Miller KF844784 Le manuel du propriétaire

Miller

April

1995

Form:

OM-1583G

Effective

With

Serial

No.

KF844784

OWNERS

MANUAL

U



Read

and

follow

these

instructions

and

all

safety

blocks

carefully.

Have

only

trained

and

qualified

persons

install,

operate,

or

service

this

unit.

Call

your

distributor

if

you

do

not

understand

the

directions.

.A



Give

this

manual

to

the

operator.



For

help,

call

your

distributor



or

MILLER

Electric

Mfg.

Co.,

P0.

Box

1079,

Appleton,

WI

54912

414-734-9821

&

SWINGARCTM

SS-12

And

SS-16



24

Volts,

10

Amperes,

50/60

Hertz

Boom

Mounted

Wire

Feeder



For

Use

With

CV/DC

Welding

Power

Source

With

Contactor



For

GMAW

And

FCAW

Welding



Rated

At

100

Volts,

750

Amperes,

100%

Duty

Cycle



Wire

Feed

Speed

Range:

50

To

780

ipm

(1.3

To

19.8

mpm)



Wire Diameter

Range:

.023

To

1/8

in

(0.6

To

3.2

mm)



Vertical

Lift

Of

Boom:

Horizontal

To

60

Above

Horizontal



For

Options

And

Accessories,

See

Rear

Cover

cover

5/94



ST-142

705-B

'

1995

MILLER

Electiic

Mfg.

Co.

PRINTED

IN

USA

I

tax

Effective

January

1,

1995

(Equipment

with

a

serial

number

preface

of

KD

or

newer)

This

limited

warranty

supersedes

all

warranties

and

is

exclusive

with

no

other

guarantees

or

warranties

expressed

or

implied.

LIMITED

WARRANTY

Subject

to

the

terms

and

conditions

below,

MILLER

Electric

Mtg.

Co.,

Appleton,

Wisconsin,

warrants

to

its

original

retail

purchaser

that

new

MILLER

equipment

sold

after

the

effective

date

of

this

limited

warranty

is

free

of

de

tests

in

material

and

workmanship

at

the

time

it

is

shipped

by

MILLER.

THIS

WAR

RANTY

IS

EXPRESSLY

IN

LIEU

DF

ALL

OThER

WARRAN11ES,

EXPRESS

DR

IMPUED,

INCLUDING

THE

WARRAN11ES

OF

MERCHANTABIUTY

AND

FIT

NESS.

Within

the

warranty

periods

listed

below,

MILLER

will

repair

or

replace

any

war

ranted

parts

or

components

that

fail

due

to

such

defects

in

material

or

workmanship.

MILLER

must

be

notified

in

writing

within

thirty

(30)

days

of

such

detect

or

failure,

at

which

time

MILLER

will

provide

instructions

on

the

warranty

claim

procedures

to

be

followed.

MILLER

shall

honor

warranty

claims

on

warranted

equipment

listed

below

in

the

event

of

such

a

failure

within

the

warranty

time

periods.

All

warranty

time

periods

start

on

the

date

that

the

equipment

was

delivered

to

the

original

retail

purchaser,

or

one

year

after

the

equipment

is

sent

to

a

North

American

distributor

or

eighteen

months

after

the

equipment

is

sent

to

an

Intemational

distributor.

1.

SYearaParts3YearsLabor



Original

main

power

rectifiers

2.

3

Years



Parts

and

Labor



Transformer/Rectifier

Power

Sources



Plasma

Arc

Cutting

Power

Sources

*

Semi-Automatic

and

Automatic

Wire

Feeders

*

Robots

3.

2

Years



Parts

and

Labor



Engine

Driven

Welding

Generators

(NOTE:

Engines

are

warranted

separately

by

the

engine

manufacturer.)



Air

Compressors

4.

1

Year



Parts

and

Labor



Motor

Driven

Guns

*

Process

Controllers



IHPS

Power

Sources

*

Water

Coolant

Systems

*

HFUnils



Grids



Spot

Welders

*

Load

Banks



SDX

Transformers



Running

Gear/Trailers



Plasma

Cutting

Torches

(except

APT,

ZIPCUT

&

PLAZCUT

Models)



Tecumaeh

Engines



Deutz

Engines

(outside

North

America)



Field

Options

(NOTE:

Field

options

are

covered

under

True

BtueTM

for

the

remaining

warranty

period

of

the

product

they

are

installed

in,

or

for

a

minimum

of

one

year



whichever

is

greater.)

5.

6

Months



Batteries

a]

6.

90

Days



Parts

and

Labor



HG

Guns/tlG

Torches

APT,

ZIPCUT

&

PLAZCUT

Model

Plasma

Cutting

Torches



Remote

Controls



Accessory

Kits



Replacement

Parts

MILLERS

True

BIueTM

Umited

Warranty

shall

not

apply

to:

1.

items

fumished

by

MILLER,

but

manufactumd

by

others,

such

as

engines

or

trade

accessories.

These

items

are

covered

by

the

manufacturers

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

improperty

installed,

improperiy

operated

or

misused

based

upon

industry

standards,

or

equipment

which

has

not

had

reasonable

and

necessary

maintenance,

orequipment

which

has

been

used

for

operation

outside

of

the

specifications

for

the

equipment.

MILLER

PRODUCTS

ARE

INTENDED

FOR

PURCHASEAND

USE

BYCOMMER

CIAL?1NDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

IN

THE

USE

AND

MAINTENANCE

OF

WELDING

EOUIPMENt

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

reasonable

cost

of

repair

or

replace

ment

at

an

authorized

MILLER

service

station;

or

(4)

payment

of

orcredit

forthe

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

mtum

of

the

goods

at

customers

risk

and

expense.

MILLERS

option

of

repair

or

replacement

will

be

FOB.,

Factonj

at

Appleton,

Wisconsin,

or

FOB.

ate

MILLER

authorized

ser

vice

facility

as

determined

by

MILLER.

Therefore

no

compensation

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

REMEDIES.

IN

NO

EVENT

SHALL

MILLER

BE

UABLE

FOR

DIRECT,

INDIRECT,

SPECIAL,

INCIDENTALOR

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

IMPLIED

WAR

RANTY,

GUARANTY

OR

REPRESENTA11ON

ASTO

PERFORMANCE,

AND ANY

REMEDY

FOR

BREACH

OF

CONTRACT

TORT

OR

ANY

OTHER

LEGAL

THEORY

WHICH,

BUT

FOR

THIS

PROVISION,

MIGI-fT

ARISE

BY

IMPUCA11ON,

OPERA11ON

OF

LAW,

CUSTOM

OF

TRADE

OR

COURSE

OF

DEALING,

IN

CLUDING

ANY

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OR

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

10

ANY

AND

ALL

EOUIPMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

AND

DISCLAIMED

BY

MILLER.

