Miller | LK400045U | Owner Manual | Miller DUAL ROI AXCESS BOOM User manual

Miller DUAL ROI AXCESS BOOM User manual
OM-226 021K
2009−09
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
(Gas-and Self-Shielding)
Submerged (SAW) Welding
Description
Wire Feeder
(Use with CV Power Sources)
R
Dual ROI Axcess Boom
8 ft, 12 ft and 16 ft Boom
Visit our website at
www.MillerWelds.com/ams
File: Advanced Manufacturing Systems
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 4/05
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Installing Swivel Into Pipe Post . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Installing Boom And Reel Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Installing Wire Guide Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Installing Insulator Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Remote Operator Interface And Wire Drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Adjusting Control Tilt Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Rear Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. 9-Pin Network Receptacle RC1 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. 10-Socket Motor Receptacle RC8 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. ROI Display At Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Dual Schedule Switch Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. Removing Safety Collar And Adjusting Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14. Installing And Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Program Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Upper Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Lower Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Feeder Set Up Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Adjust Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Process Set Up Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Jog/Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Reset Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − SETTING SEQUENCE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Sequence Parameters In A Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _2009−08
7
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of inputpower.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on equipment.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
OM-226 021 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
D 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.
D 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.
D 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 while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant
material (leather, heavy cotton, or wool) and foot protection.
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.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D 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).
D Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
D 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, sparks, and fire
hazards.
D Do not use welder to thaw frozen pipes.
OM-226 021 Page 2
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect ImplantedMedical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
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.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
OVERUSE can cause OVERHEATING
H.F. RADIATION can cause interference.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D Sparks can cause fires — keep flammables away.
D
D
D
D
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can injure.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
D
D
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-226 021 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Gasoline Engines:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (phone: 301-504-7923, website:
www.cpsc.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective
measures for persons wearing medical implants have to be taken. For
example, access restrictions for passers−by or individual risk assessment for welders. All welders should use the following procedures in
order to minimize exposure to EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-226 021 Page 4
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2009−08
7
Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
2-1. Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité.
Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est
sous tension lorsque le courant est délivré à la
sortie. Le circuit d’alimentation et les circuits internes de la machine sont également sous tension
lorsque l’alimentation est sur Marche. Dans le mode
de soudage avec du fil, le fil, le dérouleur, le bloc de
commande du rouleau et toutes les parties métalliques en contact avec le fil sont sous tension
électrique. Un équipement installé ou mis à la terre
de manière incorrecte ou impropre constitue un
danger.
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et
sans trous.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
D Ne pas se servir de source électrique à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
D Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
D Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
D D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
D Installer le poste correctement et le mettre à la terre convenablement selon les consignes du manuel de l’opérateur et les normes
nationales, provinciales et locales.
D Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
D En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
D Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
D Vérifier fréquemment le cordon d’alimentation afin de s’assurer
qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est.
Un fil à nu peut entraîner la mort.
D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
D Ne pas enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
D Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
D S’assurer que tous les panneaux et couvercles sont correctement
en place.
D Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
D Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
D Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage.
OM-226 021 Page 5
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.
D Arrêter les convertisseurs, débrancher le courant électrique et
décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie Entretien avant de toucher les pièces.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
D Ne pas toucher à mains nues les parties
chaudes.
D Prévoir une période de refroidissement avant de
travailler à l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec
des objets métalliques peut provoquer des étincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
vérifier et s’assurer que l’endroit ne présente pas de danger.
D Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
D Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
D Lire et comprendre les spécifications de sécurité des matériaux
(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégraisseurs.
D Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
D Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intense
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
D Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D Porter des vêtements confectionnés avec des matières résistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.
OM-226 021 Page 6
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 (voir les normes de sécurité).
D Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple).
D Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
D Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans
revers, des chaussures hautes et un couvre chef.
D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.
D Le soudage, l’écaillement, le passage de la pièce à la brosse en
fil de fer, et le meulage génèrent des étincelles et des particules
métalliques volantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
D Fermer l’alimentation du gaz protecteur en cas
de non-utilisation.
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction
d’air homologué.
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.
D Les porteurs de stimulateurs cardiaques
et autres implants médicaux doivent rester
à distance.
D Les porteurs d’implants médicaux doivent consulter
leur médecin et le fabricant du dispositif avant de s’approcher
de la zone où se déroule du soudage à l’arc, du soudage
par points, du gougeage, de la découpe plasma
ou une opération de chauffage par induction.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles
de gaz font normalement partie du procédé de
soudage, les manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique ;
les maintenir ainsi que les éléments associés en bon état.
D Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécurité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.
D Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
D Utiliser un équipement de levage de capacité
suffisante pour lever l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.
D Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
D Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.
L’EMPLOI
EXCESSIF
peut
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
D Porter un écran facial pour protéger le visage et
les yeux.
D Affûter l’électrode au tungstène uniquement à la
meuleuse dotée de protecteurs. Cette
manœuvre est à exécuter dans un endroit sûr
lorsque l’on porte l’équipement homologué de
protection du visage, des mains et du corps.
D Les étincelles risquent de causer un incendie − éloigner toute substance inflammable.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des
cartes de circuits imprimes.
OM-226 021 Page 7
Les PIÈCES MOBILES peuvent
causer des blessures.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE
(H.F.)
risque
de
provoquer des interférences.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en
engageant le fil de soudage.
Les PIÈCES MOBILES peuvent
causer des blessures.
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de
protection.
D Lorsque cela est nécessaire pour des travaux d’entretien et de
dépannage, faire retirer les portes, panneaux, recouvrements
ou dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’entretien en respectant les manuels d’utilisation, les
normes industrielles et les codes nationaux, d’état et locaux.
D Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs.
D Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D
D
D
D
D
D L’énergie électromagnétique risque de
provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit
compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
2-4. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des
cancers et des malformations congénitales ou autres
problèmes de procréation. Se laver les mains après manipulation.
OM-226 021 Page 8
Pour les moteurs à essence :
Les gaz d’échappement des moteurs contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.
Pour les moteurs diesel :
Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie comme provoquant des cancers et des malformations
congénitales ou autres problèmes de procréation.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, de Global
Engineering Documents (téléphone : 1-877-413-5184, site internet :
www.global.ihs.com).
National Electrical Code, NFPA Standard 70, de National Fire Protection Association, Quincy, MA 02269 (téléphone : 800-344-3555, site
Internet : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (téléphone : 703-788-2700, site Internet :
www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, de Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (téléphone :
800-463-6727, site internet : www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, de American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900,
site Internet : www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association,
P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,
site Internet : www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General
Industry, Title 29, Code of Federal Regulations (CFR), Part 1910,
Subpart Q, and Part 1926, Subpart J, de U.S. Government Printing
Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA
15250-7954 (téléphone : 1-866-512-1800) (il y a 10 bureaux
régionaux−le téléphone de la région 5, Chicago, est 312-353-2220, site
Internet : www.osha.gov).
U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (téléphone : 301-504-7923, site internet : www.cpsc.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The
National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (télé[hone : 1-800-232-4636, site internet:
www.cdc.gov/NIOSH).
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant de soudage
crée un CEM autour du circuit et du matériel de soudage. Les CEM
peuvent créer des interférences avec certains implants médicaux
comme des stimulateurs cardiaques. Des mesures de protection pour
les porteurs d’implants médicaux doivent être prises: par exemple, des
restrictions d’accès pour les passants ou une évaluation individuelle
des risques pour les soudeurs. Tous les soudeurs doivent appliquer les
procédures suivantes pour minimiser l’exposition aux CEM provenant
du circuit de soudage:
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
En ce qui concerne les implants médicaux :
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
OM-226 021 Page 9
OM-226 021 Page 10
SECTION 3 − INTRODUCTION
3-1. Specifications
Type of Input
Power
40 Volts DC
10 Amperes
Welding Power
Source Type
Wire Feed Speed Range
Standard: 40 To 1400 ipm
(1.0 To 35.6 mpm)
Axcess Series
Wire Diameter
Range
.030 To 1/8 in.
(0.8 To 3.2 mm)
Max Spool Weight:
60 lb (27 kg)
Welding Circuit
Rating
100 Volts,
750 Amperes,
100% Duty Cycle
Weight
8 ft (2.4 m):
110 lb (50 kg)
12 ft (3.7 m):
160 lb (73 kg)
16 ft (4.9 m):
210 lb (95 kg)
8 ft (2.4 m) Boom
12 ft (3.7 m) Boom
16 ft (4.9 m) Boom
Maximum Height With 4 ft (1.2 m)
Post
13 ft (4.0 m)
17 ft (5.2 m)
21 ft (6.4 m)
Vertical Lift Of Boom
Horizontal to 60° Above
Horizontal
Horizontal to 60° Above
Horizontal
Horizontal to 60° Above
Horizontal
3-2. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.
SECTION 4 − INSTALLATION
4-1. Installing Swivel Into Pipe Post
5
4
1
2
3
Swingpak Base or CBC Cart
Pipe Post With Base
Steel Bolt
Secure as shown using as a minimum 1/2 in. diameter SAE grade 5
steel bolts.
