Miller KG215483 Owner's manual

Miller
Brand
Miller
Model
KG215483
Category
Welding System
Type
Owner's manual

This manual is also suitable for

~:
UM-1584
139
168P
Miller
The
Power
~fB1ue.
June
1998
Processes
~
MIG(GMAW)
Flux
Cored
(FCAW)
(Gas-
and
Self-Shielded)
Submerged
(SAW)
Description
Wire
Feeder
(Use
with
CV
Power
Sources)
Swi
ngarc
0
Visit
our
website
at
www.MiltcrWelds.um
DS-1
2
and
DS-1
6
OWNERS
MANUAL
~flJ~flJTll~
WOrktngazhaFdazJondo~every
power
source
fvem
Mflter
is
backed
by
the
must
hassle-tree
warranty
In
the
bus1niss~
Miller
offers
a
Technical
Manual
which
provides
mote
detailed
service
and
parts
information
for
your
:
unit.
To
obialA
a
TechniCal
Manual,
contact
your
local.
distributor,
Your
distributor
scan
also
supply
you
with
Welding
Process
Manuals
~
as
SM4W,GTAW
GMAW
and
GMAW-P
From
Miller
to
You
Thank
you
and
congratulations
on
choosing
Miller.
Nov:~
you
can
get
the
job
done
and
get
it
done
right.
We
know
you
dont
have
time
to
do
it
any
other
way.
Thats
why
when
Niels
Miller
first
started
building
arc
welders
in
1929,
he
made
sure
his
products
offered
long-lasting
value
and
superior
quality.
Like
you,
his
customers
couldnt
afford
anything
less.
Miller
products
had
to
be
more
than
the
best
they
could
be.
They
had
to
be
the
best
you
could
buy.
Today,
the
people
that
build
and
sell
Miller
products
continue
the
tradition.
Theyre
just
as
committed
to
providing
equipment
and
service
that
meets
the
high
standards
of
quality
and
value
established
in
1929.
This
Owners
Manual
is
designed
to
help
you
get
the
most
out
of
your
Miller
products.
Please
take
time
to
read
the
Safety
precautions.
They
will
help
you
protect
yourself
against
potential
hazards
on
the
worksite.
Weve
made
installation
and
operation
quick
and
easy.
jL~
~i
11111
With
Miller
you
can
count
on
years
of
reliable
1.
1
1
service
with
proper
maintenance.
And
if
for
REGISTERED
QUALITY
SYSTEM
some
reason
the
unit
needs
repair,
theres
a
V
Troubleshooting
section
that
will
help
you
Miller
is
Ibe
first
welding
equipmeNt
figure
out
what
the
problem
is.
The
parts
list
manufacturer
in
the
U.S.A.
to
be
will
then
help
you
to
decide
which
exact
part
registered
to
the
ISO
9001
Quality
System
Standard.
you
may
need
to
fix
the
problem.
Warranty
and
service
information
for
your
particular
model
are
also
provided.
1
em
~:
Miller
Electric
manufactures
a
full
line
of
welders
and
welding
related
equipment.
For
information
on
other
quality
Miller
products,
contact
your
local
Miller
distributor
to
receive
the
latest
full
line
catalog
or
individual
catalog
sheets.
To
locate
your
nearest
distributor
call
1-800-4-A-Miller.
OM-1
584P
TABLE
OF
CONTENTS
SECTION
1
-
SAFETY
PRECAUTIONS
-
READ
BEFORE
USING
1
1-1.
Symbol
Usage
1
1-2.
Arc
Welding
Hazards
1
1-3.
Additional
Symbols
for
Installation,
Operation,
and
Maintenance
3
1-4.
Principal
Safety
Standards
3
1-5.
EMF
Information
4
SECTION
1
-
CONSIGNES
DE
SECURITE
-
LIRE
AVANT
UTILISATION
5
1-1.
Signification
des
symboles
5
1-2.
Dangers
relatifs
au
soudage
a
larc
5
1-3.
Dangers
supplØmentaires
en
relation
avec
Iinstallation,
le
fonctionnement
et
Ia
maintenance
7
1-4.
Principales
normes
de
sØcuritØ
8
1-5.
Information
sur
les
champs
Ølectromagnetiques
8
SECTION
2
-
INTRODUCTION
9
2-1.
Specifications
9
SECTION
3
-
INSTALLATION
9
3-1.
Installing
Swivel
Into
Pipe
Post
9
3-2.
Installing
Control
Box
And
Adjusting
Tilt
10
3-3.
Installing
Boom
And
Reel
Support
10
3-4.
Installing
Wire
Guide
Extension
11
3-5.
Motor
Start
Control
11
3-6.
Equipment
Connection
Diagram
12
3-7.
Control
Box
Connections
13
3-8.
14-Pin
Plug
Information
13
3-9.
Removing
Safety
Collar
And
Adjusting
Boom
14
3-10.
Gun
Recommendation
Table
14
3-11.
Wire
Type,
Size,
And
Feed
Speed
Capability
Table
14
3-12.
Installing
And
Threading
Welding
Wire
15
3-13.
Optional
Equipment
DIP
Switch
Settings
16
3-14.
Digital
Voltage
Control
Option
Changeover
For
Inverter-Type
Power
Source
17
SECTION
4
-
OPERATION
18
4-1.
Front
Panel
Controls
18
4-2.
Volts
Meter
Display
18
4-3.
Overload
Protection
And
Optional
Side
Panel
Controls
19
SECTION
5
-
MAINTENANCE
&
TROUBLESHOOTING
19
5-1.
Routine
Maintenance
19
5-2.
Troubleshooting
20
SECTION
6
-
ELECTRICAL
DIAGRAM
22
SECTION
7
-
PARTS
LIST
24
WARRANTY
SECTION
1
-
SAFETY
PRECAUTIONS
-
READ
BEFORE
USING
som
nd5197
1-1
Symbol
Usage
4A
Means
Warning!
Watch
Out!
There
are
possible
hazards
with
this
procedure!
The
possible
hazards
are
shown
in
the
adjoining
symbols.
A
Marks
a
special
safety
message.
~
Means
Note~
not
safety
related.
This
group
of
symbols
means
Warning!
Watch
Out!
possible
ELECTRIC
SHOCK,
MOVING
PARTS,
and
HOT
PARTS
hazards.
Consult
symbols
and
related
instructions
below
for
necessary
actions
to
avoid
the
hazards.
1-2
Arc
Welding
Hazards
A
The
symbols
shown
below
are
used
throughout
this
manual
to
call
attention
to
and
identify
possible
hazards.
When
you
see
the
symbol,
watch
out,
and
followthe
related
instructions
to
avoid
the
hazard.
