Miller DS-64M Swingarc Owner's manual

Miller

.

October

1994

Form:

OM-1588A

Effective

With

Serial

No.

KE648703

OWNERS

MANUAL

:..:~

DS-64M

(12)

And

(16)

Foot

Boom

Mounted

Wire

Feeder

U



Read

and

follow

these

instructions

and

all

safety

blocks

carefully.

Have

only

trained

and

qualified

persons

install,

operate,

or

service

this

unit.



Give

this

manual

to

the

operator.

U

For

help,

call

your

distributor

U

Call

your

distributor

if

you

do

not

understand

U

or~

MILLER

Electric

Mfg.

Co.,

P.O.

Box

1079,

the

directions.

Appleton,

WI

54912

414-734-9821



Boom-Mounted

Microprocessor

Controlled

Constant

Speed

Dual

Wire

Feeder



Multi-Power

Source

Compatible



For

GMAW,

GMAW-P,

And

FCAW

Welding



For

.023

To

1/8

in

(0.6

To

3.2

mm)

Wires



Standard

Wire

Feed

Speed

Of

50

To

780

pm

(1.3

To

19.8

mpm)



Programmable

Pulse

Weld

Parameters



For

Options

And

Accessories,

See

Rear

Cover

cover

5/94



ST-800172

'

1994

MILLER

Electnc

Mfg.

Co.

PRINTED

IN

~SA

j

1~

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

Effective

January

1,

1992

(Equipment

with

a

serial

number

preface

of

KC

or

newer)

This

limited

wsrrsnty

supsrsedes

all

wsrranties

snd

is

exclusive

with

no

other

gusrantees

or

wsrrsnties

espressed

or

implied.

.1

LIMITED

WARRANTY



Subject

to

the

terms

snd

conditions

below,

MILLER

Electric

Mfg.

Co.,

Appleton,

Wisconsin,

wsrmnts

to

its

originsl

retsil

purchsser

thst

new

MILLER

equipment

sold

sfter

the

effective

dste

of

this

limited

wsrrsnty

is

fwe

of

de

fects

in

materisl

snd

workmsnship

st

the

time

it

is

shipped

by

MILLER.

THIS

WAR

RANTY

IS

EXPRESSLY

IN

LIEU

OP

ALL

OTHER

WARRANTIES,

EXPRESS

OR

IMPUED,

INCLUDING

THE

WARRAN11ES

OF

MERCHANTABILITY

AND

FIT

NESS.

Within

the

wsrranty

periods

listed

below,

MILLER

will

wpsir

or

replsce

sny

war

mnted

psrts

or

components

thst

fsil

due

to

such

defects

in

msterial

orworkmsnship.

MILLER

must

be

notified

in

writing

within

thirty

(30)

dsys

of

such

defect

or

failure,

st

which

time

MILLER

will

provide

instructions

on

the

wsrrsnty

claim

proceduws

to

be

followed.

MILLER

shall

honor

wsrranty

clsims

on

wsrrsnted

equipment

listed

below

in

the

evenl

of

such

s

fsiluw

within

the

wsnsnty

time

periods.

All

warranty

time

periods

stsrt

on

the

dste

thst

the

equipment

wss

delivered

to

the

originsl

retsil

purchsser,

or

one

yesr

sfter

the

equipment

is

sent

to

the

distributor.

1.

5YesrxPsrta3YearsLabor

*

Original

main

power

rectifiers

2.

3

Yeam



Parts

and

Labor

*

Transformer/Rectifier

Power

Sources

Plssma

Arc

Cutting

Power

Sources



Semi-Automatic

and

Automatic

Wire

Feeders

*

Robots

3.

2

Years



Parts

and

Labor

*

Engine

Driven

Welding

Generatom

(NOTE:

Engines

are

warranted

separately

by

the

engine

manufacturer

for

a

period

of

two

years.)



Air

Compressors

4.

1

YearParts

and

Labor



Motor

Driven

Guns

*

Process

Controllers

Water

Coolant

Systems

*

HF

Units



Grids

*

Spot

Welders



Load

Banks

*

SDX

Transformers



Running

Gear/Trailers



Plasma

cutting

torches

(except

APt

ZIPCUT

&

PLAZCUT

models)



Field

Options

(NOTE:

Field

options

are

covered

under

True

BIueTM

for

the

remaining

warranty

period

of

the

product

they

are

installed

in,

or

for

a

minimum

of

one

year



whichever

is

greater.)

6

Months



Batteries

go

Days



Parts

and

Labor

*

MIG

Guna/TIG

Torches



APT,

ZIPCUT

&

PLAZCUT

model

plasma

cutting

torches

*

Remote

Controls



Accessory

Kits



Replacement

Parts

MILLERS

True

BIueTM

Limited

Warranty

shall

not

apply

to:

1.

Items

fumiahed

by

MILLER,

but

manufactured

by

others,

such

as

engines

or

trade

accessories.

These

items

are

covered

by

the

manufacturers

warranty,

if

any.

2.

Consumable

components;

such

as

contact

tips,

cutting

nozzles,

contactors

and

relays

or

parts

that

fail

due

to

normal

wear.

3.

Equipment

that

has

been

modified

by

any

party

other

than

MILLER,

or

equip

ment

that

has

been

impmperiy

installed,

impmperiy

operated

or

misused

based

upon

industry

standards,

or

equipment

which

has

not

had

reasonable

and

necessary

maintenance,

or

equipment

which

has

been

used

for

operation

outside

of

the

specifications

for

the

equipment.

MILLER

PRODUCTS

ARE

INTENDED

FOR

PURCHASE

AND

USE

BY

COMMER

CIALJINDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

IN

THE

USE

AND

MAINTENANCE

OF

WELDING

EQUIPMENT

In

the

event

of

a

warranty

claim

covered

by

this

warranty,

the

exclusive

remedies

shall

be,

at

MILLERS

option:

(1)

repair

or

(2)

replacement;

or,

where

authorized

in

writing

by

MILLER

in

appropriate

cases,

(3)

the

reaaonable

cost

of

mpairor

replace

ment

at

an

authorized

MILLER

service

station;

or

(4)

payment

of

orcmdit

forthe

pur

chase

price

(teas

reasonable

depreciation

based

upon

actual

use)

upon

retum

of

the

goods

at

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

trsnaportation

costs

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,

INCIDENTALOR

CONSEQUENTIAL

DAMAGES

(INCLUDING

LOSS

OF

PROFIT),

WHETHER

BASED

ON

CON

TRACt

TORT

OR

ANY

OTHER

LEGAL

ThEORY.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

ANDANY

IMPUED

WAR

RANTY,

GUARANTY

OR

REPRESENTA11ON

AS

TO

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

OF

CONTRACT

TORT

OR

ANY

OThER

LEGAL

ThEORY

WHICH,

BUT

FOR

THIS

PROVISION,

MIGHTARISE

BY

IMPLICA11ON,

OPERA11ON

OF

LAW,

CUSTOM

OF

TRADE

OR

COURSE

OF

DEALING,

IN

CLUDING

ANY

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OR

FITNESS

FOR

PARTICULAR

PURPOSE,

WITh

RESPECT

TO

ANY

AND

ALL

EQUIPMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

AND

DISCLAIMED

BY

MILLER.

