou

automatique,

le

fil,

le

dØvidoir,

Ic

logement

des

galets

dentraTnement

et

les

piŁces

metalliques

en

contact

avec

le

fil

de

soudage

sont

sous

tension.

Des

matØriels

ma!

installØs

ou

mal

mis

ala

terre

presentent

un

danger.

1.

Ne

jamais

toucher

es

piŁces

electnques

sous

tension.

2.

Porter

des

gants

et

des

vŒtements de

protection

secs no

corn

portant

pas

de

trous.

3.

Sisoler

de

Ia

piŁce

et

do

Ia

terre

au

moyen

do

tapis

ou

dautres

moyens

isolants

suftisamment

grands

pour

empŁcher

le

contact

physique

Øventuel

avec

a

piŁce

ou

Ia

terre.

4.

Couper

lalimentation

ou

arrŒter

le

moteur

avant

de

proceder

a

installation,

ala

reparation

ou

a

lentretien

do

lappareil.

DØver

rouiller

!alimentation

solon

Ia

norrne

OSHA

29

CFR

1910.147

(voir

norrnes

do

sØcuntØ).

5.

Installer

et

mettro

a

Ia

terre

corroctemont

cot

appareil

confom,Ø

mont

a

son

manuel

dutilisation

et

au

codes

nationaux,

provin

ciaux

ot

municipaux.

6.

Toujours

verifier

Ia

terre

du

cordon

dalimentation



Verifier

et

sassurer

quo

le

tilde

terre

du

cordon

dalimentation

ost

bien

rac

cordØ

a

Ia

borne

do

terre

du

sectionneur

ou

que

Ia

fiche

du

cor

don

est

raccordØe

a

une

pnse

correctemont

mise

a

Ia

terre.

7.

En

effectuant

los

raccordements

dentrØe

fixer

dabord

le

conductour

do

miso

a

Ia

terre

appropne

ot

contre-vØnfier

los

connexions.

8.

Verifier

frequomment

le

cordon

dalimentation

pour

voir

sil

nest

pas

endommagØ

ou

dØnudØ



romplacer

le

cordon

immediate-

mont

sliest

endommagØ



un

cable

dØnudØ

peut

provoquer

une

electrocution.

9.

Mettre

lapparoil

hors

tension

quand

on

no

lutilise

pas.

10.

Ne

pas

utiliser

dos

cables

uses,

ondommagØs,

de

grosseur

in

suffisante

ou

mal

ØpissØs.

11.

Ne

pas

enrouler

los

cables

autour

du

corps.

12.

Si

Ia

piŁce

soudØe

dolt

Łtre

mise

a

laterro,

10

faire

directement

avec

un

cable

distinct



no

pas

utilisor

10

connecteur

do

piŁce

ou

le

cable

do

rotour.

13.

Ne

pas

toucher

lØlectrode

quand

on

est

en

contact

avec

Ia

piŁce,

Ia

terre

ou

uno

electrode

provenant

dune

autre

machine.

14.

Nutilisor

quun

materiel

on

bon

etat.

RØparer

ou

romplacer

sur

le-champ

los

piŁces

endommagees.

Entretenir

lappareil

confor

mØment

a

ce

manuel.

15.

Porter

un

hamais

de

sØcuritØ

quand

on

travaille

en

hauteur.

16.

Maintonir

solidoment

en

place

tous

les

panneaux

ot

capots.

17.

Fixer

le

cable

do

rotour

do

facon

a

obtenir

un

bon

contact

metal

avoc

Ia

piŁce

a

souder

ou

Ia

table

do

travail,

10

plus

prŁs

possible

do

Ia

soudure.

RAVONNEMENT

DE

LARC

LE

RAYONNEMENT

DE

LARC

peut

brler

es

yeux

et

Ia

peau.

Le

BRUIT

peut

endommager

IouIe;

les

PROJECTIONS

DE

LAITIER

OU

LES

ETINCELLES

peuvent

blesser

les

yeux.

Larc

do

soudage

produit

des

rayons

visiblos

ot

invi

sibles

intenses

(ultraviolets

et

infrarouges)

qui

pouv

ont

brUlor

los

youx

ot

Ia

poau.

Le

bruit

produit

par

cor

tains

procØdŁs

pout

ondommager

louIe.

Des

projoc

tions

do

metal

ou

do

laitior

sont

produitos

par

10

piquago,

0

meulago

011

10

refroidissoment

dos

sou

dures.

BRUIT

2.

