Miller KG047128 Owner's manual

Miller

April

1996

Form:

OM-1584H

Effective

With

Serial

No.

KG0471

28

OWNERS

MANUAL



~

U



Read

and

follow

these

instructions

and

all

safety

blocks

carefully.

Have

only

trained

and

qualified

persons

install,

operate,

or

service

this

unit.

Call

your

distributor

if

you

do

not

understand

the

directions.



Give

this

manual

to

the

operator.

~~]

U

For

help,

call

your

distributor



or

MILLER

Electric

Mfg.

Co.,

P.O.

Box

1079,

Appleton,

WI

54912

414-734-9821

SWINGARCTM

DS-1

2

And

DS-1

6



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

Horizontal



See

Rear

Cover

For

Options

And

Accessones

cover

5/94

-

ST.142

595-B

'

1996

MILLER

Electric

Mfg.

Co.

PRINTED

IN

USA

tax

I

UMITED

WARRANTY

Subjecttotheterma

end

conditions

below,

MILLER

Electric

Mfg.

Co.,

Appleton,

Wisconsin,

wsrrants

to

its

original

retail

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

UEU

OF

ALL

OTHER

WARRANTIES,

EXPRESS

OR

IMPUED.

INCLUDING

THE

WARRANTIES

OF

MERCHANTABILITY

AND

FIT

NESS.

Within

the

warranty

periods

listed

below,

MILLER

will

repair

or

replace

any

war-

rented

parts

orcomponenta

that

fail

due

10

such

defecta

in

material

orworkmanahip.

MILLER

must

be

notified

in

writing

within

thirty

(30)

days

of

such

defect

or

failure,

at

which

time

MILLER

will

provide

inatn.ictions

on

the

warranty

claim

procedures

to

be

followed.

MILLER

shall

honor

warranty

claims

on

warranted

equipment

listed

below

in

the

event

of

such

a

failure

within

the

warranty

time

periods.

All

warranty

time

periods

start

on

the

date

that

the

equipment

was

delivered

to

the

original

retail

purchaser,

or

2.

Consumable

components;

such

as

contact

tips,

cutting

nozzles,

contactora

one

year

after

the

equipment

is

sent

to

a

North

American

diatributor

or

eighteen

and

relays

or

parta

that

fail

due

to

normal

wear.

months

after

the

equipment

is

sent

to

an

International

distributor.

3.

Equipment

that

has

been

modified

by

any

party

other

than

MILLER,

or

equip

ment

that

has

been

improperly

installed,

improperly

operated

or

misused

baaed

upon

industry

standards,

or

equipment

which

has

not

had

reasonable

and

neceaaary

maintenance,

orequipment

which

has

been

used

for

operation

outside

of

the

specifications

for

the

equipment.

MILLER

PRODUCTS

ARE

INTENDED

FOR

PURCHASE

AND

USE

BY

COMMER

CIAL/INDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

IN

ThE USE

AND

MAINTENANCE

OF

WELDING

EOUIPMENT.

In

the

event

of

a

warranty

claim

covered

by

thia

warranty,

the

exclusive

remedies

shall

be,

at

MILLERS

option:

(1)

repair,

or

(2)

replacement;

or,

where

authorized

in

writing

by

MILLER

in

appropriate

cases,

(3)

the

reasonable

coat

of

repairor

replace

ment

alan

authorized

MILLER

service

atation;

or

(4)

payment

of

orcredit

forthe

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

retum

of

the

goods

at

customers

riak

and

expense.

MILLERS

option

of

repair

or

replacement

will

be

FOB.,

Factory

at

Appleton,

Wisconsin,

or

FOB.

at

a

MILLER

authorized

ser

vice

facility

as

determined

by

MILLER.

Therefore

no

compensation

or

reimburse

ment

for

trenaportation

coats

of

any

kind

will

be

allowed.

TO

ThE

EXTENT

PERMITTED

BY

LAW,

THE

REMEDIES

PROVIDED

HEREIN

ARE

ThE

SOLE

AND

EXCLUSIVE

REMEDIES.

IN

NO

EVENTSHALL

MILLER

BE

UABLE

FOR

DIRECT,

INDIRECT,

SPECIAL,

INCIDENTAL

OR

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,

MIGHT

ARISE

BY

IMPLICATION,

OPERATION

OF

LAW,

CUSTOM

OF

TRADE

OR

COURSE

OF

DEAUNG,

IN

CLUDING

ANY

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OR

FITNESS

FOR

PARTICULAR

PURPOSE,

WITh

RESPECTTO

ANYAND

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

en

implied

warranty

lasts,

or

the

exclusion

of

incidental,

indirect,

special

or

consequential

damages,

so

the

above

limitation

or

exclusion

may

not

apply

lo

you.

This

warranty

provides

ape

cific

legal

rights,

and

other

rights

may

be

available,

but

may

vary

from

state

to

state.

in

Canada,

legialation

in

some

provinces

provides

for

certain

additional

warranties

or

remedies

other

than

as

atsted

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.

MILLERS

TRUE

BLUEﬁ

LIMITED

WARRANTY

Effective

February

7,

1996

(Equipment

with

a

serial

number

preface

of

KD

or

newer)

This

limited

wsrranty

supersedes

all

warranties

end

is

exclusive

with

no

other

guarenteea

or

warrenties

expressed

or

implied.

C

5.

6

Months



Batteries

6.

90

Days



Parts

and

Labor



MIG

Guns/hG

Torches

APT,

aPCUT

&

PLAZCUT

Model

Plasma

Cutting

Torches



Remote

Controta

*

Acceaaory

Kits



Replacement

Parts

MILLERS

True

Blueﬁ

Umited

Warranty

shall

not

apply

to:

1.