Some

states

in

the

U.S.A.

do

not

allow

imitations

of

how

long

an

implied

warranty

lasts,

or

the exclusion

of

incidental,

indirect,

special

or

consequential

damages,

so

the

above

limitation

or

exclusion

may

not

apply

to

you.

This

warranty

provides

spe

cific

legal

rights,

and

other

rights

may

be

available,

but

may

vary

from

state

to

state.

In

Canada,

legislation

in

some

provinces

provides

for

certain

additional

warranties

or

remedies

other

than

as

stated

herein,

and

to

the

extent

that

they

may

not

be

waived,

the

limitations

end

exclusions

set

out

above

may

not

apply.

This

Limited

Warranty

provides

specific

legal

rights,

and

other

rights

may

be

available,

but

may

vary

from

province

to

province.

I

I

5.

6.

.

RECEIVING-HANDLING

Before

unpacking

equipment,

check

carton

for

any

damage

that

may

have

occurred

during

shipment.

File

any

claims

for

loss

or

damage

with

the

delivering

carrier.

Assistance

for

filing

or

sealing

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

Numberof

your

unit,

The

information

is

located

on

the

rating

label

or

nameplate.

Model

_________

Serial

or

Style

No.

Date

of

Purchase

I

miller

1

W94

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.

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.

Lockoutltagout

input

poweraccording

to

OSHA

29

CFR

1910.147

(see

Safety

Standards).

5.

Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual and

national,

state,

and

local

codes.

6.

Always

verify

the

supply

ground



check

and

be

sure

that

input

power

cord

ground

wire

is

properly

connected

to

ground

ARC

RAYS

can

burn

eyes

and

skin;

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

bum

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

Chipping,

grinding,

and

welds

cooling

throw

off

pieces

of

metal

or

slag.

FUMES

AND

GASES

can

be

hazardous

to

your

health.

Welding

produces

fumes

and

gases.

Breathing

these

fumes

and

gases

can

be

hazardous

to

your

health.

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.

4.

Read

the

Material

Safety

Data

Sheets

(MSDS5)

and

the

manufacturers

instruction

for

metals,

consumables,

coatings,

cleaners,

and

deareasers.

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

fordamage

or

bare

wiring



replace

cord

immediately

if

damaged



bare

wiring

can

kill.

9.

Tum

oft

all

equipment

when

not

in

use.

10.

Do

not

use

wom,

damaged,

undersized,

or

poorly

spliced

cables.

11.

Do

not

drape

cables

over

your

body.

12.

If

earth

grounding

of

the

workpiece

is

required,

ground

it

directly

with

a

separate

cable



do

not

use

work

clamp

or

work

cable.

13.

Do

not

touch

electrode

if

you

are

in

contact

with

the

work,

ground,

or

another

electrode

from

a

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.

Clamp

work

cable

with

good

metal-to-metal

contact

to

workpiece

or

worktable

as

near

the

weld

as

practical.

ARC

RAYS

2.

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;

wam

others

not

to

watch

the

arc.

5.

Wear

protective

clothing

made

from

durable,

flame-resistant

material

(wool

and

leather)

and

foot

protection.

5.

Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

wearing

an

air-supplied

respirator.

Always

have

a

trained

watchperson

nearby.

Welding

fumes

and

gases

can

displace

air

and

lower

the

oxygen

level

causing

injury

or

death.

Be

sure

the

breathing

air

is

safe.

6.

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.

7.

Do

not

weld

on

coated

metals,

such

as

galvanized,

lead,

or

cadmium

plated

steel,

unless

the

coating

is

removed

from

the

weld

area,

the

area

is

well

ventilated,

and

if

necessary,

while

wearing

an

air-supplied

respirator.

The

coatings

and

any

metals

containinQ

these

elements

can

qive

off

toxic

fumes

if

welded.

£~

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.

15.

16.

17.

NOISE

3.

4.

ear

plugs

or

ear

muffs

if

noise

level

is

high.

S~a

I

CYLINDERS

can

explode

if

damaged.

4.

Never

drape

a

welding

torch

over

a

gas

cylinder.

i.r9~~

Shielding

gas

cylinders

contain

gas

under

high

5.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

I

~r

pressure.

If

damaged,

a

cylinder

can

explode.

Since

6.

Never

weld

on

a

pressurized

cylinder



explosion

will

result.

I

r~r~

I

gas

cylinders

are

normally

part

of

the

welding

7.

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

U

~

process,

be

sure

to treat

them

carefully.

____________

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

in

good

condition.

1.

Protect

compressed

gas

cylinders

from

excessive

heat,

8.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

mechanical

shocks,

slag,

open

flames,

sparks,

and

arcs.

9.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

2.

Install

cylinders

in

an

upright

position

by

securing

to

a

stationary

in

use

or

connected

for

use.

support

or

cylinder

rack

to

prevent

falling

or

tipping.

io.

Read

and

follow

instructions

on

compressed

gas

cylinders,

3.

Keep

cylinders

away

from

any

welding

or

other

electrical

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

circuits.

Standards.

______________________

srl.1.1

2/94

WELDING

can

cause

fire

or

explosion.

Welding

on

closed

containers,

such

as

tanks,

drums,

or

pipes,

can

cause

them

to

blow

up.

Sparks

can

fly

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.

9.

Do

not

use

welder

to

thaw

frozen

pipes.

10.

Remove

stick

electrode

from

holder

or

cutoff

welding

wire

at

contact

tip

when

not

in

use.

11.

Wear

oil-free

protective

garments

such

as

leather

gloves,

heavy

shirt,

cuffless

trousers,

high

shoes,

and

a

cap.

12.

Remove

any

combustibles,

such

as

a

butane

lighter

or

matches,

from

your

person

before

doing

any

welding.

ENGINE

EXHAUST

GASES

can

kill.

1.

Use

equipment

outside

in

open,

well-ventilated

areas.

Engines

produce

harmful

exhaust

gases.

2.

If

used

in

a

closed

area,

vent

engine

exhaust

outside

and

away

from

any

building

air

intakes.

ENGINE

FUEL

can

cause

fire

or

3.

Do

not

overfill

tank



allow

room

for

fuel

t

o

expand.

explosion.

Engine

fuel

is

highly

flammable.

4.

Do

not

spill

fuel.

If

fuel

is

spilled,

clean

engine.

up

before

starting

es.

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.

gases.

.

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.

It

is

best

to

check

coolant

level

when

engine

is

cold

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.

Le,Jeune

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

iR3.

SafePracticesForOccupationAndEducationalEyeAndFace

Protec

tion,

ANSI

Standard

Z87.1,

from

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

-

Cuffing

And

Welding

Processes,

NFPA

Standard

51

B,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

4~

WARNING

~

ENGINES

can

be

hazardous.

.4

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

flan



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

engine

before

installing

or

connecting

unit.