The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
found
in
the
Safety
Standards
listed
in
Section
1
-4.
Read and
follow
all
Safety
Standards.
A
Only
qualified
persons
should
install,
operate,
maintain,
and
repair
this
unit.
A
During
operation,
keep
everybody,
especially
children,
away.
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
touching
the
welding
wire
are
electrically
live.
Incorrectly
installed
or
improperly
grounded
equipment
is
a
hazard.
Do
not
touch
live
electrical
parts.
Wear
dry,
hole-free
insulating
gloves
and
body
protection.
Insulate
yourself
from
work
and
ground
using
dry
insulating
mats
or
covers
big
enough
to
prevent
any
physical
contact
with
the
work
or
ground.
Do
not
use
AC
output
in
damp
areas,
if
movement
is
confined,
or
if
there
is
a
danger
of
falling.
Use
AC
output
ONLY
if
required
for
the
welding
process.
If
AC
output
is
required,
use
remote
output
control
if
present
on
unit.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
LockoutJtagout
input
power
according
to
OSHA
29
CFR
1910.147
(see
Safety
Standards).
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local
codes.
Always
verify
the
supply
ground
-
check
and
be
sure
that
input
power
cord
ground
wire
is
properly
connected
to
ground
terminal
in
disconnect
box
or
that
cord
plug
is
connected
to
a
properly
grounded
receptacle
outlet.
When
making
input
connections,
attach
proper
grounding
conductor
first
-
double-check
connections.
Frequently
inspect
input
power
cord
for
damage
or
bare
wiring
-
replace
cord
immediately
If
damaged
-
bare
wiring
can
kill.
Turn
off
all
equipment
when
not
in
use.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
Do
not
drape
cables
over
your
body.
If
earth
grounding
of
theworkpieceis
required,
ground
it
directly
with
a
separate
cable
-
do
not
use
work
clamp
or
work
cable.
Do
not
touch
electrode
if
you
are
in
contact
with
the
work,
ground,
or
another
electrode
from
a
different
machine.
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.
Insulate
work
clamp
when
not
connected
to
workpiece
to
prevent
contact
with
any
metal
object.
Do
not
connect
more
than
one
electrode
or
work
cable
to
any
single
weld
output
terminal.
SIGNIFICANT
DC
VOLTAGE
exists
after
removal
of
input
power
on
inverters.
Turn
Off
inverter,
disconnect
input
power,
and
discharge
input
capacitors
according
to
instructions
in
Maintenance
Section
before
touching
any
parts.
FUMES
AND
GASES
can
be
hazardous
~
Welding
produces
fumes
and
gases.
Breathing
-
these
fumes
and
gases
can
be
hazardous
to
your
health.
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
fumes.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
If
ventilation
is
poor,
use an
approved
air-supplied
respirator.
Read
the
Material
Safety
Data
Sheets
(MSDSs)
and
the
manufacturers
instructions
for
metals,
consumables,
coatings,
cleaners,
and
degreasers.
Work
in
a
confined
space
only
if
it
is
well
ventilated,
or
while
wearing
an
air-supplied
respirator.
Always
have
a
trained
watch-
person
nearby.
Welding
fumes
and
gases
can
displace
air
and
lower
the
oxygen
level
causing
injury
or
death.
Be
sure
the
breathing
alr
is
safe.
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
weld
area,
the
area
is
well
ventilated,
and
if
necessary,
while
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
containing
these
elements
can
give
off
toxic
fumes
if
welded.
OM-1
584
Page
1
1-3.
Additional
Symbols
For
Installation,
Operation,
And
Maintenance
FIRE
OR
EXPLOSION
hazard.
Do
not
install
or
place
unit
on,
over,
or
near
combustible
surfaces.
Do
not
install
unit
near
flammables.
Do
not
overload
building
wiring
-
be
sure
power
supply
system
is
properly
sized,
rated,
and
protected
to
handle
this
unit.
FALLING
UNIT
can
cause
injury.
Use
lifting
eye
to
lift
unit
only,
NOT
running
gear,
gas
cylinders,
or
any
other
accessories.
Use
equipment
of
adequate
capacityto
lift
and
support
unit.
If
using
lift
forks
to
move
unit,
be
sure
forks
are
long
enough
to
extend
beyond
opposite
side
of
unit.
OVERUSE
can
cause
OVERHEATING
Allow
cooling
period;
follow
rated
duty
cycle.
Reduce
current
or
reduce
duty
cycle
before
starting
to
weld
again.
Do
not
block
or
filter
airflow
to
unit.
STATIC
(ESD)
can
damage
PC
boards.
Put
on
grounded
wrist
strap
BEFORE
handling
boards
or
parts.
Use
proper
static-proof
bags
and
boxes
to
store,
move,
or
ship
PC
boards.
MOVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts.
Keep
away
from
pinch
points
such
as
drive
rolls.
WELDING
WIRE
can
cause
injury.
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.
1-4.
Principal
Safety
Standards
Safety
in
Welding
and
Cutting,
ANSI
Standard
Z49.1,
from
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami
FL 33126
Safety
and
Health
Standards,
OSHA
29
CFR
1910,
from
Supennten
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,
American
Welding
Society
Standard
AWS
F4.i,
from
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126
National
Electrical
Code,
NFPA
Standard
70,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
MOVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts
such
as
fans.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
HF..
RADIATION
can
cause
interference.
High-frequency
(H.F.)
can
interfere
with
radio
navigation,
safety
services,
computers,
and
communications
equipment.
Have
only
qualified
persons
familiar
with
electronic
equipment
perform
this
installation.
The
user
is
responsible
for
having
a
qualified
electrician
promptly
correct
any
interference
problem
resulting
from
the
installation.
If
notified
by
the
FCC
about
interference,
stop
using
the
equipment
at
once.
Have
the
installation
regularly
checked
and
maintained.
Keep
high-frequency
source
doors
and
panels
tightly
shut,
keep
spark
gaps
at
correct
setting,
and
use
grounding
and
shielding
to
minimize
the
possibility
of
interference.
ARC
WELDING
can
cause
interference.
Electromagnetic
energy
can
interfere
with
sensitive
electronic
equipment
such
as
computers
and
computer-driven
equipment
such
as
robots.
Be
sure
all
equipment
in
the
welding
area
is
electromagnetically
compatible.
To
reduce
possible
interference,
keep
weld
cables
as
short
as
possible,
close
together,
and
down
low,
such
as
on
the
floor.
Locate
welding
operation
100
meters
from
any
sensitive
elec
tronic
equipment.
Be
sure
this
welding
machine
is
installed
and
grounded
according
to
this
manual.