Porter

un

masque

a

serro-tØte

muni

dun

vorre

filtrant

do

nuance

appropriØo

pour

protegor

0

visago

et

los

yeux

quand

on

soudo

ou

observe

Ia

travail

do

soudago

(voir

los

normes

ANSI

Z49.1

et

Z87.1

donnØos

sous

Ia

rubrique

Principales

normos

do

sØcun

te).

raux.

1.

Utiliser

dos

bouche-oreilles

ou

des

serro-tŁte

antibruit

approu

yes

silo

niveau

do

bruit

est

ØlevØ.

3.

Porter

des

lunottos

do

sØcuritØ

approuvØes

avoc

Øcrans

late-

4.

Utilisor

des

paravonts

ou

dos

barnŁros

do

protection

pour

protØ

ger

les

personnes

a

proximitØ

contre

los

coups

darc

et

IØblouis

semont;

avertir

es

autros

personnes

do

no

pas

regardor

arc.

5.

Porter

des

vŁtements

do

protection

en

tissu

ignifuge

durable

(Iai

no

et

cuir)

et

des

chaussures

do

secunte.

OM-1587

Page

4

LES

VAPEURS

ET

LES

FUMEES

peuvent

Œtre

dangereuses

pour

Ia

sante.

Le

soudage

produit

des

vapeurs

et

des

fumØes

quil



I

est

dangereux

de

respirer.

1.

Garder

a

tŒte

a

lextØrieur

des

vapeurs

et

des

fumØes

et

ne

pas

es

respirer.

2.

A

IintØneur,

ventiler

le

posts

de

travail

ou

utiliser

un

dispositif

place

au

niveau

de

larc

pour

Øvacuer

los

vapeurs

et

fumØes

de

soudage.

3.

Si

Ia

ventHation

est

mauvaise,

utiliser

un

appareil

respiratoire

a

adduction

dair

pur

approuvØ.

4.

Consulter

es

fiches

signaletiques

et

es

consignes

du

fabricant

relatives

au

mØtaux,

produits

dapport,

revŒtements,

nettoyants

et

dØgraissants.

LES

BOUTEILLES

peuvent

exploser

Si

elles

sont

endommagØes.

Les

bouteilles

contenant

des

gaz

de

protection

sont

a

haute

pression.

Une

bouteille

endommagee

peut

exploser.

Etant

donnØ

que

les

bouteilles

de

gaz

font

normalement

partie

du

materiel

de

soudage,

les

traiteravec

le

plus

grand

soin.

1.

ProtØger

les

bouteilles

de

gaz

comprimØ

contre

a

chaleur

intense,

les

chocs,

le

laitier,

les

flammes

nues,

les

Øtincelles

et

Iarc.

2.

Placer

les

bouteilles

a

verticale

en

es

fixant

a

un

support

fixe

ou

a

un

chariot

pour

Øviter

quolles

ne

tombent

ou ne

basculent.

3.

Tenir

es

bouteilles

a

lØcart

du

poste

de

soudage

ou

dautres

circuits

electriques.

LE

SOUDAGE

peut

causer

un

incendie

ou

une

explosion.

Ne

pas

souder

sur

des

recipients

fermØs

comme

des

reservoirs,

des

fts

ou

des

tuyaux

:

Is

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

electrode

sur

des

objets

metalliques

peut

produire

des

Øtincelles,

lexplosion,

Ia

surchauffe

ou

un

incendie.

Sassurerque

le

lieu

ne

prØsente

pas

de

danger

avant

deffectuer

le

soudage.

1.

Se

protØger

et

protØger

es

personnes

a

proximitØ

des

Øtincelles

et

du

metal

chaud.

2.

Ne

pas

souder

dans

un

endroit

o

les

Øtincelles

peuvent

atteindre

des

matØnaux

inflammables.

3.

Enlever

toutes

es

matiŁres

inflammables

dans

un

rayon

de

moms

de

10

m

de

arc.

Si

cela

nest

pas

possible,

bien

les

recouvnr

en

utilisant

des

bches

approuvees.

4.

Prendre

garde

que

es

Øtincelles

et

les

projections

ne

pØnØtrent

dans

des

zones

adjacentes

en

sinfiltrant

dans

des

petites

fissures

et

ouvertures.

UN

INCENDIE

OU

UNE

EXPLOSION

peut

Œtre

cause

par

un

appareil

place

au

contact,

au-dessus

ou

a

cote

de

surfa

ces

combustibles.

1.

