Miller KD506226 Owner's manual

Millerﬁ

October

1993

Form:

OM-1588

Effective

With

Serial

No.

KD506226



Read

and

follow

these

instructions

and

all

safety

blocks

carefully.



Have

only

trained

and

qualified

persons

install,

operate,

or

service

this

unit.



call

your

distributor

if

you

do

not

understand

the

directions.

OWNERS

MANUAL

DS-64M

(12)

And

(16)

Foot

Boom

Mounted

Wire

Feeder



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

ipm

(1.3

To

19.8

mpm)



Programmable

Pulse

Weld

Parameters



Circuit

Breaker

Protected



Give

this

manual

to

the

operator.



For

help,

call

your

distributor



or:

MILLER

Electric

Mfg.

Co.,

P.O.

Box

1079,

Appleton,

WI

54912

414-734-9821

cover

7/93



ST-800

172

'

1993

MILLER

Electric

Mig

Cc-

PRINTED

IN

USA

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

Effective

January

1,

1992

(Equipment

with

a

aerial

number

preface

of

XC

or

newer)

This

limited

werrenty

supersedes

eli

werrsntlee

end

is

exclusive

with

no

other

guerentees

or

werrenties

expressed

or

implied.

LIMITED

WARRANTY



Subject

to

the

terms

end

conditions

below,

MILLER

Electric

MIg.

Co..

Appleton,

Wisconsin,

werrents

to

its

original

retell

purcheser

Ihet

new

MILLER

equipment

sold

efter

the

effective

dete

of

this

limited

werrenfy

is

free

of

de

fects

in

materiel

end

workmanship

et

the

time

it

is

shipped

by

MILLER,

THIS

WAR

RANTY

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTHER

WARRANTIES.

EXPRESS

OR

IMPLIED,

INCLUDING

THE

WARRANTIES

OF

MERCHANTABILITY

AND

FIT

NESS.

Within

the

werrenty

periods

listed

below.

MILLER

wilt

repeir

or

reptece

any

war-

rented

perts

or

components

that

fell

due

to

such

detects

in

meteriel

or

worlrnenship.

MILLER

musf

be

notified

in

writing

within

thirty

(30)

deys

of

such

defect

or

failure,

et

which

time

MILLER

will

provide

instructions

on

the

werrenty

cleim

procedures

to

be

followed.

MILLER

shell

honor

werrenty

cleims

on

werrented

equipment

listed

below

in

the

event

of

such

e

feilure

within

the

werrenty

time

periods,

All

werrenty

time

periode

alert

on

the

dete

that

the

equipment

wee

delivered

to

the

origlnel

retelt

purcheser.

or

one

yeer

eher

the

equipment

is

sent

to

the

distributor.

1.

5

Veers

Pens

3

Years

Lebor



Original

mein

power

rectifiers

2.

3

Veers



Perle

end

Lebor



Treneformer/Rectifler

Power

Sources



Plesme

Arc

Cutting

Power

Sources



SemI-Autometic

end

Autometic

Wire

Feeders



Robote

3.

2

Veers



Pens

end

Lebor



Engine

Driven

Welding

Generetore

(NOTE:

Engines

ere

werrented

eeperetely

by

the

engine

menufecturer.)

*

Air

Compressors

4.

1

Veer



Pens

end

Lebor



Motor

Driven

Guns



Process

Controllers

*

Weter

Coolent

Systems



HF

Unite



Grids



Spot

Welders



Loed

Benks



SDX

Trensformers



Running

Geer/Treilere



Field

Options

(NOTE:

Field

options

ere

covered

under

True

Blue

TM

for

the

remelning

werrenty

period

of

the

product

they

ere

instelled

in,

or

for

e

minimum

of

one

yeer



whichever

is

greeter.)

5.

6

Months



Befteries

6.

90

Deys



Pane

end

Lebor



MIG

Gune/TIG

Torches



Plesme

Cutting

Torches

al-



Remote

Controls



Accessory

Kits



Replecement

Pens

MILLERS

True

Blue

TM

Limited

Werrenty

shell

not

epply

to:

1.

Items

furnished

by

MILLER,

but

menufectured

by

others,

such

es

engines

or

trede

ecceesoriee.

These

items

are

covered

by

the

menufecturers

werrenty.

if

eny.

2.

Coneumeble

components:

such

es

contect

tips,

cutting

nozzles.

contectors

end

releys

or

pens

thet

fell

due

to

normel

weer.

3.

Equipment

thet

hes

been

modified

by

eny

petty

other

then

MILLER,

or

equip

ment

thet

hes

been

improperly

instelled,

improperly

opereted

or

misused

beeed

upon

industry

etenderds,

or

equipment

which

he,

not

hed

reesoneble

end

neceseery

maintenance,

or

equipment

which

he,

been

used

tor

operetion

outxide

of

the

specificetione

for

the

equipment.

MILLER

PRODUCTS

ARE

INTENOED

FOR

PURCHASE

AND

USE

BY

COMMER

CIALJINDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

IN

THE

USE

AND

MAINTENANCE

OF

WELDING

EOUIPMENt

In

the

event

of

e

werrenty

cleim

covered

by

this

werrenty,

the

exclusive

remedies

shell

be,

et

MILLERS

option:

(1)

repeir:

or

(2)

replecement;

or.

where

euthorized

in

writing

by

MILLER

in

eppropriete

cexes.

(3)

the

reesoneble

cod

of

repeir

or

replece

ment

at

en

euthorized

MILLER

service

station;

or

(4)

payment

of

or

credit

for

the

pur

chese

price

(tees

reesonebledeprecietlon

based

upon

ecluel

use)

upon

return

of

the

goods

et

customers

risk

end

expense.

MILLERS

optIon

of

repair

or

replecem,ant

will

be

FOB.,

Fectory

et

Appleton.

Wisconsin.

or

FOB.

etc

MILLER

euthorized

ser

vice

facility

cx

determined

by

MILLER.

Therefore

no

compeneation

or

reimburse

ment

for

transportation

costs

of

any

kind

will

be

allowed.

TO

THE

EXTENT

PERMITTED

BY

LAW,

THE

REMEDIES

PROVIDED

HEREIN

ARE

THE

SOLE

AND

EXCLUSIVE

REMEDtES.