If
interference
still
occurs,
the
user
must
take
extra
measures
such
as
moving
the
welding
machine,
using
shielded
cables,
using
line
filters,
or
shielding
the
work
area.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
Highway,
Suite
501,
Arlington,
VA
22202.
Code
for
Safety
in
Welding
and
Cutting,
CSA
Standard
Wi
17.2,
from
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
Safe
Practices
For
Occupation
And
Educational
Eye
And
Face
Protection,
ANSI
Standard
Z87.i
,from
American
National
Standards
Institute,
14.30
Broadway,
New
York,
NY
10018.
Cutting
And
Welding
Processes,
NFPA
Standard
51
B,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
.
S
OM-i584
Page
3
Considerations
About
Welding
And
The
Effects
Of
Low
Frequency
Electric
And
Magnetic
Fields
Welding
current,
as
it
flows
through welding
cables,
will
cause
electro
magnetic
fields.
There
has
been
and
still
is
some
concern
about
such
fields.
However,
after
examining
more
than
500
studies
spanning
17
years
of
research,
a
special
blue
ribbon
committee
of
the
National
Research
Council
concluded
that:
The
body
of
evidence,
in
the
committees
judgment,
has
not
demonstrated
that
exposure
to
power-
frequency
electric
and
magnetic
fields
is
a
human-health
hazard.
However,
studies
are
still
going
forth
and
evidence
continues
to
be
examined.
Until
the
final
conclusions
of
the
research
are
reached,
you
may
wish
to
minimize
your
exposure
to
electromagnetic
fields
when
welding
or
cutting.
To
reduce
magnetic
fields
in
the
workplace,
use
the
following
procedures:
1-5
EMF
Information
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
your
body.
4.
Keep
welding
power
source
and
cables
as
far
away
from
opera
tor
as
practical.
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
possible.
About
Pacemakers:
Pacemaker
wearers
consult
your
doctorfirst.
If
cleared
by
your
doctor,
then
following
the
above
procedures
is
recommended.
OM-1584
Page
4
SECTION
1
-
CONSIGNES
DE
SECURITE
-
LIRE
AVANT
UTI
LISATION
1-1
Signification
des
symboles
a
Signifie
Mise
en
garde!
Soyez
vigilant!
Cette
procedure
prØsente
des
risques
de
danger!
Ceux-ci
sont
identifies
par
des
symboles
adjacents
aux
directives.
A
Identifie
un
message
de
sØcuritØ
particulier.
U7
Signifie
NOTA
nest
pas
relatif
Ia
sØcuritØ.
1-2
Dangers
relatifs
au
soudage
a
Iarc
A
Lea
symboles
prØsentØs
ci-aprŁs
sont
utilisØs
tout
au
long
du
present
manuel
pour
attirer
votre
attention
et
identifier
les
risques
de
danger.
Lorsque
vous
voyez
un
symbole,
soyez
vigilant
et
suivez
les
directives
mentionnØes
atm
dØviter
tout
danger.
Les
consignes
de
sØcuritØ
prØsentØes
ci-aprŁs
ne
font
que
rØsumer
Iinformation
contenue
dana
les
normes
de
sØcuritØ
ØnumØrØes
a
Ia
section
1
-4.
Veuillez
lire
et
respecter
toutes
ces
normes
de
sØcuritØ.
A
Linstallation,
lutilisation,
lentretien
et
les
reparations
ne
doi.
vent
Øtre
conflØs
qu
des
personnes
qualifiØes.
A
Au
coursde
lutilisation,
tenirtoute
personne
a
lØcartet
plus
par
ticuliŁrement
les
entants.
UN
CHOC
ELECTRIQUE
peut
tuer
Un
simple
contact
avec
des
piŁces
Ølectriques
peut
provoquer
une
electrocution
Cu
des
blessures
graves.
LŁlectrode
et
le
circuit
de
soudage
sont
sous
tension
des
que
lappareil
est
sur
ON.
Le
circuit
dentrØe
et
es
circuits
internes
de
lappareil
sont
Łgalement
sous
tension
ace
moment-l.
En
soudage
semi-automatique
ou
automatique,
le
fil,
le
dØvidoir,
le
logement
des
galets
dentraInement
et
les
piŁces
mŁtalliques
en
contact
avec
le
fil
de
soudage
sont
sous
tension.
Des
matŁriels
mal
installŁs
Cu
mal
mis
a
Ia
terre
prŁsentent
un
danger.
Ne
jamais
toucher
les
piŁces
Łlectriques
sous
tension.
Porter
des
gants
et
des
vŒtements
de
protection
secs
ne
comportant
pas
de
trous.
Sisoler
de
Ia
piŁce
et
de
Ia
terre
au
moyen
de
tapis
ou
dautres
moyens
isolants
suffisammentgrands
pourempŒcher
le
contact
phy
sique
Łventuel
avec
Ia
piŁce
ou
a
terre.
Ne
pas
se
servir
de
source
itlectrique
courant
electrique
dans
les
zones
humides,
dans
les
endroits
confines
ou
l
o
on
risque
de
tomber.
Se
servir
dune
source
Ølectrique
courant
electrique
UNIQUEMENT
si
le
procŁdŁ
de
soudage
le
demande.
Si
Iutilisation
dune
source
electrique
courant
electrique
savŁre
nØces
saire,
se
servir
de
Ia
fonction
de
tØlØcommande
Si
lappareil
en
est
equipe.
Couper
lalimentationou
arrŒter
le
moteuravant
de
procŁder
linstal
lation,
a
Ia
reparation
ou
a
lentretien
de
lappareil.
DŁverrouiller
lalimentation
aelon
Ia
norme
OSHA
29
CFR
1910.147
(voir
normes
de
sŁcuritŁ).
Installeret
mettre
laterrecorrectementcetappareil
conformŁment
son
manuel
dutilisation
et
aux
codes
nationaux,
provinciaux
et
municipaux.
Toujours
verifier
Ia
terre
du
cordon
dalimentation
-
Verifier
et
sassu
rer
que
le
flu
de
terre
du
cordon
dalimentation
est
bien
raccordØ
ala
borne
deterre
du
sectionneur
Cu
que
Ia
fiche
du
cordon
est
raccordØe
a
une
prise
correctement
mise
a
Ia
terre.
En
effectuant
lea
raccordements
dentrŁe
fixer
dabord
le
conducteur
de
mise
a
Ia
terre
approprie
et
contre-vŁrifier
les
connexions.