Some

states

in

the

U.S.A.

do

not

allow

timitations

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

Conads,

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

and

exclusions

set

out

above

may

not

apply.

This

Limited

Warranty

provides

specific

legal

rights,

and

other

rights

may

be

available,

but

may

~~very

from

province

to

province.

RECEIVING-HANDLING

Before

unpaCk(ng

equipment,

check

carton

for

any

damage

that

may

have

occurred

during

sh)pment.

Fi(e

any

claims

for

loss

or

damage

with

the

delivering

carrier

Assistance

(or

filing

or

settling

claims

may

be

obtained

from

distributor

and/or

equipment

manufacturers

Transportation

Department.

When

requesting

information

about

this

equipment,

always

provide

Model

Designation

and

Serial

or

Style

Number.

Use

the

following

spaces

to

record

Model

Designation

and

Serial

or

Style

Numberof

your

unit.

The

information

is

located

on

the

rating

label

or

nameplate.

Model

_________

Serial

or

Style

No.

Date

of

Purchase

J

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

I

1~.

miller

4/95

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.

Lockout/tagout

input

poweraccording

to

OSHA

29

CFR

1910.147

(see

Safety

Standards).

5.

Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual

and

national,

state,

and

local

codes.

6.

Always

verify

the

supply

ground



check

and

be

sure

that

input

power

cord

ground

wire

is

properly

connected

to

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

burn

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

Chipping,

grinding,

and

welds

cooling

throw

off

pieces

of

metal

or

slag.

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

(MSDSs)

and

the

manufacturer~s

instruction

for

metals,

consumables,

coatings,

cleaners,

and

degreasers.

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.

Turn

off

all

equipment

when

not

in

use.

10.

Do

not

use

worn,

damaged,

undersized,

or

poorly

spliced

cables.

11.

Do

not

drape

cables

over

your

body.

12.

If

earth

grounding

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

protectyourface

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

bamers

to

protect

others

from

flash

and

glare;

warn

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

containing

these

elements

can

give

off

toxic

fumes

if

welded.

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.

I

15.

16.

17.

:~k~

NOISE

3.

4.

ear

plugs

or

ear

muffs

if

noise

level

is

high.

s-s

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.

CYLINDERS

can

explode

if

damaged.

4.

Never

drape

a

welding

torch

over

a

gas

cylinder.

Shielding

gas

cylinders

contain

gas

under

high

5.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

pressure.

If

damaged,

a

cylinder

can

explode.

Since

6.

Never

weld

on

a

pressurized

cylinder



explosion

will

result.

gas

cylinders

are

normally

part

of

the

welding

process,

be

sure

to

treat

them

carefully.

7.

Useonlycorrectshieldinggascylinders,

regulators,

hoses,

and

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

in

good

condition.

1.

Protect

compressed

gas

cylinders

from

excessive

heat,

8.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

mechanical

shocks,

slag,

open

flames,

sparks,

and

arcs.

9.

Keepprotectivecapinplaceovervalveexceptwhencylinderis

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.

SPARKS

can

cause

BATTERY

GASES

TO

EXPLODE;

BATTERY

ACID

can

burn

eyes

and

skin.

Batteries

contain

acid

and

generate

explosive

gases.

STEAM

AND

PRESSURIZED

HOT

COOLANT

can

burn

face,

eyes,

and

skin.

It

is

best

to

check

coolant

level

when

engine

is

cold

to

avoid

scalding.

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

cut

oft

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.

Always

wear

a

face

shield

when

working

on

a

battery.

Stop

engine

before

disconnecting

or

connecting

battery

cables.

3.

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.

1.

If

the

engine

is

warm

and

checking

is

needed,

follow

steps

2

and

3.

2.

Wear

safety

glasses

and

gloves

and

put

a

rag

over

cap.

3.

Tum

cap

slightly

and

let

pressure

escape

slowly

before

completely

removing

cap.

PRINCIPAL

SAFETY

STANDARDS

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.

1,

from

American

Welding

Society,

550

N.W.

LeJeune

Ad,

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

NW.

LeJeune

Ad,

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

Jefterson

Davis

High

way,

Suite

501,

Arlington,

VA

22202.

Code

for

Safety

in

Welding

and

Cutting,

CSA

Standard

Wi

17.2,

from

Canadian

Standards

Association,

Standards

Sales,

178

Rexdale

Bou

levard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

Safe

Practices

ForOccupationAnd

Educational

EyeAnd

Face

Protec

tion,

ANSI

Standard

Z87.l,

from

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

Cutting

And

Welding

Processes,

NFPA

Standard

51

B,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

£~

WARNING

ENGINES

can

be

hazardous.

ENGINE

EXHAUST

GASES

can

kill.

1.

Use

equipment

outside

in

open,

well-ventilated

areas.

Engines

produce

harmful

exhaust

gases.

2.

If

used

in

a

closed

area,

vent

engine

exhaust

outside

and

away

from

any

building

air

intakes.

ENGINE

FUEL

can

cause

fire

or

explosion.

3.

4.

A

Engine

fuel

is

highly

flammable.

1.

2.

Stop

engine

and

let

it

cool

off

before

checking

or

adding

fuel.

Do

not

add

fuel

while

smoking

or

if

unit

is

near

any

sparks

or

open

flames.

Do

not

overfill

tank



allow

room

for

fuel

to

expand.

Do

not

spill

fuel.

If

fuel

is

spilled,

clean

up

before

starting

engine.

~

MOVING

PARTS

can

cause

injury.

Moving

parts,

such

as

fans,

rotors,

and

belts

can

cut

fingers

and

hands

and

catch

loose

clothing.

1.

Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

2.

Stop

eng

ne

before

installing

or

connecting

unit.

3.

Have

only

qualified

people

remove

guards

or

covers

for

maintenance

and

troubleshooting

as

necessary.

4.

To

prevent

accidental

starting

during

servicing,

disconnect

negative

()

battery

cable

from

battery.

5.

Keep

hands,

hair,

loose

clothing,

and

toots

awayfrom

moving

parts.

6.

Reinstall

panels

or

guards

and

close

doors

when

servicing

is

finished

and

before

starting

engine.

1.

2.

4.

5.

sIll

.1

2/94

CONSIGNES

DE

SECURITE

POUR

LE

SOUDAGE

A

LARC

UN

CHOC

ELECTRIQUE

peut

tuer.

Un

simple

contact

avec

des

piŁces

Ølectriques

peut

provoquer

une

electrocution

ou

des

blessures

graves.

Lelectrode

et

le

circuit

de

soudage

sont

sous

tension

des

que

lappareil

est

surON.

