Miller | LG390101G | Owner Manual | Miller PIPEPRO SINGLE DX User manual

Miller PIPEPRO SINGLE DX User manual
OM-230 010A
2006−09
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
(Gas- And Self-Shielded)
Description
Wire Feeder
PipePro
Single DX
File: MIG (GMAW)
Visit our website at
www.MillerWelds.com
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. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Selecting Site And Connecting Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Typical Connection Diagram For TIG Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Typical Connection Diagram For Stick Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Rear Panel Connections And Rotating Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. 14-Pin Plug Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Installing And Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Setting Internal DIP Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Jog/Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Program Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Upper Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Lower Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Setup Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9. Adjust Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-10. Sequence Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-11. Auxiliary Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-12. Remote-14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − SETTING SEQUENCE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Sequence Parameters In A Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − SETTING DUAL SCHEDULE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Optional Dual Schedule Switch Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _3/05
Y Warning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
Y 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.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
D
D
D
D
D
D
Y 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 Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D
D
D
D
D
D
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists in inverter-type
welding power sources after removal of input
power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
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.
OM-230 010 Page 1
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 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 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.
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 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 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.
OM-230 010 Page 2
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.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding 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.
MOVING PARTS can cause injury.
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.
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 as
necessary.
D Reinstall doors, panels, covers, or guards
when maintenance is finished and before reconnecting input power.
FALLING UNIT can cause injury.
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.
READ INSTRUCTIONS.
D Read Owner’s Manual before using or servicing unit.
D Use only genuine Miller/Hobart replacement
parts.
H.F. RADIATION can cause interference.
OVERUSE can cause OVERHEATING
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.
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.
D
D
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.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
D
WELDING WIRE can cause injury.
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
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.
1-4. California Proposition 65 Warnings
Y 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.)
For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
Y 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 Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
OM-230 010 Page 3
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).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
800−463−6727 or in Toronto 416−747−4044, website: www.csa−international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1 from Global Engineering Documents (phone:
1-877-413-5184, website: www.global.ihs.com).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
website: www.ansi.org).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (phone: 617−770−3000, website: www.nfpa.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000,website: www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, website: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
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 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220,website: www.osha.gov).
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-230 010 Page 4
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor before welding or going near
welding operations. If cleared by your doctor, then following the above
procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
som _3/05
Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
2-1.
Symboles utilisés
Symbole graphique d’avertissement ! Attention ! Cette procédure comporte des risques possibles ! Les dangers éventuels sont représentés par les symboles graphiques joints.
Y Indique un message de sécurité particulier
. Signifie NOTE ; n’est pas relatif à la sécurité.
2-2.
Ce groupe de symboles signifie Avertissement ! Attention ! Risques
d’ÉLECTROCUTION, ORGANES MOBILES et PARTIES
CHAUDES. Consulter les symboles et les instructions afférentes
ci-dessous concernant les mesures à prendre pour supprimer
les dangers.
Dangers relatifs au soudage à l’arc
Y 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.
Y Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
Y Pendant le fonctionnement, maintenir à distance toutes les personnes, notamment les enfants de l’appareil.
D Vérifier fréquemment le cordon d’alimentation afin de s’assurer qu’il
D
D
D
D
D
D
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
D
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
D
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et sans
D
D
D
D
D
D
D
D
D
trous.
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.
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.
Se servir d’une source électrique à courant électrique UNIQUEMENT si
le procédé de soudage le demande.
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’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 !
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).
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.
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.
En effectuant les raccordements d’entrée, fixer d’abord le conducteur
de mise à la terre approprié et contre-vérifier les connexions.
D
D
D
n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est. Un fil à nu
peut entraîner la mort.
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante
ou mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct.
Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre
ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines en
même temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à
ce manuel.
Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
S’assurer que tous les panneaux et couvercles sont correctement en
place.
Fixer le câble de retour de façon à obtenir un bon contact métal-métal
avec la pièce à souder ou la table de travail, le plus près possible de la
soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à
une même borne de sortie de soudage.
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur quand on a coupé
l’alimentation.
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 FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereuse pour la santé.
D Ne pas mettre sa tête au-dessus des vapeurs. Ne pas respirer ces vapeurs.
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 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.
OM-230 010 Page 5
LES RAYONS D’ARC peuvent entraîner des brûlures aux yeux et à la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer des brûlures 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 pendant le soudage (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.
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 peuvent
provoquer des incendies et des brûlures. Le contact accidentel de
l’électrode avec des objets métalliques peut provoquer des étincelles,
une explosion, une surchauffe 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 homologuées.
D Ne pas souder dans un endroit où des étincelles peuvent tomber sur
des substances inflammables.
D Se protéger, ainsi que toute autre personne travaillant sur les lieux,
contre les étincelles et le métal chaud.
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 Afin d’éliminer tout risque de feu, être vigilant et garder toujours un
extincteur à la portée de main.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
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 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 exempts d’huile tels que des
gants en cuir, une veste résistante, des pantalons sans revers, des
bottes et un casque.
D Avant de souder, retirer toute substance combustible de ses poches
telles qu’un allumeur au butane ou des allumettes.
D Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA 51B
pour travaux de soudage et prévoir un détecteur d’incendie et un extincteur à proximité.
DES
PARTICULES
VOLANTES
peuvent blesser 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.
OM-230 010 Page 6
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.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
D Ne pas toucher des parties chaudes à mains
nues.
D Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
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.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, rester
à distance.
D Les porteurs d’un stimulateur cardiaque doivent d’abord consulter leur médecin avant de
s’approcher des opérations de soudage à l’arc,
de gougeage ou de soudage par points.
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.
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.
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.
DES ORGANES MOBILES peuvent
provoquer des blessures.
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.
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 Seules des personnes qualifiées sont autorisées à enlever les
portes, panneaux, recouvrements ou dispositifs de protection
pour l’entretien.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
LA CHUTE DE L’APPAREIL peut
blesser.
LIRE LES INSTRUCTIONS.
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.
L’EMPLOI EXCESSIF peut
CHAUFFER L’ÉQUIPEMENT.
D Lire le manuel d’utilisation avant d’utiliser ou
d’intervenir sur l’appareil.
D Utiliser uniquement des pièces de rechange
Miller/Hobart.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE (HF) risque de provoquer
des interférences.
SUR-
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.
D
D
D
LES CHARGES ÉLECTROSTATIQUES
peuvent endommager les circuits
imprimés.
D
D
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 PC.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
D
D
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D
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.
2-4.
D Le rayonnement haute fréquence (HF) peut
provoquer des interférences avec les équipements de radio-navigation et de communication, les services de sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement
l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
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.
D
D L’énergie électromagnétique peut gêner le
fonctionnement d’appareils électroniques
comme des ordinateurs et des robots.
D 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.
Proposition californienne 65 Avertissements
Y 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)
Pour les moteurs à essence :
Y 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.
Y 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.
Pour les moteurs diesel :
Y 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.
