Miller KE661555 Owner's manual

XRTM-30R

Have

only

trained

and

qualified

persons

install,

operate,

or

service

this

unit.



Call

your

distributor

if

you

do

not

understand

the

directions.

September

1995

Form:

OM-141

3220

Effective

With

Serial

No.

KE661

555

Miller

OWNERS

MANUAL

I



Robotic

Extended

Reach

System

For

Feeding

Aluminum

Wire



Hard

Wire

Option

Available



See

Specifications



For

GMAW

And

GMAW-P

Welding



For

Use

With

CV

Or

CC

Welding

Power

Source



For

3/64-1/16

in

Aluminum

And

.030-045

in

Hard

Or

Cored

Wire



Control

Circuit

And

Motor

Overload

Protection



Water-Cooled

Gun

Rated

At

400

Amperes

At

100%

Duty

Cycle



Read

and

follow

these

instructions

and

all



Give

this

manual

to

the

operator.

safety

blocks

carefully.



For

help,

call

your

distributor



or:

MILLER

Electric

Mfg.

Co.,

P.O.

Box

1079,

Appleton,

WI

54912

414-734-9621

cover

5/94

1995

MILLER

Electric

Mfg.

Co.

PRINTED

IN

USA



~-

I

J

MILLERS

TRUE

BLUEﬁ

LIMITED

WARRANTY

Effective

January

1,

1995

(Equipment

with

a

serial

number

preface

of

KD

or

newer)

This

limited

warranty

supersedes

all

warranties

and

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

retail

purchaser

thst

new

MILLER

equipmenl

aold

after

the

effective

date

ot

this

limited

warranty

is

tree

oI

de

Iects

in

material

and

workmanship

at

the

time

it

is

shipped

by

MILLER.

THIS

WAR

RANTY

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTHER

WARRANTIES.

EXPRESS

OR

IMPLtED,

INCLUDING

THE

WARRANTIES

OF

MERCHANTABILITY

AND

FIT

NESS.

Within

the

warranty

periods

listed

below,

M1LLER

will

repair

or

replace

any

war

ranted

parts

or

components

that

tail

due

to

such

detects

in

material

or

workmanship.

MILLER

must

be

notitied

in

writing

within

thirty

(30)

days

ot

such

detect

or

lailure,

at

which

time

MILLER

will

provide

instructions

on

the

warranty

claim

procedures

to

be

lollowed.

MILLER

shall

honor

warranty

claims

on

warranted

equipment

listed

below

in

the

event

ot

auch

a

tailure

within

the

warranty

time

periods.

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

American

distributor

or

eighteen

months

after

the

equipment

Is

sent

to

an

lntemational

distributor.

1.

5

Years

Parts

3

Years

Labor



Original

main

power

rectifiers



Inverters

(input

and

output

rectitiers

only)

2.

3

Years



Pans

and

Labor



Translonner/Rectitier

Power

Sources



Plasma

Arc

Cutting

Power

Sources



Semi-Automatic

and

Automatic

Wire

Feeders



Inverter

Power

Suppliea



Intellitiga

*

Robots

3.

2

Years



Parts

and

Labor

Engine

Driven

Welding

Generators

(NOTE:

Engines

are

warranted

separately

by

the

engine

manutacturer.)

Air

Compressors

4.

1

Year



Pans

and

Labor



Motor

Driven

Guns



Process

Controllers



IHPS

Power

Sources



Water

Coolant

Systems



HF

Units



Grids



Spol

Welders



Load

Banks



SDX

Transtormers



Running

Gear/Trailers



Plasma

Cutting

Torches

(except

APT,

ZIPCUT

&

PLAZCUT

Models)



Tecumseh

Engines

*

Deutz

Engines

(outside

Nonh

America)



Field

Options

(NOTE:

Field

options

are

covered

under

True

Blueﬁ

br

the

remaining

warranty

period

ot

the

product

they

are

installed

in,

or

tor

a

minimum

ot

one

year



whichever

is

greater.)

5.

6

Months



Batteries

6.

90

Days



Pans

and

Labor



MtG

Guns/FIG

Torches



APT,

ZIPCUT

&

PLAZCUT

Model

Plasma

Cutting

Torchea



Remote

Controls

-

Accessory

Kits



Replacement

Pans

MILLERS

True

Blueﬁ

Limited

Warranty

shall

not

apply

to:

1.

Items

tumished

by

MILLER,

but

manufactured

by

others,

&uch

as

engines

or

trade

accessories.

These

items

are

covered

by

the

manufacturers

warranty,

it

any.

2.

Consumable

components:

such

as

contact

tips,

cutting

nozzles,

contectors

and

relays

or

parts

that

tail

due

to

normal

wear.

3.

Equipment

that

has

been

modified

by

any

party

other

than

MILLER,

or

equip

ment

that

has

been

improperly

installed,

improperly

operated

or

misused

based

upon

industry

standards,

or

equipment

which

has

not

had

reasonable

and

necessary

maintenance,

or

equipment

which

has

been

used

tor

operation

outside

ot

the

specifications

br

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

EQUIPMENT.

In

the

event

ot

a

warranty

claim

covered

by

this

warranty,

the

exclusive

remedies

shall

be,

at

MILLERS

option:

(t)

repair:

or

(2)

replacement;

or,

where

authorized

in

writing

by

MILLER

in

appropriate

cases,

(3)

the

reasonable

cost

ot

repair

or

replace

ment

at

an

authorized

MILLER

service

station;

or

(4)

payment

of

or

credit

for

the

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

retum

of

the

goods

al

customers

risk

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

transportalion

coats

of

any

kind

will

be

allowed.