.

finished

and

before

starting

engine.

srl.1.1

2/94

CONSIGNES

DE

SECURITE

POUR

LE

SOUDAGE

A

LARC

UN

CHOC

ELECTRIQUE

peut

tuer.

tin

simple

contact

avec

des

piŁces eloctnques

peut

provoquer

une

electrocution

ou

des

biessures

graves.

LØlectrode

et

le

circuit

de

soudage

sont

sous

tension

des

que

Iappareil

est

surON.

Lo

circuit

dentrØe

et

los

circuits

intomes

de

Iappareil

soft

egatement

sous

tension

a

ce

moment-l.

En

soudage

semi-automatique

ou

automatique,

to

f

ii,

le

dØvidoir.

le

logement

des

gaiets

dentraTnement

et

les

piŁces

mØtalliques

en

contact

avec

le

fit

de

soudage

sont

sous

tension.

Des

matØflels

mal

installØs

ou

mat

mis a

a

terre

prOsentent

un

danger.

1.

Ne

jamais

toucher

les

piŁces

electnques

sous

tension.

2.

Porter

des

gants

et

des

vOtoments

de

protection

secs

no

comportant

pas

de

trous.

3.

Sisoler

do

Ia

piŁce

et

do

Ia

terre

au

moyon

de

tapis

ou

dautres

moyens

isolants

suffisamment

grands

pour

empŒcher

to

contact

physique

Øventuol

avec

Ia

piŁce

ou

Ia

terre.

4.

Couper

Ialirnentation

ou

arrŒter

to

moteur

avant

de

procOdor

a

linstallation,

a

Ia

reparation

Cu

a

lentretien

de

lappareil.

DØvorrouillerlalimentation

selon

Ia

norme

OSHA

29

CFR

1910.147

(voir

normes

de

sBcuntØ).

5.

Installer

et

mettre

ala

terre

correctement

cet

appareit

conforniOment

a

son

manuel

dutilisation

et

au

codes

nationaux,

provinclaux

01

municipaux.

6.

Toujours

verifier

Ia

terre

du

cordon

dalimontation



VØnfier

01

sassurer

quo

le

fit

de

terre

du

cordon

dalimentation

est

bien

BRUIT

LE

RAYONNEMENT

DE

LARC

peut

brler

les

yeux

et

Ia

peau.

Le

BRUIT

peut

endommager

IouIe;

les

PROJECTIONS

DE

LA~ER

OU

LES

ETINCELLES

peuvent

blesser

les

yeux.

Larc

de

soudage

produit

des

rayons

visibles

01

invisibles

intenses

(ultraviolets

et

infrarouges)

qui

peuvent

brUler

los

yeux

et

Ia

poau.

Lo

bruit

produit

par

certains

procØdØs

pout

endommagor

touie.

Des

projections

de

metal

Cu

do

Iaitier

soft

produitos

par

to

piquage,

le

meulage

ou

to

refroidissement

des

soudures.

1.

Utilisor

dos

bouche-oreilles

Cu

des

sorre-tŒte

antibruit

approuvØs

si

Ieniveau

do

bruit

est

ØlovØ.

LES

VAPEURS

Er

LES

FUMEES

peuvent

Œtre

dangereuses

pour

Ia

sante.

Lo

soudage

produit

des

vapours

ot

des

tumØos

quit

ost

dangeroux

do

rospiror.

__I.

1.

Gardor

Ia

tŒte

a

lextØriour

dos

vapeurs

et

dos

tumØes

et

no

pas

los

respiror.

2.

A

lintØriour,

ventiler

10

posto

do

travail

ou

utiliser

un

dispositit

place

au

niveau

do

larc

pour

vacuor

los

vapeurs

ot

fumØes

do

soudage.

3.

Si

Ia

ventilation

ost

mauvaise,

utilisor

un

appareil

respiratoiro

a

adduction

dair

pur

approuve.

4.

Consultor

los

fiches

signalØtiquos

01

los

consignos

du

fabncant

relatives

au

mOtaux,

produits

dapport,

rovŒtomonts.

nettoyants

01

degraissants.

LES

BOUTEILLES

peuvent

exploser

si

elles

sont

endommagØes.

Les

boutoillos

contenant

des

gaz

do

protection

sorit

a

haute

pression.

Uno

bouteito

ondomrnageo

pout

oxploser.

Etant

donnØ

quo

les

bouteilles

do

gaz

font

normalemonl

partie

du

matØriol

do

soudage,

los

traitor

avec

to

plus

grand

soin.

1.

ProtØger

tes

boutoitlos

do

gaz

compnmØ

contro

Ia

chalour

intense.

los

chocs.

to

laitier,

los

flammes

flues.

los

Øtincellos

ot

lam.

2.

Placer

los

boutoiltos

ala

verticale

on

los

fixant

a

un

support

fixe

Cu

a

un

chariot

pour

Øvitor

quelles

no

tombent

ou

no

bascuient.

3.

Tenir

los

boutoillos

a

lØcart

du

poste

do

soudago

Cu

dautros

circuits

electriquos.

raccordØ

ala

borne

do

torro

du

sectionnour

ou

quo

Ia

ficho

du

cordon

ost

raccordØo

a

une

pflso

correctoment

mise

a

Ia

terre.

7.

En

effoctuant

los

raccordomonts

dentrØe

fixerdabord

10

conductour

do

miso

a

Ia

terre

appropnØ

01

contre-vØnfier

los

connexions.

8.

Verifier

trequemmont

to

cordon

dalimontation

pour

voir

siI

nest

pas

endommage

Cu

dØnudØ



remplacer

10

cordon

immØdiatemont

sit

est

endommage



un

cable

dØnudØ

pout

provoquor

uno

electrocution.

9.

Mettre

Iappareil

hors

tension

quand

on no

lutilise

pas.

10.

Ne

pas

utiliser

dos

cables

uses,

ondommagØs,

do

grossour

insuffisanto

Cu

mat

ØpissØs.

11.

Ne

pas

enrouler

los

cables

autour

du

corps.

12.

Si

Ia

piŁce

soudØo

doit

Œtro

mise

ala

torro,

10

faire

directemont

avoc

un

cblo

distinct



no

pas

utiliser

10

connocteur

de

piŁce

Cu

to

cable

do

retour.

13.

Ne

pas

toucher

lØlectrodo

quand

on

ost

on

contact

avec

Ia

piŁce.

Ia

terre

Cu

UflO

electrode

provonant

dune

autre

machine.

14.

Nutilisor

quun

materiel

en

bon

Øtat.

RØparor

Cu

romplacer

sur-lo-champ

los

piŁces

ondommagØes.

Entrotonir

lappareil

conformØment

a

co

manuel.

15.

Porter

un

hamais

do

sØcuntØ

quand

on

travaille

on

hautour.

16.

Maintenir

solidomont

en

place

tous

los

panneaux

et

capots.

17.

Fixor

to

cable

do

rotour

do

faon

a

obtonir

urr

bon

contact

mØtat-mØtal

avoc

Ia

piŁce

a

soudorou

Ia

table

do

travail,

to

plus

pres

possible

do

Ia

souduro.