4
Swivel Assembly
Insert into pipe post. Lubricate
swivel.
2
1
3
5
Safety Collar
!
Do
not
remove
instructed to.
until
Tools Needed:
3/4 in.
152 268-B
OM-226 021 Page 11
4-2. Installing Boom And Reel Support
1
2
Swivel Plates
Yoke
Remove hardware from swivel
plates and yoke.
3
3
Boom
Set boom into swivel as shown.
7
4
Yoke Pin
Install pin through yoke. Install cotter pin and spread ends.
5
Bolt
4
Install bolt, tighten hardware, and
back bolt off one half turn.
5
6
2
6
Locking Knob
Install locking knob but do not
tighten.
7
Reel Support
Install reel support.
1
Tools Needed:
3/8, 3/4 in.
Ref. 803 805-A
4-3. Installing Wire Guide Extension
1
4
2
3
1
2
3
4
Wire Guide Fitting
Bolt
Monocoil Liner
Wire Guide Extension
Tighten bolt to secure liner in wire
guide fitting. Do not overtighten bolt
and crush liner.
Tools Needed:
3/8 in.
152 383
OM-226 021 Page 12
4-4. Installing Insulator Kit
1
!
Turn Off and disconnect
input power.
1
2
3
4
5
6
ROI Control
Insulator Plate
Mounting Plate
1/4-20x3/4 in. Screw (4)
Nylon Shoulder Washer (4)
3/8 in. Flat Washer (4)
Place insulator plate between ROI
base and metal mounting surface.
Place nylon shoulder washer over
screw.
Place flat washer over shoulder
washer.
2
3
Tools Needed:
Insert hardware assembly through
hole in metal mounting base, insulator, and into ROI base (4 locations). Tighten hardware to secure
control.
6
1/2 in.
5
4
804 336-A
4-5. Remote Operator Interface And Wire Drive Installation
1
Typical Swingarc installation shown;
however, various installations are
possible
depending
on
the
application.
1
2
3
4
5
3
5
Remote Operator Interface
Swingarc Swivel Assembly
Boom
AA40G Wire Drive
Assembly (2)
Trigger Cable (2)
5
2
4
804 084-B
OM-226 021 Page 13
4-6. Adjusting Control Tilt Bracket
1
2
3
Tilt Bracket
Rear Pivot Screw
Front Screw
Loosen rear pivot screw. Remove
front screw. Pivot control downward to desired viewing angle. Replace and tighten front screw. Tighten pivot screw.
1
2
3
804 332-A
OM-226 021 Page 14
4-7. Connection Diagram
1
2
3
4
5
6
7
8
1
3
9
5
. Positive
(+) voltage sensing
lead is contained in the motor
cable.
6
7
9 Positive (+) Weld Cable
10 Motor Cable (2)
11 Trigger Cable (2)
10
11
Welding Power Source
Wire Feeder (2)
Gas Cylinder
Gas Hose
Network Feeder Cable
Negative (−) Weld Cable
Workpiece
Voltage Sensing Lead
(Optional)
8
4
11
2
804 085-B
4-8. Rear Panel Connections
1
2
9-Pin Network Receptacle
RC1
Motor Control/Shielding Gas
Valve Receptacle RC8
1
2
804 086-A
OM-226 021 Page 15
4-9. 9-Pin Network Receptacle RC1 Information
9
F
G
E
H
I
D
A
C
B
Pin
Pin Information
A
Capacitor C1 to ground
B
Shield
C
Volt sense
D
Can low
E
Can high
F
+24 volts DC common
G
+ 24 volts DC
H
Motor voltage −40 volts
I
Motor voltage +40 volts
4-10. 10-Socket Motor Receptacle RC8 Information
Socket
C
G
J
A
F
K
E
H
D
OM-226 021 Page 16
B
Socket Information
A
Not used
B
Motor common
C
+1.75 volts DC ±0.2 volts when tach A encoder is rotating
D
+1 volt DC per 35 IPM with respect to pin B
E
Tach common
F
Gas valve common
G
Electrode sense
H
+5 volts DC tach
J
+40 volts DC gas valve
4-11. ROI Display At Power Up
1
2
1
Program
Time
WFS
Amps
Arc Adjust
Arc Ctl
Process
Sequence
Wire Type
Gas Type
Trigger Hold
Process Set Up
Power Source
Axcess
Volts
Upper Display
Lower Display
2
Trigger Control
Adjust
Feeder Set Up
Upper Display
Lower Display
Net
Wait
DTEC
OFF
Axcs
300/450/675
Voltage Range
10
44
4-12. Dual Schedule Switch Options
1
Maint 2P (Maintained-Contact
2-Pole Switch)
DSS-9M Part# 041 793
1
DSS-9M 1
2
2
A
3
1
4
B
OM-226 021 Page 17
4-13. Removing Safety Collar And Adjusting Boom
1
Locking Knob
Tighten knob to prevent boom
movement. Loosen knob to allow
boom movement. Change knob
position to limit upward movement.
Pull boom down slightly and remove
safety collar. Boom should balance
in any position from horizontal to 60
degrees above horizontal. If
necessary, adjust boom as follows:
2
3
4
3
Loosen jam nut and turn threaded
rod until boom balances. Tighten
jam nut. Be sure several full threads
are through yoke to prevent boom
falling.
4 Yoke
2
1
Rod
Rod
Threaded Rod
Jam Nut
4
Retain safety collar for use in
disassembling or moving boom.
3
2
Tools Needed:
1-1/8 in.
OM-226 021 Page 18
Increasing Spring
Pressure For A
Heavy Gun
Decreasing Spring
Pressure For A
Light Gun
142 599-C / Ref. 803 807-A
4-14. Installing And Threading Welding Wire
Tools Needed:
3/16, 5/64 in.
15/16, 3/8 in.
Install wire spool. Adjust
tension nut so wire is taut
when wire feed stops.
Pressure
Indicator
Scale
Install wire guide.
Pressure
Adjust
Drive Rolls
Install drive rolls.
Gun Cable
End Of Liner
NONCONDUCTIVE
SURFACE
No Wire Slip
NONCONDUCTIVE
SURFACE
Wire Slips
. Be sure that outlet cable has proper size . For soft wire or small diameter stainless . To adjust drive roll pressure, hold nozzle
liner for the welding wire size. When
installing
gun,
position
liner
extending from outlet wire guide as
close as possible to drive rolls without
touching.
Install gun. Lay gun cable out straight. Cut off
end of wire. Push wire through guides up to
drive rolls; continue to hold wire. Press Jog
button to feed wire out gun.
steel wire, reduce drive roll pressure on
the rear roll to half that of the front rolls.
about 2 in (51 mm) from nonconductive
surface and press gun trigger to feed wire
against surface. Tighten knob so wire
does not slip. Do not overtighten. If contact tip is completely blocked, wire should
slip at the feeder (see pressure adjustment above).Cut wire off. Close cover.
804 333-A / 803 769-B / Ref. 137 391-A / 802 954 / Ref. S-0627-A
OM-226 021 Page 19
SECTION 5 − OPERATION
5-1. Operational Terms
The following is a list of terms and their definitions as they apply to the interface unit in the wire feeder:
General Terms:
Arc Adjust
Term used to represent arc length adjustments in pulse programs. Increasing Arc Adjust increases the
actual arc length. Likewise, decreasing arc adjust shortens arc length. Arc Adjust is replaced by volts in
MIG programs.
Trigger Control
Selecting Trigger Control allows activating trigger functions such as DS, TH, 4T, TDS, and TPS.
DS (Dual Schedule)
Dual Schedule allows selecting a pair of programs that can be used together.
TH (Trigger Hold)
Trigger Hold allows the operator to feed wire without continuously pressing the gun trigger. In trigger hold
mode, momentarily press gun trigger, and wire will feed until gun trigger is momentarily pressed again.
4T
4T allows the operator to select between weld parameters and crater parameters using the gun trigger.
Crater time must be set for at least 0.2 seconds to make this function operational. If gun trigger is
released during welding, unit goes into trigger hold, then pressing and holding trigger again causes unit to
stay in crater until trigger is released and crater parameter times out.
TDS (Trigger Dual Schedule)
TDS allows the operator to select between a pair of weld programs by using the gun trigger. In TDS mode,
momentarily pressing the gun trigger allows the operator to cycle between a pair of preselected weld programs.
TPS (Trigger Program Schedule)
TPS allows the operator to select weld programs by using the gun trigger. In TPS mode, momentarily
pressing the gun trigger allows the operator to cycle through preselected weld programs up to a total of 8
programs.
Program
Eight active slots for selection of various processes, wire type, and parameters.
Process
A selection made for MIG, Pulse, Accu-pulse, and RMD (optional).
MIG
CV weld process with individual settings of voltage and wire speed.
Pulse
Conventional pulse program using peak, background, pulse width, frequency, and peak voltage as factory
taught data. Adaptive method is controlled by frequency adjustment.
Accu-pulse
Pulse process utilizing constant current ramps with constant voltage control of peaks and backgrounds.