TO

THE

EXTENT

PERMITFED

BY

LAW,

THE

REMEDIES

PROVIDED

HEREIN

ARE

THE

SOLE

AND

EXCLUSIVE

REMEDIES.

IN

NO

EVENT

SHALL

MILLER

BE

LIABLE

FOR

DIRECT,

INDIRECT,

SPECIAL,

INCIDENTAL

OR

CONSEQUENTIAL

DAMAGES

(INCLUDtNG

LOSS OF

PROFIT),

WHETHER

BASED

ON

CON

TRACT,

TORT

OR

ANY

OTHER

LEGAL

THEORY.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPUED

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

DEALING,

IN

CLUDING

ANY

IMPUED

WARRANTY

OF

MERCHANTABILITY

OR

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

TO

ANY

AND

ALL

EQUIPMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

AND

DISCLAIMED

BY

MILLER.

Some

states

in

the

U.S.A.

do

not

allow

limitations

ot

how

long

an

implied

warranty

lasts,

or

the

exclusion

ol

incidental,

indirect,

special

or

consequential

demages,

so

the

above

limitstion

or

exclusion

may

not

apply

lo

you.

This

warranty

provides

spe

cific

legal

rights,

and

other

rights

may

be

available,

but

mey

vary

trom

state

to

state.

In

Canada,

legislation

in

some

provinces

provides

br

certain

additional

warranties

or

remedies

other

than

as

staled

herein,

and

to

the

extent

that

they

may

not

be

waived,

the

limitations

and

escluaions

set

oul

above

may

not

apply.

This

Limited

Warranty

provides

specific

legal

rights,

and

other

rights

may

be

available,

but

may

vary

tram

province

to

province.



I

-

j~i

RECEIVING-HANDLING

Before

unpacking

equipment,

check

carton

for

any

damage

fhat

may

have

occurred

during

shipment.

File

any

claims

for

loss

or

damage

with

the

delivering

carrier.

Assistance

for

tiling

or

settling

claims

may

be

obtained

from

distributor

and/or

equipment

manufacturers

Transportation

Department.

When

requesting

information

about

this

equipment,

always

provide

Model

Designation

and

Serial

or

Style

Number.

Use

the

following

spaces

to

record

Model

Designation

and

Serial

or

Style

Number

of

your

unit.

The

information

is

located

on

the

rating

label

or

nameplate.

Model

_________

Serial

or

Style

No.

Date

of

Purchase

miller

6/95

ARC

WELDING

SAFETY

PRECAUTIONS

ELECTRIC

SHOCK

can

kill.

~

Touching

live

electrical

parts

can

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

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

touchin9

the

welding

wire

are

electrically

live.

Incorrectly

installed

or

improperly

grounded

equipment

is

a

hazard.

1.

Do

not

touch

live

electrical

parts.

2.

Wear

dry,

hole-free

insulating

gloves

and

body

protection.

3.

Insulate

yourself

from

work

and

ground

using

dry

insulating

mats

or

covers

big

enough

to

prevent

any

physical

contact

with

the

work

or

ground.

4.

Disconnect

input

power

or

stop

engine

before

installing

or

servicing

this

equipment.

Lockout/tagout

input

poweraccording

to

OSHA

29

CFR

1910.147

(see

Safety

Standards).

5.

Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual and

national,

state,

and

local

codes.

6.

Always

verify

the

supply

ground



check

and

be

sure

that

input

power

cord

ground

wire

is

properly

connected

to

around

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

Æf

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

harness

if

working

above

floor

level.

16.

Keep

all

panels

and

covers

securely

in

place.

17.