IN

NO

EVENT

SHALL

MILLER

BE

LIABLE

FOR

DIRECt

INDIRECt

SPECIAL,

INCIDENTAL

OR

CONSEOUENTIAL

DAMAGES

(INCLUDING

LOSS

OF

PROFIT),

WHETHER

BASED

ON

CON

TRACT.

TORT

OR

ANY

OTHER

LEGAL

THEORY.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

tMPLIED

WAR

RANTY,

GUARANTY

OR

REPRESENTATION

AS

TO

PERFORMANCE.

AND

ANY

REMEDY

FOR

BREACH

OF

CONTRACT

TORT

OR

ANY

OTHER

LEGAL

THEORY

WHICH,

BUT

FOR

THIS

PROVISION,

MIGHT

ARISE

BY

IMPLICATION,

OPERATION

OF

LAW.

CUSTOM

OF

TRADE

OR

COURSE

OF

DEALING,

IN

CLUDING

ANY

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OR

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

TO

ANY

AND

ALL

EOUIPMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

AND

DISCLAIMED

BY

MILLER.

Some

states

in

the

U.S.A.

do

not

allow

limitations

of

how

long

en

implied

warranty

feats,

or

the

esciuxion

of

incidental,

indirect,

specisl

or

consequential

damages,

so

the

above

limitation

or

exclusion

may

nof

apply

to

you.

This

warranty

provides

spe

cific

legal

rights.

and

other

rights

may

be

available.

but

mey

vary

from

dde

to

state.

In

Canada.

legislation

in

come

provinces

providex

for

certain

additional

warranties

or

remedies

other

then

as

elated

herein,

and

to

the

eetent

that

they

may

not

be

waived,

the

limitations

and

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-u

j

I

RECEIVING-HANDLING

Before

unpacking

equipment,

check

carton

for

any

damage

that

may

have

occurred

during

shipment.

Fi(e

any

Claims

for

loss

or

damage

with

the

delivering

carrier.

Assistance

for

fi)ing

or

Settling

claims

may

be

obtained

from

distributor

and/or

equipment

manufacturers

Transportation

Department.

When

requesting

information

about

this

equipment,

always

provide

Model

Designation

and

Serial

or

Sty)e

Number.

Use

the

folloWing

spaces

to

record

Model

Designation

and

Serial

or

Style

Number

of

your

unit.

The

information

is

located

on

the

rating

label

or

nameplate.

Model

_________

Serial

or

Style

No.

Date

of

Purchase

miller

5/93a

ERRATA

SHEET

June

2,

1994

FORM:

OM-1

588

-

Use

above

FORM

number

when

ordering

extra

manuals.

After

this

manual

was

printed,

refinements

in

equipment

design

occurred.

This

sheet

lists

exceptions

to

data

appearing

later

in

this

manual.

CHANGES

TO

SECTION

3INSTALLATION

Replace

Section

3-12B.

Welding

Wire

Installation:

Installation

Of

Optional

Wire

Reel

And

Reel

Type

Wire

Figure

3-15.

Installation

Of

Optional

Wire

Reel

And

Reel

Type

Wire

CHANGES

TO

SECTION

15

ELECTRICAL

DIAGRAMS

Replace

Figure

15-1.

Circuit

Diagram

For

Wire

Feeder

(see

Pages

2

and

3

on

this

Errata

Sheet)

Replace

Figure

15-2.

Wiring

Diagram

For

Wire

Feeder

(see

Pages

4

and

5

on

this

Errata

Sheet)

1

Retaining

Ring

2

Spanner

Nut

3

Lock

4

Wire

Retainer

5

Wire

Reel

6

Hub

7

Hub

8

ReelSupport

Remove

retaining

ring.

Pull

lock

and

turn.

Remove

spanner

nut,

wire

retainer,

and

wire

reel

from

hub.

Lay

wire

reel

assembly

on

flat

sur

face,

and

install

wire

as

shown.

Tighten

spanner

nut

until

lock

is

in

position

over

hole

in

wire

retainer.

Pull

lock

and

turn

to

insert

locking

into

wire

retainer.

Slide

wire

reel

assembly

onto

hub,

and

turn

assembly

until

hub

is

seated

in

hole

in

reel.

Reinstall

re

taining

ring.

ST-143

478-A

/

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SD-164

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Page

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MICROPROCESSOR

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PLG27

eﬁﬁuI

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430(RC37-e)

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Wiring

Diagram

For

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Feeder

C

a

OM-1588

Page

4

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A

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SD-164

540-B

OM-1588

Page

5

CHANGES

TO

SECTION

16

PARTS

LIST

Change

Parts

List

as

follows:

Dia.

Mkgs.

Part

No.

Replaced

With

91-

Added

165798

91-

Added

163282

92-2

164

842

155

024

Description

Quantity

RETAINER,

spool

support

(Eff

w/KE621

826)

(consisting

of)

1

LABEL,

caution

falling

wire

reel

can

cause

damage

1

NUT,

spanner

retaining

(Eff

w/KE621

826)

1

Eff

w/KE593886

PANEL,

front

(Eff

w/KE623992)

1

WASHER,

fIat

.625

ID

nylafil

(Eff

w/KE623992)

...

1

KNOB,

pointer

(Eff

w/KE623992)

1

WASHER,

shldr

.612

ID

(Effw/KE623992)

1

RING,

ring

ext

.625

shaft

grv

x

.045

thk

E

style

(Effw/KE623992)

1

SPRING,

cprsn

.573

OD

x

.088

wire

x

1.062

Ig

(Effw/KE644333)

2

SPACER,

locating

(Eff

w/KE552693)

2

WASHER,

flat

.257

ID

stl

(Eff

w/KE644333)

2

SPRING,

pressure

arm

retaining

LH

(Effw/KE644333)

2

SPRING,

pressure

arm

retaining

RH

(Effw/KE644333)

2

NUT,

.250-28

stl

(Eff

w/KE644333)

2

LENS,

clear

anti

glare

1

**First

digit

represents

page

no



digits

following

dash

represent

item

no.

+When

ordering

a

component

originally

displaying

a

precautionary

label,

the

label

should

also

be

ordered.

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

83-12

124905

+168

104

83-13

124904

85-24

.

PLG1O3

.

135635

87-2

161714

87-10

157

113

.87-11

097924

87-

Added

87-

Added

166594

168103

Deleted

167697

010291

167700

167633

159264

91-14

133603

165934

91-32

154031

91-

Added

91-

Added

167387

165799

163281

OM-1588

Page

6

ARC

WELDING

SAFETY

PRECAUTIONS

ELECTRIC

SHOCK

can

kill.