Adaptive response is controlled by peak and minimum current levels. Benefits are shorter arc lengths,
better puddle control, more tolerant of tip-to-work variation, less audible noise, no arc wandering, allows
weld to fill in at toes increasing travel speed and deposition, and more tolerant to poor fit up and gaps.
Accuspeed
CV Pulse process designed for high travel speeds. Typically used in Robotic applications. Arc is designed
to be tight and fast. Front panel display is ACCU − SPED.
AccuCurve
CV Pulse process using a pulse waveform with modified curves at particular locations within the waveform. Has a distinguished change in arc characteristics. Front panel display is ACCU − CURV.
RMD (optional)
RMD refers to Regulated Metal Deposition. A precisely controlled short-circuit transfer. Benefits of RMD
are well suited to thin materials, improves gap filling and spatter reduction. Provides less heat input into
workpiece, minimizes distortion and allows use of larger diameter wire on thin gauge materials.
Wire Type
Selection of wire type by alloys and classification.
Gas Type
Selection of shielding gas being used in application.
Process Set Up
Selection procedure for entering program.
Program Load
Enters selected program information into program slot.
Volts
Preset voltage in MIG mode at idle, actual voltage while welding, and 3 seconds hold value at end of weld.
Time
Indicates time values being set for timed functions (e.g. Preflow, Postflow).
Arc Length
Distance from end of wire electrode to workpiece.
WFS
Term used to represent wire feed speed. In MIG mode, wire feed setting is independent of voltage setting.
In pulse, Accu-pulse, and RMD (optional) adjusting wire feed speed also increases power level on wire
electrode (one knob control).
Amps
Indicates average amperage while welding and 3 seconds hold value at end of weld.
Arc Control
Allows setting inductance in MIG mode. In pulse and Accu-pulse mode, this adjustment changes the arc
cone by adjusting the preprogrammed factory pulse data. In RMD (optional), this control affects the arc in
much the same way as inductance.
Inductance
In short circuit GMAW welding, an increase in inductance will decrease the number of short circuit metal
transfers per second (provided no other changes are made) and increase the arc-on time. The increased
arc-on time makes the welding puddle more fluid.
Adjust
Control knob used to change or set parameters and functions.
Sequence
Selecting Sequence will allow setting of preflow, start, crater, and postflow times and parameters (only
available on Auto Axcess models in the Arc On and Analog input or the Arc On and No Analog input
modes).
OM-226 021 Page 20
General Terms:
Preflow
Setting a time value for gas flow prior to arc start (only available on Auto Axcess models in the Arc On
and Analog input or the Arc On and No Analog input modes, and can only be set with the optional PDA
with File Management software).
Start
Provides voltage/arc adjust, wire feed rate, and time value for modified arc starts (only available on Auto
Axcess models in the Arc On and Analog input or the Arc On and No Analog input modes, and can only
be set with the optional PDA with File Management software).
Weld
Sequence function that allows for a timed weld operation [(0 to 999 seconds) only available on Auto Axcess models in the Arc On and Analog input or the Arc On and No Analog input modes, and can only be
set with the optional PDA with File Management software].
Crater
Allows setting of voltage/arc adjust, wire feed rate, and time value for arc ends (only available on Auto
Axcess models in the Arc On and Analog input or the Arc On and No Analog input modes, and can only
be set with the optional PDA with File Management software).
Postflow
Setting a time value for gas flow after arc end (only available on Auto Axcess models in the Arc On and
Analog input or the Arc On and No Analog input modes, and can only be set with the optional PDA with
File Management software).
Retract
Sequence function that allows the wire to move back towards the contact tip when a welding operation is
completed. Setting is both speed (IPM) and time (sec), (only available on Auto Axcess models in the Arc
On and Analog input or the Arc On and No Analog input modes, and can only be set with the optional
PDA with File Management software).
Feeder Set Up
Allow selection of Sequence functions.
Auto Thread
Method of jogging wire without holding jog or trigger switch. Pressing Jog and Retract simultaneously will
automatically feed wire. Default setting is 192 at a feed rate of 700 ipm (these values can be changed
using a PDA with File Management software). Pressing jog, purge, or trigger switch will terminate the
auto-threading feature.
5-2. Power Switch
1
Power Switch
1
804 087-A
OM-226 021 Page 21
5-3. Front Panel Controls
See
Section
5-5
See
Section
5-4
Program
Time
WFS
Amps
See
Section
5-6
Arc Adjust
Arc Ctl
Process
Sequence
Wire Type
Trigger Control
Gas Type
Trigger Hold
Process Set Up
See
Section
5-9
OM-226 021 Page 22
Volts
Adjust
See
Section
5-8
Feeder Set Up
See
Section
5-7
5-4. Program Push Button
1
Program Display
The number of the active program
is displayed.
2
3
Program Push Button
Program Push Button LED
The LED lights to indicate that
programs can be changed using
the Adjust knob.
1
Program
Momentarily press button to
illuminate LED. To change the
program number, rotate Adjust knob
to select one of eight programs.
3
Pressing and holding the push
button will display current wire size,
wire type and process.
2
To reset feeder to factory settings,
turn power source off for 10
seconds. Press and hold button in
on power up, wait until top display
shows RST and bottom display
shows NO before releasing button.
Feeder Set Up button LED will
begin flashing. Turn Adjust knob to
change bottom display to show
YES, then press Feeder Set Up
button to confirm selection. The top
display will show CYCL and the
lower display will show PWR. Turn
welding power source power off for
10 seconds, then turn power back
on again.
5-5. Upper Display
3
1
2
4
Volts
Arc Adjust
5
1
Upper Display
The upper display at idle (not welding) shows
preset volts with process selection MIG or Arc
Adjust for all other processes. When welding,
the display shows actual voltage. The display
will show actual voltage for approximately 3
seconds after welding stops before returning
to preset value.
2
Upper Display Push Button
Press the button to illuminate the LED and
allow changing information in the display.
3
Upper Display Push Button LED
The upper
display
push
button
LED
illuminates to indicate that information
displayed can be changed by the Adjust knob.
4 Volts LED
Indicates a voltage value is being displayed,
preset voltage in MIG when not welding and
actual voltage while welding.
5 Arc Adjust LED
Indicates that displayed value is an arc length
value when the process is Pulse, Accu-pulse,
or RMD (optional).
. At any
time while welding, the display
allows adjustment of the weld voltage or
arc adjust preset values by turning the
Adjust knob. The preset values will be
displayed while the knob is being rotated
and return to displaying actual values
when adjustment is completed.
To activate Carbon Arc Cutting (CAC), press
and hold the upper display push button in on
power up. CAC will appear on the upper display and NO will appear on the lower display.
Rotate adjust knob to YES on the lower display, and press the flashing Feeder Set up
push button . CYCL will appear on the upper
display and PWR will appear on the lower display. Turn welding power source off and back
on again to enable the Carbon Arc Cutting process selection.
OM-226 021 Page 23
5-6. Lower Display
5
7
Time
1
6
2
WFS
Amps
Arc Ctl
3
1
Lower Display
The lower display shows WFS (wire feed
speed), AMPS (amperage), ARC CTL (arc
control), or Time. The feeder displays only
preset wire speed at idle (not welding). While
welding, the average amperage is displayed.
The lower display shows welding sequence
time when the Time LED is illuminated.
2
WFS (Wire Feed Speed) LED
LED illuminates to indicate the preset wire feed
value is being displayed and can be adjusted
using the Adjust knob.
3
Amps LED
LED illuminates to indicate the average
amperage is being displayed while welding
and for 3 seconds after welding is terminated.
The amperage must be above a minimum
value of 25 amps for this function to operate.
OM-226 021 Page 24
4
4 Arc Ctl (Arc Control) LED
LED illuminates to indicate that inductance
(MIG) or ARC [Pulse, Accu-pulse, or RMD
(optional)] is being displayed and can be adjusted using the Adjust knob.
5 Time LED
LED illuminates to indicate that a time value is
being displayed for a sequence function and
can be adjusted using the Adjust knob.
6 Lower Display Push Button
7 Lower Display Push Button LED
Pressing the button illuminates the LED and
selects either WFS or Arc Ctl value for
changing using the Adjust knob.
To select Arc Ctl, press and hold lower display
button for 2 seconds. The top display will show
either INDU for a MIG program or ARC for
Pulse, Accu-pulse, or RMD (optional). To exit
Arc Ctl or INDU, either press the upper display
push button or press and hold the lower display
push button for 2 seconds.
During a welding program operation, it is
possible to change WFS (wire feed speed) by
using the Adjust knob regardless of the active
program sequence that appears on the display.
When the Arc Ctl LED is illuminated, it is possible to change values while welding by using
the Adjust knob. To return to actual values on
the display, exit the Arc Ctl display.
. The lower display push button has addi-
tional functions when entering the sequence and trigger control functions (see
Section 5-7).
5-7. Feeder Set Up Push Button
3
4
Sequence
Start
Time
Trigger Control
Trigger Hold
1
2
Crater
Time
Preflow
Time
Postflow
Time
5
Sequence Diagram
Feeder Set Up
1 Feeder Set Up Push Button LED
2 Feeder Set Up Push Button
• Press button to choose Sequence. Feeder
Set Up push-button LED will illuminate.