Clamp

work

cable

with

good

metal-to-metal

contact

to

workniece

or

~~~~

as

near

the

weld

as

oractical.

AA

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.

ARC

RAYS

can

burn

eyes

and

skin;

ARC

RAYS

/~

-

..



NOISE

can

damage

hearing;

FLYING

SLAG

OR

SPARKS

can

injure

eyes.

Arc

rays

from

the

welding

process

produce

intense

visible

and

invisible

(ultraviolet

and

infrared)

rays

that

can

burn

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

Chipping,

grinding,

and

welds

cooling

throw

off

pieces

of

metal

or

slag.

2.

3.

4.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

to

protect

yourface

and

eyes

when

welding

orwatching

(see

ANSI

Z49.1

and

Z87.1

listed

in

Safety

Standards).

Wear

approved

safety

glasses

with

side

shields.

Use

protective

screens

or

barriers

to

protect

others

from

flash

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.

r

FUMES

AND

GASES

can

be

hazardous

to

your

health.

Q

J

fumes

and

gases

can

be

hazardous

to

your

health.

Welding

produces

fumes

and

gases.

Breathing

these

~

1.

Keep

your

head

out

of

the

fumes.

Do

not

breathe

the

fumes.

2.

If

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

remove

welding

fumes

and

gases.

3.

If

ventilation

is

poor,

use

an

approved

air-supplied

respirator.

5.

6.

7.

Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

wearing

an

air-supplied

respirator.

Always

have

a

trained

breathing

air

is

safe.

watchperson

nearby.

Welding

fumes

and

gases

can

displace

air

and

lower

the

oxygen

level

causing

injury

or

death.

Be

sure

the

Do

not

weld

in

locations

near

degreasing,

cleaning,

or

spraying

operations.

The

heat

and

rays

of

the

arc

can

react

with

vapors

to

form

highly

toxic

and

irritating

gases.

Do

not

weld

on

coated

metals,

such

as

galvanized,

lead,

or

cadmium

plated

steel,

unless

the

coating

is

removed

from

the

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.

CYLINDERS

can

explode

if

damaged.

4.

Never

drape

a

welding

torch

over

a

gas

cylinder.

Shielding

gas

cylinders

contain

gas

under

high

pressure.

If

damaged,

a

cylinder

can

explode.

Since

gas

cylinders

are

normally

part

of

the

welding

process,

be

sure

to

treat

them

carefully.

5.

6.

7.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

Never

weld

on

a

pressurized

cylinder



explosion

will

result.

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

in

good

condition.

1.

Protect

compressed

gas

cylinders

from

excessive

heat.

8.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

mechanical

shocks,

slag,

open

flames,

sparks,

and

arcs.

9.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

2.

Install

cylinders

in

an

upright

position

by

securing

to

a

stationary

in

use

or

connected

for

use.

support

or

cylinder

rack

to

prevent

falling

or

tipping.

10.

Read

and

follow

instructions

on

compressed

gas

cylinders,

3.

Keep

cylinders

away

from

any

welding

or

other

electrical

associatedequipment,andCGApublicationP-1

listed

in

Safety

circuits.

Standards.

Srl1.I

2194

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

t0AWS

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

tire

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.

Wearoil-free

protective

garments

such

as

leather

gloves,

heavy

shirt,

cuffless

trousers,

high

shoes,

and

a

cap.

12.

Removeanycombustibles,

suchasabutanelighterormatches,

from

your

person

before

doing

any

welding.

ENGINE

FUEL

can

cause

fire

or

explosion.

Engine

fuel

is

highly

flammable.

Stop

engine

and

let

it

cool

off

before

checking

or

adding

fuel.

Do

not

add

fuel

while

smoking

or

if

unit

is

near

any

sparks

or

open

flames.

SPARKS

can

cause

BATTERY

GASES

TO

EXPLODE;

BATTERY

ACID

can

burn

eyes

and

skin.

Batteries

contain

acid

and

generate

explosive

gases.

STEAM

AND

PRESSURIZED

HOT

COOLANT

can

burn

face,

eyes,

and

skin.

It

is

best

to

check

coolant

level

when

engine

is

cold

to

avoid

scalding.

ENGINES

can

be

hazardous.

1.

Always

wear

a

face

shield

when

working

on

a

battery.

2.

Stop

engine

before

disconnecting

or

connecting

battery

cables.

3.

Do

not

allow

tools

to

cause

sparks

when

working

on

a

battery.

4.

Do

not

use

welder

to

charge

batteries

or

jump

start

vehicles.

5.

Observe

correct

polarity

(

and



on

batteries

1.

If

the

engine

is

warm

and

checking

is

needed,

follow

steps

2

and

3.

2.

Wear

safety

glasses

and

gloves

and

put

a

rag

over

cap.

3.

Turn

cap

slightly

and

let

pressure

escape

slowly

before