Le

circuit

dentrŁe

et

les

circuits

intemes

de

lappareil

sont

egalement

sous

tension

a

ce

moment-l.

En

soudage

semi-automatique

ou

automatique,

le

fil,

le

devidoir,

le

logement

des

galets

dentrainement

et

les

piŁces

mŁtalliques

en

contact

avec

le

fil

de

soudage

sont

sous

tension.

Des

matŁriels

mal

installŁs

ou

mal

mis

a

Ia

terre

presentent

un

danger.

1.

Ne

jamais

toucher

les

piŁces

Łlectriques

sous

tension.

2.

Porter

des

gants

et

des

vŁtements

de

protection

secs

ne

comportant

pas

de

trous.

3.

Sisoler

de

Ia

piŁce

et

de

Ia

terre

au

moyen

de

tapis

ou

dautres

moyens

isolants

suffisamment

grands

pour

empŁcher

le

contact

physique

Łventuel

avec

Ia

piŁce

ou

Ia

terre.

4.

Couper

lalimentation

ou

arrŁter

le

moteur

avant

de

proceder

a

linstallation,

a

Ia

reparation

ou

a

lentretien

de

lappareil.

DŁverrouiller

lalimentation

selon

Ia

norme

OSHA

29

CPA

1910.147

(voir

norrnes

de

sŁcuritŁ).

5.

Installer

et

mettre

ala

terre

correctement

cet

appareil

confomiement

a

son

manuel

dutilisation

et

au

codes

nationaux,

provinciaux

et

municipaux.

6.

Toujours

verifier

Ia

terre

du

cordon

dalimentation



Verifier

et

que

le

fil

de

terre

du

cordon

dalimentation

est

bien

LE

RAYONNEMENT

DE

LARC

peut

brler

les

yeux

et

Ia

peau.

Le

BRUIT

peut

endommager

IouIe;

les

PROJECTIONS

DE

LAITIER

OU

LES

ETINCELLES

peuvent

blesser

les

yeux.

Larc

de

soudage

produit

des

rayons

visibles

et

invisibles

intenses

(ultraviolets

et

infrarouges)

qui

peuvent

brOler

les

yeux

et

Ia

peau.

Le

bruit

produit

par

certains

procŁdŁs

peut

endommager

loute.

Des

projections

de

metal

ou

de

laitier

sont

produites

par

le

piquage,

le

meulage

ou

le

refroidissement

des

soudures.

Utiliserdes

bouche-oreilles

ou

des

serre-tŁte

antibruit

approuves

si

le

niveau

de

bruit

est

ŁlevŁ.

LES

VAPEURS

rr

LES

FUMEES

peuvent

Œtre

dangereuses

pour

Ia

sante.

1.

Garder

Ia

tŁte

a

IextŁrieur

des

vapeurs

et

des

fumŁes

et

ne

pas

les

respirer.

2.

A

lintŁrieur,

ventiler

le

poste

de

travail

ou

utiliser

un

dispositif

place

au

niveau

de

lam

pour

Łvacuer

les

vapeurs

et

fumŁes

de

soudage.

3.

Si

Ia

ventilation

est

mauvaise,

utiliser

un

appareil

respiratoire

a

adduction

dair

pur

approuve.

4.

Consulter

les

fiches

signaletiques

et

les

consignes

du

fabricant

relatives

au

metaux,

produits

dapport,

revŁtements,

nettoyants

et

dŁgraissants.

LES

BOUTEILLES

peuvent

expioser

Si

eVes

sont

endommagØes.

Les

bouteilles

contenant

des

gaz

de

protection

sont

a

haute

pres~ion.

Une

bouteille

endommagŁe

peut

exploser.

Etant

donne

que

les

bouteilles

de

gaz

font

normalement

partie

du

materiel

de

soudage,

les

traiter

___________

avec

le

plus

grand

soin.

1.

ProtŁger

Ies

bouteilles

de

gaz

comprime

contra

Ia

chateur

intense,

les

chocs,

Ie

laitier,

les

ftammes

nues,

les

Łtincelles

et

larc.

2.

Placer

les

bouteilles

ala

verticale

en

les

fixant

a

un

support

fixe

ou

a

un

chariot

pour

evfter

quelles

ne

tombeni

ou

ne

bascutent.

3.

Tenir

les

bouteilles

a

Iecart

du

poste

de

soudage

ou

dautres

circuits

Łlectriques.

raccorde

ala

bome

de

terre

du

sectionneurou

que

Ia

fiche

du

cordon

est

raccordŁe

a

une

prise

correctement

mise

a

Ia

terre.

7.

En

effectuant

les

raccordements

dentrŁe

fixer

dabord

le

conducteur

de

mise

a

Ia

terre

appropriŁ

et

contre-vŁrifier

es

connexions.

8.

VerifierfrŁquemment

le

cordon

dalimentation

pour

voir

sil

nest

pas

endommagŁ

ou

dŁnudŁ



remplacer

le

cordon

immŁdiatement

siI

est

endommagŁ



un

cable

dŁnudŁ

peut

provoquer

une

electrocution.

9.

Mettre

lappareil

hors

tension

quand

on

ne

Iutilise

pas.

10.

Ne

pas

utiliser

des

cables

uses,

endommagŁs,

de

grosseur

insuffisante

ou

mal

ŁpissŁs.

11.

Ne

pas

enrouler

les

cables

autour

du

corps.

12.

Si

Ia

piŁce

soudŁe

doit

Łtre

mise

ala

terre,

le

faire

directement

avec

un

cable

distinct



ne

pas

utiliser

le

connecteur

de

piŁce

ou

le

cable

de

retour.

13.

Ne

pas

toucher

IŁlectrode

quand

on

est

en

contact

avec

Ia

piŁce,

Ia

terre

ou

une

electrode

provenant

dune

autre

machine.

14.

Nutiliser

quun

materiel

en

bon

Łtat.

RŁparer

ou

remplacer

sur-le-champ

les

piŁces

endommagŁes.

Entretenir

Iappareil

conformŁment

a

ce

manuel.

15.

Porter

un

hamais

de

securite

quand

on

travaille

en

hauteur.

16.

Maintenir

solidement

en

place

tousles

panneaux

et

capots.

17.

Fixer

le

cable

de

retourde

faon

aobtenir

un

bon

contact

metal-metal

avec

Ia

piŁce

a

souderou

latable

detravail,

le

plus

prŁs

possible

de

Ia

soudure.

RAVONNEMENT

DE

LARC

2.

Porter

un

masque

a

serre-tete

muni

dun

verre

filtrant

de

nuance

appropriŁe

pour

proteger

le

visage

et

les

yeux

quand

on

soude

ou

observe

Ia

travail

de

soudage

(voir

les

normes

ANSI

Z49.1

et

Z87.1

donnees

sous

Ia

rubrique

Principales

normes

de

securite).