OM-230 010 Page 7
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).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone :
800-463-6727 ou à Toronto 416-747-4044, site Internet :
www.csa-international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS
F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, de American National Standards Institute, 11 West
42nd Street, New York, NY 10036-8002 (téléphone : 212-642-4900, site
Internet : www.ansi.org).
National Electrical Code, NFPA Standard 70, de National Fire Protection
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269-9101 (téléphone : 617-770-3000, site Internet : www.nfpa.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association, P.O.
Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (téléphone :
617-770-3000, site Internet : www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 1735 Jefferson Davis Highway, Suite
1004, Arlington, VA 22202-4102 (téléphone : 703-412-0900, site Internet
: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, de
Canadian Standards Association, Standards Sales, 178 Rexdale
2-6.
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 (il y a 10
bureaux régionaux−−le téléphone de la région 5, Chicago, est
312-353-2220, site Internet : www.osha.gov).
Information EMF
Considérations sur le soudage et les effets de basse fréquence et des
champs magnétiques et électriques.
Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore un
certain souci à propos de tels champs. Cependant, après avoir examiné
plus de 500 études qui ont été faites pendant une période de recherche
de 17 ans, un comité spécial ruban bleu du National Research Council a
conclu : « L’accumulation de preuves, suivant le jugement du comité, n’a
pas démontré que l’exposition aux champs magnétiques et champs électriques à haute fréquence représente un risque à la santé humaine ».
Toutefois, des études sont toujours en cours et les preuves continuent à
être examinées. En attendant que les conclusions finales de la recherche
soient établies, il vous serait souhaitable de réduire votre exposition aux
champs électromagnétiques pendant le soudage ou le coupage.
Pour réduire les champs magnétiques sur le poste de travail, appliquer
les procédures suivantes :
OM-230 010 Page 8
1. Maintenir les câbles ensemble en les tordant ou en les enveloppant.
2. Disposer les câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
4. Garder le poste de soudage et les câbles le plus loin possible de
vous.
5. Connecter la pince sur la pièce aussi près que possible de la soudure.
En ce qui concerne les stimulateurs cardiaques
Les porteurs de stimulateur cardiaque doivent consulter leur médecin
avant de souder ou d’approcher des opérations de soudage. Si le médecin approuve, il est recommandé de suivre les procédures précédentes.
SECTION 3 − DEFINITIONS
3-1. Warning Label Definitions
A
B
1
1.1
2
2.1
3
3.1
4
4.1
5
+
C
1.2
2.2
1.3
2.3
3.2
+
3.3
+
+
6
S-178 936
A. Warning! Watch Out! There
are possible hazards as
shown by the symbols.
B. Drive rolls can injure fingers.
C. Welding wire and drive parts
are at welding voltage during
operation − keep hands and
metal objects clear.
1 Electric shock can kill.
1.1 Wear dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet or
damaged gloves.
1.2 Protect yourself from electric
shock by insulating yourself
from work and ground.
1.3 Disconnect input plug or
power before working on
machine.
2 Breathing welding fumes can
be hazardous to your health.
2.1 Keep your head out of the
fumes.
2.2 Use forced ventilation or local
exhaust to remove the fumes.
2.3 Use ventilating fan to remove
fumes.
3 Welding sparks can cause
explosion or fire.
3.1 Keep flammables away from
welding. Don’t weld near
flammables.
3.2 Welding sparks can cause
fires. Have a fire extinguisher
nearby and have a watch
person ready to use it.
3.3 Do not weld on drums or any
closed containers.
4 Arc rays can burn eyes and
injure skin.
4.1 Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
5 Become trained and read the
instructions before working on
the machine or welding.
6 Do not remove or paint over
(cover) the label.
OM-230 010 Page 9
3-2. Symbols And Definitions
Note
A
IP
Some symbols are found only on CE products.
Amperes
V
Hz
Alternating Current
Hertz
Program
Wire Feed
Jog
Output
Trigger
Line Connection
Set Up
Sequence
Trigger Hold On
Trigger Hold Off
Purge
Press To Set
Start
Crater
Time
Preflow Time
Postflow Time
Read Instructions
Degree Of
Protection
I1
Increase
U1
X
Volts
Primary Voltage
A
B
Primary Current
I2
Rated Current
U2
Duty Cycle
Load Voltage
Dual Schedule
SECTION 4 − INTRODUCTION
4-1. Specifications
Type of Input
Power
Welding Power
Source Type
Wire Feed
Speed Range
Wire
Diameter
Range
Welding
Circuit
Rating
40 Volts dc
10 Amperes
PipePro 450 RFC with 14
Pin and Contactor Control
50 To 780 ipm
(1.3 To 19.8
mpm)
.023 To 1/8 in
(0.6 To 3.2
mm)
100 Volts,
750
Amperes,
100% Duty
Cycle
Max Spool
Weight: 60 lb
(27 kg)
OM-230 010 Page 10
IP
Rating
Overall
Dimensions
Weight
IP 21
Length: 27 in
(686 mm)
45 lb
(20.41 kg)
Width: 12-1/2 in
(318 mm)
Height: 14 in
(356 mm)
SECTION 5 − INSTALLATION
5-1. Selecting Site And Connecting Equipment
1
9
10
3
4
Magnet on end
of volt sense
cable should be
located as close
as possible to
the welding arc.
2
8
7
6
5
804 675-A
Y Do not mount feeder on top of power
source.
Y Do not put feeder where welding
wire hits cylinder.
Y Do not move or operate equipment
when it could tip.
1 Welding Power Source
. Magnet on end of volt sense cable
should be located as close as possible to the welding arc.
7
Wire Feeder
8
Gas Hose
Gas Cylinder
2
Negative Volt Sense Cable
3
Positive (+) Weld Cable
9
Negative (−) Weld Cable
10 14-Pin Feeder Control Cable
5
Workpiece
6
Welding Gun
. Maximum cable length not to exceed
4
150 feet.
OM-230 010 Page 11
5-2. Typical Connection Diagram For TIG Equipment
The illustration shows remote control connected through the wirefeeder.
The wirefeeder is not connected to the power source output.
1
2
3
5
4
6
10
7
9
804 779-A
8
Y Do not mount feeder on top of power source.
1
Welding Power Source
7
2
Gas Cylinder
8
Foot Control
Y Do not put feeder where welding
wire hits cylinder.
3
Gas Hose
9
Wire Feeder
4
Positive (+) Weld Cable
10 14-Pin Feeder Control Cable
Y Do not move or operate equipment
when it could tip.
5
Negative (−) Weld Cable
6
Torch
. Maximum cable length not to exceed
OM-230 010 Page 12
Workpiece
150 feet.
5-3. Typical Connection Diagram For Stick Equipment
The illustration shows remote control connected through the wirefeeder.
The wirefeeder is not connected to the power source output.
1
2
3
4
8
5
7
804 780-A
6
Y Do not mount feeder on top of power source.