completely

removing

cap.

PRINCIPAL

SAFETY

STANDARDS

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.i,

from

American

Welding

Society,

550

N.W.

LeJeune

Rd,

Miami

FL

33126

Safety

and

Health

Standards,

OSHA

29

CFR

1910,

from

Superinten

dent

of

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

Recommended

Safe

Practices

for

the

Preparation

for

Welding

and

Cutting

of

Containers

That

Have

Held

Hazardous

Substances,

Ameri

can

Welding

Society

Standard

AWS

F4.1

from

American

Welding

So

ciety,

550

N.W.

LeJeune

Rd,

Miami,

FL

33126

National

Electrical

Code,

NFPA

Standard

70,

from

National

Fire

Pro

tection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

P-i,

from

Compressed

Gas

Association,

1235

Jefferson

Davis

High

way,

Suite

501,

Arlington,

VA

22202.

Code

for

Safety

in

Welding

and

Cutting,

CSA

Standard

Wi

17.2,

from

Canadian

Standards

Association,

Standards

Sales,

178

Rexdale

Bou

levard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

Protec

tion,

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.

AA

WARNING

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.

2.

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

can

cause

injury.

~

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.

3.

4.

5.

6.

Have

only

qualified

people

remove

guards

or

covers

for

To

prevent

accidental

starting

during

servicing,

disconnect

maintenance

and

troubleshooting

as

necessary.

negative

()

battery

cable

from

battery.

Keep

hands,

hair,

loose

clothing,

and

tools

away

from

moving

parts.

Reinstall

panels

or

guards

and

close

doors

when

servicing

is

2.

Stop

eng

ne

before

installing

or

connecting

unit.

finished

and

before

starting

engine.

srl.1.1

2/94

EMF

INFORMATION

TABLE

OF

CONTENTS

SECTION

1



SAFETY

INFORMATION

1

SECTION

2-

SPECIFICATIONS

1

2-1.

Duty

Cycle

1

SECTION

3-

INSTALLATION

3-1.

Field

Installation

Instructions

For

XR-30R

Panel

Onto

Computer

Interface

3-2.

Computer

Interface



XR-30R

Interconnections

3-3.

Computer

Interface/XR-30R

Panel



Wire

Feeder

Connection

3-4.

Preparing

Robot

For

Installation

Of

XR-30R

3-5.

Installing

XR-30R

Gun

3-6.

Interconnecting

Harness

Connections

To

Feeder

3-7.

Installing

Wire

Spool

3-8.

Threading

Welding

Wire

3-9.

Coolant

Guidelines

SECTION

4-OPERATION

14

SECTION

5-

MAINTENANCE

&

TROUBLESHOOTING

5-1.

Routine

Maintenance

5-2.

Changing

Or

Cleaning

Gun

Drive

Roll

5-3.

Changing

Feeder

And

Auxiliary

Feeder

Drive

Roll

And

Wire

Inlet

Guide

5-4.

Replacing

Or

Cleaning

Gun

Drive

Roll

Bearing

5-5.

Replacing

Or

Cleaning

Feeder

And

Auxiliary

Feeder

Drive

Roll

Bearing

5-6.

Replacing

Hub

Assembly

5-7.

Adjusting

Hub

Tension

5-8.

Overload

Protection

5-9.

Water

Flow

Switch

5-10.

Troubleshooting

SECTION

6

ELECTRICAL

DIAGRAMS

24

SECTION

7-

PARTS

LIST

34

Figure

7-1.

Control

Box

34

Figure

7-2.

Tach

Drive/Motor

&

Wire

Drive

37

Figure

7-3.

Interface

Control,

Push/Pull

38

Figure

7-4.

Gun,

XR-30R

(MRH

Model

Illustrated)

40

Figure

7-5.

Auxiliary

Motor,

Push/Pull

(MRV-6)

43

Miscellaneous

Components

45

OM-141

322C9/95

NOTE

~

I

Considerations

About

Magnetic

Fields

The

following

is

a

quotation

from

the

General

Conclusions

Section

Welding

And

The

Effects

Of

Low

Frequency

Electric

And

To

reduce

magnetic

fields

In

the

workplace,

use

the

following

of

the

U.S.

Congress,

Office

of

Technology

Assessment,

Biological

procedures:

Effects

of

Power

Frequency

Electric

&

Magnetic

Fields



Background

Paper,

OTA-BP-E-53

(Washington,

DC:

U.S.

Government

Printing

Office,

May

1989):

.

. .

there

is

now

a

very

1.

Keep

cables

close

together

by

twisting

or

taping

them.

2.

Arrange

cables

to

one

side

and

away

from

the

operator.

large

volume

of

scientific

findings

based

on

experiments

at

the

3.

Do

not

coil

or

drape

cables

around

the

body.

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

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.

single

coherent

framework.

Even

more

frustrating,

it

does

not

yet

About

Pacemakers:

allow

us

to

draw

definite

conclusions

about

questions

of

possible

risk

or

to

offer

clear

science-based

advice

on

strategies

to

minimize

The

above

procedures

are

among

those

also

normally

recommended

for

pacemaker

wearers.

Consult

your

doctor

for

or

avoid

potential

risks.

complete

information.

modlO

1

4/93

2

3

4

5

7

10

11

13

17

18

19

20

21

22

SECTION

1



SAFETY

INFORMATION

modl.1

2193

6



Read

all

safety

messages

throughout

this

manual.



Obey

all