Items

furnished

by

MILLER,

but

manufactured

by

others,

such

as

engines

or

trade

accessories.

These

items

are

covered

by

the

manufacturers

warranty,

if

any.

SYeareParta3YeareLabor

*

Original

main

power

rectifiers

*

Invertera

(input

and

output

rectifiers

only)

2.

3

Years



Parts

and

Labor

*

Transformer/Rectifier

Power

Sourcea

Plasma

Arc

Cutting

Power

Sources



Semi-Automatic

and

Automatic

Wire

Feeders

*

Inverter

Power

Supplies



Intellitig

*

Robots

(1

year

labor)

3.

2

Years



Parts

and

Labor

*

Engine

Driven

Welding

Generators

(NOTE:

Engines

are

warranted

separately

by

the

engine

manufacturer.)

*

Air

Compreasore

4.

1

Year



Parts

and

Labor

*

Motor

Driven

Guns

*

Proceas

Controllers

IHPS

Power

Sources



Water

Coolant

Systems

HF

Units

*

Grids



Spot

Welders

*

Load

Banka

*

SDX

Transformers

*

Miller

Cyclomatic

Equipment



Running

Gear/Trailers



Plasma

Cutting

Torches

(except

APT,

ZIPCUT

&

PLAZCUT

Models)

*

Tecumaeh

Enginea

*

Deulz

Enginea

(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.)

.

I

J2\

I.

WHO

DO

I

CONTACT?

For

help,



contact

your

distributor

For

additional

information,

such

as

Technical

Manuals

(Service

And

Parts)

Eng)ne

Manuals

Circuit

And

Wiring

Diagrams

Process

Handbooks

Users

Guides

Distributor

Directories



contact

your

distributor

To

file

a

claim

for

loss

or

damage

during

shipment,

contact

the

delivering

carrier

For

assistance

in

filing

or

settling

claims,



contact

your

d)stributor

and/or

equipment

manufacturers

Transportation

Department

Miller

Electric

Mfg.

Co.



CALL:

414-735-4505





FAX:

800-637-2348

(in

USA),

or

414-735-4136

(outside

USA)

r

D1



WRITE:

Miller

Electric

Mfg.

Co.

EQ.

Box

1079

Appleton,

WI

54912

USA

Always

provide

Model

Name

and

Serial

or

Style

Number

miller_wart

3/96

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

or

automatic

wire

welding,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live.

Incorrectly

installed

or

improperly

grounded

equipment

is

a

hazard.

Do

not

touch

live

electrical

parts.

Wear

dry,

hole-free

insulating

gloves

and

body

protection.

Insulate

yourself

from

work

and

ground

using

dry

insulating

mats

or

covers

big

enough

to

prevent

any

physical

contact

with

the

work

or

ground.

Disconnect

input

power

or

stop

engine

before

installing

or

servicing

this

equipment.

Lockout/tagout

input

poweraccording

to

OSHA

29

CFR

191

0.147

(see Safety

Standards).

Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual

and

national,

state,

and

local

codes.

Always

verify

the

supply

ground



check

and

be

sure

that

input

power

cord

ground

wire

is

properly

connected

to

ground

terminal

in

disconnect

box

or

that

cord

plug

is

connected

to

a

properly

grounded

receptacle

outlet.

7.

When

making

input

connections,

attach

proper

grounding

conductor

first



double-check

connections.

8.

Frequently

inspect

input

powercord

for

damage

or

bare

wiring



replace

cord

immediately

if

damaged



bare

wiring

can

kill.

9.

Tum

off

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

different

machine.

14.

Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

Maintain

unit

according

to

manual.

Wear

a

safety

harness

if

working

above

floor

level.

Keep

all

panels

and

covers

securely

in

place.

17.

Clamp

work

cable

with

good

metal-to-metal

contact

to

workpiece

or

worktable

as

near

the

weld

as

practical.

a

WARNING

ARC

WELDING

can

be

hazardous.

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.

1.

2.

3.

4.

5.

6.

15.

16.

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

protectyourface

and

eyes

when

welding

orwatching

(see

ANSI

Arc

rays

from

the

welding

process

produce

intense

Z49.1

and

Z87.i

listed

in

Safety

Standards).

visible

and

invisible

(ultraviolet

and

infrared)

rays

that

3.

Wear

approved

safety

glasses

with

side

shields.

can

bum

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

off

pieces

of

metal

or

slag.

and

glare;

wam

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.

I

FUMES

AND

GASES

can

be

hazardous

5.

Work

in

a

confined

space

only

if it

is

well

ventilated,

or

white

to

your

health.

wearing

an

air-supplied

respirator.

Always

have

a

trained

I

Welding

produces

fumes and

gases.

Breathing

watchperson

nearby.

Welding

fumes

and

gases

can

displace

=9

v



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.

I

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

(MSDS5)

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.

1~~I

CYLINDERS

can

explode

if

damaged.

4.

Never

drape

a

welding

torch

over

a

gas

cylinder.

-

Shielding

cas

cylinders

contain

gas

under

high

5.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

pressure.

lfdamaged,

a

cylinder

can

explode.

Since

6.

Never

weld

on a

pressurized

cylinder



explosion

will

result.

gas

cylinders

are

normally

part

of

the

welding

~

Useonlycorrectshieldinggascylinders,regulators,hoses,and

.~

process,

be

sure

to

treat

them

carefully.

fithngs

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.

Keepprotectivecapinplaceoverva?veexceptwhencylinderis

2.