3 Sequence LED
• When the Feeder Set Up button is pressed
once, the Sequence LED will illuminate and
the upper display will show sequence
options. Use the Adjust knob to select PRE
(preflow), STRT (start), CRTR (crater), or
POST (postflow).
• Press the lower display push button and the
Lower Display push-button LED will
illuminate as well as the lower display. The
Time LED will automatically begin flashing
indicating that a time value can be entered
by turning the Adjust knob. By entering a
time value the sequence state will become
active. To turn off a sequence state, change
the time value to OFF. To step back for
selecting another sequence option, press
the Upper Display push button.
• The Sequence option STRT and CRTR will
have additional parameter settings. By
pushing the Lower Display push button a
second time, while STRT or CRTR appear
in the upper display, allows entering voltage
(MIG) or Arc Adjust [Pulse, Accu-pulse, or
RMD (optional)]. Use the Adjust knob to
change the values indicated by the flashing
LED for either Volts or Arc Adjust. Pressing
the Lower Display push button a third time
will activate the WFS setting for either STRT
or CRTR and the WFS LED will begin flashing. Use the Adjust knob to change the WFS
value.
• Pressing the Feeder Set Up button two
more times will exit the Sequence menu and
return the system to standby mode.
4 Trigger Control LED
• Press the Feeder Set Up button twice and
the Trigger Control LED will illuminate, and
the upper display will show the different trigger control selections. Use the Adjust knob
to cycle through the trigger control methods
as follows: DS, TH, TDS, TPS, and 4T (see
Section 5-1 for definitions). The lower display will show the current state of each trigger control method as being on or off. Not all
trigger control methods are compatible with
each other, therefore, turning on certain trigger selections will cause other trigger selections to turn off.
• Press the lower display push button to illuminate the push-button LED and enable the
use of the Adjust knob to allow turning selected trigger control methods on or off. If
trigger hold is set to on, the Trigger Hold
LED will illuminate.
. Trigger Hold is automatically set to On
with the 4T trigger selection. This is part
of the 4T function.
• Press the Feeder Set Up button a third time
to cycle back to standby mode.
5 Lock LED
• The lock LED is illuminated when one or more
programs have been locked using an optional
PDA with File Management/WaveWriter
software. This indicates that some programs
have been disabled. A disabled program will
not show up for selection.
Refer to the File Management/WaveWriter
Owner’s Manual for additional information.
5-8. Adjust Knob
1
Adjust Knob
The Adjust knob is used to change
functions and parameters. Refer to
the front panel sections for
information regarding use of this
control.
1
Adjust
OM-226 021 Page 25
5-9. Process Set Up Push Button
1
2
3
Process
Wire Type
Gas Type
3
Process Set Up Push Button
Process Set Up LED
Program Selection LEDs
2
1
Process Set Up
• Press the Process Set Up push button the
first time will illuminate the button LED and
the Process LED. The upper and lower
displays will be used for Accu-pulse and
only the lower display for MIG, Pulse and
RMD (optional) to show the current process
installed in this program. To change
process, turn the adjust knob.
• Pressing the Process Set Up push button a
second time will illuminate the Wire Type
LED and the lower display will show wire
types available for selected processes (see
Table 4-1 for wire abbreviation). To make a
selection, turn the Adjust knob.
• Pressing the Process Set Up push button a
third time will keep Wire Type LED lit and the
upper display will show wire alloy type (see
Table 4-1 for alloy types). The upper display
push-button LED will be flashing indicating
that turning the Adjust knob will change the
alloy type for the selected process and wire
type.
• Pressing the Process Set Up push button a
fourth time will keep Wire Type LED lit and
the upper display will show wire size. The
upper display push button will be flashing
indicating that turning the Adjust knob will
select wire sizes available for that particular
process and wire type.
• Pressing the Process Set Up push button a
fifth time will illuminate the Gas Type LED
and the lower display will show GAS and the
upper display will show gas selection (see
Table 4-1 for gas abbreviations). To make a
gas type selection, turn the Adjust knob.
• If any of the Process, wire type, alloy type,
wire size, or gas type was changed, then
pressing the Process Set Up push button a
sixth time will show PROG in the upper
display and LOAD in the lower display. The
new program would be loaded for that
particular program in slot 1 thru 8. If no
changes were made to any setup items, no
program will be loaded, and unit will return
to standby mode.
• If a custom program is loaded using an
optional PDA with File Management/WaveWriter software, the Program Display will
have a “C” in front of the program number.
This indicates that the program is not a
factory default program and has been
modified. By selecting or changing any
process variable and performing a program
load will restore the program back to the
factory default program.
• Pressing and holding the Process Set Up
push button in on power up allows viewing
the software revisions of each circuit board
in the system. The top display shows the
board (PCM, UIM, WFCM, and AIM (automated units only) and the lower display
shows the last 3 digits of the circuit board
part number plus a letter designator. Press
the flashing Feeder Set Up push button to
exit the screen displays and continue the
power up process.
Table 4-1. Welding Wire And Gas Abbreviations*
Wire Description
Wire Abbreviation
Alloy Type
Gas Type
Gas Abbreviation
Steel
STL
E70, E100, E120
100% CO2,
90% Argon/10% CO2,
85% Argon/15% CO2,
75% Argon/25% CO2,
95% Argon/5% CO2,
95% Argon /5% O2,
98% Argon/2% O2
CO2
C10
C15
C25
C5
OX5
OX2
Stainless Steel
SS
308, 309, 312, 316
98% Argon, 2% O2
(81Ar/18HE/1CO2
Accu-pulse)
90HE/7-1/2Ar/2-1/2CO 2
MIG/RMD/Accu-pulse)
OX2
Tri Gas
71, 76, 86R, 409,
439
90% Argon/10% CO2
C10
98% Argon/2% O2
OX2
4XXX, 5XXX
100% Argon
ARGN
Cored Tubular Wire
Aluminum
MCOR
ALUM
* Not all wire types may be available with your unit.
OM-226 021 Page 26
Tri Gas
5-10. Jog/Purge
1
2
3
4
5
6
3
Left Side Jog/Purge Switch
Right Side Jog/Purge Switch
Adjust Control
Left Side Gun Trigger
Receptacle
Right Side Gun Trigger
Receptacle
Left/Right Side Select Switch
5
4
1
6
2
The Jog/Purge switch provides the following
functions:
• Pressing left side of the Jog/Purge switch
allows the operator to feed wire without
energizing the weld power or gas valve
circuit. The wire will feed at a 50 ipm rate for
3 seconds, then the rate ramps up to 700
ipm until the Jog switch is released.
. “ERR STRT” will occur after the first 3
seconds of run in without starting an arc
preventing wire jog when using the gun
trigger. To use the gun trigger to jog wire,
the Start Error time must be increased
using an optional PDA with File
Management software.
804 088-A
• The unit also provides the ability to jog the
wire feeder by means of the gun trigger.
When the gun trigger is pressed without
starting an arc, the wire will feed at run-in
speed for the first 3 seconds. During this
time OCV (open circuit voltage) will be
present as indicated on feeder upper
display. After 3 seconds the weld output
turns off and the wire will feed at 50 ipm for
the next 3 seconds and then ramps up to
700 ipm until trigger is released or 30
seconds elapses. If the gun trigger is still
activated after 30 seconds, the jog
operation is terminated to prevent complete
unspooling of the wire and an “ERR STRT”
message is displayed on the upper and
lower displays. Releasing and pressing the
trigger again will clear the error.
• Pressing right side of the Jog/Purge switch
allows the operator to purge gas lines before
welding and to preset gas pressure at the
regulator.
• This unit is equipped with Auto Thread
capability. By rocking the switch from purge
to jog within 0.5 seconds will automatically
feed wire for a factory default setting of 192
in (4877 mm) of wire before stopping. The
default feed rate is 700 ipm. These settings
can be changed using an optional PDA with
File Management software.
OM-226 021 Page 27
5-11. Reset Mode
Program
. Reset mode is not active when
Program Lock is enabled.
RST
Volts
Time
NO
WFS
Amps
The reset mode allows the operator to
reload factory program settings for all
eight active programs in the unit.
Arc Adjust
Arc Ctl
. System configuration data will be
Sequence
Trigger Control
Process
Wire Type
Gas Type
Trigger Hold
Process Set up
Adjust
lost during the Reset operation.
Feeder Set Up
Enter reset mode by turning power On and pressing
the Program Push Button until the RST NO message
is displayed. RST NO message will not display until
after the power-up sequence is completed
(approximately 20 seconds).
Program
RST
Volts
Time
YES
WFS
Amps
Volts
WFS
Trigger Hold
Adjust
RST
Time
YES
Arc Ctl
Sequence
Trigger Control
Process
Wire Type
Gas Type
Process Set up
Program
Arc Adjust
Feeder Set Up
Rotate Adjust knob to change NO
to YES.