safety

messages

to

avoid

injury.



Learn

the

meaning

of

WARNING

and

CAUTION.



1

Safety

Alert

Symbol

1

2

Signal

Word

\

WARNING

means

possible

death

or

serious

injury

can

happen.

3

CAUTION

means

possible

minor

II

ELECTRIC

SHOCK

can

kIII.~

~

MOVING

PARTS

can

Injure.

injury

or

equipment

damage

can

I



Do

not

touch

live

electflcal

parts.

S

Keep

away

from

moving

parts.

happen.



Disconnect

input

power

before

4

4



Keep

all

panels

and

covers

closed

3

Statement

Of

Hazard

And

L~

Installing

or

servicing,

when

operating.

Result

/

4

Safety

Instructions

To

Avoid

5

Hazard

5

Hazard

Symbol

(If

Available)

6

Safety

Banner

READ

SAFETY

BLOCKS

at

start

of

SectIon

3-1

before

proceeding.

Read

safety

blocks

for

each

sym

bol

shown.

7

NOTE

~

~

NOTE

~

Turn

Off

switch

when

using

high

frequency.

Special

instructions

for

best

oper

ation



not

safety.

Figure

1-1.

Safety

Information

SECTION

2-

SPECIFICATIONS

Table

2-1.

Wire

Feeder

Specification

Description

Type

Of

Input

Power

115

Volts

AC,

3

Amperes

At

50/60

Or

100

Hz

Power

Control

Circuit

Voltage

Provided

At

Gun

30

Volts

DC

Wire

Feed

Speed

Range

70-875

ipm

(1.9-22.2

mpm)

Overall

Dimensions

Length:

19

in

(483

mm);

Width:

9-1/4

in

(235

mm);

Height:

15-1/4

in

(387

mm)

Maximum

Spool

Capacity

12

in

(305

mm)

Table

2-2.

Gun

Specification

Description

Input

Voltage

30

Volts

DC

Duty

Cycle

(Water-Cooled

Models)

At

400

Amperes,

100%

Using

Argon

Or

Argon

Mixture

Shielding

Gas

(See

Section

2-1)

Wire

Size

Range

3/64

To

1/16

in

(1.2

To

1.6

mm)

Aluminum

Wire



Contact

Factory

For

.035

Specifications

.030

Thru

.045

in

(0.8

Thru

1.1

mm)

Hard

Or

Cored

Wire

With

Optional

Steel

Kit:

147

183

For

MRV;

147 184

For

MRH

2-1.

Duty

Cycle

USING

GUN

BEYOND

DUTY

CYCLE

RATING

can

damage

gun.



Do

no

t

use

gun

beyond

rated

amperage

when

using

Argon

shielding

gas.

wfwam8.r

10/91

Duty

cycle

is

how

long

the

gun

can

operate

within

a

ten

minute

period

without

causing

overheating

or

damage.

This

gun

is

rated

at

100%

duty

cycle

when

operated

at

400

amperes,

allowing

continuous

welding.

a

WARNING

a

CAUTION

a

WARNING

a

CAUTION

OM-141

322

Page

1

SECTION

3-

INSTALLATION

3-1.

Field

Installation

Instructions

For

XR-30R

Panel

Onto

Computer

Interface

1

Computer

Interface

Remove

side

panels

and

top

cover.

Save

for

future

use.

Remove

RCSP-XL

side

panel

if

in

stalled.

2

XR-30R

Panel

Remove

side

panel

and

install

frame

onto

Computer

Interface.

3

Communications

Board

PC3

Disconnect

CN24

from

board.

Wrap

with

electrical

tape

to

isolate.

Connect

plug

from

XR-30R

panel

to

receptacle

on

board

where

CN24

was

removed.

4

Terminal

Strip

iT

Connect

lead

55

from

XR-30R

panel

to

Computer

Interface

iT

terminal

F.

5

Grommet

Route

remaining

XR-30R

leads

through

grommet.

6

Interface

Board

PC4

Disconnect

PLG1

from

RC1.

Connect

4-position

plug

with

4

sock

ets

from

XR-30R

panel

to

RC1.

Connect

4-position

plug

with

2

sock

ets

from

XR-30R

panel

to

PLG1.

Connect

lead

60

to

grounding

termi

nal

board.

7

Terminal

Strip

2T

Connect

two

leads

23

to

2T

terminal

A.

8

Side

Panel

Reinstall

when

connections

are

completed.

Reinstall

RCSP-XL

side

panel

if

applicable.

9

Top

Cover

Install

correct

supplied

top

cover.

ST-159

242-A

/

5T-139

887-C

/

Rel.

SD-184

013

Figure

3-1

-

Installing

XR-30R

Onto

Computer

Interface

__

a

WARNING

__



~



Turn

Off

welding

power

source,

and

disconnect

ELECTRIC

SHOCK

can

kill

S

Do

not

touch

live

electrical

parts.

input

power

before

beginning

this

installation,



Have

only

qualified

persons

familiar

with

and

following

standard

safety

practices

install

this

kit.



Put

on

grounded

wrist

strap

BEFORE

handling

STATIC

ELECTRICITY

can

damage

parts

on

circuit

boards.

boards

or

parts.

S

Use

proper

static-proof

bags

and

boxes.

twaml.1

2J93/fwam5.1

9/91

Left

Side

3

Right

Side

4

5

1

OM-141

322

Page

2

3-2.

Computer

Interface



XR-30R

Interconnections

Figure

3-2.

Computer

Interface



XR-30R

Connections

1

Computer

Interface

2

XR-30R

Panel

3

RCSP-XL

Panel

To

XR

Control

Rear

Panel

To

Welding

~Power

Source

14-Socket

Receptacle

S-0557-A/

S-O555-A

I)

I

Voltage

Sensing

Leads

PLGI

4

To

Computer

Interface

RC14

I

To

Display

Module~

PLG1

1

To

Computer

~

I

Interface

RC11

RC8

0

To

Weld

Current

~

Relay

Control

PLG8

To

Computer

Interface

RC8

PLG9

To

Computer

PLG11

Interface

RC9

To

RCSP-XL

Rd

6