Touching

live

electrical

parts

can

cause

fatal

shocks

or

severe

burns.

The

electrode

and

work

circuit

is

electrically

live

whenever

the

output

is

on.

The

input

power

circuit

and

machine

internal

circuits

are

also

live

when

power

is

on.

In

semiautomatic

or

automatic

wire

welding,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

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.

4.

Disconnect

input

power

or

stop

engine

before

installing

or

servicing

this

equipment.

FLYING

SPARKS

AND

HOT

METAL

can

cause

injury.

Chipping

and

grinding

cause

flying

metal.

As

welds

cool,

they

can

throw

oft

slag.

5.

Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual

and

national,

state,

and

local

codes.

6.

When

making

input

connections,

attach

proper

grounding

conductor

first.

7.

Turn

off

all

equipment

when

not

in

use.

8.

Do

not

use

worn,

damaged,

undersized,

or

poorly

spliced

cables.

9.

Do

not

wrap

cables

around

your

body.

10.

Ground

the

workpiece

to

a

good

electrical

(earth)

ground.

11.

Do

not

touch

electrode

if

in

contact

with

the

work

or

ground.

12.

Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

13.

Wear

a

safety

harness

if

working

above

floor

level.

14.

Keep

all

panels

and

covers

securely

in

place.

1.

Wear

approved

face

shield

or

safety

goggles.

Side

shields

recommended.

2.

Wear

proper

body

protection

to

protect

skin.

a

WARNING

ARC

WELDING

can

be

hazardous.

PROTECT

YOURSELF

AND

OTHERS

FROM

POSSIBLE

SERIOUS

INJURY

OR

DEATH.

KEEP

CHILDREN

AWAY.

PACEMAKER

WEARERS

KEEP

AWAY

UNTIL

CONSULTING

YOUR

DOCTOR.

In

welding,

as

in

most

jobs,

exposure

to

certain

hazards

occurs.

Welding

is

safe

when

precautions

are

taken.

The

safety

information

given

below

is

only

a

summary

of

the

more

complete

safety

information

that

will

be

found

in

the

Safety

Standards

listed

on

the

Read

and

follow

all

Safety

Standards.

HAVE

ALL

INSTALLATION,

OPERATION,

MAINTENANCE,

AND

REPAIR

WORK

PERFORMED

ONLY

BY

QUALIFIED

PEOPLE.

ARC

RAYS

can

burn

eyes

and

skin;

~I

NOISE

can

damage

hearing.

Arc

rays

from

the

welding

process

produce

intense

heat

and

strong

ultraviolet

rays

that

can

burn

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

NOISE

1.

Use

approved

ear

plugs

or

ear

muffs

if

noise

level

is

high.

ARC

RAYS

2.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

(see

ANSI

Z49.

1

listed

in

Safety

Standards)

to

protect

your

face

and

eyes

when

welding

or

watching.

3.

Wear

approved

safety

glasses.

Side

shields

recommended.

4.

Use

protective

screens

or

barriers

to

protect

others

from

flash

and

glare;

warn

others

not

to

watch

the

arc.

5.

Wear

protective

clothing

made

from

durable,

flame-resiŒtant

material

(wool

and

leather)

and

foot

protection.

FUMES

AND

GASES

can

be

hazardous

5.

Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

to

your

health.

wearing

an

air-supplied

respirator.

Shielding

gases

used

for

Welding

produces

fumes

and

gases.

Breathing

these

fumes

and

gases

can

be

hazardous

to

your

health.

welding

can

displace

air

causing

injury

or

death.

Be

sure

the

breathing

air

is

safe.

1.

2.

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

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.

remove

welding

fumes

and

gases.

7.

Do

not

weld

on

coated

metals,

such

.as

galvanized,

lead,

or

3.

If

ventilation

is

poor,

use

an

approved

air-supplied

respirator.

cadmium

plated

steel,

unless

the

coating

is

removed

from

the

4.

Read

the

Material

Safety

Data

Sheets

(MSDSs)

and

the

weld

area,

the

area

is

well

ventilated,

and

if

necessary,

while

manufacturers

instruction

for

metals,

consumables,

coatings,

wearing

an

air-supplied

respirator.

The

coatings

and

any

metals

and

cleaners,

containing

these

elements

can

give

oft

toxic

fumes

if

welded.

WELDING

can

cause

fire

or

explosion.

5.

Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.

Sparks

and

spatter

fly

off

from

the

welding

arc.

The

flying

sparks

and

hot

metal,

weld

spatter,

hot

6.

Be

aware

that

welding

on

a

ceiling,

floor,

bulkhead,

or

partition

can

cause

fire

on

the

hidden

side.

workpiece.

and

hot

equipment

can

cause

fires

and

burns.Accidentalcontactofelectrodeorweldingwire

7.

.

Do

not

weld

on

closed

containers

such

as

tanks

or

drums.

to

metal

objects

can

cause

sparks,

overheating,

or

fire.

8.

Connect

work

cable

to

the

work

as

close

to

the

welding

area as

practical

to

prevent

welding

current

from

traveling

long,

possibly

.

1.

Protect

yourself

and

others

from

flying

sparks

and

hot

metal.

2.

Do

not

weld

where

flying

sparks

can

strike

flammable

material.

9.

unknown

paths

and

causing

electric

shock

and

fire

hazards.

.

Do

not

use

welder

to

thaw

frozen

pipes.

3.

Remove

all

flammables

within

35

ft

(10.7

m)

of

thewelding

arc.

If

10.

Remove

stick

electrode

from

holder

or

cut

off

welding

wire

at

this

is

not

possible,

tightly

cover

them

with

approved

covers,

contact

tip

when

not

in

use.

4.

Be

alert

that

welding

sparks

and

hot

materials

from

welding

can

11.

Wear

oil-free

protective

garments

such

as

leather

gloves,

heavy

easily

go

through

small

cracks

and

openings

to

adjacent

areas.

shirt,

cuffless

trousers,

high

shoes,

and

a

cap.

Sri

9/92

CYLINDERS

can

explode

if

damaged.

Shielding

gas

cylinders

contain

gas

under

high

pressure.

If

damaged,

a

cylinder

can

explode.