Y Do not put feeder where welding
wire hits cylinder.
Y Do not move or operate equipment
when it could tip.
1
Welding Power Source
6
Hand Control
2
Negative (−) Weld Cable
7
Wire Feeder
3
Positive (+) Weld Cable
8
14-Pin Feeder Control Cable
4
Workpiece
5
Electrode Holder
. Maximum cable length not to exceed
150 feet.
OM-230 010 Page 13
5-4. Rear Panel Connections And Rotating Drive Assembly
1
2
14-Pin Control Cable
Shielding Gas Valve Fitting
Connect customer-supplied gas
hose with 5/8-18 right-hand
threads.
. Shielding gas pressure not to
exceed 100 PSI (689 kPa).
3
4
5
6
7
7
Weld Cable Terminal
Weld Cable
Drive Assembly
Drive Assembly Rotation
Knob
Rating Label Location
To rotate the drive assembly, loosen drive assembly rotation knob,
rotate drive assembly, and tighten
knob.
2
1
3
4
5
6
Tools Needed:
9/16, 5/8 in
3/16 in
Ref 804 767-A / 802 824-A / 802 825-A
OM-230 010 Page 14
5-5. 14-Pin Plug Information
Pin*
I
J
H
G
K
A
L C
M D
E
N
F
B
Pin Information
A
40 volts dc with respect to socket G.
G
Circuit common for 40 volts dc circuit.
B
Contact closure to K completes contactor control circuit.
K
Contact closure to B completes contactor control circuit.
C
+10 volts dc input from power source to wire feeder with respect to socket D.
D
Remote volt control circuit common.
E
0 to +10 volts dc remote volt/trim signal from wire feeder to power source with respect to socket D.
H
Voltage feedback; 0 to +10 volts dc, 1 volt per 10 arc volts.
F
Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes.
M
0 to +10 volts dc remote WFS signal from wire feeder to power source with respect to socket N.
N
Remote WFS control circuit common.
L
Electrode sense.
I
Remote Program Select A
J
Remote Program Select B
Notes
OM-230 010 Page 15
5-6. Installing And Threading Welding Wire
Install wire guides and
anti-wear guide.
Install wire spool. Adjust tension nut so
wire is taut when wire feed stops.
Install drive rolls.
Pressure
Adjust
Rear
Rolls
Pressure
Indicator
Scale
Pressure
Adjust
Front
Rolls
No Wire Slip
Wire Slips
NONCONDUCTIVE
SURFACE
NONCONDUCTIVE
SURFACE
Tools Needed:
Drive Rolls
Back Of Gun
3/16, 5/64 in
15/16, 3/8 in
End Of Liner
. 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.
OM-230 010 Page 16
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.
Ref. 156 929-A / Ref. 150 922 / Ref. 156 930 / S-0627-A
5-7. Setting Internal DIP Switches
Remove wrapper.
1
2
DIP Switch S1 And S4
DIP Switch S1 On Motor Board PC1
. DIP switches S1 and S4 should remain in
the factory default settings.
1
Install wrapper when finished.
Factory Set Default Settings
For DIP Switches S1 And S4
O 1
N
2
This illustration shows
the factory setting of S1.
3
4
5
6
7
8
2
804 671-A / 803 063
OM-230 010 Page 17
SECTION 6 − OPERATION
6-1. Operational Terms
The following is a list of terms and their definitions as they apply to this wire feeder:
General Terms:
Cold Wire Jog
Feeding wire without contactor or gas valve being energized.
Sequence
A portion of the weld program, such as preflow, run-in, start, weld, crater, burnback, and postflow.
Weld Program
A group of sequences that make up a weld cycle.
6-2. Power Switch
1
1
Notes
OM-230 010 Page 18
Power Switch
804 672-B
6-3. Jog/Purge
1
Jog/Purge Switch
Pressing the Jog switch allows the
operator to jog wire without energizing the weld power or gas valve circuit.
• Jog speed can be adjusted by the
Adjust control when the unit is
jogging wire. The unit displays jog
speed when the unit is being
jogged.
• Pressing the Purge switch allows
the operator to purge gas lines
before welding and to preset gas
pressure at the regulator.
2
2
3
3
Adjust Control
Gun Trigger Receptacle
1
804 673-B
6-4. Front Panel Controls
See
Section
6-6
See
Section
6-5
Program
V/Trim
Wire Speed
Amps
Start
Crater
Pre/Postflow
Dual Schedule
Trigger Hold
Adjust
Sequence
See
Section
6-10
See
Section
6-7
Time (sec)
See
Section
6-9
Setup
See
Section
6-8
OM-230 010 Page 19
6-5. Program Push Button
1
Program Display
The number of the active program
is displayed.
2
Program Push Button
Press button to activate program
select feature. To change the program number, press the Program
push button and rotate the Adjust
control.
1
3
Program
3
2
Program Push Button LED
The LED lights to indicate the Program push button is active.
6-6. Upper Display
3
1
2
4
V/Trim
Time (sec)
5
1 Upper Display
The upper display shows voltage/trim or
time. The unit displays both preset and actual arc voltage. When the unit is in a welding
state, actual arc voltage is displayed. The
upper display shows welding sequence time
when the Time LED is illuminated.
2 Upper Display Push Button
Press and hold button to adjust or display
weld time. Release button to display voltage/
trim.
3 Upper Display Push Button LED
The upper display push button LED illuminates to indicate that information displayed
OM-230 010 Page 20
can be changed by the Adjust control.
4
5
Volts/Trim LED
Time LED
The LEDs below the display illuminate to indicate which value is being shown.
At any time while welding, the unit permits
the adjustment of the weld sequence voltage
while continuing to display actual arc voltage.
• If the unit is displaying a welding sequence
that can be timed, the welding time display
mode is entered by pressing the upper display push button repeatedly until welding
time is the active parameter in the upper
display. At idle, the upper display toggles
between showing weld voltage/trim or
weld time, with subsequent presses of the
upper display push button.
• The unit defaults to displaying welding
voltage/trim when a welding sequence
display mode is first entered.
• If the weld sequence has a time set (as in
spot time) and the trigger is held, after the
weld program is completed, ERR TRG 1
will be displayed to indicate the weld program is complete. Release trigger to clear
error.
6-7. Lower Display
3
1
2
4
Wire Speed
Amps
5
1 Lower Display
The lower display shows wire speed or
amperage.
2 Lower Display Push Button
Press button to choose between wire speed or
amperage functions.
3 Lower Display Push Button LED
The lower display push button LED illuminates
to indicate that information displayed can be
changed by the Adjust control.
4 Wire Speed LED
5 Amps LED
The LEDs below the display illuminate to indi-
cate which value is being shown.
• At idle, the wire speed for the active welding
sequence may be adjusted or the amperage
of the previous weld may be displayed.