Verifier
frŁquemment
le
cordon
dauimentation
pour
voir
sil
nest
pas
endommagŁ
ou
dŁnudØ
-
remplacer
le
cordon
immŁdiatemenl
sil
eat
endommagØ
-
un
cable
dŁnudŁ
petit
provoquer
une
electrocution.
Mettre
lappareil
hors
tension
quand
on ne
lutilise
pas.
Ne
pas
utiliser
des
cables
uses,
endommagŁs,
de
grosseur
insuffi
sante
ou
mal
ØpissØs.
Ne
pas
enrouler
les
cables
autour
du
corps.
Si
Ia
piŁce
soudŁe
dolt
Œtre
mise
laterre,
le
faire
directementavec
un
cable
distinct
-
ne
pas
utiliser
le
connecteur
de
piŁce
ou
le
cable
de
retour.
sam
ndtre
5/97
Ce
groupe
de
sym
boles
signifie
Mise
en
garde!
Soyez
vigilant
Ily
a
des
risques
de
danger
relies
aux
CHOCS
ELECTIRIQUES,
aux
PIECES
EN
MOUVEMENTetaux
PIECES
CHAUDES.
Reportez-vousauxsymboles
etauxdirectivesci-dessous
afin
de
connaItre
es
mesures
prendre
pour
Øviter
tout
danger.
Ne
pas
toucher
lŁlectrode
quand
on
est
en
contact
avec
Ia
piŁce,
Ia
terre
Cu
une
electrode
provenant
dune
autre
machine.
Nutiliser
quun
materiel
en
bon
Łtat.
RŁparer
Cu
remplacer
sur-le
champ
lea
piŁces
endommagØes.
EntretenirlappareilconformŁment
a
ce
manuel.
Porter
un
harnais
de
aŁcuritŁ
quand
on
travaille
en
hauteur.
Maintenir
solidement
en
place
tous
les
panneaux
et
capots.
Fixer
le
cable
de
retour
de
facon
a
obtenir
un
bon
contact
mØtal-mŁtal
avec
Ia
piŁce
a
souderou
Ia
table
detravail,
le
plus
prŁs
possible
de
Ia
soudure.
Isoler
Ia
pince
de
masse
quand
pas
mis
a
Ia
piŁce
pour
Øviter
le
contact
avec
tout
objet
mØtallique.
Ily
a
DU
COURANT
CONTINU
IMPORTANT
dans
les
convertisseurs
aprŁs
Ia
suppression
de
Ialimenta
tion
Ølectrique.
ArrŒter
lea
convertisseurs,
dŁbrancher
le
courant
Łlectrique,
et
dŁ
charger
lea
condensateurs
dalimentation
selon
lea
instructions
indiquŁes
dana
Ia
partie
entretien
avant
de
toucher
lea
piŁces.
LES
FUMEES
ET
LESGAZ
pØuvent
Œtredangereux.
Le
soudage
gŁnŁre
des
fumŁes
et
des
gaz.
Leur
inhalation
peut
Œtre
dangereux
pour
votre
sante.
Eloigner
votre
tŒte
des
fumŁes.
Ne
pas
respirer
les
fumŁes.
A
lintŁrieur,
ventiler
Ia
zone
et/ou
utiliser
un
echappement
au
ni
veau
de
larc
pour
evacuation
des
fumŁes
et
des
gaz
de
soudage.
Si
a
ventilation
eat
insuffisante,
utiliser
un
respirateur
a
alimenta
tion
dair
homologuŁ.
Ure
lea
apŁciflcationsdesŁcuritŁ
des
matŁriaux
(MSDSs)
et
lea
ins
tructions
du
fabricant
concemant
les
mŁtaux,
les
consommables,
les
revŒtements,
lea
nettoyants
et
lea
dŁgraisseurs.
Travailler
dans
un
espace
fermŁ
seulement
sil
est
bien
ventilŁ
Cu
en
portant
un
respirateur
a
alimentation
dair.
Demander
toujoura
a
un
surveillant
dCiment
formŁ
de
se
tenir
a
proximitØ.
Des
tumØes
et
des
gaz
de
soudage
peuvent
dØplacer
lair
et
abaisaer
le
niveau
doxygŁne
provoquant
des
blessures
Cu
des
accidents
mortels.
Sassurer
que
lair
de
respiration
ne
prØsente
aucun
danger.
Ne
pas
souderdans
des
endroits
situØs
a
proximitŁ
dopØrations
de
dŁgraissage,
de
nettoyage
Cu
de
pulvŁrisation.
La
chaleur
et
les
rayons
de
larc
peuvent
rŁagir
en
presence
de
vapeurs
et
former
des
gaz
hautement
toxiques
et
irritants.
Ne
pas
souder
des
mØtaux
munia
dun
revŒtement,
tels
que
lacier
galvanisŁ,
plaque
en
p10mb
Cu au
cadmium
a
moms
que
le
revŒte
ment
nait
ØtŁ
enlevŁ
dans
Ia
zone
de
soudure,
que
lendroit
soit
bien
ventilŁ,
et
51
nŁcessaire
en
portant
un
respirateur
a
afimenta
tion
dair.
Les
revŒtements
et
tous
lea
mØtaux
renfermant
ces
ØlŁ
ments
peuvent
degager
des
fumØea
toxiques
en
cas
de
soudage.
OM-1
584
Page
5
LESRAVONS
DE
LARC
peuventpro-~
voquer
des
brluresdns
les
yCux
et
sur
Ia
peau
Le
rayonnement
de
larc
du
procØdØ
de
soudage
gØnAre
des
rayons
visibles
et
invisibles
intenses
(ultraviolets
et
infrarouges)
susceptibles
de
provoquer
des
brOlures
dans
les
yeux
et
sur
Ia
peau.
Des
Øtincelles
sont
projetees
pendant
le
soudage.
Porter
un
casque
de
soudage
muni
dun
Øcran
de
filtre
appropriØ
pour
protØger
votre
visage
et
vos
yeux
pendant
le
soudage
ou
pour
regar
der
(voirANSI
Z49.
1
et
Z87.
1
ØnumØrØ
dans
les
normes
de
sØcuritØ).
Porter
des
protections
approuvØs
pour
les
oreilles
si
le
niveau
sondre
est
trop
ØlevØ.
Utiliser
des
Øcrans
ou
des
barriŁres
pour
protØger
des
tiers
de
lØclair
et
de
lØblouissement;
demander
aux
autres
personnes
de
ne
pas
re
garder
larc.
Porter
des
vŒtements
de
protection
constituØ
dans
une
matiŁre
dura
ble,
resistant
au
feu
(cuir
Cu
lame)
et
une
protection
des
pieds.