Amps
Volts
Time
WFS
Feeder Set Up
Amps
Arc Adjust
Process Set up
Arc Ctl
Sequence
Trigger Control
Process
Wire Type
Gas Type
Trigger Hold
Adjust
CYCL
PWR
Arc Ctl
Sequence
Trigger Control
Process
Wire Type
Gas Type
Process Set up
Program
Arc Adjust
Trigger Hold
Adjust
Feeder Set Up
Press the Arc Control button to
confirm the reset.
Cycl Pwr message appears on the display
when programs complete loading.
The reset message is displayed for
2 seconds while factory program
settings are being reloaded.
Turn power off, wait 10 seconds, and turn
power back on again to complete the reset
operation.
During the reset mode the following
factory default programs are loaded
into the unit:
Program 1
Pulse
.035 Mild Steel
90% Argon, 10% CO2
Program 2
MIG
.035 Mild Steel
75% Argon, 25% CO2
Program 3
Accu-pulse
.035 Mild Steel
90% Argon, 10% O2
Program 4
Pulse
.045 Mild Steel
90% Argon, 10% CO2
Program 5
MIG
.045 Mild Steel
75% Argon, 25% CO2
Program 6
Accu-pulse
.045 Mild Steel
90% Argon, 10% O2
Program 7
Pulse
.052 Mild Steel
90% Argon, 10% CO2
Program 8
MIG
.052 Mild Steel
75% Argon, 25% CO2
. After
Reset is complete, be sure to load
appropriate programs that contain the
correct wire size, process, and shielding gas
for the welding operation
198 993 / 803 246-B
OM-226 021 Page 28
SECTION 6 − SETTING SEQUENCE PARAMETERS
6-1. Sequence Parameters In A Program
. For more information on
Sequence mode, see Feeder
Set Up Push Button in Section
5-7.
If time is set to zero in any timed
sequence, the sequence is skipped.
. Maximum IPM may actually be
Sequence
lower depending on the process
and wire type selection.
Parameters
Volts/Arc
Adjust
IPM
Seconds
1. Preflow
——
——
Off-5.0
2. Postflow
——
——
Off-5.0
3. Start
10.0-44.0/
0-99
50-1400*/
0-99
Off-5.0
4. Crater
10.0-44.0/
0-99
50-1400*/
0-99
Off-5.0
5. Weld
——
——
5. Retract
——
50-1400*
Infinite-999.9
Off-1.0
* Mimimum setting is 50 IPM or lowest taught point of a program.
Crater WFS
Preflow
Time
Start
Time
Weld WFS
Wire Speed
Weld Time
Crater
Time
Postflow
Time
Time
Retract
Preflow
Trigger
Pressed
Weld
Crater
Postflow
Sequence
Trigger
Released
OM-226 021 Page 29
SECTION 7 − MAINTENANCE
7-1. Routine Maintenance
!
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
Every
3
Months
Disconnect power
before maintaining.
~ Weld Terminals
l Damaged Gas Hose
nl Cords
nl Gun Cables
nl Cracked Parts
OR
~ Drive Rolls
OM-226 021 Page 30
~ Inside Unit
during severe conditions.
l = Replace
l Unreadable Labels
Every
6
Months
. Maintain more often
Reference
nl Weld Cables
7-2. Diagnostics
The following error messages are shown on the
upper and lower displays to indicate specific errors.
Explanations are in the text below:
ERR
ERR
ERR
ERR
ERR
ERR
TACH
MOTR
WFS
STRT
STOP
FLOW
Indicates a
tachometer error.
Indicates a motor
error.
Indicates a wire
feed speed error.
Indicates an arc
start error.
Indicates an arc
stop error.
Indicates a gas
flow error.
ERR
ERR
ERR
ERR
ERR
ERR
COOL
GND
STUK
TEMP
LINE
ARC
Indicates a coolant
flow error.
Indicates a ground
current error.
ERR TACH
• The tach error occurs 2 seconds after the
loss of tachometer feedback. The motor
speed is regulated through the monitoring of
voltage and current. Press Jog/Purge
button to clear error.
ERR MOTR
• The motor error indicates that the motor
has been drawing too much current for too
long. To remedy this, reduce the wire feed
speed or the wire feeder torque load/duty
cycle. Press Jog/Purge button to clear error.
ERR WFS
• The wire feed speed error indicates actual
wire feed speed does not match wire feed
speed command. Press Jog/Purge button
to clear error.
ERR STRT
• The start error occurs if the user has the
trigger held for more than 3 seconds without
striking an arc, or if a valid arc voltage and
current is not detected. The 3 second arc
start error time can be changed using an optional PDA with File Management software.
Indicates a wire
stuck error.
Indicates a
temperature error.
ERR STOP
• The stop error occurs as result of
obstructions in the wire feed system or a
faulty wire drive system. Check wire feed
and wire drive systems. Press Jog/Purge
button to clear error.
ERR FLOW
• The flow error indicates no gas flow to the
gun. The error may be reset by
reestablishing gas flow to the gun, and then
pressing the Jog/Purge button.
ERR COOL
• The cool error indicates no coolant flow in
water flow switch option. The error may be
reset by reestablishing coolant flow to the
gun, and then pressing the Jog/Purge
button.
ERR GND
• The ground current error occurs if weld
current is detected in the earth ground
connection. May be caused by a conductor
making contact with unit chassis. Check
and repair feeder weld connections. Press
Jog/Purge button to clear error.
Indicates a line
error.
Indicates an arc
error.
ERR STUK
• The stuck error occurs if the welding wire
sticks to the workpiece at the end of a weld.
May be caused by poor weld conditions.
The error may be cleared by cutting wire
from workpiece, and pressing the Jog/
Purge button.
ERR TEMP
• The temperature error indicates welding
power source has overheated and
shutdown. The error may be cleared by
allowing unit to cool down, and pressing the
Jog/Purge button.
ERR LINE
• The line error indicates input power is
outside of unit operating range. Check and
correct input power. Press Jog/Purge
button to clear error.
ERR ARC
• The arc error indicates an arc outage
occurred possibly from a wire feeder error
or power source error. Check wire feeder
and power source. Press Jog/Purge button
to clear error.
OM-226 021 Page 31
7-2.
Diagnostics (Continued)
WELD
MOTR
PLS
OVER
LOW
E
WAIT
COM
WAIT
CRNT
WFS
STOP
Indicates a weld
cycle wait error.
Indicates a motor
communication error.
Indicates a UIM
communication error.
Indicates an
overcurrent error.
RMD
OVER
REL
ERR
DONE
AVER
TRIG
UNKN
Indicates an arc
error.
Indicates an over
Indicates a trigger
average current error. closed error.
WELD WAIT
• The weld wait error indicates unit was not
ready for a weld sequence. Press Jog/
Purge button to clear error.
MOTR COM
• The motor communication error indicates motor board lost data communications. Press Jog/Purge button to clear error.
PLS WAIT
• The uim communication error indicates
user
interface
board
lost
data
communications. Press Jog/Purge button
to clear error.
OVER CRNT
• The over current error indicates welding
power source primary current is too high.
Check and correct input power. Press Jog/
Purge button to clear error.
OM-226 021 Page 32
Indicates a low WFS Indicates an
emergency stop error.
command error.
Indicates an
unknown error.
LOW WFS
OVER AVER
• The low wire feed speed error indicates
actual wire feed speed is lower than wire
feed speed command. Check for
obstructions in the wire feed system or a
faulty wire drive system. Press Jog/Purge
button to clear error.
• The over average error indicates that current is outside the average range for the set
program parameters. Check and correct
program parameters. Press Jog/Purge button to clear error.
E STOP
REL TRIG
• The emergency stop error occurs if the
user presses an emergency stop button.
Reset the emergency stop button and press
Jog/Purge button to clear error.
• The release trigger error indicates the
user held the trigger when starting a weld
program Press Jog/Purge button to clear
error.
RMD DONE
ERR UNKN
• The RMD done error indicates the RMD
demo is completed. Press Jog/Purge button
to clear error.
• The unknown error indicates a malfunction in the system somewhere. Press Jog/
Purge button to clear error.
7-3. Troubleshooting
!
Disconnect power before troubleshooting
Trouble
Remedy
Wire feeds, shielding gas flows, but
electrode wire is not energized.
Check and secure weld cable connections (see Section 4-7).
Electrode wire feeding stops or feeds
erratically during welding.
Check gun trigger connection. See gun Owner’s Manual.
Check gun trigger. See gun Owner’s Manual.
Readjust hub tension and drive roll pressure (see Section 4-14).
Change to correct size drive roll (see Table 9-1).
Clean or replace dirty or worn drive roll.
Incorrect size or worn wire guides.
Replace contact tip or liner. See gun Owner’s Manual.
Remove weld spatter or foreign matter from around nozzle opening.
Have Factory Authorized Service Agency check drive motor or motor control board PC1.
Motor runs slowly.
Check for correct input voltage.
Wire feeder power is on, displays light
up, but unit is inoperative.
Check welding gun trigger leads for continuity, and repair leads or replace gun.