Installcylindersinanuprightpositionbysecuringtoastationary

in

use

orconnected

for

use.

support

or

cylinder

rack

to

prevent

failing

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.

srtl.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

off

from

the

welding

arc.

The

flying

sparks,

hot

workpiece,

and

hot

equipment

can

cause

fires

and

burns.

Accidental

contact

of

electrode

to

metal

objects

can

cause

sparks,

explosion,

overheating,

or

fire.

Check

and

be

sure

the

area

is

safe

before

doing

any

welding.

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.

Do

not

use

welder

to

thaw

frozen

pipes.

Remove

stick

electrode

from

holder

or

cut

off

welding

wire

at

contact

tip

when

not

in

use.

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.

a

WARNING

ENGINES

can

be

hazardous.

ENGINE

EXHAUST

GASES

can

kill.

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.

1.

Stop

engine

and

let

it

cool

off

before

checking

or

adding

fuel.

2.

Do

not

add

fuel

while

smoking

or

if

unit

is

near

any

sparks

or

open

flames.

MOVING

PARTS

can

cause

injury.

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

awayfrom

moving

parts.

6.

Reinstall

panels

or

guards

and

close

doors

when

servicing

is

finished

and

before

starting

engine.

SPARKS

can

cause

BATTERY

GASES

1.

Always

wear

a

face

shield

when

working

on

a

battery.

TO

EXPLODE;

BATTERY

ACID

can

2.

Stop

engine

before

disconnecting

or

connecting

battery

burn

eyes

and

skin,

cables.

3.

Do

not

allow

tools

to

cause

sparks

when

working

on

a

battery.

Batteries

contain

acid

and

generate

explosive

4.

Do

not

use

welder

to

charge

batteries

or

jump

start

vehicles.

ases.

5.

Observe

correct

polarity

(+

and

)

on

batteries.

STEAM

AND

PRESSURIZED

HOT

1.

If

the

engine

is

warm

and

checking

is

needed,

follow

steps

2

COOLANT

can

burn

face,

eyes,

and

3.

skin.

2.

Wear

safety

glasses

and

gloves

and

put

a

rag

over

cap.

Itisbesttocheckcoolantlevelwhenengineiscold

3.

Turn

cap

slightly

and

let

pressure

escape

slowly

before

to

avoid

scalding.

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

Haza

rdous

Substances,

Ameri

can

Welding

Society

Standard

AWS

F4.1

,from

American

Welding

So

ciety,

550

N.W.

LeJeune

Rd,

Miami,

FL

33126

National

Electncal

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.

SafePractices

ForOccupafionAnd

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.

9.

10.

a

T

ENGINE

FUEL

can

cause

fire

or

explosion.

Engine

fuel

is

highly

flammable.

3.

Do

not

overfill

tank



allow

room

for

fuel

to

expand.

4.

Do

not

spill

fuel.

If

fuel

is

spilled,

clean

up

before

starting

engine.

Moving

parts,

such

as

fans,

rotors,

and

belts

can

cut

fingers

and

hands

and

catch

loose

clothing.

1.

Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

2.

Stoł enqine

before

installing

or

connecting

unit.

.

Sri

.1.1

2/94

CONSIGNES

DE

SECURITE

POUR

LE

SOUDAGE

A

LARC

UN

CHOC

ELECTRIQUE

peut

tuer.

Un

simple

contact

avec

des

piŁces

Olectnques

peul

provoquer

une

electrocution

ou

des

blessures

graves.

LŁlectrode

et

le

circuit

de

soudage

sont

sous

tension

des

que

lappareil

est

surON.

Le

circuit

dentrØe

et

los

circuits

intemes

de

lappareil

sont

egalement

sous

tension

a

ce

moment-la.

En

soudage

semi-automatique

ou

automatique,

le

fil,

le

dOvidoir,

10

logement

des

galets

dentrainoment

et

les

piŁces

metalliques

en

contact

avec

le

fil

do

soudage

sont

sous

tension.

Des

matØriels

mal

installØs

ou

mal mis

a

terre

presentent

un

danger.

1.

Ne

jamais

toucher

los

piŁces

Olectnquos

sous

tension.

2.

Porter

des

gants

et

des

vŒtements

de

protection

secs

ne

comportant

pas

de

trous.

3.

Sisoler

de

Ia

piŁce

et

de

Ia

terre

au

moyen

do

tapis

ou

dautres

moyens

isolants

suffisamment

grands

pour

empØcher

le

contact

physique

Oventuel

avec

Ia

piŁce

ou a

terre.

4.

Couper

lalimentation

ou

arrOter

le

moteur

avant

de

proceder

a

installation,

a

Ia

reparation

ou

a

lentretien

de

lappareil.

DØverrouillor

lalimentation

selon

Ia

norme

OSHA

29

CFR

1910.147

(voir

normes

de

sØcuntŁ).

5.

Installeret

mettre

a

laterre

correctement

cot

appareil

conformØment

a

son

manuel

dutilisation

et

au

codes

nationaux,

provinciaux

et

municipaux.

6.

Toujours

verifier

a

terre

du

cordon

dalimentation



Verifier

et

sassurer

cue

le

fil

de

terre

du

cordon

dalimentation

ost

bien

BRUIT

LE

RAYONNEMENT

DE

LARC

peut

brUler

les

yeux

et

Ia

peau.

Le

BRUIT

peut

endommager

IouIe;

les

PROJECTIONS

DE

LAITIER

OU

LES

ETINCELLES

peuvent

blesser

les

yeux.

Larc

de

soudage

produit

des

rayons

visibles

et

invisibles

intenses

(ultraviolets

et

infrarouges)

qui

peuvent

brOler

los

yeux

et

a

peau.

Le

bruit

produit

par

certains

procedØs

pout

endommager

louie.