LE
SOUDAGE
peut
provoquer
un
incendie
ou
uneexplosion
Le
souda9e
effectuØ
sur
des
conteneurs
fermØs
tels
que
des
reservoirs,
tambours
ou
des
conduites
peut
provo9uerleurØclatement.
DesØtincellespeuventŒtre
projetees
de
arc
de
soudure.
La
projection
dØtincel
les,
des
piŁces
chaudes
et
des
Øquipements
chauds
peut
provoquerdes
incendies
et
des
brOlures.
Le
contact
accidentel
de
electrode
avec
des
objets
mŁtalliques
peut
provoquer
des
Øtincelles,
une
explosion,
un
surchauffement
cu
un
incendie.
Avant
de
commencer
le
soudage,
verifier
et
sassurer
que
lendroit
ne
prØsente
pas
de
danger.
Se
protØger
et
dautres
personnes
de
Ia
projection
dØtincelles
et
de
metal
chaud.
Ne
pas
souder
dans
un
endroit
l
oii
des
Øtincelles
peuvent
tomber
sur
des
substances
inflammables.
DØplacertoutes
les
substances
inflammables
a
une
distance
del
0,7
mde
arc
desoudage.
Encas
dimpossibilitØ
es
recouvrirsoigneuse
ment
avec
des
protections
homologues.
Des
Øtincelles
et
des
matŁriaux
chauds
du
soudage
peuvent
facile
ment
passer
dans
dautres
zones
en
traversant
de
petites
fissures
et
des
ouvertures.
SurveillertoutdØclenchementdincendieettenirunextincteuraproxi
mite.
Le
soudage
effectuØ
sur
un
plafond,
plancher,
paroi
ou
separation
peut
dØclencher
un
incendie
de
lautre
ctŁ.
Ne
pas
effectuer
le
soudage
sur
des
conteneurs
fermØs
tels
que
des
reservoirs,
tambours,
ou
conduites,
a
moms
quils
naient
ØtØ
prØpa
rØs
correctement
conformØment
a
AWS
F4.l
(voir
les
normes
de
sØcuritØ).
Brancher
le
cable
sur
Ia
piŁce
le
plus
prŁs
possible
de
Ia
zone
de
sou
dage
pour
Øviter
le
transport
du
courant
sur
une
longue
distance
par
des
chemins
inconnus
Øventuels
en
provoquant
des
risques
dØlec
trocution
et
dincendie.
Ne
pas
utiliser
le
poste
de
soudage
pour
dŁgeler
des
conduites
ge
lees.
En
cas
de
non
utilisation,
enlever
Ia
baguette
dŁlectrode
du
porte
electrode
Cu
couper
le
fil
a
Ia
pointe
de
contact.
Porter
des
vŒtements
de
protection
dØpourvus
dhuile
tels
que
des
gants
en
cuir,
une
chemise
en
matŁriau
lourd,
des
pantalons
sans
re
vers,
des
chaussures
hautes
et
un
couvre
chef.
Avant
de
souder,
retirer
toute
substance
combustible
de
vos
poches
telles
quun
allumeur
au
butane
ou
des
allumettes.
DES
PARTICULESVOLANTES
peuvent
blesser
es
yeux.
S
Le
soudage,
IØcaillement,
le
passage
de
Ia
piŁce
a
Ia
brosse
en
fil
de
fer,
et
le
meulage
gØnŁrent
desØtincellesetdesparticules
mØtalliquesvolan
tes.
Pendant
Ia
pŁriode
de
refroidissement
des
soudures,
elles
risquent
de
projeter
du
laitier.
Porter
des
lunettes
de
sØcuntØ
avec
Øcrans
latØraux
ou
un
Øcran
facial.
LESACCUMULATIONSDE~GAZ
ris
~queflt
de
provoquerdesbiessures
ou
rnŒme
Ia
mort.
:
,.
Fermer
lalimentation
du
gaz
protecteur
en
cas
de
non
utilisation.
Veiller
toujours
a
bien
aØrer
les
espaces
confines
Cu se
servir
dun
respi
rateur
dadduction
dair
homologuØ.
DES
PIECES
ICHAUDES
peuvent
pro
voquer
des
brlures
graves..
Ne
pas
toucher
des
parties
chaudes
a
mains
nues
PrŁvoir
une
pØriode
de
refroidissement
avant
dutiliser
le
pistolet
ou
Ia
torche.
LES
CHAMPS
MAGN
TIQUES
peuvent
affecter
les
stimulateurs
cardiaques.
Porteurs
de
stimulateur
cardiaque,
restez
a
distance.
Les
porteurs
dun
stimulateur
cardiaque
doivent
dabord
consulter
leur
mØdecin
avant
de
sapprocher
des
operations
de
soudage
a
arc,
de
gougeage
ou
de
soudage
par
points.
LE
BRUIT
peut
affecter
IouIe.
Le
bruit
des
processus
et
des
Øquipements
peut
affecter
Iouie.
Porter
des
protections
approuvØs
pour
les
oreilles
si
le
niveau
sondre
est
trop
ØlevØ.
Si
des
BOUTEILLES
sont
endomma
gØes,
elles
pourrontexploser.
Des
bouteilles
de
gaz
protecteur
contiennent
du
gaz
sous
haute
pression.
Si
une
bouteille
est
endomma
gee,
elle
peut
exploser.
Du
faitque
es
bouteilles
de
gaz
font
normalement
partie
du
procØdŁ
de
soudage,
les
manipuler
avec
precaution.
Proteger
les
bouteilles
de
gaz
comprime
dune
chaleur
excessive,
des
chocs
mØcaniques,
du
laitier,
des
flammes
ouvertes,
des
Øtin
celles
et
des
arcs.
Placer
les
bouteilles
debout
en
es
fixant
dans
un
support
station
naire
ou
dans
un
porte-bouteilles
pour
les
empØcher
de tomber
ou
de
se
renverser.
Tenir
les
bouteilles
eloignees
des
circuits
de
soudage
ou
autres
cir
cuits
etectriques.
Ne
Jamais
placer
une
torche
de
soudage
sur
une
bouteille
a
gaz.
Une
electrode
de
soudage
ne
doit
jamais
entrer
en
contact
avec
une
bouteille.
Ne
jamais
souder
une
bouteille
pressurisØe
-
risque
dexplosion.
Utiliser
seulement
des
bouteilles
de
gaz
protecteur,
regulateurs,
tuyaux
et
raccords
convenables
pour
cette
application
specifique;
les
maintenir
ainsi
que
les
ØlŁments
associØs
en
ban
Øtat.
Ne
pas
tenir
Ia
tŒte
en
face
de
Ia
sortie
en
ouvrant
Ia
soupape
de
Ia
bouteille.