OM-226 021 Page 33
SECTION 8 − ELECTRICAL DIAGRAM
Figure 8-1. Circuit Diagram
OM-226 021 Page 34
223 225-D
OM-226 021 Page 35
SECTION 9 − PARTS LIST
. Hardware is common and
16
15
19
2
18
22
26 − Fig 9-4
15
27
28
30 − Fig 9-4
29
31
2
25
24
32
23
21
20
14
17
31
1 − Fig 9-2
2
14 − Fig 9-3
13
12
11 − Fig 9-5
10
9
8
3
6
8
7
4
5
not available unless listed.
Ref. 803 697-E
Figure 9-1. Main Assembly
OM-226 021 Page 36
Quantity
Item
No.
Dia.
Mkgs.
Part
No.
Description
8
Model
12
16
Figure 9-1. Main Assembly
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
3
4
5
6
6
7
8
9
10
11
12
12
12
12
13
13
14
15
16
17
18
19
20
21
22
23
24
25
. . . . . . . . . . . . . 195 433
. . . . . . . . . . . . . 223 783
. . . . . . . . . . . . . 139 600
. . . . . . . . . . . . . 139 599
. . . . . . . . . . . . . 159 297
. . . . . . . . . . . . . 600 324
. . . . . . . . . . . . . 149 884
. . . . . . . . . . . . . 080 947
. . . . . . . . . . . . . 132 053
. . . . . . . . . . . . . 602 243
. . . . . . . . . . . . . 602 213
. . . . . . . . . . . . . 601 872
. . . . . . . . . . . . . . Fig 9-5
. . . . . . . . . . . . . 149 838
. . . . . . . . . . . . . 149 839
. . . . . . . . . . . . . 078 264
. . . . . . . . . . . . . 079 216
. . . . . . . . . . . . . 075 078
. . . . . . . . . . . . . 079 217
. . . . . . . . . . . . . . Fig 9-3
. . . . . . . . . . . . . . 224 116
. . . . . . . . . . . . . 139 813
. . . . . . . . . . . . . 139 816
. . . . . . . . . . . . . 605 227
. . . . . . . . . . . . . 238 791
. . . . . . . . . . . . . 159 647
. . . . . . . . . . . . . 156 243
. . . . . . . . . . . . . 159 360
. . . . . . . . . . . . . 235 932
. . . . . . . . . . . . . 145 639
. . . . . . . . . . . . . 200 814
. . . 26 . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . .
. . . . . . . . RC13 . . . .
...................
225 867
157 295
604 612
082 050
225 868
149 251
080 328
079 531
. . . . . . . . . . . . . . . . . . . 605 156
. . . . . . . . PLG6 . . . . 079 878
. . . 32 . . . . . . . . . . . . . . 211 989
. . . . . . . . . . . . . . . . . . . 208 810
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
REMOTE OPERATOR INTERFACE (Fig 9-2) . . . . . . . . . 1 . . . . 1 . . . . 1
CABLE, motor/gas 40V DC 20ft . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . . 2
HOSE, gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
HOSE, gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HOSE ASSEMBLY, gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1
CABLE, weld cop strd No. 4/0 (order by ft) . . . . . . . . . . . 22ft . . 26ft . . 30ft
BRACKET, spring retaining . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
BRACKET, spring retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SCREW, cap stl hexhd .375-16 x 1.500 lg . . . . . . . . . . . . 4 . . . . 4 . . . . 4
WASHER, flat stl std .375 . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . 8 . . . . 8
WASHER, lock stl split .375 . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 4 . . . . 4
NUT, stl hex full .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 4 . . . . 4
SUPPORT, hub & reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1
PIPE POST, 4ft w/base or (optional) . . . . . . . . . . . . . . . . . 1 . . . . 1
PIPE POST, 6ft w/base (optional) . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
PIPE POST, 4ft w/base or (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
PIPE POST, 6ft w/base (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
PIPE POST, 4ft w/o base or (optional) . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1
PIPE POST, 6ft w/o base (optional) . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1
BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1
RECEPTACLE, w/leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . . 2
COVER, protector motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1
PANEL, encl cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1
NUT, nyl hex jam .750NPST . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . . 2
VALVE, 40VDC 2way custom port .054 orf w/frict . . . . . . 2 . . . . 2 . . . . 2
INSULATOR, motor clamp . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . . 2
CLAMP, motor top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . . 2
INSULATOR, screw machine . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . 8 . . . . 8
CLAMP, motor base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . . 2
STRIP, buna N compressed sheet .062 x 4.000sq . . . . . 2 . . . . 2 . . . . 2
HOSE ASSY, SAE
.187 ID X .410 OD X 17.000 w/clamps . . . . . . . . . . . . . . . 2 . . . . 2 . . . . 2
. . DRIVE ASSY, wire s/l 4 roll Fig 9-4 . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1
. . GUIDE, monocoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . . 2
. . SCREW, set stl sch 8-32 x .125 cup point . . . . . . . . . . . . 4 . . . . 4 . . . . 4
. . LINER, monocoil inlet wire . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . . 2
. . DRIVE ASSY,WIRE RT 4 ROLL . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1
. . CABLE, trigger 17 ft (including) . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . . 2
. . . . CONNECTOR w/SOCKETS, free hanging . . . . . . . . . . 2 . . . . 2 . . . . 2
. . . . CONNECTOR, circ clamp str rlf
size 11 Amp 206358-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 4 . . . . 4
. . . . CABLE, port No18 4/C (order by ft) . . . . . . . . . . . . . . . 17ft . . 17ft . . 17ft
. . . . HOUSING PLUG & PINS, (service kit) . . . . . . . . . . . . . 1 . . . . 1 . . . . 1
. . FITTING, w/screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . . 2
. . CABLE, volt sense 50 ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . 1
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-226 021 Page 37
. Hardware is common and
not available unless listed.
19
4
1
5
3
2
4
6
8
7
18
9
12
17
11
13
14
10
15
20
21
16
804 089-D
Figure 9-2. Dual Remote Operator Interface
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-2. Dual Remote Operator Interface
. . . 1 . . . . . . . . . . . . . . +223 084
. . . 2 . . . . . . . . . . . . . . . 233 581
. . . 3 . . . . . . . . . . . . . . . 212 808
. . . 4 . . . . . . . . . . . . . . . 097 132
. . . 5 . . . . PC6 . . . . . 221 280
. . . 6 . . . . . . . . . . . . . . . 098 691
. . . 7 . . . . RC1 . . . . . 211 018
. . . . . . PLG40,43,48 . 115 093
. . . 8 . . . . . . . . . . . . . . . 223 082
. . . 9 . . PC2,PC3 . . . 217 362
. . . 10 . . . . . . . . . . . . . . . 200 553
. . . 11 . . . . . S1 . . . . . . 213 632
. . . 12 . . . . PC1 . . . . . 212 459
OM-226 021 Page 38
. . WRAPPER, feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, pc card switch/overlay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BAFFLE, pc mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND−OFF SUPPORT, pc card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WIRE FEED MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND−OFF, no 6−32 x .500 lg .250 hex stl m&f . . . . . . . . . . . . . . . . . .
. . CONNECTOR, circ 97/met 9 pin size 20 rcpt . . . . . . . . . . . . . . . . . . . . . .
. . . . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ENCLOSURE, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSY, motor filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BRACKET, mtg control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SWITCH, rocker dpdt 10A 250VAC/20A 30VAC on-none-on . . . . . . . . .
. . CIRCUIT CARD ASSY, trigger filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
6
1
2
1
1
1
2
1
1
2
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-2. Dual Remote Operator Interface (Continued)
. . . 13 . . . . RC1 . . . . .
. . . 14 . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . . .
. . . 16 . . . . S2,S3 . . . .
.....................
.....................
.....................
. . . 17 . . . . S100 . . . . .
. . . 18 . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . . .
. . . 21 . . . . . . . . . . . . . . .
. . . . . . . . . PLG47 . . . .
. . . . . . . . . PLG48 . . . .
. . . . . . . . . . PLG4 . . . . .
. . . . . . . . . PLG81 . . . .
. . . . . . . . . PLG10 . . . .
. . . . . . . . . PLG50 . . . .
. . . . . . . . . PLG44 . . . .
. . . . . . . . . PLG45 . . . .
. . . . . . . . . PLG42 . . . .
. . . . . . . . . PLG40 . . . .
.....................
.....................
.....................
.....................
.....................
.....................
.....................
.....................
.....................
.....................