Des

projections

de

metal

ou

de

laitier

sont

produites

par

10

piquage,

le

meulage

ou

le

ref

roidissement

des

soudures.

1.

Utiliser

des

bouche-oreilles

ou

des

serre-tOte

antibruil

approuves

si

le

bruit

est

ØlevØ.

LES

VAPEURS

Er

LES

FUMEES

peuvent

Œtre

dangereuses

pour

Ia

sante.

Le

soudage

produit

des

vapeurs

et

des

fumØes

quil

est

dangereux

de

respirer.

1.

Garder

Ia

tŒte

a

lexterieur

des

vapeurs

et

des

fumØes

et

ne

pas

les

respirer.

2.

A

lintØneur,

ventiler

le

poste

do

travail

ou

utiliser

un

dispositif

place

au

niveau

de

larc

pour

Øvacuer

les

vapeurs

et

fumØes

de

soudage.

3.

Si

Ia

ventilation

est

mauvaise,

utiliser

un

appareil

respiratoire

a

adduction

dair

pur

approuvØ.

4.

Consulter

les

fiches

signaletiques

et

les

consignos

du

fabncant

relatives

au

mØtaux,

produits

dapport,

rovŒtements,

nottoyants

et

degraissants.

LES

BOUTEILLES

peuvent

exploser

Si

elles

sont

endommagØes.

Los

bouteilles

contenani

des

gaz

de

protection

sont

a

haute

pression.

Une

bouteifle

endommagØe

pout

exploser.

Etani

donnØ

que

les

bouteilles

do

gaz

font

normalement

partie

du

matØnel

do

soudage,

les

traiter

avec

le

plus

grand

soin.

1.

Protegor

los

bouteilles

de

gaz

compnme

centre

Ia

chaleur

intense,

los

chocs,

le

laitier,

los

flammes

nues,

los

Øtincelles

et

Iarc.

2.

Placer

les

bouteilles

ala

verticale

en

los

fixani

a

un

support

fixe

ou

a

un

chariot

pour

Øviter

quelles

no

tombent

ou

no

basculont.

3.

Tenir

los

bouteiltes

a

lØcarl

du

poste

do

soudago

ou

dautres

circuits

e!ectriques.

raccordØ

ala

borne

do

terre

du

sectionneur

ou

que

Ia

fiche

du

cordon

est

raccordØe

a

une

prise

correctement

mise

a

Ia

terre.

7.

En

effectuant

es

raccordements

dentrØe

fixerdabord

le

conducteur

de mise

a

Ia

terre

appropriØ

et

contre-vØrifier

los

connexions.

8.

VerifierfrØquemment

le

cordon

dalimentation

pour

voir

sil

nest

pas

endommago

ou

dŁnudØ



remplacer

10

cordon

immØdiatement

siI

est

endommagØ



un

cable

dØnudO

peut

provoquer

une

electrocution.

9.

Mottre

lappareil

hors

tension

quand

on no

Iutilise

pas.

10.

Ne

pas

utiliser

des

cables

uses,

endommages,

de

grosseur

insuffisante

ou

mal

epissØs.

11.

Ne

pas

enrouler

les

cables

autour

du

corps.

12.

Si

Ia

piŁce

soudØe

doit

Łtre

mise

ala

terre,

le

faire

directement

avec

un

cable

distinct



no

pas

utiliser

le

connocteur

de

piŁce

ou

Ie

cable

do

retour.

13.

No

pas

toucher

IØlectrode

quand

on

est

en

contact

avec

Ia

piŁce,

Ia

terre

ou

une

electrode

provenant

dune

autre

machine.

14.

Nutiliser

quun

matØnel

en

bon

Øtat.

RØparer

ou

remplacer

sur-le-champ

les

piŁces

endommagØes.

Entretenir

Iappareil

conformØment

ace

manuel.

15.

Porter

un

hamais

de

securitØ

quand

on

travaille

en

hauteur.

16.

Maintenir

solidement

en

place

tous

los

panneaux

et

capots.

17.

Fixerle

cable

de

retourde

faon

aobtenr

un

bon

contact

mØtal-mOtal

avec

Ia

piŁce

a

souderou

Ia

table

do

travail,

le

plus

pres

possible

de

Ia

soudure.

RAVONNEMENT

DE

LARC

2.

Porter

un

masque

a

sorre-tŒte

muni

dun

verre

filtrant

de

nuance

appropnee

pour

proteger

le

visage

et

los

yeux

quand

on

soude

ou

observe

Ia

travail

do

soudage

(voir

los

normes

ANSI

Z49.1

et

Z87.1

donnØes

sous

Ia

rubrique

Principales

normes

de

sOcuritØ).

Porter

dos

lunettes

de

sØcuritØ

approuvees

avec

Øcrans

latØraux.

Utiliser

des

paravents

ou

des

barriŁres

de

protection

pour

protegor

les

personnes

a

proximite

centre

les

coups

darc

et

lØblouissemerrt;

avertir

los

autres

personnes

de

no

pas

regarder

Iarc.

5.

Porter

des

vØtements

de

protection

en

tissu

ignifuge

durable

(lame

et

cuir)

et

des

chaussures

de

sØcuritØ.

5.

Ne

travaillor

dans

un

espace

confine

quo

siI

est

bien

vontilØ,

ou

en

portantun

appareilrespiratoireaadductiondairpur.

Demandera

un

observateur

ayant

recu

Ia

bonne

formation

do

toujours

se

tenir

a

proximite.

Los

vapeurs

et

fumØes

do

soudago

peuvent

dØplacer

lair

et

abaisser

Ie

niveau

doxygŁne

et

causer

des

blessuros

graves

voire

mortelles.