Since

gas

cylinders

are

normally

part

of

the

welding

process,

be

sure

to

treat

them

carefully.

1.

Protect

compressed

gas

cylinders

from

excessive

heat,

mechanical

shocks,

and

arcs.

2.

Install

and

secure

cylinders

in

an

upright

position

by

chaining

them

to

a

stationary

support

or

equipment

cylinder

rack

to

prevent

falling

or

tipping.

3.

Keep

cylinders

away

from

any

welding

or

other

electrical

circuits.

4.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

5.

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

in

good

condition.

6.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

7.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

in

use

or

connected

for

use.

8.

Read

and

follow

instructions

on

compressed

gas

cylinders,

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

Standards.

ENGINE

EXHAUST

GASES

can

kill.

1.

Use

equipment

outside

in

open,

well-ventilated

areas.

2.

If

used

in

a

closed

area,

vent

engine

exhaust

outside

and

Engines

produce

harmful

exhaust

gases.

away

from

any

building

air

intakes.

ENGINE

FUEL

can

cause

fire

or

1.

Stopenginebeforecheckingoraddingfuel.

explosion.

2.

Do

not

add

fuel

while

smoking

or

if

unit

is

near

any

sparks

or

open

flames.

3.

Allow

engine

to

cool

before

fueling.

If

possible,

check

and

add

Engine

fuel

is

highly

flammable.

fuel

to

cold

engine

before

beginning

job.

4.

Do

not

overfill

tank



allow

room

for

fuel

to

expand.

5.

Do

not

spill

fuel.

If

fuel

is

spilled,

clean

up

before

starting

engine.

MOVING

PARTS

can

cause

injury.

3.

Have

only

qualified

people

remove

guards

or

covers

for

maintenance

and

troubleshooting

as

necessary.

Moving

parts,

such

as

fans,

rotors,

and

belts

can

cut

fingers

and

hands

and

catch

loose

clothing.

SPARKS

can

cause

BATTERY

GASES

TO

EXPLODE;

BATTERY

ACID

can

burn

eyes

and

skin.

Do

not

allow

tools

to

cause

sparks

when

working

on

a

battery.

Do

not

use

welder

to

charge

batteries

or

jump

start

vehicles.

Observe

correct

polarity

(+

and

)

on

batteries.

ir~

~

.

.~

/

STEAM

AND

COOLANT

can

skin.

The

coolant

in

the

r

under

pressure.

PRESSURIZED

HOT

burn

face,

eyes,

and

adiator

can

be

very

hot

and

1.

2.

3.

Donotremoveradiatorcapwhenengineishot.Allowengine

to

cool.

Wear

gloves

and

put

a

rag

over

cap

area

when

removing

cap.

Allow

pressure

to

escape

before

completely

removing

cap.

PRINCIPAL

SAFETY

STANDARDS

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.1,

from

American

Welding

Society,

550

N.W.

LeJeune

Rd,

Miami

FL 33126

Safety

and

Health

Standards,

OSHA

29

CFR

1910,

from

Superinten

dent

of

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

Recommended

Safe

Practices

for

the

Preparation

for

Welding

and

Cutting

of

Containers

That

Have

Held

Hazardous

Substances,

Ameri

can

Welding

Society

Standard

AWS

F4.i

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

I

R3.

Safe

Practices

For

OccupafionAnd

EducationalEyc

And

Face

Protec

tion,

ANSI

Standard

Z87.1,

from

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

Cutting

And

Welding

Processes,

NFPA

Standard

518,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

a

WARNING

ENGINES

can

be

hazardous.

I.

Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

2.

Stoc

enaine

before

installing

or

connecting

unit.

4.

To

prevent

accidental

starting

during

servicing,

disconnect

negative

()

battery

cable

from

battery.

5.

Keep

hands,

hair,

loose

clothing,

and

tools

away

from

moving

parts.

6.

Reinstall

panels

or

guards

and

close

doors

when

servicing

is

finished

and

before

starting

engine.

Batteries

contain

acid

and

generate

explosive

gases.

1.

2.

3.

4.

5.

Always

wear

a

face

shield

when

working

on

a

battery.

Stop

engine

before

disconnecting

or

connecting

battery

cables.

srI

9/92

PRECAUTIONS

DE

SECURITE

EN

SOUDAGE

A

LARC

DESSAI.

LELECTROCUTION

peut

Œtre

mortelle.

Une

decharge

electrique

peut

vous

tuer

ou

vous

briDler

gravement.

LØlectrode

et

le

circuit

de

soudage

sont

sous

tension

au

dØmarrage.

Le

circuit

dentrØe

et

les

circuits

internes

des

matØriels

sont

aussi

sous

tension

des

Ia

mise

en

marche.

En

soudage

automatique

ou

semi-automatique

avec

fil,

ce

dernier,

le

support

de

roquette,

le

logement

des

galets

dentraInement

et

toutes

les

piŁces

metalliques

en

contact

avec

le

tilde

soudage

sont

sous

tension.

Des

matØriels

mal

installØs

ou

mal

mis

a

Ia

terre

sont

dangereux.

1.

Ne

touchez

pas

a

des

piŁces

sous

tension.

2.

Portez

des

gants

et

des

vØtements

isolants,

secs

et

non

trouŁs.

3.

lsolez-vous

de

Ia

tle

a

souder

et

de

Ia

mise

ala

terre

au

moyen

de

petits

tapis

isolants

ou

autres.

4.

DØconnectez

Ia

prise

dentrØe

des

matØriels

ou

arrŒtez

leur

moteur

avant

de

les

installer

ou

den

faire

Ientretien.

LE

SOUDAGE

A

LARC

est

dangereux.

5.

Veillez

a

installer

ces

matØriels

eta

es

mettre

ala

terre

selon

le

manuel

dutilisation

et

es

codes

nationaux,

provinciaux

et

locaux

applicables.

6.

ArrŒtez

tous

les

matØriels

aprŁs

utilisation.

7.

Nutilisez

pas

de

cables

uses,

endommagØs,

mat

ØpissØs

ou

de

calibre

trop

petits.

8.

Nenroulez

pas

de

cables

autour

de

votre

corps.

9.

Mettez

ala

terre

Ia

tote

a

souder

au

moyen

dune

bonne

prise

de

terre.

10.

Ne

touchez

pas

a

lØlectrode

si

vous

Œtes

en

contact

avec

le

circuit

de

soudage

(terre).