Porter

des

lunettes

de

sŁcurite

approuvees

avec

ecrans

Iateraux.

Utiliser

des

paravents

ou

des

barriŁres

de

protection

pour

proteger

les

personnes

a

proximitŁ

contra

les

coups

dam

et

Ieblouissement;

avertir

les

autres

personnes

de

ne

pas

regarder

larc.

5.

Porter

des

vOtements

de

protection

en

tissu

ignifuge

durable

(lame

et

cuir)

et

des

chaussures

de

securitŁ.

5.

Ne

travailler

dans

un

espace

confine

que

sil

est

bien

ventile,

ou

en

portant

un

appareil

respiratoire

a

adduction

dairpur.

Demander

a

un

observateur

ayant

reu

Ia

bonne

formation

de

toujours

se

tenir

a

proximite.

Les

vapeurs

et

fumŁes

de

soudage

peuvent

dŁplacer

Iair

et

abaisser

le

niveau

doxygŁne

et

causerdes

blessures

gravesvoire

mortelles.

Sassurer

que

Iair

est

propre

a

Ia

respiration.

6.

Ne

pas

souder

~

proximite

dopŁrations

de

dŁgraissage,

de

nettoyage

ou

de

pulvŁrisation.

La

chaleur

et

les

rayons

de

lam

peuvent

reagir

avec

les

vapeurs

pour

tormer

des

gaz

hautement

toxiques

et

irritants.

7.

Ne

pas

souder

sur

des

mŁtaux

revŒtus

comme

lacier

galvanise,

au

p10mb

ou

cadmiŁ

a

moms

que

Ia

piŁce

naitŁtŁ

entiŁrementdecapŁe,

que

le

poste

de

travail

soft

bien

ventilŁ.

SiI

y

a

lieu,

porter

un

appareil

respiratoire

a

adduction

dair

pur.

Les

revetements

et

les

mŁtaux

qui

contiennent

de

tels

elements

peuvent

dŁgager

des

vapeurs

toxiques

lore

du

soudage.

4.

Ne

jamais

poser

un

chaiumeau

soudeur

sur

une

bouteille

de

gaz.

5.

Ne

jamais

laisser

une

electrode

de

soudage

toucher

une

bouteille.

6.

Ne

jamais

souder

sur

une

bouteille

sous

prassion

:

elle

exploserait.

7.

Nutiliser

que

des

bouteilles

de

gaz

de

protection,

des

dŁtendeurs,

des

tuyaux

souples

et

des

raccords

appropriŁs

conus

pour

Iapplication

particuliŁre;

conserver

ces

materiels

et

Ieurs

piŁces

en

bon

Łtat.

8.

Eloigner

le

visage

de

Ia

sortie

du

robinet

de

Ia

bouteille

quand

on

Iouvre.

9.

Replacer

le

chapeau

sur

Ia

bouteille

aprŁs

utilisation.

10.

Lire

et

suivre

les

consignes

relatives

aux

bouteilles

de

gazcomprime,

au

materiel

connexe

ainsi

que

Ia

publication

P-i

de

Ia

CGA

donnŁe

sous

Ia

rub

rique

Principales

normes

de

securitŁ.

______________

a

MISE

EN

GARDE

LE

SOUDAGE

A

LARC

peut

Œtre

dangereux.

SE

PROTEGER

Er

PROTEGER

LES

AUTRES

CONTRE

LES

BLESSURES

GRAVES

VOIRE

MORTELLES.

TENIR

LES

ENFANTS

A

LECA~Rt

LES

PERSONNES

GUI

PQRTENT

UN

STIMULATEUR

CARDIAQUE

NE

DOIVENT

PAS

NON

PLUS

SAPPROCHER

DU

POSTE

DE

SOUDAGE,

A

MOINS

DAVOIR

CONSULTE

UN

MEDECIN.

Le

soudage,

comme

Ia

plupart

des

travaux,

presente

certains

dangers.

Par

contre,

le

soudage

peut

Łtre

effectuØ

en

toute

sŁcuritØ

quand

on

prend

les

mesures

qui

simposent.

Les

consignes

de

sŁcuritØ

donnØes

ci-aprŁs

ne

font

que

resumer

linformation

contenue

dans

les

normes

de

sŁcuritŁ

ŁnumerŁes

a

Ia

page

suivante.

Lire

et

respecter

toutes

ces

norrnes

de

sŁcuritO.

LINSTALLATION,

LUTILISATION,

LENTRETIEN

ET

LES

REPARATIONS

NE

DOIVENT

ETRE

CONFIES

QUA

DES

PERSONNES

QUALIFIEES

I

BRUIT

3.

4.

Le

soudage

produit

des

vapeurs

et

des

fumees

quiI

est

dangereux

de

respirer.

srl.1.1

2/94

LE

SOUDAGE

peut

causer

un

incendie

ou

une

explosion.

Ne

pas

souder

sur

des

recipients

femiØs

comme

des

reservoirs,

des

tOts

ou

des

tuyaux:

us

peuvent

exploser.

Larc

de

soudage

peut

produire

des

Otincelles.

Des

Øtincelles,

une

piŁce

chaude

et

un

materiel

chaud

peuvent

provoquer

des

incendies

et

des

blessures.

Le

contact

accidentel

de

lØlectrode

sur

des

objets

mØtalliques

peut

produire

des

Øtincelles,

explosion,

Ia

surchauffe

ou

un

incendie.

Sassurer

que

le

lieu

ne

presente

pas

de

danger

avant

deffectuer

le

soudage.

1.

Se

protegeret

proteger

les

personnes

a

proximite

des

Øtincelleset

du

metal

chaud.

2.

Ne

pas

souder

dans

un

endroit

oO

es

Øtincelles

peuvent

atteindre

des

matOnaux

inflammables.

3.

Enlevertoutes

les

matiŁres

inflammables

dans

un

rayon

de

moms

de

10

m

de

larc.

Si

cela

nest

pas

possible,

bien

es

recouvrir

en

utilisant

des

bches

approuvees.

4.

Prendre

garde

que

les

Øtincelles

et

es

projections

ne

penØtrent

dans

des

zones

adjacentes

en

sinfiltrant

dans

des

petites

fissures

et

ouvertures.

5.

Prendre

garde

aux

incendies

et

toujours

avoir

un

extincteur

a

proximite.

6.

Se

rappelerque

si

Ion

soude

sur

un

plafond,

un

plancher,

une

cloison

ou

autre,

le

feu

peut

prendre

de

lautre

ctØ.

7.

Ne

pas

souder

sur

des

recipients

fernies

comme

des

reservoirs,

des

fOts

ou

des

tuyaux

a

moms

quits

ne

soient

prepares

de

faon

appropnØe

conformØment

ala

norme

F4.