Sassurer

que

lair

est

propre

a

Ia

respiration.

6.

Ne

pas

souder

a

proximite

doperations

de

degraissage,

do

nettoyage

ou

de

pulvØrisation.

La

chaleur

et

les

rayons

do

larc

peuvent

reagir

avec

los

vapeurs

pour

former

des

gaz

hautement

toxiques

et

irritants.

7.

Ne

pas

souder

sur

des

mØtaux

revŒtus

comme

Iacier

galvanise,

au

p10mb

ou

cadmiØ

a

moms

que

Ia

piŁce

nait

ØtØ

entiŁrementdecapØe,

quo

le

poste

do

travail

soit

bien

ventilØ.

Sil

y

a

lieu,

porter

un

appareil

respiratoire

a

adduction

dair

pur.

Los

revŒtements

et

les

mØtaux

qui

contiennentde

tols

ØlŁmonts

peuvent

degagerdes

vapeurs

toxiques

lors

du

soudage.

4.

Ne

jamais

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

uno

boutoille

sous

pression

:

elle

exploserait.

7.

Nutiliser

que

des

boutoilles

de

gaz

do

protection,

des

dØtendeurs,

des

tuyaux

souples

et

des

raccords

appropnes

concus

pour

lapplication

particuliere;

conserver

ces

matØriels

et

leurs

piŁces

en

bon

Øtat.

8.

Eloigner

le

visage

do

Ia

sortie

du

robinet

de

Ia

bouteille

quand

on

louvre.

9.

Replacer

le

chapeau

sur

Ia

bouteille

aprŁs

utilisation.

10.

Lire

et

suivre

les

consignes

relatives

aux

bouteilles

do

gazcompnme,

au

matØnel

connexe

ainsi

que

Ia

publication

P-i

de

Ia

CGA

donnØe

sous

Ia

rubnque

Pnncipates

normes

do

sØcurttØ

£~

MISE

EN

GARDE

LE

SOUDAGE

A

LARC

peut

Łtre

dangereux.

SE

PROTEGER

ET

PROTEGER

LES

AUTRES

CONTRE

LES

BLESSURES

GRAVES

VOIRE

MORTELLES.

TENIR

LES

ENFANTS

A

LECP~RT.

LES

PERSONNES

QUI

PORTENT

UN

STIMULATEUR

CARDIAQUE

NE

DOIVENT

PAS

NON

PLUS

SAPPROCHER

DU

POSTE

DE

SOUDAGE,

A

MOINS

DAVOIR

CONSULTE

UN

MEDECIN.

Le

soudage,

comme

Ia

plupart

des

travaux,

prØsente

certains

dangers.

Par

contre,

le

soudage

peut

Œtre

eflectuØ

en

toute

sØcuritØ

quand

on

prend

les

mesures

qui

simposent.

Les

consignes

de

sOcuntØ

donnØes

ci-aprŁs

ne

font

que

rØsumer

linformation

contenue

dans

les

normes

de

sØcufltØ

ØnumrØes

a

Ia

page

suivante.

Lire

et

respecter

toutes

ces

normes

de

sØcuntØ.

LUTlLISATION,

LENTRETIEN

ET

LES

REPARATIONS

NE

DOIVENT

ETRE

CONFIES

QUA

DES

PERSONNES

QUALIFIEES

3.

4.

S

srl.1.2

2f94

LE

SOUDAGE

peut

causer

un

incendie

ou

une

explosion.

Ne

pas

souder

sur

des

recipients

fermOs

comme

des

reservoirs,

des

fOts

ou

des

tuyaux:

us

peuvent

exploser.

Larc

de

soudage

peut

produire

des

Øtincelles.

Des

Øtincelles,

une

piŁce

chaude

et

un

matØnel

chaud

peuvent

provoquer

des

incendies

et

des

blessures.

Le

contact

accidentel

de

lØlectrode

sur

des

objets

metalliques

peut

produire

des

Øtincelles,

lexplosion,

Ia

surchauffe

ou

un

incendie.

Sassurer

que

le

lieu

ne

presente

pas

de

danger

avant

deffectuer

le

soudage.

1.

Se

protØgeret

protegerles

personnes

proximite

des

Øtincelleset

du

metal

chaud.

2.

Ne

pas

souder

dans

un

endroit

ł

les

etincelles

peuvent

atteindre

des

matØnaux

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

recouvnr

en

utilisant

des

bªches

approuvØes.

4.

Prendre

garde

que

les

Øtincelles

et

los

projections

ne

penetrent

dans

des

zones

adjacentes

en

sinfiltrant

dans

des

petites

fissures

et

ouvertures.

5.

Prendre

garde

aux

incendies

et

toujours

avoir

un

extincteur

a

proximite.

6.

Se

rappeler

quo

si

Ion

soude

sur

un

plafond,

un

plancher,

une

cloison

ou

autre,

le

feu

peut

prendre

do

lautre

ctØ.

7.

Ne

pas

souder

sur

des

recipients

fermØs

comme

des

reservoirs,

des

fOts

ou

des

tuyaux

Ł

moms

quils

no

soient

prepares

de

facon

appropnŁe

conforrnement

ala

norme

F4.1

do

lAWS

(voir

Ia

rubnque

Prmncipales

normes

de

sØcurftØ).

8.

Raccorder

le

cable

de

retour

a

Ia

piŁce,

le

plus

pres

possible

de

Ia

zone

de

soudage,

pour

empØcher

que

10

courant

de

soudage

ne

suive

une

trajectoire

longue

et

Øventuellement

inconnue

et

quil

no

provoque

des

nsques

dØlectrocution

et

dincendie.