Ne

pas

placer

Iappareil

au

contact,

au-dessus,

ou

a

ctØ

dune

surface

combustible.

2.

Ne

pas

installer

Iappareil

a

ctŁ

dun

objet

ou

dun

produit

inflammable.

EN

TOMBANT,

LE

MATERIEL

peut

sen

dommager

ou

causer

des

blessures

graves.

1.

Nutiliser

Ianneau

de

Ievage

que

pour

soulever

lappareil;

NE

PAS

Iutiliser

pour

soulever

los

cha

riots,

es

bouteilles

do

gaz

ou

autres

accessoiros.

2.

Pour

soulevor

Ia

source

do

courant,

utiliser

des

appareils

de

puissance

suffisante.

3.

Si

Ion

utilise

un

ØlØvateur

a

fourche

pour

dØplacer

Iappareil,

sassurerque

Ia

fourthe

est

suffisarnment

et

dØpasse

de

Iautre

cotØ

do

lappareil.

5.

Ne

travailler

dans

un

espace

confine

que

sil

est

bien

ventilO,

ou

en

portant

un

appareil

respiratoire

a

adduction

dair

pur.

Demander

a

un

observateur

ayant

reu

Ia

bonne

formation

de

toujours

se

tenir

a

proximitØ.

Les

vapeurs

et

fumØes

de

soudage

peuvent

dØplacer

lair

et

abaisser

le

niveau

doxygene

et

causer

des

blessures

graves

voire

mortelles.

Sassuror

que

lair

est

propre

a

Ia

respiration.

6.

Ne

pas

souder

a

proximitØ

doperations

de

dØgraissage,

de

nettoyage

ou

de

pulvØnsation.

La

chaleur

et

les

rayons

do

larc

peuvent

reagir

avec

les

vapeurs

pour

former

des

gaz

hautement

toxiques

et

irritants.

7.

Ne

pas

souder

sur

des

mØtaux

revŒtus

comme

Iaciergalvanise,

au

p10mb

ou

cadmiØ

a

moms

que

Ia

piŁce

nalt

ØtØ

entiŁrement

dØcapee,

que

le

poste

de

travail

soit

bien

ventilØ.

Sil

y

a

lieu,

porter

un

appareil

respiratoire

a

adduction

dalr

pur.

Les

revŒtements

et

les

mOtaux

qui

contiennent

do

tels

OlØments

peuvent

degager

des

vapeurs

toxiques

lors

du

soudage.

4.

Najamais

poser

un

chalumeau

soudeur

sur

une

bouteille

do

gaz.

5.

Ne

jamais

laisser

une

electrode

de

soudage

toucher

une

bouteille.

6.

Ne

jamais

souder

sur

une

bouteille

sous

pression

:

elle

exploserait.

7.

Nutiliser

que

des

bouteilles

de

gaz

de

protection,

des

dØtendeurs,

des

tuyaux

souples

et

des

raccords

appropnes

concus

pour

application

particuliere;

conserverces

matØriels

et

leurs

piŁces

en

bon

Øtat.

8.

Eloigner

le

visage

de

Ia

sortie

du

robinet

do

Ia

bouteille

quand

on

louvre.

9.

Replacer

le

chapeau

sur

Ia

bouteille

aprŁs

utilisation.

10.

Lire

et

suivre

les

consignes

relatives

aux

bouteilles

de

gaz

comprime,

au

materiel

connexe

ainsi

quo

Ia

publication

P-i

do

Ia

CGA

donnØe

sous

Ia

rubnquo

Principales

normes

do

sØcuritØ

5.

Prendre

garde

aux

incendies

et

toujours

avoir

un

oxtincteur

a

proximite.

6.

Se

rappeler

quo

si

Ion

soude

sur

un

plafond,

un

plancher,

une

cloison

ou

autre,

le

feu

pout

prondre

de

lautre

ctØ.

7.

No

pas

souder

sur

des

recipients

fermØs

commo

dos

reservoirs,

des

Wits

ou

des

tuyaux

a

moms

quils

no

soient

prØparØs

de

facon

appropriee

conformement

a

Ia

norme

F4.1

do

lAWS

(voir

Ia

rubrique

Pnncipales

normes

do

securitØ).

8.

Raccorder

lo

cable

do

retour

Ia

piece,

le

plus

pres

possible

do

Ia

zone

do

soudage,

pour

empŒcher

quo

10

courant

do

soudage

ne

suive

une

trajoctoire

longue

et

Øventuellemont

inconnue

et

quiI

no

provoque

des

nsques

dØlectrocution

et

dincendio.