11.

Nutilisez

que

des

matØriels

en

bon

Øtat.

ROparez

ou

remplacez

sur-le-champ

les

piŁces

endommagØes.

12.

Portez

un

harnais

de

sØcuritØ

Si

vous

travaillez

en

hauteur.

13.

Fermez

solidement

tous

es

panneaux

et

les

capots.

Le

RAYONNEMENT

DE

LARC

peut

brUler

les

yeux

et

Ia

peau;

le

BRUIT

peut

endommager

IouIe.

Larc

de

soudage

produit

une

chaleur

et

des

rayons

ultraviolets

intenses,

susceptibles

de

brler

les

yeux

et

a

peau.

Le

bruit

cause

par

certains

procØdØs

peut

endommager

louIe.

1.

Portez

un

casque

de

soudeur

avec

Øcran

filtrant

de

teinte

appropriee

(consultez

Ia

norme

ANSI

Z49

indiquØe

ci-apres),

pour

vous

proteger

le

visage

et

les

yeux

lorsque

vous

soudez

ou



I

Les

VAPEURS

ET

LES

FUMEES

sont



dangereuses

pour

Ia

sante.

I!

Le

soudage

dØgage

des

vapeurs

et

des

fumØes

quil

est

dangereux

de

respirer.

1.

Ecartez

le

visage

pour

Øviter

de

respirer

les

fumØes.

2.

A

lintØrieur,

assurez-vous

que

laire

de

soudage

est

bien

ventilØe

ou

que

les

fumØes

et

es

vapeurs

sont

aspirØes

a

arc.

3.

Si

Ia

ventilation

est

mauvaise,

portez

un

respirateur

a

adduction

dair

approuve.

4.

Lisez

es

fiches

signalØtiques

et

les

consignes

du

fabricant

relatives

aux

mØtaux,

aux

produits

consummables,

aux

revŒtements

et

aux

produits

nettoyants.

Le

SOUDAGE

peut

causer

un

incendie

ou

une

explosion.

Larc

produit

des

Øtincelles

et

des

projections.

Avec

Ia

chaleur

intense

degagee

par

Ia

tote

et

es

matØriels,

elles

peuvent

causer

un

incendie

et

des

brlures.

Le

contact

accidentel

de

IØlectrode

avec

un

objet

metallique

peut

provoquer

des

Øtincelles,

un

Øchauffement

ou

un

incendie.

1.

ProtØgez-vous,

ainsi

que

es

autres,

contre

es

Øtincelles

et

les

projections.

2.

Ne

soudez

pas

dans

un

endroit

oiD

des

Øtincelles

peuvent

atteindre

des

matØriaux

inflammables.

3.

Enlevez

toutes

les

matiŁres

intlammables

dans

un

rayon

de

10,7

metres

autour

de

Iarc,

ou

couvrez-les

soigneusement

avec

des

bches

approuvØes.

4.

MØfiez-vous

des

Øtincelles

et

des

Øclats

brCilants,

susceptibles

de

pØnØtrer

dans

des

aires

adjacentes

par

de

petites

ouvertures

ou

fissures.

que

vous

observez

IexØcution

dune

soudure.

-

2.

Portezdes

lunettes

de

sØcuritØ

approuvØes.

Des

Øcrans

latØraux

sont

recommandØes.

3.

Entourez

Iaire

de

soudage

de

rideaux

ou

de

cloisons

de

protection

contre

es

coups

darc

ou

IØblouissement;

avertissez

es

observateurs

de

ne

pas

regarder

arc.

4.

Portez

des

vØtements

en

tissus

ignifuge

durable

(lame

et

cuir)

et

des

chaussures

de

sØcuritØ.

5.

Portez

un

casque

antibruit

ou

des

bouchons

doreille

approuvØs

site

niveau

de

bruit

est

ØlevØ.

5.

Ne

travaillez

dans

un

espace

confine

que

sit

est

bien

ventilØ;

sinon,

portez

un

reSpirateur

adduction

dair.

Les

gaz

protecteurs

de

soudage

peuvent

dØplacer

loxygŁne

de

lair

et

causer

des

blessures

ou

Ia

mort.

Assurez-vous

que

air

est

propre

a

Ia

respiration.

6.

Ne

soudez

pas

a

proximitØ

dopØrations

de

dØgraissage,

de

nettoyage

ou

de

pulvØrisation.

La

chaleur

et

les

rayons

de

Iarc

peuvent

reagir

avec

des

vapeurs

et

former

des

gaz

hautement

toxiques

et

irritants.

7.

Ne

soudez

pas

de

tOles

galvanisØes

ou

plaquees

en

p10mb

ou

en

cadmium

sans

es

avoir

grattees

a

fond,

car

ces

mØtaux,

et

tout

revØtement

qui

en

contient,

peuvent

alors

dØgager

des

fumØes

toxiques.

Assurez-vous

dune

bonne

ventilation

et

portez

un

respirateur

a

adduction

dair

si

cest

nØcessaire.

5.

Mefiez-vous

des

incendies

et

gardez

un

extincteur

a

portee

de

Ia

main.

6.

Noubliez

pas

quune

soudure

sur

un

plafond,

un

plancher,

une

cloison

ou

une

paroi

peut

en

enflammer

Iautre

ctØ.

7.

Ne

soudez

pas

un

recipient

termØ,

comme

un

reservoir

ou

un

tonneau.

8.

Connectez

le

cable

de

soudage

le

plus

pres

possible

de

Ia

tote

de

soudage

pour

empOcher

le

courant

de

suivre

un

parcours

long

et

inconnu,

et

prØvenir

ainsi

tes

risques

dOlectrocution

et

dincendie.

9.

Ne

faites

pas

degeler

des

tuyaux

avec

un

chalumeau.

10.

Videz

votre

carquois

porte-electrodes

ou

coupez

le

fit

au

tube-

contact

aprŁs

le

soudage.

11.

Portez

des

vOtements

protecteurs

non

huileux,

tels

des

gants

en

cuir,

une

chemise

Øpaisse,

un

pantalor,

sans

revers,

des

chaussures

montantes

et

un

casque.

MISE

EN

GARDE

PROTEGEZ-VOUS,

AINSI

QUE

LES

AUTRES,

CONTRE

LES

BLESSURES

GRAVES

POSSIBLES

OU

LA

MORT.