Maintenir
le
chapeau
de
protection
sur
Ia
soupape,
sauf
en cas
dutilisation
ou
de
branchement
de
Ia
bouteille.
Ure
et
suivre
les
instructions
concernant
les
bouteilles
de
gaz
corn
prime,
les
Øquipements
associŁs
et
les
publications
P-i
CGA
Ønu
mØrØes
dans
les
normes
de
sØcuritØ.
.
OM-1584
Page
6
1-3.
Dangers
supplØmentaires
en
relation
avec
Iinstallation,
le
fonctionnement
et
Ia
maintenance
Risque
DINCENDJE
OU
DEXPLOSION~
Ne
pas
placer
lappareil
sur,
au-dessus
ou
a
proximitØ
de
surfaces
infliammables.
Ne
pas
installer
Iappareil
a
proximitØ
de
produits
inflammables
Ne
pas
surcharger
Iinstallation
Ølectrique
-
sassurer
que
lalimen
tation
est
correctement
dimensionnØ
et
protØgØ
avant
de
mettre
Iappareil
en
service.
LACHUTE
DE
LAPPAREILpeut
bIesser~
Utiliser
lanneau
de
levage
uniquement
pour
sou
lever
lappareil,
NON
PAS
les
chariot,
les
bouteil
es
de
gaz
ou
tout
autre
accessoire.
Utiliser
un
engin
dune
capacitØ
appropriee
pour
soulever
lappareil.
En
utilisant
des
fourches
de
levage
pour
dØplacer
lunitØ,
sassurer
que
lesfourches
sont
suffisamment
longues
pourdØpasserdu
ctØ
oppose
de
lappareil.
LEMPLOI
EXCESSIF
peut
SURCHAUFFER
LEOUIPEMENT.
PrØvoir
une
pØriode
de
ref
roidissement,
respec
ter
le
cycle
opØratoire
nominal.
RØduirelecourantou
le
cycle
opØratoire
avantde
recommancer
le
soudage.
Ne
pas
obstruer
les
passages
dair
du
poste.
LES
CHARGES
ELECTROSTATIQUES
peuvent
endommager
les
circuits
im
pnmØs.
Etablir
Ia
connexion
avec
Ia
barrette
de
terre
avant
de
manipuler
des
caries
ou
des
piŁces.
Utiliser
des
pochettes
et
des
boltes
antistatiques
pour
stocker,
dØplacer
ou
expØdier
des
caries
de
circuits
imprimes.
DES
ORGANES
MOBILES
peuvent
provoquer
des
blessures.
Ne
pas
sapprocher
des
organes
mobiles.
Ne
pas
sapprocher
des
points
de
coincement
tels
que
des
rouleaux
de
commande.
LES
FILS
DE
SOUDAGE
peuvent
pro
voquer
des
blessures.
Ne
pas
appuyer
sur
Ia
gachette
avant
den
avoir
recu
linstruction.
Ne
pas
diriger
le
pistolet
vers
soi,
dautres
per
sonnes
ou
toute
piŁce
mØcanique
en
engageant
le
Ill
de
soudage.
DES
ORGANES
MOBILES
peuvent
provoquer
des
blessures.
Rester
a
lØcart
des
organes
mobiles
comme
le
ventilateur.
MaintenirfermØsetfixementen
place
es
portes,
panneaux,
recouvrements
et
dispositifs
de
protection.
LE
RAVONNEMENT
HAUTE
FRE
QUENCE
(H.F.)
risque
de
provoquer
des
interferences.
Lerayonnementhautefrequence
peutprovoquer
des
interferences
avec
les
Øquipements
de
ra
dio-navigationetdecommunication,
lesservices
de
sØcuritØ
et
les
ordinateurs.
Demander
seulement
a
des
personnes
qualifiees
familiarisØes
avec
des
Øquipements
Ølectroniques
de
faire
fonctionner
linstalla
tion.
Lutilisateur
est
tenu
de
faire
corriger
rapidement
par
un
Ølectricierr
qualifiØ
les
interferences
resultant
de
installation.
Si
le
FCC
signale
des
interferences,
arrŒter
immØdiatement
lappa
reil.
Effectuer
regulierement
le
contrle
ot
lentretien
de
installation.
Maintenir
soigneusement
fermØs
les
portes
et
les
panneaux
des
sources
do
haute
frequence,
maintenir
les
Øclateurs
a
une
distance
correcte
et
utiliser
une
terre
et et
un
blindage
pour
rØduire
los
inter
fØrences
Øventuelles.
LE
SOUDAGE
A
LARC
risque
de
provoquer
des
interferences.
Lenergie
Ølectromagnetique
risque
de
provoquer
des
interferences
pour
lequipemont
Ølectronique
sensible
tel
que
les
ordinateurs
et
IØquipement
commandØ
par
ordinateur
tel
quo
los
robots.
Veiller
ace
que
tout
lequipement
de
Ia
zone
de
soudage
soit
com
patible
ØlectromagnŁtiquement.
Pour
rØduire
Ia
possibilitØ
dinterfŁrence,
maintenir
es
cables
do
soudage
aussi
courts
que
possible,
les
grouper,
ot
los
poser
aussi
bas
quo
possible
(ox.
par
terre).
Veiller
a
souder
a
une
distance
de
100
metres
de
tout
Øquipement
electronique
sensible.
Veiller
a
ce
que
Co
posto
do
soudago
soit
pose
et
mis
a
Ia
terre
conformØment
a
ce
mode
domploi.
En
cas
dinterfØrences
aprØs
avoir
pris
los
mesures
prØcØdentes,
il
incombe
a
lutilisateur
de
prendre
des
mesures
supplØmentaires
telles
quo
le
dØplacement
du
poste,
lutilisation
de
cables
blindØs,
lutilisation
de
filtres
do
tigne
ou
Ia
pose
de
protecteurs
dans
Ia
zone
de
travail.
LES
CHAMPS
MAGNETIQUES
peuvent
affecter
les
stimulateurs
cardiaques.
Porteurs
de
stimulateur
cardiaque,
restez
a
dis
tance.
Los
porteurs
dun
stimulateur
cardiaque
doivent
dabord
consutter
leur
mØdecin
avant
do
sappro
cher
des
operations
do
soudage
a
arc,
de
gou
geage
ou
de
soudage
par
points.
OM-1584
Page
7
Safety
in
Welding
and
Cutting,
norme
ANSI
Z49.
1,
de
lAmerican
Wel
ding
Society,
550
N.W.