RC1

4

0

RC9

0

RC1

2

RC1O

RC11

O\

ToWelding~~

Power

Source

17-Socket

Receptacle

RC1

7

RC16

0

To

Robot

Manipulator

RC18

RC1

9

o~

RC2O

Not

Used

For

This

Installation

OM-141

322

Page

3

3-3.

Computer

lnterlace/XR-30R

Panel



Wire

Feeder

Connection

Figure

3-3.

Computer

Interface/XR-30R

Panel



Wire

Feeder

Connection

3-4.

Preparing

Robot

For

Installation

Of

XR-30R

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

wire

feeder,

welding

power

source,

and

robot,

and

disconnect

input

power

before

disassembly.

The

welding

wire,

drive

rolls,

drive

assembly,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live

when

welding

rT~~~1

Fl

1

Wire

Feeder

Receptacle

RC5

Locate

lOft

(3m)

cord

with

1

4-posi

tion

plugs

on

both

ends.

Connect

one

end

to

RC5.

Connect

remain

ing

end

to

Rd

9

on

Computer

Inter

face/XR-30R

Panel.

Align

keyway,

insert

plug,

and

tighten

threaded

collar.

~

0000

Ret.

ST-159

241-A

__

a

WARNING

5

Ref.

ST-155

650

/

Ref.

ST-146

992

1

MRH

Manipulator

2

Wire

Spool

3

Wire

Drive

Assembly

4

Outlet

Cable

5

Welding

Gun

6

Gun

Mounting

Plate

7

MRV

Manipulator

B

Strain Relief

Bracket

9

Gun

Mounting

Bracket

Remove

items

from

manipulator

and

retain

for

future

use.

Retain

hardware.

9

Figure

3-4.

Preparing

Robot

For

XR-30R

Installation

OM-141

322

Page

4

3-5.

Installing

XR-30R

Gun

A.

Gun

Mounting

Figure

3-5.

Gun

Mounting

B.

Interconnecting

Harness

Connections

To

Auxiliary

Feeder

Install

auxiliary

feeder

in

position

shown

in

Figure

3-7.

Make

con

nections

as

follows:

1

Wire

Conduit

From

Feeder

2

5-Socket

Wire

Drive

Motor

Plug

3

Cover

4

Tach

Auxiliary

Drive

Assembly

5

Thumbscrew

Loosen

and

Insert

wire

conduits

until

tip

almost

touches

drive

roll.

Tighten

thumbscrews.

6

Auxiliary

Wire

Drive

Assembly

7

Wire

Conduit

To

Gun

8

Gas

Hose

To

Gun

9

Gun

Motor

Control

Plug

(MRH

Shown)

10

2-Socket

Tach

Feedback

Plug

To

connect

plugs,

align

keyway,

In

sert

plug

into

matching

receptacle

on

auxiliary

feeder,

and

tighten

threaded

collar.

11

Shock

Sensor

Plug

Connect

to

matching

plug

from

ro

bot

manipulator.

12

Voltage

Sensing

Cable

Install

onto

rear

mounting

block

of

auxiliary

feeder.

ST.158

972-c

1

Gun

2

Bracket

3

Robot

Manipulator

Attach

bracket

to

gun

and

manipu

lator.

Adjust

gun

position

accord

ing

to

Section

4.5

In

the

Robot

Owners

Manual.

2

ST-158

869/

ST-159

881

Figure

3-6.

Auxiliary

Feeder

Connections

OM-141

322

Page

5

C.

Clamping

Harness

A~

CAUTION

INSUFFICIENT

SLACK

IN

HARNESS

can

cause

equipment

damage.



Allow

sufficient

slack

in

harness

between

clamping

points

for

proper

robot

movement.

Hamess

needs

to

be

clamped

so

that

it

can

follow

robot

movement

without

getting

caught

or

binding.

1

Bracket

Insulator

2

Nylon

Shoulder

Washer

3

Cable

Support

Bracket

______________

4

Interconnecting

Hamess

5

Rubber

Strain

Relief

6

Rubber

Tie

7

Auxiliary

Feeder

8

Ring

9

Tool

Balancer

10

Hanger

Insulator

11

Adjustable

Cable

Hanger

12

Bracket

13

Insulated

Conduit

Clamp

14

Clamp

17

15

Stop

Collar

16

Spring

17

Gun

7

11

16 15

8

____________

~~___

14

4

3

1

2

13

Mount

according

to

Figure

3-5.

=

Alternate

Harness

Routing

ST-160

942-B

I

ST-160

941-B

/

ST-800

269-A

/

ST-800

270-A

I

ST-800

268

Figure

3-7.

Clamping

Harness

OM-141

322

Page

6

3-6.

Interconnecting

Harness

Connections

To

Feeder

£~

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

wire

feeder,

welding

power

source,

and

robot,

and

disconnect

input

power

before

inspecting

or

installing.

The

welding

wire,

drive

rolls,

drive

assembly,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live

when

welding.

A.

Wire

Conduit

And

Auxiliary

Feeder

Connections

HIGH

GAS

PRESSURE

can

cause

gun

gas

valve

to

leak.



Do

not

use

gas

pressure

above

50

psi

(345

kPa)

or

mechanical

gas

valve

in

gun

can

leak.

OVERHEATING

can

damage

gun

parts.



Make

connections

from

coolant

supply

to

flow

switch

in

unit.

Figure

3-8.

Wire Conduit

And

Auxiliary

Feeder

Connections

C



YLINDERS

can

explode

if

damaged.

Keep

cylinders

away

from

welding

and

other

INCORRECT

COOLANT

FLOW

RATE

can

damage

gun

parts.

electrical

circuits.

S

Maintain

minimum

1

qt/min

flow

rate at

all

times.



Never

touch

cylinder

with

welding

electrode.



Always

secure

cylinder

to

running

gear,

wall,

or

other

stationary

support.

wfwam7.I

9/91

Internal

Water

Connections

Not

Shown

Front

View

1

Side

View

1

Wire

Feeder

2