RAVONNEMENT

DE

LARC

2.

Porter

un

masque

a

sorre-tŁto

muni

dun

verro

tiltrant

do

nuance

appropnoe

pour

protØger

to

visage

01

los

youx

quand

on

soude

Cu

observe

Ia

travail

do

soudage

(voir

los

normos

ANSI

Z49.1

et

Z87.1

donnØos

sous

Ia

rubnque

Principalos

normos

do

sŁcuritØ).

Porter

dos

lunettos

do

sØcuntØ

approuvØos

avoc

Øcrans

latØraux.

Utiliser

dos

paravonts

Cu

dos

barriŁros

do

protection

pour

protegor

los

porsonnes

a

proximitØ

contro

los

coups

darc

01

IØblouissoment;

avortir

los

autros

porsonnos

do

no

pas

rogardor

larc.

5.

Porter

des

vŁtomonts

do

protection

en

tissu

ignifuge

durable

(lame

et

cuir)

et

dos

chaussuros

de

sØcuritØ.

5.

Ne

travaitlor

dans

un

espaco

confine

quo

sil

ost

bion

vontilO.

Cu

Ofl

portant

un

apparoil

rospiratoiro

a

adduction

dair

pur.

Demander

a

un

obsorvatour

ayant

rou

Ia

bonno

formation

do

toujours

se

tenir

a

proximitØ.

Los

vapours

et

fumØes

do

soudago

pouvont

dØplacor

lair

et

abaissor

to

niveau

dCxygŁne

et

causer

dos

blessuros

graves

voire

mortellos.

Sassuror

quo

lair

est

propro

a

Ia

rospiration.

6.

No

pas

souder

a

proximitØ

dopØrations

do

degraissage,

do

notloyago

Cu

do

pulvØnsatrCn.

La

chalour

et

los

rayons

do

Iarc

peuvont

reagir

avoc

los

vapeurs

pour

former

dos

gaz

hautement

toxiques

et

irritants.

7.

Ne

pas

soudor

sur

des

mOtaux

rovŒtus

commo

lacier

gatvanisØ,

au

p10mb

Cu

cadmiØ

a

moms

quota

piŁco

nail

ØtŁ

entiŁromont

decapØe,

quo

le

posto

do

travail

soil

bien

vontilØ.

Sit

y

a

lieu,

porter

un

appareil

rospiratoire

a

adduction

dair

pur.

Los

revØtomonts

ot

los

mØtaux

qul

contiennont

do

loIs

ØlŁmonts

peuvont

dØgager

des

vapeurs

toxiques

lors

du

soudago.

4.

Ne

jamais

poser

un

chalumoau

soudeur

sur

une

bouteillo

do

gaz.

5.

No

jamais

laissor

une

Ølectrodo

do

soudage

toucher

une

boutoille.

6.

No

jamais

souder

sur

uno

boutoillo

sous

pression

:

ollo

exploserait.

7.

Nutitisor

quo

des

bouteittos

do

gaz

do

protection,

dos

dØtondours.

dos

tuyaux

souplos

et

des

raccords

appropnØs

conus

pour

Iapplication

particutiŁro:

conserver

cos

matØnols

01

leurs

piŁces

en

bon

etat.

8.

Etoignor

10

visage

do

Ia

sortie

du

robinel

do

Ia

boutoillo

quand

on

louvre.

9.

Replacer

to

chapoau

sur

Ia

boutoillo

aprØs

utitisation.

10.

Lire

ot

suivro

los

consignos

relatives

aux

bouteillos

do

gaz

compnme.

au

materiel

connoxe

ainsi

quota

publication

P-i

do

Ia

CGA

donnØe

sous

Ia

rubnque

Pnncipaies

norrnos

do

sØcuntØ.

a

MISE

EN

GARDE

LE

SOUDAGE

A

LARC

peut

Œtre

dangereux.

SE

PROTEUER

ET

PROTEGER

LES

AUTRES

CONTRE

LES

BLESSURES

GRAVES

VOIRE

MORTELLES.

TENIR

LES

ENFANTS

A

LECART.

LES

PERSONNES

Qul

PQRTENT

UN

STIMULATEUR

CARDIAQUE

NE

DOIVENT

PAS

NON

PLUS

SAPPROCHER

DU

POSTE

DESOUDAGE,

A

MOINS

DAVOIR

CONSULTE

UN

MEDECIN.

Le

soudage,

comrne

Ia

plupart

des

travaux,

prØsente

certains

dangers.

Par

contre,

le

soudago

pout

Łtre

effectuØ

en

toute

sØcuntØ

quand

on

prend

los

mesures

qui

simposent.

Los

consignes

de

sØcuntØ

donnØes

ci-apres

ne

font

que

rØsumer

Iinforrnation

contonue

dans

los

normes

de

sØcuritØ

ØnumØrØos

a

Ia

page

suivante.

Lire

et

respecter

toutes

ces

norrnes

de

sOcuntØ.

LINSTALLATION,

LUllLISATION,

LENTRETlEN

Er

LES

REPARATIONS

NE

DOIVENT

ETRE

CONFIES

OuA

DES

PERSONNES

OUALIFIEES

3.

4.

srl.1.1

2194

LE

SOUDAGE

peut

causer

un

Incendle

ou

une

explosion.

Ne

pas

souder

sur

des

recipients

fermØs

comme

des

reservoirs,

des

Wits

ou

des

tuyaux

:

us

peuvent

exploser.

Larc

do

soudage

peut

produire

des

Øtincelles.

Des

Øtincelles,

une

piŁce

chaude

at

un

materiel

chaud

peuvent

provoquer

des

incendies

et

des

blessures.

Lo

contact

accidental

de

lØlectrode

sur

des

objets

mØtalliques

peut

produire

des

Otincelles,

lexplosion,

Ia

surchauffe

ou

un

incendie.

Sassurer

que

10

lieu

no

presento

pas

do

danger

avant

deffectuer

le

soudage.

Se

protOgeret

protØger

los

personnes

a

proximite

des

Øtincelles

et

du

metal

chaud.

Ne

pas

souder

dans

un

endroit

o

les

Øtincelles

peuvent

atteindre

des

matØnaux

inflammables.

Enlevertoutes

los

matiŁres

inflammables

dans

un

rayon

de

moms

do

10

m

de

larc.

Si

cola

nest

pas

possible,

bien

les

recouvnren

utilisant

dos

bchos

approuvØes.

Prondre

garde

quo

los

Atincelles

et

los

projections

no

penetront

dans

dos

zones

adjacentos

en

sinfiltrant

dans

dos

petites

fissures

et

ouvertures.

5.

Prendre

garde

aux

incendies

at

toujours

avoir

un

extincteur

a

proximitØ.

6.

Se

rappelerquo

Si

Ion

soude

sur

un

plafond,

un

plancher,

une

cloison

ou

autre,

le

lou

pout

prendre

de

lautre

ctØ.

7.