NE

LAISSEZ

PAS

LES

ENFANTS

SAPPROCHER,

NI

LES

PORTEURS

DE

STIMULATEUR

CARDIAQUE

(A

MOINS

QUILS

NAIENT

C0NSL,LTE

UN

MEDECIN).

Le

soudage,

comme

Ia

plupart

des

activitØs

industrielles,

expose

a

certains

risques.

Le

soudage

nest

pas

dangereux

lorsquon

prend

des

precautions.

Les

consignes

di~ØcuritØ

suivantes

ne

font

que

rØsumer

linformation

contenue

dans

les

normes

ØnumØrØes

ci-aprŁs.

Lisez

et

respectez

toutes

ces

normes.

SEULES

DES

PERSONNES

OUALIFIEES

DOIVENT

FAIRE

DES

TRAVAUX

DINSTALLATION,

DE

REPARATION,

DENTRETIEN

ET

=~

Les

BOUTEILLES

endommagØes

peuvent

exploser.

Les

bouteilles

contiennent

des

gaz

protecteurs

sous

haute

pression.

DesbouteillesendommagŁespeuvent

exploser.

Comme

les

bouteilles

font

normalement

partie

du

procede

de

soudage,

traitez-les

avec

soin.

1.

Les

bouteilles

doivent

Œtre

protegees

contre

les

sources

de

chaleur

intense,

les

chocs

et

les

arcs

de

soudage.

2.

EnchaInez

verticalement

es

bouteilles

a

un

support

ou

a

un

cadre

fixe

pour

es

empŒcher

de

tomber

ou

dŒtre

renversØes.

3.

Eioignez

les

bouteilles

de

tout

circuit

Ølectrique

ou

de

soudage.

4.

EmpŒchez

tout

contact

entre

une

bouteille

et

une

electrode.

5.

Nutilisez

que

des

bouteilles

de

gaz

protecteur,

des

dØtendeurs,

des

flexibles

et

des

raccords

concus

pour

chaque

application

spØcifique;

ces

matØriels

et

les

piŁces

connexes

doivent

Œtre

en

bon

etat.

6.

Ne

mettez

pas

le

visage

devant

le

robinet

de

bouteille

en

louvrant.

7.

Remettez

le

chapeau

de

bouteille

aprŁs

utilisation.

8.

Lisez

et

respectez

los

consignes

relatives

aux

bouteilles

de

gaz

comprimØ

et

aux

matØriels

connexes,

ainsi

que

Ia

publication

P-i

de

Ia

CGA,

ŁnumØrees

dans

les

normes

ci-dessous.

Les

GAZ

DECHAPPEMENT

DES

MOTEURS

PEU

VENT

ETRE

MORTELS.

Les

moteurs

produisent

des

gaz

dØchappement

nocifs.

Le

CARBURANT

peut

causer

un

incendie

ou

une

explosion.

Le

carburant

est

hautement

inflammable.

1.

ArrŒtez

le

moteur

avant

de

verifier

le

niveau

de

carburant

ou

de

faire

le

plein.

2.

Ne

faites

pas

le

plein

en

fumant

.ou

proche

dune

source

Des

PIECES

EN

MOUVEMENT

peuvent

causer

des

blessures.

Des

piŁces

en

mouvement,

telles

des

ventilateurs,

des

rotors

et

des

courroies

peuvent

couper

les

doigts

et

es

mains,

ou

accrocher

des

vŁtements

amples.

1.

Assurez-vous

que

les

portes,

les

panneaux,

les

capots

et

les

protecteurs

sont

bien

fermŁs.

2.

Avant

dinstaller

ou

de

connecter

un

systeme,

arrŒtez-en

le

moteur.

3.

Seules

des

personnes

qualifiees

doivent

dØmonter

des

Des

ETINCELLES

peuvent

FAIRE

EXPLOSER

UN

ACCUMULATEUR;

LELECTROLYTE

DUN

ACCUMULATEUR

peut

brUler

Ia

peau

et

les

yeux.

Les

accumulateurs

contiennent

de

lelectrolyte

et

degagent

des

vapeurs

explosives.

1.

Portez

toujoUrs

un

Øcran

facial

en

travaillant

sur

Safety

in

Welding

and

Cutting

norme

ANSI

Z49.

1,

American

Welding

Society,

550,

N.W.

LeJeune

Rd.,

Miami

FL

33128.

Safety

and

Health

Standards

OSHA

29

CFR

1910,

Superintendent

of

Documents,

U.S.

Government

Printing

Office,

Washington

D.C.

20402.

Recommended

Safe

Practices

For

the

Preoaration

For

Welding

and

Cutting

of

Containers

That

Have

Held

Hazardous

Substances

norme

AWS

F4.1,

American

Welding

Society,

550.

NW.

LeJeune

Rd.,

Miami

FL

33128.

Les

MOTEURS

peuvent

Œtre

dangereux.

1.

Utilisez

des

machines

a

lextØrieur

dans

des

aires

ouvertes

et

bien

ventilØes.

2.

Si

vous

utilisez

des

machines

dans

un.

endroit

confine,

les

fumØes

dØchappement

doivent

Œtre

envoyØes

a

lextØrieur,

loin

des

prises

dair

du

btiment.

dØtincelles

ou

dune

flamme

nue.

3.

Si

cest

possible,

laissez

le

moteur

refroidir

avant

de

faire

le

plein

de

carburant

Cu

den

verifier

le

niveau

au

debut

du

soudage.

4.

Ne

faites

pas

le

plein

de

carburant

a

ras

bord

:~prevoyez

de

lespace

pour

son

expansion.

5.

Faites

attention

de

ne

pas

renverserde

carburant.

NettOyez

tout

carburant

renversØ

avant

de

faire

dØmarrer

le

moteur.

protecteurs

ou

des

capots

pourfaire

lentretien

ou

le

depannage

nØcessaire.

4.

Pour

empecher

un

demarrage

accidentel

dun

systŁme

pendant

lentretien,

dŁbranchez

le

cable

daccumulateur

a

Ia

borne

negative.

5.

Napprochez

pas

les

mains

ou

les

cheveux

do

piŁces

en

mouvement;

elles

peuvent

aussi

accrocher

des

vØtements

amples

et

des

outils.

6.

RŁinstallez

les

capots

ou

es

protecteurs

et

fermez

les

portes

aprŁs

des

travaux

dentretien

et

avant

de

faire

dØmarrer

le

moteur.

un

accumulateur.