Wire

Conduit

3

Securing

Screw

Loosen

screw,

insert

wire

conduit

through

front

panel

and

into

wire

drive.

Secure

conduit

as

close

to

drive

roll

as

possible

without

touching.

4

Auxiliary

Feeder

Cord

5

Receptacle

RC6

To

make

connection,

align

keyway,

insert

plug

Into

matching

recep

tacle

RC6,

and

tighten

threaded

collar.

4~

Ref.

5T-159

241-B

/

Ref.

ST-159

238.A

5

OM-141

322

Page

7

B.

Weld

Cable

Connections

Figure

3-9.

Weld

Cable

Connections

1

Wire

Feeder

2

Weld

Cable

From

Intercon

necting

Harness

Route

through

front

panel

and

con

nect

as

shown.

3

Weld

Cable

From

Welding

Power

Source

See

welding

power

source

Own.

ers

Manual

for

correct

size

cable.

Obtain

cable

with

proper

size

lugs

and

connect

as

shown.

Front

View

Rear View

Side

View

3

Ref.

ST-I

59

238-Al

ST-159

237-B

OM-141

322

Page

8

C.

Water

Connections

Rear View

5

Front

View

Side

View

Side

View

Figure

3-10.

Water

Connections

1

Wire

Feeder

All

fittings

have

left-hand

threads.

2

Water

Hose

From

Gun

3

WaterHoseToGun

Connect

water

hoses

from

inter

connecting

harness

to

fittings

on

front

panel.

4

Coolant

In

Opening

Route

hose

from

coolant

system

outfitting,

through

opening,

and

to

fitting

on

rear

of

front

panel.

Con

nect

hose.

5

Coolant

Out

Fitting

Connect

hose

from

coolant

supply

In

fitting

to

coolant

out

fitting.

6

Flow

Switch

SB

The

switch

has

a

normally-open

spring

contact

which

closes

when

0.25

gpm

(0.95

1pm)

flows

through

it.

If

the switch

contact

does

not

close,

wire

does

not

feed.

Ref.

ST-i

59

236-A

I

ST-159

238-B

I

ST-i

59239-B

1

2

Internal

Water

Connections

Not

Shown

3

Internal

Water

Connections

Shown

OM-141

322

Page

9

3-7.

Installing

Wire

Spool

Turn

Off

wire

feeder

and

welding

power

source.

1

Wire

Spool

2

Tension

Ami

3

Gun

Contact

Tip

If

wire

spool

is

being

replaced,

re

move

gun

cover,

open

tension

arm

in

gun,

and

cut

welding

wire

off

at

contact

tip.

For

welding

power

sources

without

ontactor,

retract

wire

onto

spool.

For

welding

power

sources

with

a

contactor,

energize

power

source,

turn

On

feeder,

press

Brake

Re

lease

button

(see

Figure

4-6),

and

retract

wire

onto

spool.

Remove

retaining

ring

and

slide

wire

spool

oft.

Close

gun

tension

arm

and

reinstall

gun

cover.

4

Hub

5

Hub

6

Retaining

Ring

Slide

spool

onto

hub

so

wire

feeds

off

bottom.

Turn

spool

until

hub

fits

hole

in

back

of

spool.

Reinstall

retaining

ring.

7

Jog

Switch

Thread

welding

wire

using

Jog

switch

(see

Section

3-8).

Close

and

latch

door.

Ref.

ST-159

237-B

/

Ref.

ST-072

573-B

/

Ref.

ST-158

974-A

Figure

3-11.

Installing

Wire

Spool

Tools

Needed:

OM-141

322

Page

10

3-8.

Threading

Welding

Wire

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.

The

welding

wire,

drive

rolls,

drive

assembly,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live

when

welding.

HOT

SURFACES

can

burn

skin.



Allow

gun

to

cool

before

touching.

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.

WELDING

WIRE

can

cause

puncture

wounds.



Do

not

press

gun

trigger

until

instructed

to

do

so.



Do

not

point

gun

toward

any

part

of

the

body,

other

people,

or

any

metal

when

threading

welding

wire.

wfwaml.r

9/91

A.

Threading

Welding

Wire

Through

Feeder

And

Auxiliary

Feeder

a

WARNING

Tools

Needed:

7

Be

sure

proper

drive

roll

groove

is

in

position

for

wire

size

selected

(see

Table

3-1).

Change

drive

roll

to

selected

wire

size

according

to

Sections

5-2

and

5-3.

1

Wire

Spool

Loosen

wire

from

spool,

cut

off

bent

wire,

and

pull

6

in

(150mm)

of

wire

off

spool.

2

Tension

Arm

3

Tension

Screw

To

open

tension

arm

loosen

screw

and

lift

arm.

4

Wire

Inlet

Guide

5

Drive

Roll

6

Wire

Conduit

Fitting

Thread

wire

through

wire

Inlet

guide,

along

drive

roll

groove,

and

Into

fitting.

Close

and

secure

tension

arm.

Tighten

tension

screw

all

the

way

down.

7

Motor

Torque

Switch

Place

switch

in

proper

position

for

wire

size

selected

(see

Figure

4-6).

8

Jog

Switch

9

Wire

Conduit

At

the

auxiliary

feeder,

loosen

ten

sion

screws

and

lift

tension

arms.

Remove

conduit

from

rear

drive

assembly.

Feed

welding

wire

until

10

in

(254

mm)

extends

from

wire

conduit.

10

Tach

Auxiliary

Drive

Assembly

11

Auxiliary

Drive

Assembly

Thread

wire

through

both

wire

drive

assemblies

and

Into

wire

conduit

going

to

gun.

Reinstall

wire

conduit.

Close

and

secure

tension

arms.

Tighten

tension