Ne

pas

utilisor

le

chalumeau

soudeur

pour

dØgeler

dos

tuyaux.

EnleverlØlectrode

onrobØe

du

porte-electrode

ou

couperle

fil

do

soudage

au

ras

du

bec

contact

quand

on ne

Iutilise

pas.

11.

Porter

des

vŒtements

do

protection

non

huileux

comme

dos

gants

en

cuir,

une

chemise

Øpaisse,

des

pantalons

sans

revers,

dos

chaussures

montantes

et

un

casque.

12.

Ne

pas

porter

des

matiŁres

combustibles

sur

soi

comme

un

bnquet

a

gaz

ou

des

allumettos

quand

on

soudo

LES

PI¨CES

CHAUDES

peuvent

provo

quer

des

brlures

graves.

1.

No

pas

toucher

les

piŁces

chaudes

los

mains

nues.

2.

Laissor

une

pØnode

do

refroidissemont

avant

do

toucher

le

pistolet

ou

Ia

torche.

LES

PI¨CES

MOBILES

peuvent

causer

des

blessures.

1.

Se

tenir

a

lØcart

des

piŁces

en

mouvement

corn-

me

los

ventilateurs.

2.

Sassurer

quo

tous

les

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

do

sØcuritØ

avec

Øcrans

late

raux

ou

Øcran

facial.

9.

10.

1-3.

Autres

dangers

relatifs

a

Iinstallation,

Iutilisation

et

Ientretien

OM-i

587

Page

5

LES

PI¨CES

MOBILES

peuvent

quer

des

blessures.

provo



1.

Se

tenir

a

lØcart

des

piŁces

mobiles.

2.

Se

tenir

a

lØcart

des

points

de

pincemen

lets

dentraInement.

t,

ex.

:

ga

LE

1.

2.

FIL

DE

SOUDAGE

peut

percer

Ia

peau.

Attendre

es

instructions

avant

dappuyer

sur

Ia

gchette.

Ne

pas

pointer

le

pistolet

sur

une

partie

du

corps,

sur

dautres

personnes,

ou

sur

une

piŁce

mØtalli

que

lorsquon

enfile

le

fil

de

soudage.

?

UNE

UTILISATION

EXCESSIVE

peut

se

traduire

par

une

SURCHAUFFE

DU

MA

TERIEL.

1.

Laisser

une

penode

de

ref

roidissement.

2.

RØduire

le

courant

ou

le

facteur

de

marche

avant

de

recommencer

a

souder.

3.

Utiliser

le

facteur

de

marche

nominal.

1-4.

Principales

normes

de

sØcuritØ

Safety

in

Welding

and

Cutting,

norme

ANSI

Z49.i,

de

lAmencan

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

Safety

and

Health

Sandards,

OSHA

29

CFR

1910,

du

Highway,

Suite

501,

Arlington,

VA

22202.

Superintendent

of

Documents,

U.S.

Government

Printing

Office,

Regles

de

sØcuritØ

en

soudage,

coupage

et

procØdØs

connexes,

Washington,

D.C.

20402.

norme

CSA

Wi

17.2,

de

IAssociation

canadienne

de

normalisation,

vente

de

norrnes,

178

Rexdale

Boulevard,

Rexdale

(Ontario)

Recommended

Safe

Practice

for

the

Preparation

for

Welding

arid

Canada

M9W

1

R3.

Cutting

of

Containers

That

Have

Held

Hazardous

Substances,

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

normeAWS

F4.

1,

de

lAmerican

Welding

Society,

550

N.W.

Lejeune

Protection,

norme

ANSI

Z87.

1,

de

l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,

do

a

National

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

1-5.

Informations

sur

les

champs

ØlectromagnØtiques

NOTA

DonnØes

sur

le

soudage

et

sur

es

effets

des

champs

Ølectn-

Pour

rØduire

lintensitØ

des

champs

magnØtiques

au

poste

de

travail:

ques

et

magnetiques

basse

frequence.

Void

une

citation

tirØe

des

conclusions

gØnØrales

du

document

Biolo-

1.

Grouper

solidement

les

cables

en

es

entrelaant

ou

en

les

serrant

avec

un

ruban

adhØsif.

gical

Effects

of

Power

Frequency

Electric

&

Magnetic

Fields

-

Back

ground

Paper

(Effets

biologiques

des

champs

electnques

et

magneti-

2.