Lejeune
Rd,
Miami
FL 33126
Safetyand
Health
Sandards,
OSHA
29
CFR
1910,
du
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
Recommended
Safe
Practice
for
the
Preparation
for
Welding
and
Cut
ting
of
Containers
Thai
Have
Held
Hazardous
Substances,
norme
AWS
F4.1
,
de
American
Welding
Society,
550
N.W.
Lejeune
Rd,
Mia
mi
FL
33126
National
Electrical
Code,
NFPA
Standard
70,
de
Ia
National
Fire
Pro
tection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
DonnØes
sur
le
soudage
Ølectrique
et
sur
les
effets,
pour
Iorganisme,
des
champs
magnØtiques
basse
frequence
Le
courant
de
soudage,
pendant
son
passage
dans
les
cables
de
sou
dage,
causera
des
champs
ØlectromagnØtiques.
II
y
a
eu
et
ii
y
a
encore
un
certain
souci
a
propos
de
tels
champs.
Cependant,
aprŁs
avoir
examine
plus
de
500
etudes
qui
ont
ØtØ
faites
pendant
une
pØ
node
de
recherche
de
17
ans,
un
comitØ
special
ruban
bleu
du
National
Research
Council
a
conclu:
Laccumulation
de
preuves,
sui
vant
le
jugement
du
comitØ,
na
pas
dØmontrØ
que
Iexposition
aux
champs
magnØtiques
et
champs
Ølectriques
a
haute
frequence
reprØ
sente
un
risque
a
Ia
sante
humaine.
Toutefois,
des
etudes
sont
toujours
en
cours
et
les
preuves
continuent
a
Œtre
examinØes.
En
at
tendant
que
les
conclusions
finales
de
Ia
recherche
soient
Øtablies,
1
vous
serait
souhaitable
de
rØduire
votre
exposition
aux
champs
Ølec
tromagnØtiques
pendant
le
soudage
ou
le
coupage.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,
de
Ia
Compressed
Gas
Association,
1235
Jefferson
Davis
High
way,
Suite
501,
Arlington,
VA
22202.
RŁgles
de
sØcuritØ
en
soudage,
coupage
etprocØdØs
connexes,
nor-
me
CSA
Wi
17.2,
de
IAssociation
canadienne
de
normalisation,
vente
de
normes,
178
Rexdale
Boulevard,
Rexdale
(Ontario)
Canada
M9W
1R3.
Safe
Practices
ForOccupationAndEducational
EyeAnd
Face
Protec
tion,
norme
ANSI
Z87.1,
de
IAmerican
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
Cutting
and
Welding
Processes,
norme
NFPA
51
B,
de
Ia
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Afin
de
rØduire
les
champs
ØlectromagnØtiques
dans
lenvironnement
de
travail,
respecter
les
consignes
suivantes
1
Garder
es
cables
ensembles
en
Ies
torsadant
ou
en
es
attachant
avec
du
ruban
adhØsif.
2
Mettre
tous
les
cables
du
ctØ
oppose
de
lopØrateur.
3
Ne
pas
courber
pas
et
ne
pas
entourer
pas
les
cables
autour
de
votre
corps.
4
Garder
le
poste
de
soudage
et
les
cables
le
plus
loin
possible
de
vous.
5
Relier
Ia
pince
de
masse
le
plus
prŁs possible
de
Ia
zone
de
soudure.
Consignes
relatives
aux
stimulateurs
cardiaques
Les
personnes
qui
portent
un
stimulateur
cardiaque
doivent
avanttout
consulter
leur
docteur.
Si
vous
Œtes
dØclarØ
apte
par
votre
docteur,
il
est
alors
recommandØ
de
respecter
es
consignes
ci-dessus.
1-4
Principales
normes
de
sØcurite
1-5
Information
sur
les
champs
Ølectromagnetiques
.
.
OM-1584
Page
8
SECTION
2-
INTRODUCTION
Welding
Power
Source
Type
Wire
Feed
Speed
Range
Standard:
50
To
780
ipm
(1.3
To
19.8
mpm)
Optional
High
Speed:
92
To
1435
1pm
(2.3
To
36.5
mpm)
Wire
Diameter
Range
.023
To
1/8
in
(0.6
To
3.2
mm)
Max
Spool
Weight:
60
lb
(27
kg)
3-1.
Installing
Swivel
Into
Pipe
Post
Type
of
Input
Power
2-1.
Specifications
24
Volts
AC
Single-Phase
10
Amperes
50/60
Hertz
Constant
Voltage
(CV)
DC
With
14-Pin
And
Contactor
Control
Welding
Circuit
Rating
Weight
100
Volts,
750
Amperes,
100%
Duty
Cycle
l2ft(3.7m):
207
lb
(94
kg)
16ft(4.9m):
280
lb
(127
kg)
12
ft
(3.7
m)
Boom
Maximum
Height
With
4
ft
(1.2
m)
Post
17
ft
(5.2
m)
16
ft
(4.9
m)
Boom
21
ft
(6.4
m)
Vertical
Lift
Of
Boom
Horizontal
to
60
Above
Horizontal
Horizontal
to
60
Above
Horizontal
SECTION
3-
INSTALLATION
1
Swingpak
Base
or
CBC
Cart
2
1
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
A
Do
not
remove
until
instructed
to.
3
ST-152
382
Tools
Needed:
~
3/4
in
OM-1584
Page
9
3-2.
Installing
Control
Box
And
Adjusting
Tilt
7
Reel
Support
S
1
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.
5
Tilt
Bracket
6
6
Rear
Pivot
Screw
7
Front
Screw
Loosen
rear
pivot
screw.
Remove
4
front
screw.
Pivot
control
down
ward
to
desired
viewing
angle.
Re
place
and
tighten
front
screw.
Tighten
pivot
screw.
Tools
Needed:
1T~ZTJnZZZ1J
3/8
in
ST-lbS
1741ST-801
280
3
7
3-3.
Installing
Boom
And
Reel
Support
1
Swivel
Plates
2
Yoke
3
Remove
hardware
from
swivel
plates
and
yoke.
3
Boom
Set
boom
into
swivel
as
shown.
4
Yoke
Pin
4
7
Install
pin
through
yoke.
Install
cot
ter
pin
and
spread
ends.
5
Bolt
6~
Install
bolt,
washers,
and
nut.
Tighten
hardware,
and
back
bolt
off
one
half
turn.
6
Locking
Knob
Install
locking
knob
but
do
not
tighten.
2
a0
Tools
Needed:
r
3/8,
3/4
in
Install
reel
support.
ST-I
53
170
OM-1584
Page
10
3-4.
Installing
Wire
Guide
Extension
To
change
wire
feed
starting
speed
proceed
as
follows:
Turn
Off
wire
feeder
and
welding
power
source.
Remove
wrapper.