2.

ArrŒtez

le

moteur

avant

de

connecter

ou

de

dŁconnecter

des

cables

daccumulateur.

3.

Nutilisez

que

des

outils

anti-Øtincelles

pour

travailler

sur

un

accumulateur.

4.

Nutilisez

pas

un

paste

de

soudage

pourchargerun

accumulateur

Cu

connecter

provisoirement

un

vØhicule.

Utilisez

Ia

polarite

correcte

(+

et

-)

de

laccumulateur.

Safe

Handling

of

Compressed

Gases

in

Cylinders

document

P-i,

Compressed

Gas

Association,

1235

Jefferson

Davis

Highway,

Suite

501,

Arlington,

Va

22202.

Code

for

Safety

in

Weldina

and

Cutting

norme

CSA

Wi

17.2,

Asso

ciation

canadienne

de

normalisation,

Standards

Sales,

176

Rexdale

Boulevard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

Safe

Practices

for

Occupation

and

Educational

Eve

and

Face

Protec

Ii~n,

norme

ANSI

Z87.

1

,American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

5.

National

Electrical

Code

norme

70

NFPA,

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

srlf

9/91

Cutting

and

Welding

Processes

norme

51B

NFPA,

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

LES

ETINCELLES

ET

LES

metaL

En

refroidissant,

Pa

soudure

peut

projeter

du

laitier.

PROJECTIONS

BRULANTES

peuvent

causer

des

blessures.

Le

piquage

et

le

meulage

produisent

des

Øclats

de

1.

2.

Portez

un

Øcran

facial

ou

des

lunettes

a

coques

approuvees.

Des

Øcrans

latØraux

sont

recommandØs.

Portez

des

vŒtements

de

protection

individuelle

appropriØs.

MISE

EN

GARDE

La

VAPEUR

ET

LE

LIQUIDE

DE

1.

Ntez

pas

le

bouchon

de

radiateur

tant

que

le

moteur

na

pas

REFROIDISSEMENT

BRULANT

SOUS

PRESSION

peuvent

brler

Ia

peau

et

les

eux

Le

liquide

de

refroidissement

dun

radiateur

peut

etre

2.

3.

refroidi.

Mettez

des

gants

et

posez

un

torchon

sur

le

bouchon

pour

lter.

Laissez

Pa

pression

sØchapper

avant

dter

completement

le

bouchon.

brlant

et

sous

pression.

PRINCIPALES

NORMES

DE

SECURITE

EMF

INFORMATION

TABLE

OF

CONTENTS

SECTION

1



SAFETY

IN

FORMATION

SECTION

2

SPECIFICATIONS

3INSTALLATION

Equipment

Connection

Diagram

Installing

Swivel

Into

Pipe

Post

Installing

Control

Box

Onto

Swivel

Installing

Boom

And

Reel

Support

Installing

Wire

Guide

Extension

Wire

Guide

And

Drive

Roll

Installation

Welding

Gun

Connections

Wire

Feed

Motor

And

Gas

Valve

Control

Connections

Control

Connection

Shielding

Gas

And

Weld

Cable

Connections

Removing

Safety

Collar

And

Adjusting

Boom

Welding

Wire

Installation

Motor

Start

Control

Threading

Welding

Wire

SECTION

4GLOSSARY

14

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

lnverter

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

27

SECTION

8

GETTING

STARTED

8-1.

Welding

With

Only

Front

Panel

Controls

36

8-2.

Setting

Sequence

Pulse

Welding

Parameters

On

Side

Panel

Display

37

OM-1580



10/93

NOTE

~

Considerations

About

Welding

And

The

Effects

Of

Low

Frequency

Electric

And

Magnetic

Fields

The

following

is

a

quotation

from

the

General

Conclusions

Section

of

the

U.S.

Congress.

Office

of

Technology

Assessment,

Biological

Effects

of

Power

Frequency

~lectric

&

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

ofter

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

SECTION

3-1.

3-2.

3-3.

3-4.

3-5.

3-6.

3-7.

3-8.

3-9.

3-10.

3-11.

3-12.

3-13.

3-14.

2

3

4

5

6

7

8

9

10

11

12

17

19

20

21

22

24

SECTION

9-TEACHING

A

PULSE

WELDING

PROGRAM

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

SECTION

11



SETTING

DUAL

SCHEDULE

PARAMETERS

51

SECTION

12

USING

THE

OPTIONAL

DATA

CARD

12-1.

Installing

Data

Card

53

12-2.

Using

The

Data

Card

53

SECTION

13SETUP

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

Voltage

Error

Shutdown

68

13-19.

Selecting

Program

Name

Feature

69

13-20.

Software

Version

Number

69

SECTION

14

MAINTENANCE

&

TROUBLESHOOTING

14-1.

Routine

Maintenance

70

14-2.

Replacing

The

Hub

Assembly

71

14-3.

Overload

Protection

71

14-4.

Error

Displays

72

14-5.

Diagnostic

Indicator

LEDs

73

14-6.

Troubleshooting

74

SECTION

15

ELECTRICAL

DIAGRAMS

76

SECTION

16

PARTS

LIST

Figure

16-1.

Main

Assembly

80

Figure

16-2.

Support,

Hub

&

Reel

83

Figure

16-3.

Control

Box

84

Figure

16-4.

Panel,

Front

w/Cornponents

87

Figure

16-5.

Boom

Assembly

88

Figure

16-6.

Wire

Drive

Assembly

90

Figure

16-7.

Panel,

Side

w/Components

92

Table

16-1.

Drive

Roll

And

Wire

Guide

Kits

93

SECTION

1



SAFETY

IN

FORMATION

Figure

1-1.

Safety

Information

modl.1

2/93

1

Safety

Alert

Symbol

2

Signal

Word

WARNING

means

possible

death

or

serious

injury

can

happen.

CAUTION

means

possible

minor

injury

or

equipment

damage

can

happen.

3

Statement

Of

Hazard

And

Result

4

Safety

Instructions

To

Avoid

Hazard

5

Hazard

Symbol

(If

Available)

6

Safety

Banner

Read

safety

blocks

for

each

sym

bol

shown.

7

NOTE

Special

instructions

for

best

oper

ation



not

safety.

SECTION

2

SPECIFICATIONS

Table

2-1.