Disposer

les

cables

sur

un

seul

ctØ

et

a

lØcart

de

lopØra

ques

aux

froquences

dutilisation

-

Document

de

base),

OTA-BP

teur.

-E-53

(Washington,

DC:

U.S

Govemment

Printing

Office,

mail

989)

publtØ

par

Office

of

Technology

Assessment

(Congres

des

Etats-

3.

Eviter

denrouler

les

cables

ou

de

les

poser

sur

lØpaule.

Unis):

.....

des

experiences

au

niveau

cellulaire

et

des

etudes

sur

lhomrrie

et

lanimal

nous

ont

apporte

une

foule

de

renseignements

:

II

4.

Eloigner

le

plus

possible

Ia

source

de

courant

et

los

cables

est

maintenant

clair

que

les

champs

magnØtiques

basse

frØquence

de

soudage.

peuvent

influer

sur

les

systŁmes

biologiques

et

les

modifier.

Ces

tra

vaux

sont

gØnØralement

dexcellente

qualitØ,

mais

les

rØsultats

obte-

5.

Raccorder

le

connecteur

de

piŁce

a

Ia

piŁce

a

souder,

le

plus

nus

sont

complexes.

Dans

lØtat

actuel

de

nos

connaissances

dans

le

prØs

possible

de

Ia

soudure.

domaine

scientifique,

nous

ne

sommes

pas

en

mesure

dinterpreter

nos

observations

a

lumiŁre

dune

thØorie

gØnerale.

Et.

cc

qui

est

Stimulateurs

cardiaques:

encore

plus

regrettable,

nous

ne

pouvons

nen

affirmer

de

dØfinitif

au

Les

recommandations

cl-avant

sadressent

aussi,

normalement,

sujet

des

nsques

Øventuels,

ii

proposer

des

mØthodes

scientiflques

aux

personnes

qul

utilisent

un

stimulateur

cardiaque.

Pour

de

plus

precises

pour

rØduire

ces

nsques

ou

pour

es

Øviter.

amples

renseignements,

consultez

votre

mØdecin.

=9-4

LES

CHAMPS

MAGNETIQUES

PRO

DUITS

PAR

LES

COURANTS

ELEVES

peuvent

nuire

au

fonctionnement

du

sti

mulateur

cardiaque

1.

Les

personnes

qui

portent

un

slimulateurcardiaque

doivent

se

tenir

Øloignees

du

poste

de

soudage.

2.

Les

personnes

qui

portent

un

stimulateur

cardia

que

devraient

consulter

leur

mØdecin

avant

de

sapprocherdun

poste

de

soudage

ou

de

gougea

go

a

arc

ou

de

soudage

par

points.

LELECTRICITE

STATIQUE

peut

endom

mager

es

piŁces

des

circuits

imprimØs.

1.

Mettre

un

bracelet

antistatique

AVANT

de

manipu

ler

los

cartos

de

circuits

impnmØs

ou

los

piŁces.

2.

Utiliser

des

sacs

et

boites

antistatiques

adequats

pour

ranger,

dØplacer

ou

expØdier

les

cartes

do

circuits_imprimes.

_________________________

LA

HAUTE

FREQUENCE

peut

crØer

~es

interferences

dans

les

systŁmes

de

ra

dionavigation,

les

services

de

sØcutitØ,

les

ordinateurs

et

le

materiel

de

tØlØ

communications.

~HFJ

ii,

1.

No

confier

cette

installation

qua

un

personnel

qua

liflØ

et

connaissant

bion

lØquipement

electronique.

2~

Lutilisatour

ala

responsabilitØ

de

faire

comger

ra

pidement

par

un

Ølectncien

qualifiØ

les

problŁmes

dintrfØrences

resultant

de

linstallation.

3.

Dans

10

cas

dun

avertissement

dinterfØrence

donnØ

par

le

Conseil

fØdØral

des

communications,

arrOter

dutilisor

immØdiatement

lequipement.

4.

Faire

vØnfier

et

entretenir

regulierement

installa

tion.

5.

Tenir

los

portes

et

panneaux

do

Ia

source

do

haute

frØquence

bieri

fermØs,

maintenir

les

Øclateurs

au

bon

rØglage

et

utiliser

une

mise a

Ia

terre

et

un

Øcran

de

protection

atm

do

rØduire

au

minimum

Ia

possibilitØ

dinterfØrences.

LACCUMULATION

DE

GAZ

DE

PRO

TECTION

peut

Œtre

nuisible

a

Ia

sante

voire

mortel.