• If the unit is in a welding state that does not
involve feeding wire, such as pre−flow or
post−flow, the unit displays the weld sequence wire speed; otherwise, the wire
speed of the active sequence segment of the
weld program (run−in, start, weld, crater,
etc.), is displayed.
• Adjusting wire speed while in a welding state
will modify the weld segment of the weld program. Wire speed for other segments of the
weld program can only be modified via the
Sequence menu.
• When the unit is displaying amperage, the
Amps LED illuminates. While in a welding
state, the actual weld current is shown.
While idle, the amperage at the end of the
previous welding state is shown.
• Amperage values of less than 5 Amps are
displayed as “−−−−”.
6-8. Setup Push Button
3
4
Trigger Hold
Dual Schedule
2
1
Setup
1
Setup Push Button
Press button to choose between trigger hold
or dual schedule functions.
2
Setup Push Button LED
3
Trigger Hold LED
4
Dual Schedule LED
• When the Setup button is pressed, the Setup push button LED flashes and the Trigger
Hold LED flashes.
• Trigger hold is a per program setting.
• The flashing LED indicates that the unit is in
the trigger hold display mode. In this mode
the upper display indicates HOLD and the
lower display indicates the trigger hold sta-
tus On/Off. Use the Adjust control to change
the trigger hold status or press the lower display push button. If trigger hold is turned On,
the trigger hold LED illuminates and stays
On.
• When trigger hold is On, the user must
press and hold the trigger for a predefined
amount of time (the trigger hold delay time−
see Section 6-11), then release it for the trigger hold function to be active. To shut off the
weld when trigger hold is On, the user must
press and release the trigger.
• If a weld time is programmed, trigger hold is
disabled.
• Dual Schedule is a per program pair setting.
• When the Setup button is pressed a second
time, the dual schedule LED flashes. In this
mode the upper display indicates DUAL and
the lower display indicates dual schedule
status On/Off. Use the Adjust control to
change the dual schedule status if desired.
• Pressing the Setup button again exits the
Setup mode. The dual schedule LED stops
flashing to indicate the dual schedule status
is Off, or remains on if dual schedule was
enabled.
• While in the Setup mode, if the trigger is activated, Setup mode is terminated.
• Dual schedule and trigger select cannot be
used concurrently. See Section 6-11 for
Trigger Program Select.
OM-230 010 Page 21
6-9. Adjust Control
1
Adjust Control
The Adjust control is used to
change various sequence parameters, and to select various sequences. Refer to the section for
the function in question for information related to using the Adjust control.
1
Adjust
6-10. Sequence Push Button
3
1
2
3
Start
Crater
Pre/Postflow
2
1
Sequence
. For more information on Setting
Sequence Parameters see Section 7-1.
Start
Time
Weld
Time
Crater
Time
Preflow
Time
Postflow
Time
Welding Sequence Diagram
the weld display mode is activated.
If zero time is programmed for a timed sequence except for Weld, that sequence will
be skipped.
• The Sequence push button allows the
selection of welding sequences. Five welding sequences are available. The default
sequence is the Weld sequence. The Weld
sequence is active on power up. Three
welding sequence LEDs are located above
the Sequence push button: Start, Crater,
and Preflow/Postflow. The applicable LED
illuminates to indicate which welding sequence is active.
• In the weld sequence display mode, the Sequence push button LED is Off. When the
Sequence push button is pressed, the Sequence push button flashes and the Start
LEDs flash. In this condition, the unit is in the
Start sequence display mode, and Start sequence parameters are displayed (see Section 7-1) for details.
• The LED illuminates to indicate that a welding sequence display mode other than Weld
is active. Welding sequences other than
Weld must be set prior to initiating the arc.
When the unit enters a welding state, all sequence display modes are terminated and
• When the Sequence push button is pressed
a second time, the Crater sequence LED
flashes. The Sequence push button LED remains flashing. In this condition, the unit is
in the Crater sequence display mode, and
Crater sequence parameters are displayed.
OM-230 010 Page 22
Sequence Push Button
Sequence Push Button LED
Welding Sequence LEDs
• When the Sequence push button is pressed
a third time, the Preflow/Postflow sequence
LED flashes. The Sequence push button
LED remains flashing. In the Preflow display
mode the upper display shows the preflow
time and the lower display indicates the abbreviation PRE, to inform the operator that
preflow time is displayed. If the upper display push button is pressed, the Adjust control can be used to adjust preflow.
• If the lower display push button is pressed,
the Adjust control can be used to select between preflow (PRE) and postflow (POST).
When POST is selected, the upper display
can be used to specify postflow time.
• When the Sequence push button is pressed
a fourth time, the unit returns to the welding
sequence display mode.
6-11. Auxiliary Menus
1
2
3
4
5
6
7
8
9
Program Display
Program Push Button
Sequence Push Button
Upper Display
Upper Display Push Button
Lower Display
Lower Display Push Button
Adjust Control
Setup Push Button
4
5
1
2
7
Program
V/Trim
Time (sec)
Wire Speed
Amps
6
Start
Trigger Hold
Crater
Pre/Postflow
Dual Schedule
3
Sequence
Adjust
9
Setup
8
OM-230 010 Page 23
6-11 Auxiliary Menus (Continued)
Reset To Factory Settings
Trigger Hold Setup
A reset menu is displayed if the following four
push buttons are pressed simultaneously:
Program, Sequence, upper display, and Setup. The upper display indicates “WIPE” . The
lower display indicates “OFF”. The lower
push button is active indicating that the Adjust
control can be used to change the unit to
“WIPE ON”. When “WIPE ON” is set, if the original four push buttons are simultaneously
pressed a second time, the unit will reset all
settings to factory default except the arc time
and arc cycle counts. If a reset is not desired,
set the display to “WIPE OFF” and simultaneously press the Program, Sequence, upper
display, and Setup push buttons to exit the reset menu.
Trigger hold delay time is indicated by
”HOLD” in the lower display and the hold
delay time in the upper display. The adjust
control can be used to specify a new delay
time for trigger hold. Trigger hold delay time is
the minimum amount of time the trigger must
be held for trigger hold to work when the trigger is released (the trigger hold function must
be on). For example, if a trigger hold delay
time of 2.0 seconds is defined, the operator
must hold the trigger for at least 2 seconds before releasing it in order for the trigger hold
function to work. Once the trigger hold function is in effect, the wire feeder will stay On until the trigger is pressed and released again.
Auxiliary Menu
• An auxiliary menu is provided if both the Sequence and Setup push buttons are
pressed simultaneously. The Setup push
button and sequence push button LEDS
flash when the auxiliary menu is displayed.
Pushing the Setup push button will step
through the menu. Pushing the sequence
push button will step through the menu in reverse.
. The auxiliary menu may be exited at any
time by pressing both the Sequence and
Setup push buttons simultaneously.
Run-In
• The run-in modes are program specific (i.e.
each program may be set to its own run-in
mode).