9.

Ne

pas

utiliser

le

chalumeau

soudeur

pour

degeler

des

tuyaux.

10.

Enlever

IØlectrode

enrobØe du

porte-electrode

ou

couper

le

fil

de

soudage

au

ras

du bec

contact

quand

on

no

lutilise

pas.

11.

Porter

des

vŒtements

de

protection

non

huileux

comme

des

gants

en

cuir,

une

chemise

epaisse,

des

pantalons

sans

revers,

des

chaussures

montantes

et

un

casque.

12.

Ne

pas

porterdes

matiŁres

combustibles

sursoi

comme

un

briquet

a

gaz

ou

des

allumettes

quand

on

soude.

£~

MISE

EN

GARDE

1.

2.

I-.~

PRINCIPALES

NORMES

DE

SECURITE

.

Safety

in

Welding

and

Cutting,

norme

ANSI

Z49.1,

do

lAmencan

Welding

Society,

550

N.W.

Lojeune

Rd,

Miami

FL

33126

Safety

and

Health

Sandards,

OSHA

29

CFR

1910,

du

Superintendent

of

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

Recommended

Safe

Practice

for

the

Preparation

for

Welding

and

Cutting

of

Containers

That

Have

Held

Hazardous

Substances,

norme

AWS

F4.1,

de

lAmencan

Welding

Society,

550

NW.

Lejeune

Rd,

Miami

FL

33126

National

Electrical

Code,

NFPA

Standard

70,

do

Ia

National

Fire

Protection

Association,

Batterymarch

Park,

Qumncy,

MA

02269.

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

P-i,

de

Ia

Compressed

Gas

Association,

1235

Jefferson

Davis

Highway,

Suite

501,

Arlington,

VA

22202.

Regles

de

sØcuritØ

en

soudage,

coupage

et

procddes

connexes,

norrne

CSA

W117.2,

do

lAssociation

canadienne

do

normalisation,

vente

do

normes,

i

78

Rexdalo

Boulevard,

Rexdalo

(Ontario)

Canada

M9W

1

R3.

Safe

Practices

ForOccupation

And

Educational

Eye

And

Face

Protection,

norme

ANSI

Z87.i,

de

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

Cutting

and

Welding

Processes,

norme

NFPA

SiB,

de

Ia

National

Fire

Protection

Association,

Batteryrnarch

Park,

Qumncy,

MA

02269.

I

I

LES

MOTEURS

peuvent

presenter

un

danger.

LES

GAZ

DECHAPPEMENT

DES

MOTEURS

peuvent

Ctre

mortels.

Los

moteurs

produisent

des

gaz

dŁchappemont

nocifs.

1.

2.

Utiliser

le

matØnel

a

lextØneur,

dans

des

lieux

ouverts

et

bien

ventilØs.

Si

on

utilise

un

moteur

dans

un

local

fermØ,

Øvacuer

los

gaz

dechappement

a

lextØrieur

et

loin

des

pnses

dair

du

btiment.

lid,

LE

CARBURANT

peut

provoquer

un

incendie

ou

une

explosion.

Le

carburant

est

hautement

inflammable.

1.

ArrŒter

le

moteur

ot

to

laisser

refroidir

avant

do

verifier

10

niveau

do

carburant

ou

do

refaire

10

plein.

2.

3.

4.

Ne

pas

fumer

en

faisant

le

plein

ou

Si

lappareil

so

trouve

a

proximite

dØtincellos

ou

do

flammes

nues.

Ne

pas

romplir

0

reservoir

a

ras

bord:

prevoir

do

lespace

pour

Ia

dilatation

du

combustible.

Ne

pas

renvorser

du

carburant.

Si

on

renvorso

du

carburant,

nettoyer

es

Iioux

avant

do

faire

dØmarrer

lo

motour.

LES

PI¨CES

EN

MOUVEMENT

peuvent

causer

3.

Seules

des

personnes

qualifiees

doivent

dØmonter

los

protecteurs

des

blessures.

ou

les

capots

pour

faire

lentretien

ou

les

reparations

nØcessaires.

4.

Pour

empØcher

un

demarrago

accidentel

dun

systŁme

pendant

Los

piŁces

en

mouvement

comme

es

ventilateurs,

es

lentretien

ou

les

reparations,

dØbrancher

le

cable

negatif

()

do

Ia

rotors

ot

los

courroios

peuvent

coupor

los

doigts

et

los

mains

ot

happor

los

vŒtomonts

amplos.

battene.

5.

Eloigner

los

mains,

les

cheveux,

lesvŒtements

amples

et

les

outils

Sassurorque

les

portes,

los

panneaux,

les

capots

et

los

protectours

des

piŁces

on

mouvement.

sont

bien

formØs

ot

bien

a

lour

place.

6.

Replacer

los

capots

ou

les

protecteurs

et

refermer

los

portes

une

fois

ArrØter

le

moteur

avant

do

mettre

en

place

ou

de

raccorder

un

lentretien

et

les

reparations

terminØs

et

avant

do

faire

dØmarrer

le

moteur.

LES

ETJNCELLES

peuventjaire

EXPLOSER

LE

2.

ArrŒter

le

moteur

avant

do

brancher

ou

do

dØbrancher

les

cables

do

GAZ

DES

BATrERIES;

LELECTROLYTE

peut

Ia

battono.

brler

Ia

peau

et

les

yeux.

3.

Ne

pas

fairo

des

Øtincelles

avec

les

outils

quand

on

travaille

sur

une

battorie.

Los

batteries

contionnent

un

produit

acide

et

degagent

des

vapeurs

e~osives.