1.

Quand

on

nutilise

pas

le

gaz

de

protection,

fermer

le

robinet

de

Ia

bouteille.

UNE

TENSION

C.C.

IMPORTANTE

est

prØsente

sur

les

onduleurs

aprŁs

que

lon

ait

coupØ

Ialimentation.

1.

Avant

de

toucher

los

piŁces,

mettre

londuleur

hors

tension,

coupor

lalimentation

et

dØcharger

es

condensateurs

dentrØe

conforrnØment

aux

di

rectives

de

Ia

section

Entretien.

OM-1

587

Page

6

SECTION

2-

DEFINITIONS

Warning!

Watch

Out!

There

are

possible

hazards

as

shown

by

the

symbols.

Drive

rolls

can

injure

fingers

Welding

wire

and

drive

parts

are

at

welding

voltage

during

operation



keep

hands

and

metal

objects

clear.

1

Electric

shock

can

kill.

1.1

Wear

dry

insulating

gloves.

Do

not

touch

electrode

with

bare

hand.

Do

not

wear

wet

or

damaged

gloves.

1.2

Protect

yourself

from

electric

shock

by

insulating

yourself

from

work

and

ground.

1.3

Disconnect

input

plug

or

power

before

working

on

machine.

2

Breathing

welding

fumes

can

be

hazardous

to

your

health.

2.1

Keep

your

head

Out

of

the

fumes.

2.2

Use

forced

ventilation

or

local

exhaust

to

remove

the

fumes.

2.3

Use

ventilating

fan

to

remove

fumes.

3

Welding

sparks

can

cause

explosion

or

fire.

3.1

Keep

flammables

away

from

welding.

Dont

weld

near

flammables.

3.2

Welding

sparks

can

cause

fires.

Have

a

fire

extinguisher

nearby

and

have

a

watch

person

ready

to

use

it.

3.3

Do

not

weld

on

drums

or

any

closed

containers.

4

Arc

rays

can

bum

eyes

and

injure

skin.

4.1

Wear

hat

and

safety

glasses.

Use

ear

protection

and

button

shirt

collar.

Use

welding

helmet

with

correct

shade

of

filter.

Wear

complete

body

protection.

5

Become

trained

and

read

the

instructions

before

working

on

the

machine

or

welding.

6

Do

not

remove

or

paint

over

(cover)

the

label.

2-1.

Warning

Label

Definitions

OM-1

587

Page

7

2-2.

Manufacturers

Rating

Label

For

CE

Products

NOTE

~

Some

symbols

are

found

only

on

CE

products.

).~.

Output

Alternating

Current

A

Amperes

~J

Volts

()

Off

Duty

Cycle

p

Degree

Of

Protection

Hz

Hertz

O~O

Jog

>

Parameter

Select



Trigger

~J

~f

Line

Connection

Purge

Read

Instructions

~b

Trigger

Hold

On

Trigger

Hold

Off

()



Increase

~



I.

Trigger

Hold

On

IndicatorLight

0

Trigger

Hold

Off

IndicatorLight

(J1

Primary

Voltage

U2

Load

Voltage

Primary

Current

12

Rated

Current

O,/~

Percent

1

f\~_,

Single

Phase

For

label

location

see

Section

3-4.

ST-178

794-A

2-3.

Symbols

And

Definitions

OM-1

587

Page

8

SECTION

3-

INSTALLATION

Process

Gun

GMAW-P



Hard

or

Cored

Wires

GW-500

Or

GW-600

GMAW



Hard

or

Cored

Wires

M25,

M40,

Or

GA-50C

FCAW



Self-Shielding

Wires

GA-4OGL

Or

GA-5OGL

3-1.

Site

Selection

3-2.

Gun

Recommendation

Table

OM-1

587

Page

9

3-3.

Equipment

Connection

Diagram

1

300/400

Ampere

Model

CC/CV

Inverter

Welding

Power

Source

f~

Use

switch

settings

shown

for

pulse

welding.

Change

switch

to

CV

for

other

wire

feed

weld

ing

processes.

2

450

Ampere

Model

CCICV

Inverter

Welding

Power

Source

Use

switch

settings

shown

for

all

wire

feed

welding

processes.

3

17-Pin

Cord

4

14-Pin

Cord

5

Positive

(+)

Weld

Cable

6

Negative

()

Weld

Cable

Be

sure

weld

cables

are

sized

properly

for

peak

amperage

if

pulse

welding

(see

welding

power

source

Owners

Manual).