1
Front
Panel
Front
panel
shown
open
for
il
lustration
purposes.
2
Motor
Board
PCi
3
Motor
Start
Control
Poten
tiometer
R70
Turn
potentiometer
clockwise
to
in
crease
time
it
takes
the
motor
to
ramp
up
to
speed.
Remove
protec
tive
white
rubber
cap
before
mak
ing
adjustment.
Adjust
potentiome
ter
R70
using
a
small
nonconduc
tive
screwdriver.
Reinstall
wrapper.
1
Wire
Guide
Fitting
2
Bolt
3
Monocoil
Liner
4
Wire
Guide
Extension
Tighten
bolt
to
secure
liner
in
wire
guide
fitting.
Do
not
overtighten
bolt
and
crush
liner.
Repeat
procedure
for
opposite
side.
Tools
Needed:
cT~~TJ===in
3/8
in
ST-152
383
3-5.
Motor
Start
Control
Tools
Needed:
Non-Conductive
_
-
cTIJ==i1
114
in
Ref.
ST-142
710-A
/
Ref.
SB-146
882-D
OM-1584
Page
11
3-6.
Equipment
Connection
Diagram
Welding
Power
Source
Remote
14
Connection
Negative
(-)
Weld
Output
Cable
Positive
(+)
Weld
Output
Cable
Workpiece
Voltage
Sensing
(Optional)
Weld
Control
Boom
Gun
Swivel
Pipe
Post
And
Base
Gas
Hose
Gas
Supply
.
OM-1584
Page
12
3-7.
Control
Box
Connections
3-8.
14-Pin
Plug
Information
REMOTE
~
~j~*
Pin
Information
jo
OA
H0
30
0M
0D
0
A
24
volts
ac
with
respect
to
socket
G.
B
Contact
closure
to
A
completes
24
volts
ac
contactor
control
circuit.
G
Circuit
common
for
24
volts
AC
circuit.
C
+10
volts
dc
output
to
remote
control
with
respect
to
socket
D.
D
Remote
control
circuit
common.
E
0
to
+10
volts
dc
input
command
signal
from
remote
control
with
respect
to
socket
D.
H
Voltage
feedback;
0
to
+10
volts
dc,
1
volt
per
10
arc
volts.
F
Current
feedback;
0
to
+10
volts
dc,
1
volt
per
100
amperes.
*The
remaining
pins
are
not
used.
OM-1584
Page
13
3-9.
Removing
Safety
Collar
And
Adjusting
Boom
3-11.
Wire
Type,
Size,
And
Feed
Speed
Capability
Table
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
slightly
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:
2
Threaded
Rod
3
Jam
Nut
Loosen
jam
nut
and
turn
threaded
rod
until
boom
balances.
Tighten
jam
nut.
Be
sure
several
full
threads
are
through
yoke
to
pre
vent
boom
falling.
4
Yoke
Retain
safety
collar
for
use
in
dis
assembling
or
moving
boom.
Motor
Speed
Wire
Type
Wire
Size
Feed
Speed
Capabiity
Standard
All
.023
To
5/64
in
(0.6
To
2mm)
50 To
780
ipm
(1.3
To
19.8
mpm)
Standard
All
3/32
To
7/64
in
(2.4
To
2.8
mm)
50
To
700
ipm
(1.3
To
17.8
mpm)
Standard
All
1/8
in
(3.2
mm)
50 To
300
pm
(1.3
To
7.6
mpm)
Optional
High
All
.023
To
5/64
in
(0.6
To
2
mm)
92
To
1440
ipm
(2.3
To
35.6
mpm)
.
2
E
Tools
Needed:
Increasing
Spring
Pressure
For
A
~
1-1/8
in
Heavy
Gun
0
1
Rod
3-10.
Gun
Recommendation
Table
Decreasing
Spring
Pressure
For
A
Lighter
Gun
ST-142
599-B
Process
Gun
GMAW
-
Hard
or
Cored
Wires
M25,
M40,
GA-50C,
GW-500,
Or
GW-600
FCAW
-
Self-Shielding
Wires
GA-4OGL
Or
GA-5OGL
OM-1
584
Page
14
3-12.
Installing
And
Threading
Welding
Wire
3/16,
5/64
in
Tools
Needed:
Be
sure
that
outlet
cable
has
proper
size
liner
for
the
welding
wire
size.
When
installing
gun,
position
liner
extending
from
outlet
wire
guide
as
close
as
possible
to
drive
rolls
without
touching.
install
gun.
Lay
gun
cable
out
straight.
Cut
offend
of
wire.
Push
wire
through
guides
up
to
drive
rolls;
continue
to
hold
wire.
Press
Jog
button
to
feed
wire
out
gun.
ltT
Forsoft
wire
orsmall
diameter
stainless
steel
wire,
use
2
drive
rolls
and
set
drive
roll
pressure
from
0
to
a
maximum
of
4
on
the
pressure
indicator
scale
(so
that
only
the
inner
spring
is
compressed).
This
setting
will
generally
give
the
best
performance
for
these
types
of
wires.
To
adjust
drive
roll
pressure,
hold
nozzle
about
2
in
(51
mm)
from
nonconductive
surface
and
press
gun
trigger
to
feed
wire
against
surface.
Tighten
knob
so
wire
does
not
slip.
Do
not
overtighten.
If
contact
tip
is
completely
blocked,
wire
should
slip
at
the
feeder
(see
pressure
adjustment
above).
Cut
wire
off.
Close
cover.
Repeat
for
other
side.
ST-153
171
1
ST-153
073/
Ret
ST-137
391-Al
ST-142
597-A/
Ref.
S-0627-A/
Ret
ST-iSO
922
3/8,15/l6in
Install
wire
spool.
Adjust
tension
nut
so
wire
is
taut
when
wire
feed
stops.
1~
Install
wire
guide.
4-
-~
NONCONDUCTIVE
NONCONDUCTIVE
SURFACE
SURFACE
No
Wire
Slip
Wire
Slips
OM-1584
Page
15
3-13.
Optional
Equipment
DIP
Switch
Settings
I~T
If
wire
feeder
is
equipped
with
a
voltage
sensing
lead,
set
DIP
switch
S3
to
the
OFF
position
(up).
If
wire
feeder
is
NOT
equipped
with
a
voltage
sensing
lead,
set
DIP
switch
S3
to
the
ON
position
(down).
.
X
Means
switch
can
be
in
either
position.
I
Means
switch
must
be
in
this
position.
OM-1584
Page
16
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Miller KG215483 Owner's manual

Miller
Brand
Miller
Model
KG215483
Category
Welding System
Type
Owner's manual
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