Ne

pas

souder

sur

dos

recipients

fermØs

comme

des

reservoirs,

des

tOts

ou

des

tuyaux

a

moms

quils

ne

soient

prepares

do

faon

appropflee

conformØment

ala

norma

F4.1

do

lAWS

(voir

Ia

rubrique

Principales

norrnes

de

sØcuritØ).

8.

Raccorder

Ia

cable

de

retour

a

Ia

piŁce,

le

plus

prŁs

possible

do

Ia

zone

do

soudage,

pour

empØcher

quo

Ia

courant

do

soudage

no

suivo

une

trajectoire

longue

et

Øventuellemont

inconnue

et

quil

ne

provoque

des

nsques

dØlectrocution

et

dincendie.

9.

Ne

pas

utiliser

le

chalumoau

soudeur

pour

degeler

des

tuyaux.

10.

Enlever

relectrode

enrobØe

du

porte-electrode

ou

coupe,

le

fil

de

soudage

au

ras

du

bec

contact

quand

on

no

lutilise

pas.

11.

Porterdes

vØtements

do

protection

non

huileux

comme

des

gants

en

cuir,

uno

chemise

Øpaisse,

des

pantalons

sans

revers,

des

chaussures

montantes

ot

un

casque.

12.

Ne

pas

porter

des

matiŁres

combustibles

sur

sol

comme

un

bnquet

a

gaz

ou

des

allumettes

quand

on

soude.

p4I

~.

LE

CARBURANT

peut

provoquer

un

Incendie

ou

une

explosion.

La

carburant

est

hautement

inflammable.

1.

ArrŒter

le

~noteur

et

le

laisser

refroidir

avant

do

verifier

le

niveau

do

refaira

le

ploin

LES

PI¨CES

EN

MOUVEMENT

peuvent

causer

I

des

blessures.

Los

piŁces

en

mouvement

comme

los

ventilateurs.

los

rotors

et

los

courroies

pouvont

couper

les

doigts

et

les

mains

at

happer

les

vŁtements

amples.

1.

Sassurer

quo

los

portes,

los

panneaux,

los

capots

et

los

protecteurs

sont

bien

fermØs

et

bien

a

leur

place.

2.

ArrŁter

Ia

moteur

avant

de

mettre

en

place

ou

do

raccorder

un

LES

ETINCELLES

peuvent

faire

EXPLOSER

LE

GAZ

DES

BATrERIES;

LELECTROLYTE

peut

brUler

Ia

peau

et

les

yeux.

Les

batteries

contiennent

un

produit

acido

et

degagent

des

vapeurs

explosives.

iorter

un

Øcran

facial

auand

on

travaille

sur

une

battene.

2.

Ne

pas

fumer

on

faisant

le

plain

ou

si

lappareil

so

trouve

a

proximitO

dØtincelles

ou

do

flammes

nues.

3.

Ne

pas

romplir

Ia

reservoir

a

ras

bord

:

prØvoir

de

lespace

pour

Ia

dilatation

du

combustible.

4.

Ne

pas

renverser

du

carburant.

Si

on

renvorse

du

carburant,

nettoyor

les

lioux

avant

do

faire

dØmarrer

lo

motaur.

3.

Seules

des

personnes

qualifiØes

doivent

dØmonter

les

protecteurs

ou

los

capots

pour

faire

lentretien

ou

los

reparations

nØcessaires.

4.

Pour

empØcher

un

demarrage

accidental

dun

systŁme

pendant

lentretien

ou

los

reparations.

dØbrancher

lo

cable

negatif

()

de

Ia

battene.

5.

Eloignor

los

mains,

las

cheveux,

las

vØtements

amplos

ot

les

outils

des

piŁces

en

mouvemont.

6.

Replacer

los

capots

ou

les

protecteurs

ot

rofermer

los

portos

une

fois

lentretien

et

les

reparations

torminØs

at

avant

cIa

faire

demarrer

le

moteur.

2.

ArrØtor

Ia

moteur

avant

do

brancher

ou

do

dØbrancher

los

cables

cIa

Ia

battene.

3.

Ne

pas

faire

des

Øtincelles

avec

les

outils

quand

on

travaille

sur

une

batterie.

4.

Ne

pas

utiliser

Ia

source

do

courant

de

soudage

pour

charger

las

batteries

ou

pour

faire

dØmarrer

un

vØhiculo.

5.

Ne

oas

intervortir

Ia

colantØ

des

batteries.

1.

2.

3.

4,

A~

MISE

EN

GARDE

LES

MOTEURS

peuvent

presenter

un

danger.

LES

GAZ

DECHAPPEMENT

DES

MOTEURS

1.

Utitiser

le

materiel

a

IextOneur,

dans

des

lieux

ouverts

ot

bion

peuvent

Œtre

mortels.

vontilØs.

Los

moteurs

produisent

des

gaz

d

echapp

ement

nocifs.

2.

Si

on

utiliso

un

moteur

dans

un

local

temiO.

Øvacuer

les

gaz

dechappoment

a

lextØriour

et

loin

des

pnses

dair

du

bÆtiment.

1.

Touioursl

.

~

4$~~

~

LA

VAPEUR

El

LE

LIQUIDE

DE

REFROIDISSEMENT

BRULANT

SOUS

PRESSION

peuvent

brler

Ia

peau

et

les

yeux.

II

vaut

mieux

verifier

10

niveau

du

liquide

de

refroidissemant

quand

lo

motour

est

froid

attn

d~Øviter

los

brUlures.

1.

2.

3.

Si

Ion

dolt

verifier

10

niveau

quand

le

moteur

ost

chaud,

suivre

los

Otapes

2

ot

3.

Porter

des

lunottes

do

sØcuntØ

et

des

gants

ot

placer

un

chiffon

sur

le

bouchon.

Toumer

lentement

10

bouchon

at

laisser

Ia

pression

sechapper

lenternent

avant

denlever

complØtemont

Ia

bouchon.

PRINCIPALES

NORMES

DE

SECURITE

Safety

in

Welding

and

Cutting,

norme

ANSI

Z49.1,

do

lAmencan

Welding

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

P.1,

do

Society,

550

N.W.

Lojeune

Ad,

Miami

FL

33126

Ia

Compressed

Gas

Association,

1235

Jefferson

Davis

Highway,

Suite

501.

Arlington,

VA

22202.

Safety

and

Health

Sandards,

OSHA

29

CFR

1910,

du

Superintendent

of

Reg!es

de

sØcuntØ

ensoudage.

coupage

et

procØdØs

connexes,

norrne

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

CSA

W117.2,

de

lAssociation

canadienne

do

normalisation,

vonte

do

norrnes,

178

Rexdalo

Boulevard.

Rexdale

(Ontario)

Canada

M9W

1

R3.

Recommenaed

Safe

Practice

for

the

Preparation

for

Welding

and

Cutting

of

Containers

That

Have

Held

Hazardous

Substances,

normo

AWS

F4.1.

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

Protection.

do

lAmerican

Welding

Socioty,

550

NW.

Lejoune

Ad,

Miami

FL

33126

normo

ANSI

Z87.1.

de

lAmorican

National

Standards

Institute.

1430

Broadway,

New

York,

NY

10018.