7

Workpiece

8

Voltage

Sensing

Lead

9

Gun

Be

sure

gun

is

rated

for

peak

amperage

if

pulse

welding.

Install

according

to

its

Owners

Manual.

10

Wire

Feeder

ST-i

62129

/

Ref.

ST.i

54

197/

ST-146

127-C

/

Ref.

ST-163

420-A

~jf

~

owl

~D~IZ

3

OM-1

587

Page

10

3-4.

Rear

Panel

Connections

*The

remaining

pins

are

not

used.

12]

REMOTE

14

~j~*

Information

A

24

volts

ac

with

respect

to

socket

G.

B

Contact

closure

to

A

completes

24

volts

ac

contactor

control

circuit.

G

Circuit

common

for

24

volts

AC

circuit.

C

+10

volts

dc

output

to

remote

control

with

respect

to

socket

D.

0

Remote

control

circuit

common.

E

0

to

+10

volts

dc

input

command

signal

from

remote

control

with

respect

to

socket

D.

I-I

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.

3-6.

17-Socket

Receptacle

Information

Socket

Information

CC/CV

select;

+13

to

+24

volts

dc

is

CV,

0

volts

dc

is

CC.

Arc

control/inductance

control;

0

to

+10

volts

dc.

Actual

weld

amperage

output

signal;

+1

volt

dc

is

100

amps.

Actual

weld

voltage

output

signal;

+1

volt

dc

is

10

volts

dc.

Circuit

common.

*The

remaining

sockets

are

not

used.

3-5.

14-Pin

Plug

Information

OM-1

587

Page

11

3-7.

Wire

Type,

Size,

And

Feed

Speed

Capability

Table

Motor

Speed

Wire

Type

Wire

Size

Feed

Speed

Capability

Standard

All

.023

To

5/64

in

(0.6

To

2

mm)

50

To

780

1pm

(1.3

To

19.8

mpm)

Standard

Au

3/32

To

7/64

in

(2.4

To

2.8

mm)

50

To

700

1pm

(1.3

To

17.8

mpm)

Standard

All

1/8

in

(3.2

mm)

50

To

300

1pm

(1.3

To

7.6

mpm)

Optional

High

All

.023

To

5/64

in

(0.6

To

2

mm)

92

To

1440

ipm

(2.3

To

35.6

mpm)

3-8.

Rotating

The

Drive

Assembly

OM-1587

Page

12

3-9.

Installing

And

Threading

Welding

Wire

ri~d~

*4

NONCONDUCTIVE

SURFACE

No

Wire

Slip

Wire

Slips

Install

wire

guides

and

anti-wear

guide.

-,

Install

drive

rolls.

Be

sure

that

outlet

cable

has

proper

size

liner

for

the

welding

wire

size.

When

installing

gun,

position

liner

extending

from

outlet

wire

guide

as

close

as

possible

to

drive

rolls

without

touching.

Install

gun.

Lay

gun

cable

out

straight.

Cut

oft

end

of

wire.

Push

wire

through

guides

up

to

drive

rolls;

continue

to

hold

wire.

Press

Jog

button

to

feed

wire

out

gun.

Tools

Needed:

ff~

Forsoft

wire

orsmalldiameterstainless

steel

wire,

use

2

drive

rolls

and

set

drive

roll

pressure

from

0

to

a

maximum

of

4

on

the

pressure

indicator

scale

(so

that

only

the

inner

spring

is

compressed).

This

setting

will

generally

give

the

best

performance

for

these

types

of

wires.

To

adjust

drive

roll

pressure,

hold

nozzle

about

2

in

(51

mm)

from

nonconductive

surface

and

press

gun

trigger

to

feed

wire

against

surface.

Tighten

knob

so

wire

does

not

slip.

Do

not

overtighten.

If

contact

tip

is

completely

blocked,

wire

should

slip

at

the

feeder

(see

pressure

adjustment

above).

Cut

wire

off.

Close

cover.

:::~~:~z~

~

3~16,5~64

in

~

~

15/16,3/Bin

Ref.

ST.1

56

929

1

Ref.

SC.1

50

922

/

Ref.

ST.1

56

930

/

S-0627-A

If

necessary,

move

hub

and

spool

support

so

wire

runs

straight

from

the

spool

through

the

drive

rolls.

Install

wire

spool.

Adjust

tension

nut

so

wire

is

taut

when

wire

feed

stops.

1~

aM-i

587

Page

13

4-1.