1

de

lAWS

(voir

Ia

rubnque

Principales

normes

de

sØcurite).

8.

Raccorder

le

cable

de

retour

a

Ia

piŁce,

le

plus

pres

possible

de

Ia

zone

de

soudage,

pour

empØcher

que

le

courant

de

soudage

ne

suive

une

trajectoire

longue

et

Øventuellement

inconnue

et

quil

ne

provoque

des

nsques

dØlectrocution

et

dincendie.

9.

Ne

pas

utiliser

le

chalumeau

soudeur

pour

degeler

des

tuyaux.

10.

Enlever

IØlectrode

enrobØe

du

porte-electrode

ou

couper

le

fil

de

soudage

au

ras

du

bec

contact

quand

on

ne

lutilise

pas.

11.

PorterdesvŒtements

de

protection

non

huileux

comme

des

gants

en

cuir,

une

chemise

Øpaisse,

des

pantalons

sans

revers,

des

chaussures

montantes

et

un

casque.

12.

Ne

pas

porter

des

matiŁres

combustibles

sursoi

comme

un

briquet

a

ciaz

ou

des

allumettes

quand

on

soude.

a

MISE

EN

GARDE

LES

MOTEURS

peuvent

presenter

un

danger.

1

,

~

LES

GAZ

DECHAPPEMENT

DES

MOTEURS

1.

Utiliser

le

materiel

a

lextØrieur,

dans

des

Ileux

ouverts

et

bien

peuvent

Œtre

mortels.

ventilØs.

2.

Si

on

utilise

un

moteur

dans

un

local

ferrnØ,

Øvacuer

les

gaz

Les

moteurs

produisent

des

gaz

dØchappement

nocifs.

dechappement

a

lextØneur

et

loin

des

pnses

dair

du

btiment.

~g

1.

ArrŒter

le

carburant

LE

CARBURANT

peut

provoquer

un

incendie

2.

Nepasfumerenfaisantleplemnousilappareilsetrouveaproximite

ou

une

explosion.

dØtincelles

ou

de

flammes

nues.

Le

carburant

est

hautement

inflammable.

3.

Ne

pas

remplir

le

reservoir

a

ras

bord:

prØvoir

de

lespace

pour

Ia

dilatation

du

combustible.

moteur

et

le

laisser

refroidir

avant

de

verifier

le

niveau

de

4.

Ne

pas

renverser

du

carburant.

Si

on

renverse

du

carburant,

ou

de

refaire

le

plein.

nettoyer

les

lieux

avant

de

faire

dØmarrer

le

moteur.



LES

PIECES

EN

MOUVEMENT

peuvent

causer

3.

Seules

des

personnes

qualifiØes

doivent

dØmonter

les

protecteurs

~

des

blessures.

ou

les

capots

pour

faire

Ientretien

ou

les

reparations

nŁcessaires.

4.

Pour

empecher

un

demarrage

accidentel

dun

systŁme

pendant

Les

piŁces

en

mouvement

comme

les

ventilateurs,

les

Ientretien

ou

les

reparations,

dØbrancher

10

cable

negatif

()

do

Ia

rotors

et

les

courroies

peuvent

couper

es

doigts

et

tes

mains

et

happer

les

vŁtements

amples.

battene.

5.

Eloigner

les

mains,

les

cheveux,

les

vØtements

amples

et

les

outils

1.

Sassurerque

les

portes,

les

panneaux,

les

capots

et

les

protecteurs

des

piŁces

en

mouvement.

sont

bien

fermØs

et

bien

a

leur

place.

6.

Replacerles

capots

ou

es

protecteurs

et

refermer

es

portes

une

fois

2.

ArrØter

le

moteur

avant

de

mettre

en

place

ou

de

raccorder

un

lentretien

et

es

reparations

terminØs

et

avant

de

faire

dØmarrer

le

dispositif.

moteur.

1.

Toujours

LES

ETINCELLES

peuventfaire

EXPLOSER

LE

2.

ArrŒter

le

moteur

avant

de

brancher

ou

de

dŁbrancher

les

cables

de

GAZ

DES

BATrERIES;

LELECTROLVTE

peut

Ia

battene.

brUler

Ia

peau

et

les

yeux.

3.

Ne

pas

faire

des

Łtincelles

avec

los

outils

quand

on

travaille

sur

une

battene.

Les

batteries

contiennent

un

produit

acide

et

degagent

des

vapeurs

explosives.

4.

Ne

pas

utiliser

Ia

source

de

courant

de

soudage

pour

charger

los

batteries

ou

pour

faire

dØmarrer

un

vehicule.

porter

un

Øcran

facial

quand

on

travaille

sur

une

batterie.

5.

Ne

pas

intervertir

Ia

polante

des

batteries.

~.

~4

(r\

~

LA

VAPEUR

E1

LE

LIQUIDE

DE

1.

Si

Ion

doit

vØnfierle

niveau

quand

le

moteurest

chaud,

suivre

les

PRESSION

peuvent

brler

Ia

peau

et

les

yeux.

2.

PorterdeslunettesdesØcuntØetdesgantsetplacerunchiffonsurle

REFROIDISSEMENT

BROLANT

SOUS

etapes

2

et

3.

II

vaut

mieux

verifier

le

niveau

du

liquide

de

bouchon.

refroidissement

quand

le

moteur

est

froid afin

dØviter

les

3.

Toumer

lentement

le

bouchon

et

laisser

Ia

pression

sechapper

brUlures.

Ientement

avant

denlever

completement

le

bouchon.

PRINCIPALES

NORMES

DE

SECURITE

Safety

in

Welding

and

Cutting,

nornie

ANSI

Z49.1,

de

lAmencan

Welding

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

P-ide

Society,

550

NW.

Lejeune

Rd,

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

Regles

de

sdcuritd

en

soudage,

coupage

et

procedes

connexes,

none

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

CSA

W117.2,

de

lAssociation

canadienne

de

normalisation,

vente

de

normes,

178

Rexdale

Boulevard,

Rexdale

(Ontario)

Canada

M9W

1

P3.

Recommended

Safe

Practice

for

the

Preparation

for

Welding

and

Cutting

of

Containers

That

Have

Held

Hazardous

Substances,

norme

AWS

F4.1,

Safe

Practices

ForOccupationAnd

Educational

Eye

And

Face

Protection,

de

IAmeflcan

Welding

Society,

550

N.W.

Lejeune

Rd,

Miami

FL 33126

norme

ANSI

Z87.1,

de

IAmencan

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

National

Electrical

Code,

NFPA

Standard

70,

de

Ia

National

Fire

Protection

Cutting

and

Welding

Processes,

none

NFPA

51

B,

de

Ia

National

Fires

Association,

Batterymarvh

Park,

Quincy,

MA

02269.