The upper display indicates “RUNI”. The
lower display indicates “AUTO”, meaning
the factory set automatic run-in speed is selected.
Pressing the lower display button allows
manual setting of the run-in wire speed.
Speed may be adjusted from 10% to 100%
of weld wire speed.
Pressing the lower display button again allows disabling of the run-in feature. When
the lower display indicates “OFF”, run-in is
disabled.
Burnback
Burnback time and voltage can be specified
when the lower display indicates “BURN” and
the upper display indicates the burnback time
or voltage. The Adjust control is used to set
the desired burnback time or voltage. Burnback settings are program specific. The active program is displayed in the Program display and can be adjusted (see Section 6-5).
OM-230 010 Page 24
• There is an additional function built in called
”maximum trigger hold time” which is the
maximum length of time the trigger can be
held and the trigger hold function still work
when the trigger is released (the trigger hold
function must be on). The maximum trigger
hold time is set at 4.0 seconds after the trigger hold delay time. For example, if a trigger
hold delay time of 2.0 seconds is defined,
and the operator held the trigger in for more
than 6.0 seconds, the trigger hold function
would not be in effect and the wire feeder
would stop when the trigger is released.
Trigger Program Select
The upper display shows “TSEL”. Lower display shows “On” or “Off”. The Adjust control
is used to select either “On” or “Off”.
Trigger Program Select allows the operator to
select programs by clicking the trigger (pulling
and releasing the trigger in a maximum of 0.2
seconds). The feeder will switch between any
programs that have a minimum of 0.2 seconds of preflow time set in the weld sequence.
• Any combination of programs may be used.
• If only programs 1 and 3 have a minimum of
0.2 seconds of preflow time, clicking the
trigger will toggle between programs 1 and
3.
• If only programs 1, 2, and 4 have a minimum
of 0.2 seconds of preflow time, clicking the
trigger will switch from 1 to 2 to 4 to 1 to 2.
• Trigger Program Select cannot be used
while welding or with Dual Schedule.
Range Locks
Range locks are indicated by “LOCK” in the
upper display for wire speed or “LOCK” in the
lower display for voltage range.
In a MIG program, the voltage range lock
ranges from +/− 0 to 10 volts.
In a pulse program, the trim range lock ranges
from +/− 0 to 100.
The wire speed range lock ranges from +/− 0
to 195 IPM.
Locks are program dependent and wire
speed locks are independent from voltage/
trim command locks (i.e. you can have a wire
speed lock with or without locking the voltage/
trim command and vice versa).
Press the Upper Display Pushbutton to select
Voltage/Trim Command Range Locks.
Press the Lower Display Pushbutton to select
Wire Speed Range Locks.
To set a Voltage/Trim Command Range Lock,
you must choose the type of command being
locked, voltage or trim based on the type of
weld process selected at the power source.
This is done by repeatedly pressing the Upper
Display Pushbutton to cycle between OFF, T
(trim) or V (voltage), as indicated on the Upper
Display.
Use the adjust knob to set the range value.
Once any program has a lock enabled, the remaining programs with all locks “OFF” will not
be accessible. To enable additional programs, set the lock values for one or more
Voltage/Trim Command or Wire Speed to appropriate ranges for each program.
Only one of the values needs to be set to enable the program. For example, setting a Trim
of 100 and leaving the Wire Speed at OFF will
allow the welder to adjust the Wire Speed to
full range
Wire Feed Speed Units
Wire feed speed setting indicated by “WFS” in
the upper display is set to “IPM” inches−per−
minute or ”MPM” meters−per−minute. This
setting is independent of the program selected.
OPT1
The upper display shows “OPT1”. Lower display shows “On” or “Off”. The Adjust Control
is used to select either “On” or “Off”.
“OPT1” is used by the Water Flow Shutdown
Option to stop the weld sequence if water flow
to a water cooled gun is interrupted. A closed
set of contacts between pins 1 and 2 of RC26
on Interface Board (PC20) will allow feeder to
operate normally. Opening the contacts will
stop the weld sequence and display “ERR” in
the upper display and “OPT1” in the lower
display.
6-11 Auxiliary Menus (Continued)
OPT2
The upper display shows “OPT2”. Lower display shows “On” or “Off”. The Adjust Control
is used to select either “On” or “Off”.
“OPT2” is a second input that may be used
with an external device, such as a gas flow
switch, to end the weld sequence. The gas
flow switch may be used to stop the weld sequence if shielding gas flow to the gun is interrupted. A closed set of contacts between pins
1 and 2 of RC24 on Interface Board (PC20)
will allow feeder to operate normally. Opening
the contacts will stop the weld sequence and
display “ERR” in the upper display and
“OPT2” in the lower display.
Software Revision Level
• The unit displays the software version being
used by the interface PCB (PC20).
• When the Setup button is pressed again, the
menu repeats.
Code
Upon leaving the auxiliary menu, the user is
asked if a password code, indicated by
“CODE” in the top display should be activated.
By default the code is “OFF” in the lower display. The user may enter a numerical password between 0 and 999 by turning the Adjust
control.
If a code is set, when the user re-enters the
auxiliary menu, the password code must be
selected to gain access to the auxiliary menu.
Press Setup and Sequence buttons simultaneously to enter the auxillary menu. A failed
attempt returns the user to the weld screen
and a counter is incremented. A counter in the
program display shows the number of incorrect attempts. The user has five attempts to
enter the correct password code before being
locked out of the auxiliary menu, indicated by
“LOCK” in the lower display.
The power may be cycled to continue welding,
but the user will remained locked out of the
auxiliary menu.
The counter can be reset in the weld screen by
pressing the Program, Sequence, upper display, and Set-up push buttons simultaneously.
Resetting the counter is indicated by “CODE”
in the upper display and “RSET” in the lower
display. Pressing the Program, Sequence, upper display, and Set-up push buttons simultaneously again resets the counter to 0.
To reset the password, follow the directions
under Reset To Factory Settings at the beginning of this section. Note: this will reset all settings and programs to the factory defaults.
6-12. Remote-14 Receptacle Information
1
2
Remote Switch
Remote-14 Receptacle
If the remote switch is set to MIG,
the feeder operates normally. A remote control may be left attached
while the remote switch is in the
MIG mode, as the remote has no affect on the operation of the wire
feeder.
If the remote switch is set to Stick/
TIG, the feeder controls and meter
displays are disabled, allowing control from a standard remote control.
When a remote control is connected to the remote-14 receptacle,
the PipePro 450 RFC will automatically adjust output control in a primary/secondary configuration, but
the power source must be set for remote operation (see the PipePro
450 RFC Owner’s Manual for information).
1
2
In this configuration, the Amp Adjust control on the PipePro 450 RFC
power source becomes the primary, and sets the maximum amperage output of the unit. The remote
control becomes the secondary,
and provides an amperage range
adjustment of 0 to 100% of what is
set on the Amp Adjust control on the
power source.