4.

Ne

pas

utiliser

Ia

source

do

courant

de

soudago

pour

charger

los

batteries

ou

pour

faire

dØmarrer

un

vØhicule.

1.

Toujours

eorter

un

Øcran

facial

quand

on

travaille

sur

une

batterie.

5.

Ne

pas

intervertir

Ia

polaritØ

dos

batteries.



~

LA

VAPEUR

ET

LE

LIQUIDE

DE

1.

Si

lon

doit

vŁflfier

le

niveau

quand

le

moteur

est

chaud,

suivro

los

PRESSION

peuvent

brUler

Ia

peau

et

es

yeux.

2.

Porter

des

lunottes

do

sØcuntØ

ot

des

gants

et

placer

un

chiffon

sure

REFROIDISSEMENT

BRULANT

SOUS

Øtapes

2

ot

3.

II

vaut

mioux

verifier

10

niveau

du

liquide

do

bouchon.

refroidissement

quand

le

moteur

est

froid

afin

dØviter

los

3.

Toumer

lentement

le

bouchon

et

laisser

Ia

pression

sechapper

brUlures.

lentoment

avant

denlevor

completemont

10

bouchon.

.

srl.1.22/94

EMF

INFORMATION

TABLE

OF

CONTENTS

SECTION

1

-

SAFETY

INFORMATION

SECTION

2-

SPECIFICATIONS

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.

WeldingWire

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.

Adjusting

Control

Tilt

Bracket

3-18.

Threading

Welding

Wire

1

SECTION

4-

OPERATION

18

SECTION

5-

MAINTENANCE

&

TROUBLESHOOTiNG

24

5-1.

Routine

Maintenance

24

5-2.

Overload

Protection

25

5-3.

Troubleshooting

25

OM-1584H

-4~6

NOTE

~

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



Backg

round

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

2(93

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



Read

all

safety

messages

throughout

this

manual.



Obey

all

safety

messages

to

avoid

injury.



Learn

the

meaning

of

WARNING

and

CAUTION.

1

2

a

CAUTION

ELECTRIC

SHOCK

can

klII.~

I

MOVING

PARTS

can

injure.

I

~

II

~

I



Do

not

touch

live

electrical

parts.

~

S

Keep

away

from

moving

parts.

I



Keep

all

panels

and

covers

closed

I



Disconnect

input

power

before

when

operating.

I

installing

or

servicing.



/

5

~ATI~1~II~e

READ

SAFETY

BLOCKS

at start

of

I

Section

3-1

before

proceeding.

~

7H

NOTE

~

Turn

Off

switch

when

using

high

frequency.

Specification

Description

Type

Of

Input

Power

From

Welding

Power

Source

Maximum

Weld

Circuit

Rating

Welding

Power

Source

Type

Wire

Feed

Speed

Range

Wire

Diameter

Range

Welding

Processes

Input

Power

Cord

Maximum

Height

With

4

ft

(1.2

m)

Post

Weight

VerbcaJ

Uft

Of

Boom

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.)

100

Volts,

750

Amperes,

100%

Duty

Cycle

Constant

Voltage

(CV)

DC,

With

Contactor

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

.023

Thru

1/8

in

(0.6

To

3.2

mm)

Gas

Metal

Arc

(GMAW)

And

Flux

Cored

Arc

Welding

(FCAW)

lOft

(3.1

m)

12

ft

(3.7

m)

Boom

17

ft

(5.2

m)

Net:

207

lb

(94

kg)

Ship:

318

lb

(144

kg)

Horizontal

To

60

Above

Horizontal

16

ft

(4.9

m)

Boom

21

ft(6.4m)

Net:

280

lb

(127

kg)

Ship:

411

lb

(186

kg)

Horizontal

To

60

Above

Horizontal

OM-1584

Page

1

SECTION

3-INSTALLATION

3-1.

Equipment

Connection

Diagrams

4~

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.

HOT

SURFACES

can

burn

skin.



Allow

gun

to

cool

before

touching.

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

wire

feederand

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.



Have

only

qualified

persons

install

this

unit.

wfwam9.1

2/93

2.

13

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-153

176-A

10

Figure

3-1.

Typical

System

Connections

OM-1

584

Page

2

3-2.

Installing

Swivel

Into

Pipe

Post

£~

WARNING

I..

I

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.

4

1

Swing

pak

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:

~

314in

ST-i

52 382

Figure

3-2.

Swivel

Installation

3-3.

Installing

Control

Box

Onto

Swivel

2

4

Toots

Needed:

cII~3===fJ

3/8

in

3

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-i53

174

Figure

3-3.

Control

Box

Installation

OM-1584

Page

3

3-4.

Installing

Boom

And

Reel

Support

READ

SAFETY

BLOCKS

at

start

of

Section

3-2

before

proceeding.

.

3-5.

Installing

Wire

Guide

Extension

Figure

3-5.

Wire

Guide

Extension

Installation

I

1

Swivel

Plates

2

Yoke

Remove

hardware

from

swivel

plates

and

yoke.

3

Boom

Set

boom

into

swivel

as

shown.

4

Yoke

Install

through

yoke.

Install

cot

ter

and

spread

ends.

5

Bolt

Install

bolt,

tighten

hardware,

and

back

bolt

off

one

half

tum.

6

Locking

Knob

Install

locking

knob

but

do

not

tight

en.

7

Reel

Support

Install

reel

support.

Ref.

ST-153

170

Tools

Needed:

~

3/4,3/8

in

Figure

3-4.

Boom

Installation

1

4

Tools

Needed:

~

3/8

in

1

Wire

Guide

Fitting

2

Bolt

3

Monocoil

Liner

4

Wire

Guide

Extension

Tighten

bolt

to

secure

liner

in

wire

guide

fitting.