screws

all

the

way

down.

Feed

wire

to

gun.

Ref.

ST-i

59

240-B

/

Ref.

ST-i

Si

7781

Ref.

ST-i

58

972.C

4

56

Figure

3-12.

Threading

Welding

Wire

Through

Feeder

OM-141

322

Page

11

B.

Threading

Welding

Wire

Through

Gun

a

WARNING

READ

SAFETY

BLOCKS

at

start

of

Section

3-8

before

proceeding.

1

Wire

Conduit

2

Secunng

Screw

Loosen

screw

and

remove

wire

conduit.

3

Tension

Arm

4

Tension

Screw

To

open

tension

arm

loosen

screw

and

lift

arm.

5

Jog

Switch

Feed

wire

until

5

in

(127

mm)

of

wire

extends

from

wire

conduit.

6

Drive

Roll

(See

Table

3-1)

7

Contact

Tube

(See

Table

3-1)

Manually

thread

wire

along

drive

roll

groove

and

out

contact

tip.

Re

install

wire

conduit.

Close

and

secure

tension

arm.

Tighten

tension

screw

all

the

way

down.

Turn

Off

feeder

and

welding

power

source.

Reinstall

gun

cover.

Close

and

latch

feeder

door.

Ref.

ST-i

58

973-A

/

Ret.

ST-158

974-A

I

Ref.

5-0651

Figure

3-13.

Threading

Welding

Wire

Through

Gun

Table

3-1.

Gun

Part

Recommendations

For

Wire

Size

Changing

Parts

Aluminum

Wire

Hard

And

Flux

Cored

Wire*

.035

In

.045

In

3/64

in

1/16

In

.030

in

.035

in

.045

In

Drive

Roll

Grove

A

(small

groove)

X

Drive

Roll

Grove

B

(large

groove)

X X

X

Contact

Tip

Part

No.

108

786

1.2

R

Contact

Tip

Part

No.

108

788

0.8

R

Contact

Tip

Part

No.

108

789

0.9

A

Contact

Tip

part

no.

108

790

1.6

R

1.6

A

Contact

Tip

Part

No.

125

988

Contact

Tip

Part

No.

113954

1.2

M

Contact

Tip

Part

No.

113955

1.6

M

Liner

Part

No.

141

222

.055

in

ID

.055

in

ID

.055

in

ID

.055

in

ID

.055

in

ID

.055

in

ID

Liner

Part

No.

141

223

.093

in

ID

Motor

Torque

Switch

Setting

.035

Other

Other Other

*Requires

optional

kit



see

Table

2-2.

OM-141

322

Page

12

3-9.

Coolant

Guidelines

4~

CAUTION

INCORRECT

COOLANT

OR

COOLANT

CONTAINING

STOP-LEAK

ADDITIVES

can

corrode

and/or

plug

gun/

feeder

cooling

passages.



Use

only

a

mix

of

50%

distilled

water

and

50%

high

quality

automotive

antifreeze

as

proper

coolant

for

this

product.



Do

not

use

antifreeze

containing

stop-leak

additives.



Use

of

other

coolant

voids

warranty.

Figure

3-14.

Coolant

Guidelines

1

50

50

Distilled

Water

&

Antifreez

Follow

these

guidelines

to

decrease

corrosion

In

gun/feeder

and

cooling

system:

I

Coolant

2~

Mix

distilled

water

and

high

quality

automotive

antifreeze.

Use

anti

freeze

which

does

not

contain

stop-leak

additives.

Use

of

other

coolant

voids

warranty.

2

Coolant

System

Tank

3

Changing

Coolant

Change

coolant

only

if

dirty.

FULL

Add

coolant

to

keep

level

full.

4

lighten

Connections

Keep

gun

connections

tight.

Flume

3

lighten

Connections

4

S-o76o

OM-141

322

Page

13

SECTION

4-

OPERATION

a

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Always

wear

dry

insulating

gloves.

Insulate

yourself

from

work

and

ground.

Keep

all

panels

and

covers

securely

in

place.

FUMES

AND

GASES

can

be

hazardous

to

your

health.



Keep

your

head

out

of

the

fumes.



Ventilate

area,

or

use

breathing

device.



Read

Material

Safety

Data

Sheets

(MSDSs)

and

manufacturers

instructions

for

material

used.

WELDING

can

cause

tire

or

explosion.



Do

not

weld

near

flammable

material.



Watch

for

fire;

keep

extinguisher

nearby.



Do

not

locate

unit

over

combustible

surfaces.



Do

not

weld

on

closed

containers.



Allow

work

and

equipment

to

cool

before

handling.

/~

~

ARC

RAYS

can

burn

eyes

and

skin;

NOISE

can

damage

hearing.



Wear

welding

helmet

with

correct

shade

of

filter.



Wear

correct

eye,

ear,

and

body

protection.

9~I~IIIIItrii~

MOVING

PARTS

can

cause

injury.



Keep

away

from

pinch

points

such

as

drive

rolls.



Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

I

~

MAGNETIC

FIELDS

FROM

HIGH

CUR

RENTS

can

affect

pacemaker

operation.



Pacemaker

wearers

keep

away.



Wearers

should

consult

their

doctor

before

going

near

any

welding

operations.

See

Safety

Precautions

at

beginning

of

welding

power

source

Owners

Manual

for

basic

welding

safety

information.

wfwam3.1

8/92

Figure

4-2.

Safety

Equipment

1

Pilot

Light

2

Power

Switch

3

Jog

Switch

Figure

4-1.

Front

Panel Controls

Of

Feeder

Ref.

ST-159

236~A

2

3

Wear

the

following

while

welding:

/

1

Dry,

Insulating

Gloves

2

Safety

Glasses

With Side

Shields

______

3

Welding

Helmet

With

Correct

Shade

Of

Filter

(See

ANSI

Z49.

1)

Bb3.1

1/94

OM-141

322

Page

14

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