National

Electrical

Code,

NFPA

Standard

70,

data

National

Fire

Protection

Cutting

and

Welding

Processes,

norme

NFPA

51

B,

do

Ia

National

Fire

Association,

Batterymarch

Park,

Quincy,

MA

02269.

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

Srl.1.1

2/94

EMF

INFORMATION

TABLE

OF

CONTENTS

SECTION

1

-

SAFETY

INFORMATION

SECTION

2

SPECIFICATIONS

SECTION

3

INSTALLATION

3-1.

Equipment

Connection

Diagram

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.

Control

Connection

3-10.

Shielding

Gas

And

Weld

Cable

Connections

3-11.

Removing

Safety

Collar

And

Adjusting

Boom

3-12.

Welding

Wire

Installation

3-13.

Motor

Start

Control

3-14.

Threading

Welding

Wire

SECTION

4-

GLOSSARY

SECTION

5-OPERATION

5-1.

Front

Panel

Controls

5-2.

Side

Panel

Controls

5-3.

Rear

Panel

Controls

5-4.

Setting

Switches

On

450

Ampere

Inverter

Model

Welding

Power

Source

SECTION

6

STEPPING

THROUGH

THE

MICROPROCESSOR

CONTROLS

6-1.

Front

Panel

Microprocessor

Controls

6-2.

Side

Panel

Microprocessor

Push

Buttons

SECTION

7

STANDARD

PULSE

WELDING

PROGRAMS

NOTE

D~

Considerations

About

Welding

And

The

Effects

Of

Low

Frequency

Electric

And

Magnetic

Fields

The

following

is

a

quotation

from

the

General

Conclusions

Section

of

the

U.S.

Congress,

Office

of

Technology

Assessment,

Biological

Effects

of

Power

Frequency

Electric

&

Magnetic

Fields



Background

Paper~

OTA-BP-E-53

(Washington,

DC:

U.S.

Government

Printing

Office,

May

1989):

.

. .

there

is

now

a

very

large

volume

of

scientific

findings

based

on

experiments

at

the

cellular

level

and

from

studies

with

animals

and

people

which

clearly

establish

that

low

frequency

magnetic

fields

can

interact

with,

and

produce

changes

in,

biological

systems.

While

most

of

this

work

is

of

very

high

quality,

the

results

are

complex.

Current

scientific

understanding

does

not

yet

allow

us

to

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

10

11

12

14

16

17

19

20

21

22

24

27

SECTION

8-

GETTING

STARTED

35

8-1.

Welding

With

Only

Front

Panel

Controls

36

8-2.

Setting

Sequence

Pulse

Welding

Parameters

On

Side

Panel

Display

37

OM-1588A-

10194

SECTION

9TEACHING

A

PULSE

WELDING

PROGRAM

41

9-1.

Pulse

Waveform

Explained

41

9-2.

Teach

Points

Explained

42

9-3.

Teaching

A

Pulse

Welding

Program

43

9-4.

Changing

To

Adaptive

Pulse

Welding

46

SECTION

10-

TEACHING

A

MIG

WELDING

PROGRAM

47

10-1.

Changing

To

MIG

Welding

47

10-2.

Setting

Sequence

MIG

Welding

Parameters

On

Side

Panel

Display

48

SECTION

11

-

SETTING

DUAL

SCHEDULE

PARAMETERS

51

SECTION

12

USING

THE

OPTIONAL

DATA

CARD

53

12-1.

Installing

Data

Card

53

12-2.

Using

The

Data

Card

53

SECTION

13-SETUP

57

13-1.

Setup

Flow

Chart

57

13-2.

Using

Setup

Displays

58

13-3.

Selecting

Process

Capability

58

13-4.

Selecting

Welding

Power

Source

Range

59

13-5.

Selecting

Security

Lock

60

13-6.

Selecting

Or

Changing

Access

Code

61

13-7.

Selecting

Voltage

Correction

62

13-8.

Selecting

Voltage

Sensing

Method

62

13-9.

Selecting

Regular

Or

Hot

Arc

Start

63

13-10.

Selecting

Type

Of

Dual

Schedule

Switch

63

13-11.

Selecting

Trigger

Program

Select

64

13-12.

Selecting

Remote

Increase/Decrease

Capability

65

13-13.

Resetting

Arc

Time

65

13-14.

Using

Self

Test

66

13-15.

Selecting

Units

For

Wire

Feed

Speed

And

Motor

Type

67

13-16.

Selecting

Bench

Or

Boom

Model

Type

67

13-17.

Resetting

Memory

68

13-18.

Selecting

Arc

Start/Volt

Sense

Error

Shutdown

68

13-19.

Selecting

Program

Name

Feature

69

13-20.

Software

Version

Number

69

SECTION

14-

MAINTENANCE

&

TROUBLESHOOTING

70

14-1.

Routine

Maintenance

70

14-2.

Replacing

The

Hub

Assembly

71

14-3.

Overload

Protection

71

14-4.

Error

Displays

72

14-5.

Troubleshooting

73

SECTION

15-

ELECTRICAL

DIAGRAMS

74

SECTION

16

PARTS

LIST

78

Figure

16-1.

Main

Assembly

78

Figure

16-2.

Support,

Hub

&

Reel

81

Figure

16-3.

Control

Box

82

Figure

16-4.

Panel,

Front

w/Components

85

Figure

16-5.

Boom

Assembly

86

Figure

16-6.

Drive

Assembly,

Wire

88

Figure

16-7.

Panel,

Side

w/Components

90

Table

16-1.

Dnve

Roll

And

Wire

Guide

Kits

91

SECTION

1

-

SAFETY

INFORMATION



Read

all

safety

messages

throughout

this

manual.



Obey

all

safety

messages

to

avoid

injury.



Learn

the

meaning

of

WARNING

and

CAUTION.

Figure

1-1.

Safety

Information

SECTION

2-

SPECIFICATIONS

Table

2-1.

Wire

Feeder

modl.1

2/93

These

are

wire

feed

speed

ranges

for

GMAW.

While

Pulse

welding,

wire

feed

speed

ranges

may

be

more

limited

(see

Section

9).

OM-1

588

Page

1

2

\

a

WARNING

2

\

/

a

CAUTION

ELECTRIC

SHOCK

can

kill

~

MOVING

PARTS

can

injure.



Do

not

touch

live

electrical

parts.

fi

S

Keep

away

from

moving

parts.

I



Disconnect

input

power

before

L

t~P

installing

or

servicing

4



Keep

all

panels

and

covers

closed

I

wtien

operating.

I

5

.

Ii~~

~

READ

SAFETY

BLOCKS

at

start

of

Section

3-1

before

proceeding.

7-H

NOTE

~

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.