Do

not

overtighten

bolt

and

crush

liner.

Repeat

procedure

for

opposite

side.

ST-152 383

OM-1584

Page

4

3-6.

Wire

Guide

And

Drive

Roll

Installation

B.

Drive

Roll

Installation

READ

SAFETY

BLOCKS

at

start

of

Section

3-1

before

proceeding.

Figure

3-7.

Drive

Roll

Installation

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

Secunng

Screws

Loosen

wire

guide

screws.

3

InletWireGuide

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.

ST-137

391-F

/

ST-142

597-A

Tools

Needed:

-

Figure

3-6.

Wire

Guide

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

cam

ers.

Close

spring

shaft

carrier.

Turn

nut

one

dick.

5

Drive

Assembly

Cover

Close

cover.

Repeat

procedure

for

opposite

side

of

wire

feeder.

ST-i

42

597-A

2 3

OM-1584

Page

5

3-7.

Welding

Gun

Connections

AA

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.

wfwaml.1

2/93

1

Drive

Assembly

Cover

2

Gun

Secunng

Knob

3

Gun

Connector

Loosen

secunng

knob.

Insert

gun

connector,

and

position

as

close

as

possible

to

drive

rolls

without

touching.

Tighten

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

for

gun

on

oppo

site

drive

assembly.

2

4

.

Figure

3-8.

Gun

And

Trigger

Lead

Connections

ST-153

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

into

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

1

2

1

Plug

PLG1O

2

Keyway

3

Threaded

Collar

Connect

14-pin

plug

PLG1O

to

matching

receptacle

on

welding

power

source

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.

0

Control

circuit

common.

E

Remote

power

source

voltage

command

signal

from

feeder(potentiometerwtperorO-1

0

volts

dc

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-A/

Ref.

S-0512

OM-1584

Page

7

3-10.

Shielding

Gas

And

Weld

Cable

Connections

£~

WARNING

Tools

Needed:

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.

E

LECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Tum

Oft

wire

feederand

welding

powersource,

and

disconnect

input

power

before

inspecting

or

installing.

BUILDUP

OF

SHIELDING

GAS

can

harm

health

or

kill.



Shut

off

shielding

gas

supply

when

not

in

use.

warn4.1

2193

Ref.

ST-i

53

175-B

.

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

er

source

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.

OR

5

Shielding

Gas

Y

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

5/8in

OM-1584

Page

8

3-il.

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

____

AA

WARNING

I.

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

Tighten

knob

to

prevent

boom

movement.

Loosen

knob

to

allow

boom

movement.

Change

knob

position

to

limit

upward

movement.

Tools

Needed:

increasin

Pressu

Heavy

E

3

2

g

Spring

Decreasing

spring

re

ForA

Pressure

ForA

Gun

Light

Gun

Pull

boom

down

slightly

and

re

move

safety

collar.

Boom

should

zontal

to

60

degrees

above

hori

balance

in

any

position

from

hori

zontal.

If

necessary,

adjust

boom

as

follows:

2

Threaded

Rod

3

Jam

Nut

Loosen

jam

nut

and

turn

threaded

rod

until

boom

balances.

Tighten

jam

nut.

Be

sure

several

full

threads

are

through

yoke

to

pre

vent

boom

falling.

4

Yoke

Retain

safety

collar

for

use

in

dis

~=Z~

1-1/8

in

assembling

or

moving

boom.

Ref.

ST-i

42

599-B

/

Ref

ST-152

380-A

Figure

3-12.

Boom

Adjustments

3-13.

Welding

Wi

re

Installation

A.

Installation

Of

Sp

ool-Type

Wire

4

.3

1

Retaining

Ring

2

Wire

Spool

3

Hub

Remove

retaining

ring

and

slide

spool

unto

hub.

4

Hub

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-153

171

Figure

3-13.

Installation

Of

Spool-Type

Wire

OM-1584

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

.

5

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.

(

I

~

I~~o

,Z~

Wire

Installation

ST-143

478-A

/

ST-152

463

Turn

Oft

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:

~

5/8

in

ST-153

173

Figure

3-15.

Adjusting

Hub

Tension

OM-1584

Page

10

3-14.

Motor

Start

Control

4~

WARNING

~I

~fTDIf

~UfW~V

-~P~

1,111



Do

not

touch

live

electrical

parts.



TumOffwirefeederandwelding

powersource,

and

disconnect

input

power

before

inspecting

or

installing.

QTATUf~

~I

~

on

circuit

boards.



Put

on

grounded

wrist

strap

BEFORE

handling

boards

or

parts.

wtwami.1

2/93

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

potentiometerclockwiseto

in

crease

time

it

takes

the

motor

to

ramp

up

to

speed.

Remove

protec

tive

white

rubber

cap

before

mak

ing

adjustment.

Adjust

potentiome

ter

R70

using

a

small

nonconduc

tive

screwdriver.

Close

and

secure

front

panel,

and

reinstall

wrapper.

ci~J=~n

1/4

in

Ref.

ST-i

42

71

0-A

I

SB-i

46

862-D

Figure

3-16.

Motor

Start

Control

On

Motor

Control

Board

PCi

OM-1

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.

non-conductive

c:I:::::::J=::=31J

1/4

in

STATIC

ELECTRICITY

can

damage

parts

on

circuit

boards.



Put

on

grounded

wrist

strap

BEFORE

handling

boards

or

parts.

wfwarnl.r

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

Oft

wire

feeder

and

welding

power

source.

Remove

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

PC30

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:

OM-1584

Page

12

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