048 282
223 083
222 481
210 998
200 295
131 056
131 052
201 641
179 851
134 327
220 063
134 201
115 094
202 592
136 810
115 092
130 203
136 810
131 058
188 352
131 054
201 665
149 251
080 328
079 531
605 156
079 878
224 363
224 193
159 360
010 910
604 224
. . RCPT W/SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . NAMEPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SWITCH ASSY, jog/purge (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . SWITCH, rocker spdt 15A 12V (on)-off-(on) . . . . . . . . . . . . . . . . . . . . . 2
. . . . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . SWITCH, rocker SPDT 15A 12V (ON)−OFF−(ON) W/LEDS . . . . . . . . . 1
. . KNOB, pointer 1.670 dia x .250 id push on w/spring . . . . . . . . . . . . . . . . 1
. . LABEL, Warning General Precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CIRCUIT CARD ASSY, relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . STAND−OFF SUPPORT, pc card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOUSING PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOUSING RCPT+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOUSING RCPT+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOUSING RCPT PLUG+SKTS, (service kit) . . . . . . . . . . . . . . . . . . . . . . 1
. . CABLE, trigger 17 ft (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR w/SOCKETS, free hanging . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR, circ clamp str rlf size 11 Amp 206358-2 . . . . . . . . . . . 2
. . . . CABLE, port No18 4/C (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17ft
. . . . HOUSING PLUG & PINS, (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . KIT, insulator ROI (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . INSULATOR, plate ROI mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . INSULATOR, screw machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . WASHER, flat .406 ID x .812 OD x .65 T stl pld . . . . . . . . . . . . . . . . . . 4
. . . . SCREW, 250-20 x .75 hexwhd .50 D stl pld . . . . . . . . . . . . . . . . . . . . . . 4
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-226 021 Page 39
15
16
8
13
14
9
12
6
7
8
9
11
3
10
5
4
17
21
27
30
1
28
26
2
not available unless listed.
23
26
24
25
22
18
20
19
29
. Hardware is common and
Ref. 804 335-A
Figure 9-3. Boom Assembly
OM-226 021 Page 40
Quantity
Item
No.
Dia.
Mkgs.
Part
No.
Description
8
Model
12
16
Figure 9-3. Boom Assembly (Fig 9-1 Item 13)
. . . 1 . . . . . . . . . . . . . 000 527
. . . 2 . . . . . . . . . . . . . 237 736
. . . 2 . . . . . . . . . . . . . 159 999
. . . 2 . . . . . . . . . . . . . 160 513
. . . 3 . . . . . . . . . . . . . 237 740
. . . 3 . . . . . . . . . . . . . 079 665
. . . 3 . . . . . . . . . . . . . . 080 811
. . . 4 . . . . . . . . . . . . . 079 664
. . . 5 . . . . . . . . . . . . . 139 633
. . . 6 . . . . . . . . . . . . . 073 742
. . . 7 . . . . . . . . . . . . . 073 741
. . . 8 . . . . . . . . . . . . . 079 029
. . . 9 . . . . . . . . . . . . . 075 462
. . . 10 . . . . . . . . . . . . . 602 250
. . . 11 . . . . . . . . . . . . . 079 020
. . . 12 . . . . . . . . . . . . . 149 858
. . . 12 . . . . . . . . . . . . . 080 723
. . . 13 . . . . . . . . . . . . . 150 258
. . . 14 . . . . . . . . . . . . . 024 605
. . . 15 . . . . . . . . . . . . . 075 101
. . . 16 . . . . . . . . . . . . . 079 030
. . . 17 . . . . . . . . . . . . +174 754
. . . . . . . . . . . . . . . . . . . 080 157
. . . 18 . . . . . . . . . . . . . 174 688
. . . . . . . . . . . . . . . . . . . 142 804
. . . . . . . . . . . . . . . . . . . 134 327
. . . 19 . . . . . . . . . . . . . 073 666
. . . 20 . . . . . . . . . . . . . 047 224
. . . 21 . . . . . . . . . . . . . 602 246
. . . 22 . . . . . . . . . . . . . 236 033
. . . 22 . . . . . . . . . . . . . 079 667
. . . 22 . . . . . . . . . . . . . 080 812
. . . 23 . . . . . . . . . . . . . 079 632
. . . 24 . . . . . . . . . . . . . 602 243
. . . 25 . . . . . . . . . . . . . 079 622
. . . 26 . . . . . . . . . . . . . 010 313
. . . 27 . . . . . . . . . . . . . 079 621
. . . 28 . . . . . . . . . . . . . 139 336
. . . 29 . . . . . . . . . . . . . 237 442
. . . 29 . . . . . . . . . . . . . 220 330
. . . 30 . . . . . . . . . . . . . 220 331
. . . . . . . . . . . . . . . . . . . 149 322
. . PLUG, 0.875 inch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . BOOM, dual 8ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BOOM, dual 12ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BOOM, dual 16ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GUIDE, wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . GUIDE, wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . GUIDE, wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GUIDE, wire inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . .
. . LINER, monocoil 3/32-1/8 wire x 15.687 . . . . . . . . . . . . . . 2 . . . . 2 . . . .
. . PIN, clevis .750 OD x 2.156 lg . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . CLEVIS, .812 yoke 6.062 lg .750-16thd . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . NUT, stl hex full fnsh .750-16 . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . .
. . SHAFT, boom counterbalance . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . WASHER, flat stl SAE .750 . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . .
. . NUT, stl hex elastic stop .750-16 . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . SPRING, cprsn 3.750 OD x .625 wire x 36.000 . . . . . . . . 1 . . . . 1
. . SPRING, cprsn 3.750 OD x .687 wire x 33.750 . . . . . . . . . . . . . . . . . . . . . .
. . RETAINER, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . BEARING, ball thr sgl row .750 x 1.625 x .625 . . . . . . . . . 1 . . . . 1 . . . .
. . NUT, stl hex special .750-16 x 1.250 . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . WASHER, lock stl ext tooth .750 . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . BASE, swivel boom (consisting of) . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . . FITTING, grease 1/8NPT . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . . BRACKET, mtg control tilt . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . LABEL, Swingarc caution heavy spring . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . LABEL, warning general precautionary . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . BOLT, mach stl hexhd .750-16 x 2.750 . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . KNOB, T-bar .500-13 thd . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . WASHER, flat stl std .500 . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . PIPE, plstc .500 X 85.750 . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . PIPE, plstc .500 x 133.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . PIPE, plstc .500 x 181.750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BOLT, U stl .250-20 x .875 wide x 1.375 deep . . . . . . . . . 8 . . . . 8 . . . .
. . WASHER, flat stl std .375 . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . 8 . . . .
. . WASHER, shldr .381 ID x .750 OD . . . . . . . . . . . . . . . . . . 4 . . . . 4 . . . .
. . PIN, cotter hair .072 x 1.437 . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 4 . . . .
. . PULLEY, V sgl grv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . .
. . GUARD, motor protector . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . CHANNEL, harness wire 85.500 in 2.188 in wide . . . . . . 1
. . CHANNEL, harness wire 67 in 2.093 in wide . . . . . . . . . . . . . . . . . 1 . . . .
. . CHANNEL, harness wire 67 in 2.125 in wide . . . . . . . . . . . . . . . . . 1 . . . .
. . CLAMP, hose .405 − .485clp . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . .
1
1
2
2
2
1
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
10
8
4
4
2
1
1
2
2
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-226 021 Page 41
16
17
18
See Table 9-1
Drive Roll & Wire Guide Kits
19
20
21
. Hardware is common and
15
22
23
24
not available unless listed.
25
26
6
5
7
51
10
52
8
3
2
1
2
9
4
3
12
11
27
53
14
13
43
1
32
3130
29
28
35
36
42
41
39
40
38
34
44
51
7
3
37
2
1
4
42
33
2
52
5
6
3
1
48
47
46
49
50
Ref. 804 105-D
Figure 9-4. Drive Assembly, Wire
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-4. Drive Assembly, Wire
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
10
11
12
13
14
15
15
. . . . . . . . . . . . . 010 668
. . . . . . . . . . . . . 172 075
. . . . . . . . . . . . . 149 962
. . . . . . . . . . . . . 149 486
. . . . . . . . . . . . . 163 281
. . . . . . . . . . . . . 165 799
. . . . . . . . . . . . . 132 750
. . . . . . . . . . . . . 133 493
. . . . . . . . . . . . . 133 350
. . . . . . . . . . . . . 221 627
. . . . . . . . . . . . . 223 885
. . . MOTOR . 199 446
. . . . . . . . . . . . . 130 204
. . . . . . . . . . . . . . 115 091
. . . . . . . . . . . . {229 550
. . . . . . . . . . . . . 203 631
. . . . . . . . . . . . . 203 642
OM-226 021 Page 42
. . SCREW, cap stl sch .250-20 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CARRIER, drive roll w/comp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SPACER, carrier drive roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PIN, rotation arm rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SPRING, pressure arm retaining LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, flat .257 ID x 0.615 OD x .091t stl pld . . . . . . . . . . . . . . . . . . . . .
. . ARM, pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RING, retaining ext .250 shaft x .025thk . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PIN, hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . MOTOR, gear LH (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . MOTOR, gear RH (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . MOTOR, gear 1/8hp 40VDC 500 RPM . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HOUSING PLUG PINS+SKTS,(service kit) . . . . . . . . . . . . . . . . . . . . . . . .
. . . . HOUSING PLUG + SKTS (service kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . ENCODER, quadrature 500 ppr incremental 5V shaftless . . . . . . . . . . .