Protection

Association,

Batlerymarch

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

Diagrams

3-2.

Installing

Swivel

Into

Pipe

Post

3-3.

Installing

Boom

And

Reel

Support

3-4.

Installing

Wire

Guide

Extension

3-5.

Wire

Guide

And

Drive

Roll

Installation

3-6.

Welding

Gun

Connections

3-7.

Wire

Feed

Motor

And

Gas

Valve

Control

Connections

3-8.

14-Pin

Plug

Connection

3-9.

Shielding

Gas

And

Weld

Cable

Connections

3-10.

Voltage

Sensing

Lead

(Optional)

3-11.

Removing

Safety

Collar

And

Adjusting

Boom

3-12.

We~dingWire

Installation

3-13.

Motor

Start

Control

3-14.

Dip

Switches

Options

3-15.

Changing

Optional

Digital

Voltage

Control

For

Use

With

A

MILLER

Inverter-Type

Power

Source

3-16.

Threading

Welding

Wire

SECTION

4-

OPERATION

SECTION

5-

MAINTENANCE

&

TROUBLESHOOTING

5-1.

Routine

Maintenance

5-2.

Replacing

The

Hub

Assembly

5-3.

Overload

Protection

5-4.

Troubleshooting

SECTION

6-

ELECTRICAL

DIAGRAMS

SECTION

7-

PARTS

LIST

Figure

7-1.

Main

Assembly

Figure

7-2.

Control

Box

Figure

7-3.

Support,

Hub

&

Reel

Figure

7-4.

Boom

Assembly

Figure

7-5.

Drive

Assembly,

Wire

Figure

7-6.

Control

Panel

Optional

Equipment

I

NOTE

L~

Considerations

About

We

Magnetic

Fields

The

following

isa

quotation

from

the

General

Conclusions

Section

Iding

And

The

Effects

Of

Low

Frequency

Electric

And

To

reduce

magnetic

fields

in

the

workplace,

use

the

following

of

the

U.S.

Congress,

Office

of

Technology

Assessment,

Biological

procedures:

Effects

of

Power

Frequency

Electric

&

Magnetic

Fields



Background

Paper~

OTA-BP-E-53

(Washington,

DC:

U.S.

Government

Printing

Office,

May

1989):

.

. .

there

is

now

a

very

1.

Keep

cables

close

together

by

twisting

or

taping

them.

2.

Arrange

cables

to

one

side

and

away

from

the

operator.

large

volume

of

scientific

findings

based

on

experiments

at

the

3.

Do

not

coil

or

drape

cables

around

the

body.

cellularlevel

and

from

studies

with

animals

and

people

which

clearly

establish

that

low

frequency

magnetic

fields

can

interact

with,

and

produce

changes

in,

biological

systems.

While

most

of

this

work

is

of

very

high

quality,

the

results

are

complex.

Current

scientific

understanding

does

not

yet

allow

us

to

interpret

the

evidence

in

a

4.

Keep

welding

power

source

and

cables

as

far

away

as

practical.

5.

Connect

work

clamp

to

workpiece

as

close

to

the

weld

as

possible.

single

coherent

framework.

Even

more

frustrating,

it

does

not

yet

About

Pacemakers:

allow

us

to

draw

definite

conclusions

about

questions

of

possible

nskortoofferclearscience-basedadviceonstrategiestominimize

The

above

procedures

are

among

those

also

normally

recommended

for

pacemaker

wearers.

Consult

your

doctor

for

or

avoid

potential

risks.

complete

information.

modlO.1

4/93

1

2

3

4

5

6

7

8

10

11

14

15

17

23

24

25

27

32

34

37

38

40

42

43

Table

7-1.

Drive

Roll

And

Wire

Guide

Kits

44

OM-1583G

-4195

.

SECTION

1

-

SAFETY

INFORMATION

modl.1

2193



Read

all

safety

messages

throughout

this

manual.



Obey

all

safety

messages

to

avoid

injury.



Learn

the

meaning

of

WARNING

and

CAUTION.

P,~YiI~1;h~II~eu

I

Figure

1-1.

Safety

Information

SECTION

2-

SPECIFICATIONS

Table

2-1.

Wire

Feeder

1

2

a

CAUTION

/

L

~

ELECTRIC

SHOCK

can

kiII.~

MOVING

PARTS

can

injure.

I



Do

not

touch

l~e

el~h~l

parts.



Keep

away

from

moving

parts.

I



Keep

all

panels

and

covers

closed

I



Disconnect

input

power

before

installing

or

servicing.

when

operating.

I

5

1

Safety

Alert

Symbol

2

SignaiWord

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

READ

SAFETY

BLOCKS

at start

of

6

Section

3-1

before

proceeding

7H

NOTE

~

4

Safety

Instructions

To

Avoid

Hazard

Turn

Off

switch

when

using

high

frequency.

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.

Specification

Type

Of

Input

Power

From

Welding

Power

Source

Maximum

Weld

Circuit

Rating

Welding

Power

Source

Type

Wire

Feed

Speed

Range

Description

Wire

Diameter

Range

Welding

Process

Input

Power

Cord

Single-Phase

24

Volts

AC,

10

Amperes,

50/60

Hertz.

(If

115

Volts

AC

Is

The

Only

Power

Available,

Use

Optional

Power

Supply

Adapter

Model

PSA-2.)

100

Volts,

750

Amperes,

100%

Duty

Cycle

Constant

Voltage

(CV)

DC,

With

Contactor

50 To

780

ipm

(1.3

To

19.8

mpm);

Standard

Motor

14

To

213

ipm

(0.6

To

5.4

mpm);

Low

Speed

Motor

9010

1400

ipm

(2.3

To

35.6

mpm);

High

Speed

Motor

.023

To

1/8

in

(0.6

To

3.2

mm)

Gas

Metal

Arc

(GMAW)

Or

Flux

Cored

Arc

Welding

(FCAW)

lOft(3.1

m)

Maximum

Height

With

4

ft

(1.2

m)

Post

Weight

12

ft

(3.7

m)

Boom

17ft(5.2m)

Vertical

Lift

Of

Boom

Net:

160

lb

(73

kg)

Ship:

280

lb

(127

kg)

16

ft

(4.9

m)

Boom

21

ft

(6.4

m)

Horizontal

To

60

Above

Horizontal

Net:

210

lb

(95

kg)

Ship:

350

lb

(159

kg)

Horizontal

To

60

Above

Horizontal

OM-1583

Page

1

SECTION

3-

INSTALLATION

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

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.

wfwam9.1

2/93

3-1.