Wire

Feeder

These

are

wire

feed

speed

ranges

for

GMAW.

While

Pulse

welding.

wire

feed

speed

ranges

may

be

more

limited

(see

Section

9).

OM-1588

Page

1



Read

all

safety

messages

throughout

this

manual.



Obey

all

safety

messages

to

avoid

injury.



Learn

the

meaning

of

WARNING

and

CAUTION.

2

a

WARNING

2

a

CAUTION

L

~

ELECTRIC

SHOCK

can

kiII.~~

~

_______________________________



Keep

away

from

moving

parts.



Oo

not

touch

live

electrical

parts



Oisconnect

input

power

beforej~

4

MOVING

PARTS

can

injure.



Keep

all

panels

and

covers

closed

when

operating

nstalling

or

servicing

/

5

READ

SAFETY

BLOCKS

at

start

of

Section

3-1

before

proceeding.

7H

NOTE

~

Turn

Off

switch

when

using

high

frequency.

Specification

Description

Type

Of

Input

Power

From

Welding

Power

Source

Maximum

Weld

Circuit

Rating

Welding

Power

Source

Type

Wire

Feed

Speed

Range*

Wire

Diameter

Range

Welding

Processes

Input

Power

Cord

Maximum

Height

With

4

ft

(1.2

m)

Post

Weight

Vertical

Lift

Of

Boom

Single-Phase

24

Volts

AC.

10

Amperes,

50/60

Hertz

100

Volts,

750

Amperes,

100%

Duty

Cycle

Constant

Voltage

(CV)

DC,

With

Contactor

Standard:

5OTo

780

ipm

(1.3

To

19.8

mpm)

High

Speed:

92

To

1435

ipm

(2.3

To

36.5

mpm)

Low

Speed:

13

To

213

ipm

(0.3470

5.38

mpm)

.023

Thru

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)

12

ft

(3.7

m)

Boom

17ft(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

(6.4

m)

Net:

280

lb

(127

kg)

Ship:

411

lb

(186

kg)

Horizontal

To

60

Above

Horizontal

SECTION

3INSTALLATION

3-1.

Equipment

Connection

Diagram

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,

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

feeder

and

welding

power

source,

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.

2

wfwarn91

2/93

4

1

Welding

Power

Source

2

Remote

14

Connections

3

Negative

()

Weld

Output

Cable

4

Positive

(+)

Weld

Output

Cable

5

Workpiece

6

Voltage

Sensing

Clamp

7

Weld

Control

8

Boom

9

Gun

10

Swivel

11

Pipe

Post

And

Base

12

Gas

Hoses

12

13

Gas

Supplies

5T-800

173

10

11

9

Figure

3-1.

Typical

System

Connections

OM-1

588

Page

2

3-2.

Installing

Swivel

Into

Pipe

Post

a

WARNiNG

I.

RELEASE

OF

SPRING

PRESSURE

WITHOUT

BOOM

ATTACHED

can

cause

serious

personal

injury.



Do

not

remove

safety

collar

until

instructed

to

do

so.

FALLING

BOOM

can

cause

serious

personal

injury

and

equipment

damage.



Securely

mount

pipe

post

to

base

that

can

support

weight

of unit

with

boom

in

horizontal

position.



Use

proper

equipment

for

lifting

swivel

and

boom

into

place.

Figure

3-2.

Swivel

Installation

Figure

3-3.

Control

Box

Installation

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

3-3.

Installing

Control

Box

Onto

Swivel

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-BOO

174

4

OM1588

Page

3

3-4.

InstaHing

Boom

And

Reel

Support

READ

SAFETY

BLOCKS

at

start

of

Section

3-2

before

proceeding.

Figure

3-4.

Boom

Installation

1

Swivel

Plates

2

Yoke

Remove

hardware

from

swivel

plates

and

yoke.

3

Boom

7

Set

boom

into

swivel

as

shown.

4

Yoke

Install

through

yoke.

Install

cot

ter

and

spread

ends.

5

Bolt

Install

bolt,

washers,

and

nut.

lighten

hardware,

and

back

bolt

off

one

half

turn.

6

Locking

Knob

Install

locking

knob

but

do

not

tighten.

7

Reel

Support

Install

reel

support.

Tools

Needed:

~

3/8,3/41n

S~-153

170

3-5.

Installing

Wire

Guide

Extension

1

Wire

Guide

Fitting

2

Bolt

3

Monocoil

Liner

4

Wire

Guide

Extension

lighten

bolt

to

secure

liner

in

wire

guide

fitting.

Do

not

overtighten

bolt

and

crush

liner.

Repeat

procedure

for

opposite

side.

5T-152

383

Tools

Needed:

~T.~~J==~O

3/8

in

Figure

3-5.

Wire

Guide

Extension

Installation

OM-1588

Page

4

3-6.

Wire

Guide

And

Drive

Roll

Installation

a

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.

A.

Wire

Guide

Installation

B.

Drive

Roll Installation

Figure

3-6.

Wire

Guide

Installation

Figure

3-7.

Drive

Roll

Installation

wtwłrnl.1

2/93

When

changing

wire

size

or

type,

check

guide

size

(see

Table

16-1).

1

Drive

Rolls

Remove

drive

rolls

before

installing

wire

guides

(see

Figure

3-7).

2

Wire

Guide

Securing

Screws

Loosen

wire

guide

screws.

3

Inlet

Wire

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

597A

Tools

Needed:

5

4

~



When

chaRging

wire

size

or

type,

check

drive

roll

size

(see

Table

16-1).

1

Spring

Shaft

Carrier

2

Drive

Roll

Nut

3

Drive

Roll

Carrier

Turn

all

nuts

one

click

until

lobes

of

nut

line

up

with

lobes

of

drive

roll

carrier.

4

Drive

Roll

Slide

drive

rolls

onto

drive

roll

carri

ers.

Turn

nut

one

click.

5

Drive

Assembly

Cover

Close

cover.

Repeat

procedure

for

opposite

side

of

wire

feeder.

ST.142

597-A

2

3

OM-1588

Page

5

3-7.

Welding

Gun

Connections

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.

___

a

WARNING

wfw~rn1

.1

2/93

4

3

I

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

recep

tacle

and

tighten

threaded

collar.

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

site

drive

assembly.

Ref.

ST

152

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

Figure

3-9.

Boom

Connections

OM-1588

Page

6

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