Operational

Terms

SECTiON

4-

OPERATION

NOTE

~

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:

Adaptive

Pulse

Welding

The

wire

feeder

automatically

regulates

pulse

frequency

to

maintain

a

constant

arc

length,

regardless

of

change

in

welding

wire

stickout.

Cold Wire

Jog

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.

Inductance

As

inductance

increases,

arc

on

time

increases,

and

the

weld

puddle

becomes

more

fluid.

Trim

Arc

length

adjustment

in

pulse

welding.

Increasing

trim

increases

the

actual

arc

length.

Trim

is

replaced

by

volts

in

MIG

programs.

Synergic

The

operator

programs

pulse

parameters

for

a

specific

wire

feed

speed.

The

wire

feeder

determines

the

pulse

parameters

between

these

wire

feed

speed

increments.

Side

Panel

Terms:

Card

Mode

Is

used

to

select

use

of

the

optional

data

card

storage

and

retrieval

capabilities.

Dual

Schedule

Mode

Is

used

to

select

a

pair

of

programs

that

can

be

used

together.

Process

Mode

Is

used

to

select

the

type

of

process

to

be

used,

including

Pulse,

Adaptive

Pulse,

or

Mig.

Sequence

Mode

Is

used

to

select

and

program

the

weld

sequences

which

include

weld,

crater,

burnback,

postflow,

preflow,

and

run-in.

4-2.

Pulse

Welding

Terms

1

Apk

=

Peak

Amperage

Increasing

Apk

increases

penetra

tion.

2

Abk

=

Background

Amperage

Maintains

arc

between

pulses.

3

PPS

=

Pulses

Per

Second

I

3

Increasing

PPS

increases

travel

speed.

/

~

I:c;:si:re~

bead

Amps

Time

OM-1

587

Page

14

4-3.

Front

Panel

Controls

8

7

4

ST-182

127

1

Display

2

Parameter

Select

Button

Press

button

to

move

>

on

display.

3

Display

Control

Turn

control

to

change

value

pointed

to

by

>.

Turning

control

one

click

causes

Trim

(arc

length)

to

increase/decrease

by

one

or

Volt

to

increase/decrease

by

0.1.

When

1PM

is

selected,

turning

control

one

click

causes

wire

feed

speed

(1PM)

to

in

crease/decrease

by

one.

When

MPM

is

selected,

turning

control

three

clicks

causes

wire

feed

speed

(MPM)

to

increase

by

0.1.

When

Prg

#

is

selected,

turning

control

one

click

causes

program

number

(Prg

#)

to

in

crease/decrease

by

one.

The

program

number

cannot

be

changed

while

welding,

with

exception

of

Dual

Schedule

Mode

(see

Section

6).

Pulse

is

a

default

setting.

To

change

type

of

process

(Pulse,

Adaptive

Pulse,

or

MIG)

use

side

panel

controls.

4

Active

Side

Indicator

Light

5

Trigger

Hold

Button

And

Indicator

Light

To

weld

without

holding

gun

trigger

through

out

weld

cycle,

press

and

release

button

to

turn

feature

on

(indicator

light

turns

on).

To

start

weld

cycle,

press

and

release

gun

trigger

within

three

seconds

after

an

arc

has

been

struck.

To

end

weld

cycle,

press

and

release

gun

trigger.

6

Side

Select

Button

7

Jog

Button

Push

to

momentarily

feed

welding

wire

with

out

energizing

welding

circuit

or

shielding

gas

valve.

Jog

speed

is

varied

using

the

Display

Con

trol

while

Jog

button

is

pressed.

Default

set

ting

is

200

1PM.

8

Purge

Button

Push

to

momentarily

energize

gas

valve

without

energizing

the

welding

circuit.

Holding

the

Jog

and

Purge

buttons

atthe

same

time

displays

pulse

parameters

on

the

side

panel

display

and

voltage

on

front

panel

display.

5

6

5

OM-1587

Page

15

4-4.

Side

And

Rear

Panel

Controls

1

Mode

Display

2

Mode

Select

Button

Press

button

to

move>

in

display.

3

Parameter

Display

4

Parameter

Select

Button

Press

button

to

move

>

in

display.

5

Parameter

Increase

Button

6

Parameter

Decrease

Button

7

Power

Switch

8

Circuit

Breaker

CB1

protects

the

wire

feeder

from

overload.

Ref.

ST-162

128

/

Ref.

ST-i

62

133

O~~6

J

OM-1

587

Page

16

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