Equipment

Connection

Diagrams

I

1

Welding

Power

Source

1

2

3

2

Remote

14

Connection

3

Positive

(+)

Weld

Output

Cable

4

Negative

()

Weld

Output

Cable

13

~

Workpiece

6

Voltage

Sensing

Clamp

7

Weld

Control

8

Boom

9

Gun

10

Swivel

11

Pipe

Post

And

Base

12

Gas

Hose

13

Gas

Supply

ST-i

52

324

9

Figure

3-1.

Typical

System

Connections

OM-1

583

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

1

Swivel

Plates

2

Yoke

Remove

hardware

from

swivel

plates

and

yoke.

3

Boom

Set

boom

into

swivel

as

shown.

4

Yoke

Install

through

yoke.

Install

cot

ter

and

spread

ends.

5

Bolt

Install

bolt,

tighten

hardware,

and

back

bolt

oft

one

half

turn.

6

Locking

Knob

Install

locking

knob

but

do

not

tighten.

7

Reel

Support

Install

reel

support.

I

5

4

3

Tools

Needed:

~

3/4in

1

Swing

pak

Base

or

CBC

Cart

2

Pipe

Post

With

Base

3

Steel

Bolt

Secure

as

shown

using

as

a

mini

mum

1/2

in

diameter

SAE

grade

5

steel

bolts.

4

Swivel

Assembly

Insert

into

pipe

post.

Lubricate

swivel.

5

Safety

Collar

Do

not

remove

until

instructed

to.

ST-152

268

3-3.

Installing

Boom

And

Reel

Support

READ

SAFETY

BLOCKS

at start

of

Section

3-2

before

proceeding.

4

7

1

2

~~0

Tools

Needed:

Z~

3/4,3/8

in

Figure

3-3.

Boom

Installation

Ref.

ST-142

596-C

OM-1583

Page

3

3-4.

Installing

Wire

Guide

Extension

I

~

READ

SAFETY

BLOCKS

at

start

of

Section

3-1

before

proceeding.

.

1

Wire

Guide

Fitting

2

Bolt

3

Monocoil

Liner

4

Wire

Guide

Extension

lighten

bolt

to

secure

liner

in

wire

guide

titling.

Do

not

overtighten

bolt

and

crush

liner.

Tools

Needed:

c:I:z]==i]

3/8

in

ST-i

52

323

Figure

3-4.

Wire

Guide

Extension

Installation

3-5.

Wire

Guide

And

Drive

Roll

Installation

I

A.

Wire

Guide

Installation

When

changing

wire

size

or

type,

check

guide

size.

See

Table

7-1.

1

Drive

Rolls

Remove

drive

rolls

before

install

ing

wire

guides

(see

Figure

3-6).

2

Wire

Guide

Secunng

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

3-6).

Ref.

ST-137

391-F

/

ST-142

597-A

Tools

Needed:

1

Figure

3-5.

Wire

Guide

Installation

.

OM-1

583

Page

4

B.

Drive

Roll

Installation

Figure

3-6.

Drive

Roll

Installation

3-6.

Welding

Gun

Connections

2

3

When

changing

wire

size

or

type,

check

drive

roll

size.

See

Table

7-1.

1

Spring

Shaft

Carrier

Close

spring

shaft

carrier.

2

Drive

Roll

Nut

3

Drive

Roll

Carrier

Turn

all

nuts

one

click

until

lobes

of

nut

line

up

with

lobes

of

drive

roll

carrier.

Open

spring

shaft

carrier.

4

Drive

Roll

Slide

drive

rolls

onto

drive

roll

carri

ers.

Close

spring

shaft

carrier.

Turn

nut

one

click.

5

Drive

Assembly

Cover

Close

cover.

ST-142

597-A

£~

WARNING

ELECTRIC

SHOCK

can

kill.

~



Do

not

touch

live

electrical

parts.



Turn

Oft

wire

feeder

and

welding

power

source,

and

disconnect

input

power

before

inspecting

or

installing.

wfwaml.1

2/93

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

recep

tacle

and

tighten

threaded

collar.

6

Trigger

Cord

7

Trigger

Plug

8

Weld

Control

Trigger

Receptacle

Ref.

ST-153

072/

ST-152

321

/

Ref.

ST-142

708-B

Insert

tighten

plug

threa

into

receptacle

and

ded

collar.

Figure

3-7.

Gun

And

Trigger

Lead

Connections

OM-1583

Page

5

3-7.

Wire

Feed

Motor

And

Gas

Valve

Control

Connections

3-8.

14-Pin

Plug

Connection

Table

3-1.

Remote

14

Information

*The

remaining

pins

are

not

used.

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.

Ref.

ST-142

708-B

Figure

3-8.

Boom

Connections

eQ

~joo~

~

2

1

Plug

PLG1O

2

Keyway

3

Threaded

Collar

Connect

14-pin

plug

PLG1O

to

matching

receptacle

on

welding

powersource

as

follows:

align

key

ways,

insert

plug,

and

tighten

threaded

collar.

ST-162

179/Ref.

S-0512

Figure

3-9.

14-Pin

Plug

Connection

~j~*

Information

A

24

volts

ac.

B

Contact

closure

to

A

completes

24

volts

ac

contactor

control

circuit.

G

Circuit

common

for

24

volts

ac

circuit.

C

+10

volts

dc

input

to

remote

control.

D

Remote

control

circuit

common.

E

0

to

+10

volts

dc

output

command

signal

from

remote

control.

F

Current

feedback;

Oto

+10

volts

dc,

1

volt

per

100

amperes.

H

Voltage

feedback;

0

to

+10

volts

dc,

1

volt

per

10

arc

volts.

.

OM-1

583

Page

6

3-9.

Shielding

Gas

And

Weld

Cable

Connections

£~

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.

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.

BUILDUP

OF

SHIELDING

GAS

can

harm

health

or

kill.



Shut

off

shielding

gas

supply

when

not

in

use.

wam4.1

2/93

The

weld

cable

and

shielding

gas

hose

extend

10

ft

(3

m)

from

the

boom.

If

the

welding

power

source

or

gas

supply

are

further

from

the

boom,

extend

cable

or

hose

as

follows:

1

Weld

Cable

2

Insulated

Sleeving

Bolt

together

weld

cables

from

welding

power

source

and

boom.

Use

electrical

tape

and

insulated

sleeving

to

cover

connection.

3

Shielding

Gas

Hose

Connect

hose

to

gas

supply

or

ex

tension

hose.

The

hose

from

the

boom

has

5/8-18

right-hand

threads.

Tools

Needed:

~r

5/8

in

Figure

3-10.

Shielding

Gas

And

Weld

Cable

Connections

ST-152

800-A

OM-1583

Page

7

3-10.