. When in
Stick/Tig mode, remote program select is still
functional from the feeder.
Y Do not connect a Stick electrode holder and a MIG gun
to the same output terminal
at the same time, as both will
be live when the contactor is
on. An external polarity reversing isolation control
should be used to isolate the
outputs.
804 673-B
OM-230 010 Page 25
SECTION 7 − SETTING SEQUENCE PARAMETERS
7-1. Sequence Parameters In A Program
. For more information on
Sequence Push Button see
Section 6-10.
Sequence
If time is set to zero in Weld
sequence, welding continues until
gun trigger is released.
Parameters
Volts
IPM
1. Preflow
If time is set to zero in any timed
sequence except Weld, the
sequence is skipped.
Seconds
0-9.9
2. Run-In
X
3. Start
X
X
0.00-5.00
4. Weld
X
X
0-100.0
5. Crater
X
X
0-5.00
6. Burnback
X
0-0.25
7. Postflow
0-9.9
X = Setting available.
Weld Time
Crater
Time
Preflow
Time
Burnback
Time
Start
Time
Postflow
Time
Time
Burnback
Preflow
Trigger
Pressed
OM-230 010 Page 26
Run-In Start
Weld
Crater
Trigger
Released
Postflow Sequence
End
SECTION 8 − SETTING DUAL SCHEDULE PARAMETERS
8-1. Optional Dual Schedule Switch Diagrams
1
1
1
DSS-9
2
2
1
DSS-8
2
3
1
2
TR
B
A
2
Maint 2P (Maintained-Contact
2-Pole Switch)
Maint 1P (Maintained-Contact
1-Pole Switch)
3
A
4
B
4
SECTION 9 − MAINTENANCE
9-1. Routine Maintenance
Y Disconnect power before maintaining.
Δ = Repair
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
l = Replace
Every
3
Months
nl Labels
~ Weld Terminals
n l Gas Hoses
Every
3
Months
nΔ lCables And Cords
Every
6
Months
Or
~:Durning heavy service, clean monthly.
OM-230 010 Page 27
9-2. Diagnostics
1
2
3
4
Wrapper
Motor Control Board PC1
LED3
DIP Switch S1
. There
is a two-position DIP
switch S1 located on motor
control board PC1. These
switches are factory-set in the
off position and must remain in
that position for the unit to operate correctly.
2
3
1
4
Front panel is shown removed for purpose of
illustration only. In actual use, front panel
would be in place.
Ref. 802 687
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
COM1
TRG1
TCH1
MTR1
OPT1
OPT2
Indicates a
communication
error.
Indicates a trigger
error.
LED3-Related Error Indications
Error conditions are indicated by LED3 on
PC1. To view LED3, turn Off unit, remove
wrapper, and turn unit On. LED3 is most easily
observed from the left side of the unit.
The LED blinks in a 2.5 second cycle. The
number of blinks in this period indicates the
type of error.
The priority of the errors is related to the number of blinks indicating the error. The more
blinks, the more severe the error (motor error
is top priority). A higher priority error overrides
a lower one (if a motor error and a communication error existed, the light would blink four
times for the motor error).
Since blink On time and blink Off time are
equal in a four-blink cycle, the four−blink sequence appears as a constant blink.
1 blink = Communication Error
2 blinks = Trigger Error
3 blinks = Tach Error
OM-230 010 Page 28
Indicates a
tachometer error.
Indicates a motor
error.
4 blinks = Motor Error
ERR COM1
No gas flow
detected.
Optional error
condition.
speed is regulated through the monitoring of
voltage and current.
• The communication error occurs 2.5 seconds after a loss of communication between
the motor and front panel boards. The user
may continue to weld with this error. The error may be cleared by resetting the unit (see
Section 6-11).
ERR MTR1
ERR TRG1
ERR OPT1
• The trigger error occurs if the user has the
trigger held for more than two minutes without striking an arc, or if the user holds the
trigger past the postflow phase in a timed
weld. This error also occurs if the trigger is
held when the feeder is powered up. The error may be cleared by releasing the trigger.
• The optional 1 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 any button on
front panel.
ERR TCH1
• The tach error occurs 2 seconds after the
loss of tachometer feedback. The user may
continue to weld with this error. The motor
• 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.
ERR OPT2
• The optional 2 error indicates a problem
with optional device connected to RC24 on
Interface Board (PC20). The error may be
reset by correcting the problem, and then
pressing any button on front panel.
9-3. Troubleshooting
Y Disconnect power before troubleshooting
Trouble
Wire feeds, shielding gas flows, but
electrode wire is not energized.
Remedy
Check cable connections. Check cables for continuity, and repair or replace cables if necessary
(see Section 5-4).
Wire feeder is on, display does not light Check and reset circuit breaker at welding power source.
up, motor does not run, gas valve and
welding power source contactor do not
pull in.
Electrode wire feeding stops or feeds
erratically during welding.
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 5-6).
Change to correct size drive roll (see 5-6).
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.
When triggered, wire feeds, but no
contactor.
If the gun trigger does not enable output, make sure that remote switch is in the correct position
(see Section 6-12).
OM-230 010 Page 29
SECTION 10 − ELECTRICAL DIAGRAM
Figure 10-1. Circuit Diagram
OM-230 010 Page 30
230 222-A
OM-223 606 Page 31
SECTION 11 − PARTS LIST
6
. Hardware is common and
not available unless listed.
7
5
8
9
10
11
12
11
10
13
15
16
4
17
14
Fig 11-3
3
2
1
18
19
20
21
Fig 11-2
804 744-A
Figure 11-1. Main Assembly
OM-230 010 Page 32
Item
No.
Part
No.
Description
Quantity
Figure 11-1. Main Assembly
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
. . . . . . . . . . . . . . . 159 647
. . . . . . . . . . . . . . . 159 646
. . . . . . . . . . . . . . . 159 360
. . . . . . . . . . . . Figure 11-3
. . . . . . . . . . . . . . . 141 753
. . . . . . . . . . . . . . . 058 427
. . . . . . . . . . . . . . . 180 571
. . . . . . . . . . . . . . . 010 233
. . . . . . . . . . . . . . . 057 971
. . . . . . . . . . . . . . . 010 191
. . . . . . . . . . . . . . . 058 628
. . . . . . . . . . . . . . . 058 428
. . . . . . . . . . . . . . . 135 205
. . . . . . . . . . . . . . . 200 556
. . . . . . . . . . . . . . . 201 781
. . . . . . . . . . . . . . . 156 243
. . . . . . . . . . . . . . . 145 639
. . . . . . . . . . . . . . . 200 552
. . . . . . . . . . . . . . . 134 306
. . . . . . . . . . . . . . . 200 557
. . . . . . . . . . . . Figure 11-2
. . Insulator, Motor Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Clamp, Motor Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Insulator, Screw Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Drive Assembly, Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Hub & Spindle Assembly, (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Ring, Retaining Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Shaft, Support Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Spring, Cprsn .970 Od X .120 Wire X 1.250pld . . . . . . . . . . . . . . . . . . .