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

Single-Phase

24

Volts

AC,

10

Amperes,

50/60

Hertz

100

Volts,

750

Amperes,

100%

Duty

Cycle

Constant

Voltage

(CV)

DC,

With

Contactor

For

GMAW

Welding

Constant

Current

(CC)

DC,

With

Contactor

For

GMAW-P

Welding

Standard:

50

To

780

ipm

(1.3

To

19.8

mpm)

High

Speed:

92

To

1435

ipm

(2.3

To

36.5

mpm)

.023

To

1/8

in

(0.6

To

3.2

mm)

Gas

Metal

Arc

(GMAW),

Gas

Metal

Arc

-

Pulse

(GMAW-P),

Flux

Cored

Arc

Welding

(FCAW)

lOft(3.1

m)

Maximum

Height

With

4

ft

(1.2

m)

Post

Weight

Vertical

Lift

Of

Boom

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

Honzontal

SECTION

3-INSTALLATION

3-1.

Equipment

Connection

Diagram

AA

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.

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.

wfwamg1*

2/93

.

Figure

3-1.

Typical

System

Connections

OM-1

588

Page

2

3-2.

Installing

Swivel

Into

Pipe

Post

4~

WARNING

41

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.

3-3.

Installing

Control

Box

Onto

Swivel

5

4

3

1

Swingpak

Base

or

CBC

Cart

2

Pipe

Post

With

Base

3

Steel

Bolt

Secure

as

shown

using

as a

mini

mum

1/2

in

diameter

SAE

grade

5

steel

bolts.

4

Swivel

Assembly

Insert

into

pipe

post.

Lubricate

swivel.

5

Safety

Collar

Do

not

remove

until

instructed

to.

Tools

Needed:

~

3/4

in

ST-152382

Figure

3-2.

Swivel

Installation

2

3~

1

Weld

Control

2

Bracket

3

Screw

Bracket

and

screws

are

installed

onto

bottom

of

control

at

factory.

4

Swivel

Loosen

screws.

Place

control

on

swivel

and

slide

forward.

Tighten

screws.

ST-800

174

Tools

Needed:

4

Figure

3-3.

Control

Box

Installation

OM-1

588

Page

3

3-4.

Installing

Boom

And

Reel

Support

READ

SAFETY

BLOCKS

at

start

of

Section

3-2

before

proceeding.

3

4

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,

washers,

and

nut.

Tighten

hardware,

and

back

bolt

off

one

half

turn.

6

Locking

Knob

Install

locking

knob

but

do

not

~ghten.

7

Reel

Support

Install

reel

support.

Tools

Needed:

~

3/8,

3/4

in

ST-153

170

2

*0

Figure

3-4.

Boom

Installation

3-5.

Installing

Wire

Guide

Extension

.

Figure

3-5.

Wire

Guide

Extension

Installation

OM-1588

Page

4

3-6.

Wire

Guide

And

Drive

Roll

Installation

A~

WARNING

A.

Wire

Guide

Installation

Figure

3-6.

Wire

Guide

Installation

B.

Drive

Roll

Installation

When

changing

wire

size

or

type,

check

drive

roll

size

(see

Table

16-1).

1

Spring

Shaft

Garner

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.

4

Drive

Roll

Slide

drive

rolls

onto

drive

roll

cam

ers.

Turn

nut

one

click.

5

Drive

Assembly

Cover

Close

cover.

Repeat

procedure

for

opposite

side

of

wire

feeder.

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.

wfwarnl.i

2/93

When

changing

wire

size

or

type,

check

guide

size

(see

Table

16-1).

1

Drive

Rolls

Remove

drive

rolls

before

install

ing

wire

guides

(see

Figure

3-7).

2

Wire

Guide

Securing

Screws

Loosen

wire

guide

screws.

3

InletWire

Guide

4

Intermediate

Wire

Guide

Insert

intermediate

guide

until

flange

on

guide

rests

against

cast

ing,

and

secure

with

guide

screw.

Install

drive

rolls

(see

Figure

3-7).

Repeat

procedure

for

opposite

side

of

wire

feeder.

Ref.

ST-137

391-F/ST-142

597-A

Tools

Needed:



2

3

ST-i

42 597-A

Figure

3-7.

Drive

Roll

Installation

OM-1588

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.

.

wfwarni.i

2193

4

3

1

Drive

Assembly

Cover

2

Gun

Securing

Knob

3

Gun

Connector

Loosen

securing

knob.

Insert

gun

connector

until

it

bottoms

against

drive

assembly.

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

Receptacle

Insert

plug

into

receptacle

and

tighten

threaded

collar.

Repeat

procedure

for

gun

on

oppo

drive

assembly.

Ref.

ST-i

52

466/

Ref.

ST-800

178

/

Ref.

ST-800

175

Figure

3-8.

Gun

And

Trigger

Lead

Connections

3-8.

Wire

Feed

Motor

And

Gas

Valve

Control

Connections

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.

ST-800

177

/

Ref.

5T-800

175

Figure

3-9.

Boom

Connections

.

OM-1

588

Page

6

3-9.

Control

Connection

Table

3-1.

Remote

17

Socket

Information

REMOTE

17

Socket*

Socket

Information

E

l

~

C

G

CCICV

select;

+13

to

+24

volts

dc

is

CV,

0

volts

dc

is

CC.

Arc

control/inductance

control;

0

to

+10

volts

dc.

E

Actual

weld

current

output

signal;

+1

voltdc

is

100

amps.

.

M

Actual

weld

voltage

output

signal;

+1

voltdc

is

10

volts

dc.

F

H

Current

feedback

from

welding

power

source;

0

to

+10

volts

dc,

1

volt

per

100

amperes.

Voltage

feedback

from

welding

power

source;

0

to

+10

volts

dc,

1

volt

per

10

arc

volts.

The

remaining

sockets

are

not

used.

Table

3-2.

Remote

14-Pin

Information

REMOTE

14

~j~*

Information

A

24

volts

ac.

()g~

OUTPUT

(CONTACTOR)

B

G

Contact

closure

to

A

completes

24

volts

ac

contactor

control

circuit.

Circuit

common

for

24

volts

ac

circuits.

C

+10

volts

dc

input

to

remote

control.

A

Al

AMPERAGE

I

VOLTAGE

D

E

Remote

control

circuit

common.

Oto

+10

volts

dc

output

command

signal

from

feeder

voltage

control.

The

remaining

pins

are

not

used.

3.

2

1

17-Pin

Receptacle

(See

Table

3-1)

2

Keyway

To

connect

interconnecting

cord

to

receptacle,

align

keyway,

insert

plug,

and

tighten

threaded

collar.

3

Weld

Current

Sensor

Recep

tacle

(For

Use

With

Field

op

tion

Only)

4

35

ft

(10.6

m)

Voltage

Sens

ing

Lead

Connect

to

workpiece

(see

Figure

3-1).

5

Threaded

Collar

6

14-Pin

Plug

(see

Table

3-2)

To

connect

plug

to

matching

recep

tacle

on

welding

power

source,

align

keyway,

insert

plug,

and

tight

en

threaded

collar.

ST-800

177/Ref.

S-051

2/

S-0003-A

/

5-0828

Figure

3-10.

Control

Connections

With

Information

OM-1

588

Page

7

3-10.

Shielding

Gas

And

Weld

Cable

Connections

AA

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,

other

stationary

support.

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

wire

feederand

welding

powersource,

and

disconnect

input

power

before

inspecting

or

installing.