Voltage

Sensing

Lead

(Optional)

A

35

ft

(10.6

m)

voltage

sensing

lead

is

provided

with

several

options.

Connect

voltage

sensing

lead

to

workpiece

(see

Figure

3-1).

3-11.

Removing

Safety

Collar

And

Adjusting

Boom

RELEASE

OF

SPRING

PRESSURE

FALLING

BOOM

can

cause

serious

WITHOUT

BOOM

ATTACHED

can

cause

serious

personal

ifljUflJ.



Do

not

remove

safety

collar

until

instructed

to

do

so.

personal

injury

and

equipment

damage.



Adjustment

rod

must

be

threaded

fully

through

yoke.

1

Locking

Knob

Tighten

knob

to

prevent

boom

movement.

Loosen

knob

to

allow

4

boom

movement.

Change

knob

3

position

to

limit

upward

movement.

Tools

Needed:

~~==z~

1-1/Sin

Pull

boom

down

slightly

and

re

move

safety

collar.

Boom

should

balance

in

any

position

from

hori

O

~

~_

I~Li~

~

3

2

Increasing

Spring

Decreasing

Spring

Pressure

For

A

Pressure

For

A

Heavy

Gun

Light

Gun

zontal

to

60

degrees

above

hori

zontal.

If

necessary,

adjust

boom

as

follows:

2

Threaded

Rod

3

Jam

Nut

4

Yoke

Loosen

jam

nut

and

tum

threaded

rod

until

boom

balances.

Tighten

jam

nut.

Be

sure

several

full

threads

are

through

yoke

to

pre

vent

boom

falling.

Retain

safety

collar

for

use

in

dis

assembling

or

moving

boom.

Ref.

ST-i

52380-A

Figure

3-11.

Boom

Adjustments

3-12.

Welding

Wire

Installation

A.

Ins

tallation

Of

Spoo

I-Type

Wire

~c

1

Retaining

Ring

2

Wire

Spool

3

Hub

Remove

retaining

ring

and

slide

spool

onto

hub.

4

Hub

Tum

spool

until

hub

fits

hole

in

spool.

Reinstall

retaining

ring.

2

1

ST-152

648-A

£~

WARNING

1

Figure

3-12.

Installation

Of

Spool-Type

Wire

.

OM-1583

Page

8

B.

Installation

Of

Optional

Wire

Reel

And

Reel

Type

Wire

C.

Adjusting

Hub

Tension

Figure

3-14.

Adjusting

Hub

Tension

7

5

4

2

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

I

ST-152

463

Figure

3-13.

Installation

Of

Optional

Wire

Reel

And

Reel

Type

Wire

1

Turn

Off

unit

and

welding

power

source.

1

Hex

Nut

2

Spool

Grasp

spool

in

one

hand

and

turn

while

using

a

wrench

to

adjust

hex

nut.

When

a

slight

force

is

needed

to

turn

spool,

tension

is

set.

2

E

Tools

Needed:

~

5/8

in

ST-152

649

OM-1583

Page

9

3-13.

Motor

Start

Control

£~

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

wire

feederand

welding

powersource,

and

disconnect

input

power

before

inspecting

or

installing.

STATIC

ELECTRICITY

can

damage

parts

on

circuit

boards.



Put

on

grounded

wrist

strap

BEFORE

handling

boards

or

parts.

wfwaml.1

2/93

Tools

Needed:

C111Z1U

1/4

in

~~=====~

non-conductive

Remove

wrapper.

1

Front

Panel

Remove

screw

from

upper

left

cor

ner,

and

open

hinged

front

panel.

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

making

adjustment.

Adjust

poten

tiometer

R70

using

a

small

non

conductive

screwdriver.

Figure

3-15.

Motor

Start

Control

On

Motor

Control

Board

PCi

To

change

wire

feed

starting

speed

proceed

as

follows:

Turn

Off

unit

and

welding

power

source.

Close

and

secure

front

panel,

and

reinstall

wrapper.

ST-i

52

318!

SB-146

662-D

.

OM-1

583

Page

10

3-14.

Dip

Switches

Options

AA

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



TumOffwirefeederaridwelding

powersource,

disconnect

input

power

before

inspecting

installing.

STATIC

ELECTRICITY

can

damage

parts

on

circuit

boards.



Put

on

grounded

wrist

strap

BEFORE

handling

boards

or

parts.

wfwaml.1*

2/93

ci~zj===~n

1/4

in

Figure

3-16.

Spot

Time

DIP

Switch

Si

SA-146

866-B

/

Ref.

SB-152

378

A.

Spot

Time

DIP

Switch

Si

Change

DIP

switch

position

if

a

different

range

of

Spot

Time

is

desired.

Turn

Off

wire

feeder

and

welding

power

source.

Remove

wrapper.

1

Front

Panel

Remove

screw

from

upper

left

cor

ner,

and

open

hinged

front

panel.

2

4-In-i

Board

PC3O

3

Spot

Time

DIP

Switch

Si

Place

switch

in

desired

position:

Long

Time

for

0-5

seconds,

and

Short

Time

for

0-2.5

seconds

(see

Figure

4-12

for

control

operation).

Close

and

secure

front

panel,

and

reinstall

wrapper.

Tools

Needed:

OM-i

583

Page

ii

B.

Digital

Meter

Functions

And

Positions

NOTE

~

The

Digital

Meter

Board

PC6O

for

the

Two

Meter

Option

is

equipped

with

DIP

____________________

switch

S3.

This

switch

is

shipped

from

the

factoiyin

the

Off

position,

and

shouldnot

be

changed.

Tools

Needed:

cII~ZI===u

1/4

in

2

3

X

Means

switch

can

be

in

either

position.

I

Means

place

switch

in

this

position.

Change

DIP

switch

positions

if

a

different

mode

of

operation

is

desired.

Turn

Off

wire

feeder

and

welding

power

source.

Remove

the

three

(3)

screws

from

front

edge

of

wrapper.

1

Front

Panel

Remove

screw

from

upper

left

cor

ner,

and

open

hinged

front

panel.

2

Digital

Meter

Board

PC6O

3

Meter

Functions

DIP

Switch

S2

Place

DIP

switch

in

appropriate

po

sition

for

desired

mode

(see

Figure

4-7

for

meter

operation).

Close

and

secure

front

panel,

and

reinstall

wrapper

screws.

SB-137

395-B

/

SA-148

666-E/

S-0389

A

Figure

3-17.

Digital

Meter

Functions

DIP

Switch

S2

Standard

Motor

Inches/Minute

I

-,



Standard

Motor

Meters/Minute

I

I,

IC

Or

High

Speed

Motor

Inches/Minute

.~

I~

.c~1

High

Speed

Motor

Meters/Minute

I

I~

IV)



Or

OM-1

583

Page

12

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