. . . . Washer, Flat Stl Keyed 1.500dia X .125thk . . . . . . . . . . . . . . . . . . . . . .
. . . . Washer, Fbr .656 Id X 1.500 Od X .125thk . . . . . . . . . . . . . . . . . . . . . . .
. . . . Washer, Brake Stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Hub, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Nut, Stl Slflkg Hex Reg .625-11 W/Nylon Insert . . . . . . . . . . . . . . . . . . .
. . Support, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Knob, W/Extension Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Clamp, Motor Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Strip, Buna N Compressed Sheet .062 X 4.000 X 4.000 . . . . . . . . . . . . .
. . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Foot, Rubber 1.250 Dia X 1.375 High No 10 Screw . . . . . . . . . . . . . . . . .
. . Stiffener, Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
4
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
4
1
1
+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-230 010 Page 33
. Hardware is common and
not available unless listed.
1
4
8
9
10
12
11
3
2
27
12
15
13
11
14
7
5
26
16
6
17
21
22
23
24
25
18
19
20
804 745-A
Figure 11-2. Control Box
Item
No.
Diagram
marking
Part
No.
Description
Quantity
Figure 11-2. Control Box (Figure 11-1 Item 21)
. . . 1 . . . . . . . . . . . . . . . 200 555 . . Wrapper, Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Upper (Order By Model And Serial No.) . . . . . . . . . . . . . . . . 1
. . . 3 . . . . PC21 . . . . . 200 693 . . Circuit Card Assy, Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . PC20 . . . . . 224 322 . . Circuit Card Assy, Display W/Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . 200 551 . . Enclosure, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . 134 201 . . Stand-Off Support, PC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 7 . . . . . . . . . . . . . . . 200 554 . . Enclosure, Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . 010 494 . . Bushing, Snap-In Nyl 1.375 Id X 1.750 Mtg Hole . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . 057 357 . . Bushing, Snap-In Nyl .937 Id X 1.125 Mtg Hole . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 230 972 . . Cable, Power (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . L2 . . . . . . 131 447 . . . . Core,Toroidal 1.332 Id X 1.932 Od X .625 Thk . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . . 185 574 . . . . Cable, Port No 18−14 14/C Type Awm 2−14 12−18 Cndct . . . . . . . . 2 Ft
. . . 12 . . . . . . . . . . . . . . . 010 916 . . . . Conn, Clamp Cable .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . 200 545 . . . . Conn, Circ 97/Met Clamp Str Size 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . PLG12 . . . . 215 031 . . . . Conn, Circ 97/Met 14 Pin Size 20 Plug (X) Solder . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG31 . . . . 202 592 . . . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG33 . . . . 115 092 . . . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG35 . . . . 115 094 . . . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . . 223 182 . . Choke, Common Mode W/Leads & Cable Tie Mount . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . 211 989 . . Fitting, W/Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . . 220 805 . . Nut, 750-14 Nps 1.48Hex .41H Nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . GS1 . . . . . 219 047 . . Valve, 40VDC 2Way Custom Port 1/8 Orf W/Frict . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . PC1 . . . . . 230 018 . . Circuit Card Assy, Motor Control (Standard Speed) . . . . . . . . . . . . . . . . . 1
OM-230 010 Page 34
Item
No.
Diagram
marking
Part
No.
Description
Quantity
Figure 11-2. Control Box (Figure 11-1 Item 21) (Continued)
. . . 20 . . L13,21,27 . . . 213 030 . .
. . . 21 . . . . . S1 . . . . . . 111 997 . .
. . . 22 . . . . PC3 . . . . . 229 724 . .
. . . 23 . . . . . . . . . . . . . . . 229 744 . .
. . . 24 . . . . . S2 . . . . . . 200 295 . .
. . . 25 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . . . 213 134 . .
. . . 27 . . . . RC13 . . . . . 048 282 . .
. . . . . . . . PLG6,28 . . . 115 094 . .
. . . . . . . . PLG1,32 . . . 202 592 . .
. . . . . . . . . . PLG4 . . . . . 136 810 . .
. . . . . . . . PLG7,27 . . . 115 091 . .
. . . . . . . . . PLG10 . . . . 130 203 . .
. . . . . . . . . . . . . . . . . . . . . 134 464 . .
. . . . . . . . . . PLG3 . . . . . 115 093 . .
. . . . . . . . . . PLG5 . . . . . 131 204 . .
. . . . . . . . PLG11,21 . . . 131 055 . .
. . . . . . . . . PLG34 . . . . 131 052 . .
. . . . . . . . . . PLG2 . . . . . 164 899 . .
Core, Toroidal 19.00mm Id X 29.01mm Od X 7.62mm Th . . . . . . . . . . . .
Switch, Rocker Spst 10a 250 VAC On-Off . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card Assy, Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Rocker Spdt 15a 12v (On)-Off-(On) . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Lower (Order By Model And Serial No.) . . . . . . . . . . . . . . . .
Knob, Encoder 1.670 Dia X .250 Id Push On W/Spring . . . . . . . . . . . . . .
Rcpt W/Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing Plug Pins+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing Plug Pins+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Warning General Precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing Rcpt+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing Rcpt+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing Plug Pins+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
OM-230 010 Page 35
. Hardware is common and
13
not available unless listed.
19
11
14
15
See Table 11-1 For
Drive Roll & Wire Guide Kits
16
17
18
9
1
2
3
4
5
7
6
8
19
12
10
20
11
22
21
37
34
36
35
27
33
23
24
25
26
28
32
31
30
29
3
4
5
6
2
1
803 790-A
Figure 11-3. Drive Assembly, Wire
Item
No.
Diagram
marking
Part
No.
Description
Quantity
Model
S-74S S-74D
Figure 11-3. Drive Assembly, Wire (Figure 11-1 Item 4)
. . . 1 . . . . . . . . . . . . . . . 010 668
. . . 2 . . . . . . . . . . . . . . . 172 075
. . . 3 . . . . . . . . . . . . . . . 149 962
. . . 4 . . . . . . . . . . . . . . . 149 486
. . . 5 . . . . . . . . . . . . . . . 132 750
. . . 6 . . . . . . . . . . . . . . . 150 520
. . . 7 . . . . . . . . . . . . . . . 133 493
. . . 8 . . . . . . . . . . . . . . . 133 350
. . . 9 . . . . . M1 . . . . . . 201 230
. . . 9 . . . . . M1 . . . . . . 201 231
. . . . . . . . . . . . . . . . . . . . . 153 491
. . . . . . . . . . . . . . . . . . . . . 153 492
. . . . . . . . . . . . . . . . . . . . *153 493
. . . . . . . . . . . . . . . . . . . . . 184 136
. . . 10 . . . . . . . . . . . . . . . 155 098
. . . . . . . . . . . . . . . . . . . . . 153 550
. . . . . . . . . . . . . . . . . . . . . 155 099
. . . . . . . . . . . . . . . . . . . . . 155 100
. . . . . . . . . . . . . . . . . . . . . 154 031
. . . . . . . . . . . . . . . . . . . . . 133 493
OM-230 010 Page 36
. . Screw, Cap Stl Sch .250-20 X 1.500 . . . . . . . . . . . . . . . . . . . . . . . .