. . PRESSURE ARM ASSY LH (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PRESSURE ARM ASSY RH (including) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
4
2
2
2
2
2
1
1
1
1
1
1
1
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-4. Drive Assembly, Wire (Continued)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
34
35
36
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
.............
203 637
602 200
604 772
182 156
182 155
132 746
182 415
181 522
182 414
203 632
133 739
203 640
167 387
168 825
133 308
108 940
604 224
179 263
184 685
184 686
149 959
179 265
179 264
604 538
151 437
128 237
010 910
602 213
601 872
601 966
235 932
159 360
604 535
604 538
156 243
159 647
145 639
150 520
163 282
200 814
. . . . KNOB, w/extension arm long pressure arm . . . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER, lock stl split No. 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER, flat stl SAE No. 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SPRING, cprsn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . BUSHING, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . PIN, cotter hair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SHAFT, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER, flat .406 ID x 0.73 OD x .065 t stl pld 3/8type b . . . . . . . . . . .
. . . . CARRIER, shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER, flat buna .375 ID x .625 OD x .062thk . . . . . . . . . . . . . . . . . . .
. . . . KNOB, w/extension short pressure arm . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SPACER, locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . DRIVE, pinion 24 pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RING, retaining ext .375 shaft x .025thk . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, cap stl hexhd .250-20 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, 250−20 x .75 hex whd .50d stl pld slf fmg tap−rw . . . . . . . . . . . .
. . COVER, drive roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ADAPTER ASSY, gun/feeder LH (including) . . . . . . . . . . . . . . . . . . . . . . . . .
. . ADAPTER ASSY, gun/feeder RH (including) . . . . . . . . . . . . . . . . . . . . . . . .
. . . . FITTING, brs barbed M 3/16tbg x .312-24 . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . ADAPTER, gun/feeder LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . ADAPTER, gun/feeder RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER, flat stl SAE .312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . KNOB, plstc T 1.125 lg x .312-18 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SCREW, mach stl hexwhd 10-32 x .500 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . WASHER, flat .406 ID x 0.812 OD x .065t stl pld ansi.375 . . . . . . . . . .
. . . . WASHER, lock stl split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . NUT, stl hex full fnsh .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SCREW, cap stl hexhd .375-16 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, motor base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . INSULATOR, screw machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, 312−18 x 1.50 hex hd−pln gr5 pld . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, flat .344ID x 0.688OD x .065T stl pld ansi.312 . . . . . . . . . . . . .
. . CLAMP, motor top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . INSULATOR, motor clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STRIP, buna-n .062 x 3.000 x 4.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SPACER, rotation pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT, 250−28 .37HEX .25H STL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HOSE ASSY, SAE .187 ID X .410 OD X 17.000 w/clamps . . . . . . . . . . . .
1
1
1
2
2
2
1
1
1
1
1
1
2
1
1
4
2
1
1
1
1
1
1
1
1
2
1
1
1
1
1
4
1
3
1
1
1
2
2
1
{Have nearest Factory Authorized Service Agent replace encoder.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-226 021 Page 43
. Hardware is common and
not available unless listed.
081 7690-D
Figure 9-5. Support, Hub & Reel
Item
No.
Part
No.
Description
Quantity
Figure 9-5. Support, Hub & Reel (Fig 9-1 Item 10)
. . . . . . 1 . . . . . . 058 427
. . . . . . 2 . . . . . . 136 684
. . . . . . 3 . . . . . . 605 941
. . . . . . 4 . . . . . . 010 233
. . . . . . 5 . . . . . . 057 971
. . . . . . 6 . . . . . . 010 191
. . . . . . 7 . . . . . . 058 628
. . . . . . 8 . . . . . . 058 428
. . . . . . 9 . . . . . . 080 393
. . . . . 10 . . . . . ♦108 008
. . . . . . 11 . . . . . . 124 900
. . . . . 12 . . . . . . 124 905
. . . . . 12 . . . . . +168 104
. . . . . . . . . . . . . . . 166 594
. . . . . 13 . . . . . . 124 904
. . . . . 13 . . . . . . 168 103
. . RING, retaining spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT, stl slflkg hex reg .625-11 w/nyl insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, flat stl .640 ID x 1.000 OD x 14ga thk . . . . . . . . . . . . . . . . . . . . . . . . .
. . SPRING, cprsn .970 OD x .120 wire x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, flat stl keyed 1.500dia x .125thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, fbr .656 ID x 1.500 OD x .125thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, brake stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HUB, spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SUPPORT, reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . REEL, wire 60 lb (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . SUPPORT, reel spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . RETAINER, spool support (Prior to KE623992) . . . . . . . . . . . . . . . . . . . . . . . .
. . . . RETAINER, spool support (Eff w/KE623992) (consisting of) . . . . . . . . . . . . .
. . . . . . LABEL, caution falling wire reel can cause damage . . . . . . . . . . . . . . . . . . .
. . . . NUT, spanner spool support (Prior to KE623992) . . . . . . . . . . . . . . . . . . . . . . .
. . . . NUT, spanner retaining (Eff w/KE623992) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
2
2
2
4
4
2
1
2
1
1
1
1
1
1
♦OPTIONAL
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-226 021 Page 44
Inlet Guide
221030
221030
221030
229919
229919
Wire Sizes
.023 to .040 in. (0.6 to 1.0mm)
.045 to .052 in. (1.1 to 1.4mm)
1/16 to 5/64 in. (1.6 to 2mm)
3/32 to 7/64 in. (2.4 to 2.8mm)
1/8 in. (3.2mm)
Wire Guides
*Accommodates .045 and .047 (3/64 in) wire
**Requires a low *speed wire feeder
149522
149521
149520
149519
149518
Intermediate Guide
151042
151043**
151076**
151075
151074
151073
151072
151071
151070
”U” COGGED FOR
EXTREMELY SOFT
WIRE OR SOFT
*
SHELLED CORED
WIRES
1/16 in. (1.6mm)
.047 in. (1.2mm)
.035 in. (0.9mm)
Wire Size
221912
221912
221912
Inlet Guide
Nylon Wire Guides for Feeding Aluminum Wire
151060**
151059
151058
1/8 in. (3.2 mm)
151055
7/64 in. (2.8 mm)
151039
151054
151053
151041
151029
1/16 in. (1.6 mm)
151038
151037*
3/32 in. (2.4 mm)
151028
.052 in. (1.3/1.4 mm)
151057
151027
.045 in. (1.1/1.2 mm)
151056
161190
.040 in. (1.0 mm)
151052
151040
151026
.035 in. (0.9 mm)
”V” KNURLED FOR
HARD*SHELLED
CORED WIRES
5/64 in. (2.0 mm)
151025
.030 in. (0.8 mm)
”U” GROOVE FOR
SOFT*SHELLED
CORED WIRES
.068/.072 in. (1.8 mm)
151024
.023/.025 in. (0.6 mm)
WIRE SIZE
”V” GROOVE FOR
HARD WIRE
205937
205936
242417
Intermediate Guide
243235
243234*
243233
”U” GROOVE FOR
ALUMINUM WIRES
CONTAINS NYLON
WIRE GUIDES
Table 9-1. Drive Roll And Wire Guide Kits
OM-226 021 Page 45
Notes
Effective January 1, 2009
(Equipment with a serial number preface of LK or newer)
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions
* Induction Heating Coils and Blankets, Cables, and
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
Non-Electronic Controls
its original retail purchaser that new Miller equipment sold after
* APT & SAF Model Plasma Cutting Torches
the effective date of this limited warranty is free of defects in
* Remote Controls
material and workmanship at the time it is shipped by Miller. THIS
* Accessory (Kits)
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* Replacement Parts (No labor)
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or
* Canvas Covers
replace any warranted 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 defect 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 delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.
1.
2.
3.
4.
5.
5 Years Parts — 3 Years Labor
* Original main power rectifiers only to include SCRs,
diodes, and discrete rectifier modules
3 Years — Parts and Labor
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Sources (Unless Otherwise Stated)
* Water Coolant Systems (Integrated)
* Intellitig
* Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
1 Year — Parts and Labor Unless Specified
* Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources, Coolers, and
Electronic
Controls/Recorders
* Water Coolant Systems (Non-Integrated)
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Spot Welders
* Load Banks
* Fume Extractors
* Arc Stud Power Sources & Arc Stud Guns
* Racks
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF
Models)
* Field Options
(NOTE: Field options are covered under True Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
* Bernard-Branded Mig Guns (No Labor)
* Weldcraft-Branded TIG Torches (No Labor)
* Subarc Wire Drive Assemblies
6 Months — Batteries
90 Days — Parts
* MIG Guns and Subarc (SAW) Guns
Miller’s True Blue® Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
(Exception: brushes, slip rings, and relays are
covered on Bobcat, Trailblazer, and Legend
models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
3.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement 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 LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
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,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
Some states in the U.S.A. do not allow limitations 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 specific
legal rights, and other rights may be available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations 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.
miller_warr 2009−01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2009 Miller Electric Mfg. Co.
2009−01
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