BUILDUP

OF

SHIELDING

GAS

can

harm

health

or

kill.



Shut

off

shielding

gas

supply

when

not

in

use.

wam4.1

9/91

I

wfwaml.1

2/93

.

Theweldcablesandshieldinggashosesex-

Bolttogetherweldcablesfromwelding

pow-

Connect

boom

shielding

gas

hoses

to

gas

tend

10

ft

(3m)

from

the

boom.

ersource

and

boom.

Use

electrical

tape

and

supplies

or

extension.

The

hoses

from

the

If

the

welding

power

source

or

gas

supply

insulated

sleeving

to

cover

connection,

boom

have

5/8-18

right-hand

threads.

are

further

from

the

boom,

extend

cables

5

Supplied

Shielding

Gas

V

Adapter

and

hoses

as

follows:

Connect

single

end

fitting

of

V

adapterto

gas

supply,

and

connect

boom

shielding

gas

4

Boom

Shielding

Gas

Hose(s)

hoses

to

fittings

on

V

end

of

adapter.

Figure

3-11.

Shielding

Gas

And

Weld

Cable

Connections

A.

Connecting

Weld

Cables

And

Gas

Hose

Tools

Needed:

~

5/8in

1

Weld

Cables

2

Insulated

Sleeving

Ref.

ST-i

53 175-A

3

Shielding

Gas

Extension

Hose

.

OM-1588

Page

8

B.

Shielding

Gas

Connections

To

Regulator/Flowmeter

Figure

3-12.

Typical

Regulator/Flowmeter

Installation

1

2

4

6

5

Tools

Needed:

~

5/8,

1-1/8

in

Obtain

gas

cylinder

and

chain

to

running

gear,

wall,

or

other

station

ary

support

so

cylinder

cannot

fall

and

break

off

valve.

1

Cap

2

Cylinder

Valve

Remove

cap,

stand

to

side

of

valve,

and

open

valve

slightly.

Gas

flow

blows

dust

and

dirt

from

valve.

Close

valve.

3

Cylinder

4

Regulator/Flowmeter

Install

so

face

is

vertical.

5

Gas

Hose

Connection

Fithng

has

5/8-18

right-hand

threads.

Install

gas

hose

according

to

Figure

3-11.

6

Flow

Adjust

Typical

flow

rate

is

20

cfh

(cubic

feet

per

hour).

Check

wire

manufactur

ers

recommended

flow

rate.

Make

sure

flow

adjust

is

closed

when

opening

cylinder

to

avoid

damage

to

the

flowmeter.

7

CO2

Adapter

8

0-Ring

Install

adapter

with

0-ring

between

regulator/flowmeter

and

CO2

cylinder.

ssb3.1

5/94



ST-158

697-A

Argon

Gas

.2

CO2

Gas

3-11.

Removing

Safety

Collar

And

Adjusting

Boom

a

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.

Pull

boom

down

slighfly

and

re

move

safety

collar.

Boom

should

balance

in

any

position

from

hori

zontal

to

60

degrees

above

hori

zontal.

If

necessary,

adjust

boom

as

follows:

E

Tools

Needed:

r

1-1/8in

Increasing

Spring

Pressure

ForA

HeavyGun

Decreasing

Spring

Pressure

ForA

LightGun

Retain

safety

collar

for

use

in

dis

assembling

or

moving

boom.

ST-142599-B

0

1~

Rod

2

Threaded

Rod

3

Jam

Nut

3

Loosen

jam

nut

and

turn

threaded

rod

until

boom

balances.

Tighten

jam

nut.

Be

sure

several

full

threads

are

through

yoke

to

pre

2

vent

boom

falling.

4

Yoke

Figure

3-13.

Boom

Adjustments

OM-1588

Page

9

3-12.

Welding

Wire

Installation

A.

Installation

Of

Spool-Type

Wire

Figure

3-14.

Installation

Of

Spool-Type

Wire

.

B.

Installation

Of

Optional

Wire

Reel

And

Reel

Type

Wire

Figure

3-15.

Installation

Of

Optional

Wire

Reel

And

Reel

Type

Wire

.

4

3

1

Retaining

Ring

2

Wire

Spool

3

Hub

Remove

retaining

nng

and

slide

spool

onto

hub.

4

Hub

Turn

spool

until

hub

fits

hole

in

spool.

Reinstall

retaining

ring.

Repeat

procedure

for

opposite

side.

ST-153

171

E

2

8

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

1

hub.

C

Wire

lnstallat~on

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

taming

ring.

ST-143

478-A/

ST.152

463

OM-1

588

Page

10

C.

Adjusting

Hub

Tension

3-13.

Motor

Start

Control

4~

WARNING



Do

not

touch

live

electrical

parts.

ELECTRIC

SHOCK

can

kill.



Tum0ffwirefeederandweldingpowersource,and

disconnect

input

power

before

inspecting

or

installing.

on

circuit

boards.

STATIC

ELECTRICITY

can

damage

parts



Put

on

grounded

wrist

strap

BEFORE

handling

boards

or

parts.

wfwaml.1

2/93

To

change

wire

feed

starting

speed

Right

Side

~II

~

-

~

~:

~

E~D

~~

.~

~

~\

~4_~

~

Tools

Needed:

EIZJ~tI

i/4in

1

2

Non-conductive

proceed

as

follows:

Turn

Oft

wire

feeder

and

welding

power

source.

Remove

wrapper.

1

Motor

Board

PCi

2

Motor

Start

Control

Poten

tiometer

R70

Turn

potentiometer

clockwise

to

in

crease

time

it

takes

the

motor

to

ramp

up

to

speed.

Remove

protec

tive

white

rubber

cap

before

mak

ing

adjustment.

Adjust

potentiome

ter

R70

using

a

small

nonconduc

tive

screwdriver.

Reinstall

wrapper.

Ref.

ST-162

i32IRef.

SB-146

862-0

Figure

3-17.

Motor

Start

Control

On

Motor

Control

Board

PCi

Turn

Oft

unit

and

welding

power

source.

1

Hex

Nut

2

Spool

2

Grasp

spool

in

one

hand

arid

turn

while

using

a

wrench

to

adjust

hex

nut.

When

a

slight

force

is

needed

to

turn

spooi,

tension

is

set.

Repeat

procedure

for

opposite

side.

Tools

Needed:

~

5/8

in

ST-i

53

173

Figure

3-16.

Adjusting

Hub

Tension

CM-i

588

Page

ii

3-14.

Threading

Welding

Wire

a

WARNING

CYLINDERS

can

explode

if

damaged.



Keep

cylinders

away

from

welding

and

other

electrical

circuits.



Never

touch

cylinder

with

welding

electrode.



Always

secure

cylinder

to

running

gear,

wall,

other

stationary

support.

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

or

feeding

wire

using

gun

trigger.

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.

HOT

SURFACES

can

burn

skin.



Allow

gun

to

cool

before

touching.

wfwam2.1

I

wfwarn7.1

9/91

S

OM-1588

Page

12

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Miller DS-64M Swingarc Owner's manual

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