. . Carrier, Drive Roll W/Components . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Spacer, Carrier Drive Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Pin, Rotation Arm Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Arm, Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Spacer, Flat Stl .257 Id X .619 Od X .105 . . . . . . . . . . . . . . . . . . .
. . Ring, Retaining Ext .250 Shaft X .025thk . . . . . . . . . . . . . . . . . . . .
. . Pin, Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Motor, Gear 1/8Hp 24VDC Standard Speed . . . . . . . . . . . . . . . . .
. . Motor, Gear 1/8Hp 24VDC High Speed (Optional On S-74D) . . .
. . . . Kit, Brush Replacement (Consisting Of) . . . . . . . . . . . . . . . . . . .
. . . . . Cap, Brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . Brush, Carbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Kit, Brush Holder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Kit, Cover Motor Gearbox (Consisting Of) . . . . . . . . . . . . . . . . . . .
. . . . Cover, Motor Gearbox (Consisting Of) . . . . . . . . . . . . . . . . . . . .
. . . . . Gasket, Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . Screw, Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Spacer, Locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . Ring, Rtng Ext .250 Shaft Grv X .025Thk . . . . . . . . . . . . . . . . . .
4
4
4
2
2
2
2
1
1
0
1
2
2
1
1
1
1
5
2
1
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
4
4
4
2
2
2
2
1
1
1
1
2
2
2
1
1
1
5
2
1
Item
No.
Diagram
marking
Part
No.
Description
Quantity
Model
S-74S S-74D
Figure 11-3. Drive Assembly, Wire (Continued)
.....................
. . . 11 . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . . . . . .
. . . 21 . . . . PC51 . . . . .
. . . . . . . . . . PLG5 . . . . .
.....................
. . . 22 . . . . . . . . . . . . . . .
.....................
. . . 23 . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . . . . . .
. . . 26 . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . . . . . .
. . . 28 . . . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . . . . . .
.....................
. . . 34 . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . . . . . .
. . . 36 . . . . . . . . . . . . . . .
. . . 37 . . . . . . . . . . . . . . .
203 631
203 641
182 415
203 640
182 156
182 155
132 746
203 633
203 632
133 739
203 637
201 225
131 204
604 311
132 611
603 115
167 387
168 825
133 308
134 834
149 959
179 265
108 940
604 538
151 437
151 290
179 277
196 956
601 872
602 213
602 243
601 966
. . Pressure Arm, S/L & Vert S/R 4 Roll (Consisting Of) . . . . . . . . . . 1 . . . . 1
. . . . Washer, Flat Indicator Spring Tension . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
. . . . Pin, Cotter Hair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . . Knob, W/Extension Short Pressure Arm . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . . Spring, Cprsn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
. . . . Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
. . . . Bushing, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
. . . . Shaft, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . . Carrier, Shaft Dual Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . . Washer, Flat Buna .375 Id X .625 Od X .062thk . . . . . . . . . . . . 2 . . . . 2
. . . . Knob, W/Extension Long Pressure Arm . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . Circuit Card, Digital Tach (Consisting Of) . . . . . . . . . . . . . . . . . . . . 0 . . . . 1
. . . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 . . . . 1
. . . . Grommet, Rbr .250 Id X .375mtg Hole .062 Groove . . . . . . . . . 0 . . . . 1
. . Optical Encoder Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 . . . . 1
. . Weather Stripping, Adh .125 X .375 . . . . . . . . . . . . . . . . . . . . . . . . 0 . . . . 1
. . Spacer, Locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
. . Drive, Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 2
. . Ring, Retaining Ext .375 Shaft X .025thk . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . Hose, Sae .187 Id X .410 Od (Order By Ft) . . . . . . . . . . . . . . . . . 2 Ft (0.6 m)
. . Fitting, Brs Barbed M 3/16Tbg X .312-24 . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . Adapter, Gun/Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . Screw, Cap Stl Hexhd .250-20 X .750 . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 4
. . Washer, Flat Stl Sae .312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . Knob, Plstc T 1.125 Lg X .312-18 X 1.500 . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . Screw, Mach Stl Hexwhd 10-32 X .500 . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
. . Cover, Drive Roll (Consisting Of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . . Label, Warning Electric Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . Nut, Stl Hex Full Fnsh .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . Washer, Lock Stl Split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . Washer, Flat Stl Std .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . Screw, Cap Stl Hexhd .375-16 X 1.250 . . . . . . . . . . . . . . . . . . . . . 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-230 010 Page 37
Table 11-1. Drive Roll And Wire Guide Kits
OM-230 010 Page 38
2.4 mm
2.8 mm
3.2 mm
3/32 in.
(.094 in.)
7/64 in.
(.110 in.)
1/8 in.
(.125 in.)
150 997
150 996
150 996
150 995
149 522
149 521
149 521
149 520
151 029
151 028
151 027
161 190
151 026
151 025
151 024
4 Roll Kit
053 699
053 698
053 697
053 700
053 695
087 130
Drive Roll
V-GROOVE
151 043
151 042
151 041
151 040
151 039
151 038
151 037
151 036
4 Roll Kit
053 707
053 705
053 703
053 704
053 706
053 702
053 701
072 000
Drive Roll
U-GROOVE
151 060
151 059
151 058
151 057
151 056
151 055
151 054
151 053
151 052
4 Roll Kit
132 963
132 962
132 961
132 960
132 959
132 955
132 956
132 957
132 958
Drive Roll
VK-GROOVE
Each kit contains an inlet guide, intermediate guide, and 045 233 antiwear guide W/604 612 setecrew 8-32 x .125, along with 4 drive rolls.
2.0 mm
149 520
150 995
.068-.072 in. 1.8 mm
5/64 in.
(.079 in.)
149 520
150 995
149 519
149 519
149 518
149 518
149 518
149 518
1.6 mm
1/16 in.
(.062 in.)
1.3/1.4 mm 150 994
.052 in.
150 993
1.1/1.2 mm 150 994
1.0 mm
.040 in.
150 993
150 993
150 993
Inlet Guide
.045 in.
0.9 mm
0.8 mm
.035 in.
.030 in.
.023-.025 in. 0.6 mm
Fraction Metric
Wire Size
Intermediate
Guide
151 076
151 075
151 074
151 073
151 072
151 071
151 070
4 Roll Kit
Ref. S-0527-C
053 712
053 711
053 709
053 710
053 708
083 490
083 489
Drive Roll
UC-GROOVE
Notes
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