OM-1500-14 207 499H
2007−07
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
(Gas-and Self-Shielding)
Submerged (SAW) Welding
Description
Wire Feeder
(Use with CV Power Sources)
™
DS-74DX Swingarc
Visit our website at
www.MillerWelds.com
DS-74DX12, and DS-74DX16
File: MIG (GMAW)
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
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001:2000 Quality
System Standard.
parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
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
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 7 . . . . . .
2-4. Proposition californienne 65 Avertissements 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Information EMF 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INTRODUCTION 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Specifications 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Installing Swivel Into Pipe Post 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Installing Control Box And Adjusting Tilt 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Installing Boom And Reel Support 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Installing Wire Guide Extension 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Equipment Connection Diagram 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Control Box Connections 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. 14-Pin Plug Information 15
4-8. Removing Safety Collar And Adjusting Boom 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Gun Recommendation Table 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Wire Type, Size, And Feed Speed Capability Table 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Installing And Threading Welding Wire 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Setting Internal DIP Switches 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. Power Source Selection Menu 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − OPERATION 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Operational Terms 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Power Switch 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Left/Right Select Switch 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Jog/Purge Switch 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Front Panel Controls 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Program Push Button 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Upper Display 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Lower Display 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. Setup Push Button 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Adjust Control 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Sequence Push Button 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12. Auxiliary Menus 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − SETTING SEQUENCE PARAMETERS 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Sequence Parameters In A Program 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − SETTING DUAL SCHEDULE PARAMETERS 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Optional Dual Schedule Switch Diagrams 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Diagnostics 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Diagnostics For User Defined Options 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − MAINTENANCE & TROUBLESHOOTING 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Routine Maintenance 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Troubleshooting 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS
SECTION 9 − ELECTRICAL DIAGRAM 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − PARTS LIST 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
7
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
som _2007−04
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
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 follow-
ing 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.
power circuit and machine internal circuits are also
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
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 conduc-
tor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Do not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be
present.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists in inverter-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.
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.
OM-1500-14 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying op-
erations. 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.
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 fil-
ter 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 mate-
rial (leather, heavy cotton, or wool) and foot protection.
WELDING can cause fire or explosion.
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 After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or by-
pass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
MAGNETIC FIELDS can affect Implanted
Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
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
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
OM-1500-14 Page 2
workpiece, and hot equipment can cause fires and
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, mechani-
cal 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 fit-
tings 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 num-
ber of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING 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.
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.
FLYING SPARKS can cause injury.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D Sparks can cause fires — keep flammables away.
STATIC (ESD) can damage PC boards.
MOVING PARTS can cause injury.
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.
READ INSTRUCTIONS.
D Read Owner’s Manual before using or servic-
ing unit.
D Use only genuine replacement parts from the
manufacturer.
H.F. RADIATION can cause interference.
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.
D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the
equipment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
D 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.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
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.
ARC WELDING can cause interference.
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.
D To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
D Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
D Be sure this welding machine is installed and grounded
according to this manual.
D If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-1500-14 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
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).
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).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:
617-770-3000, website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 5060 Mississauga,
For Gasoline Engines:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
Ontario, Canada L4W 5NS (phone: 800-463-6727 or in Toronto
416-747-4044, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036–8002 (phone:
212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, Quincy, MA 02269-9101 (phone: 617-770-3000, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 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:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
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 Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
OM-1500-14 Page 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
7
Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
2-1. Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité.
Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est
sortie. Le circuit d’alimentation et les circuits internes de la machine
sont également sous tension lorsque l’alimentation est sur Marche.
Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de
commande du rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement installé ou mis
à la terre de manière incorrecte ou impropre constitue un danger.
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et
sans trous.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
D Ne pas se servir de source électrique à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
D Se servir d’une source électrique à courant électrique UNIQUE-
MENT si le procédé de soudage le demande.
D Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
D D’autres consignes de sécurité sont nécessaires dans les condi-
tions 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
sous tension lorsque le courant est délivré à la
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’in-
stallation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
D Installer le poste correctement et le mettre à la terre convenable-
ment selon les consignes du manuel de l’opérateur et les normes
nationales, provinciales et locales.
D Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
D En effectuant les raccordements d’entrée, fixer d’abord le conduc-
teur de mise à la terre approprié et contre-vérifier les connexions.
D Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
D Vérifier fréquemment le cordon d’alimentation afin de s’assurer
qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est.
Un fil à nu peut entraîner la mort.
D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
sante ou mal épissés.
D Ne pas enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
D Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
champ les pièces endommagées. Entretenir l’appareil
conformément à ce manuel.
D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
D S’assurer que tous les panneaux et couvercles sont correctement
en place.
D Fixer le câble de retour de façon à obtenir un bon contact métal-
métal avec la pièce à souder ou la table de travail, le plus près
possible de la soudure.
D Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
D Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage.
fre_som_2007−04
OM-1500-14 Page 5
Il reste une TENSION DC NON NÉGLIGEABLE dans
s
e
r
e
o
e
e
e
u
n
e
f
e
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.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
D Ne pas toucher à mains nues les partie
chaudes.
D Prévoir une période de refroidissement avant d
travailler à l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les outils recomman
dés et porter des gants de soudage et des vêtements épais pou
éviter les brûlures.
LES FUMÉES ET LES GAZ peuvent êtr
dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
D Eloigner votre tête des fumées. Ne pas respirer les fumées.
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.
LES RAYONS DE L’ARC peuvent pr
voquer des brûlures dans les yeux
sur la peau.
Le rayonnement de l’arc du procédé de soudag
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
dans les yeux et sur la peau. Des étincelles sont projetées pendant l
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 résistan-
tes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.
OM-1500-14 Page 6
génère des rayons visibles et invisibles intense
LE SOUDAGE peut provoquer un in
cendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tel
que des réservoirs, tambours ou des conduites pe
provoquer leur éclatement. Des étincelles peuve
être projetées de l’arc de soudure. La projection d’étincelles, des pièce
chaudes et des équipements chauds peut provoquer des incendies
des brûlures. Le contact accidentel de l’électrode avec des objet
métalliques peut provoquer des étincelles, une explosion, un surchau
fement ou un incendie. Avant de commencer le soudage, vérifier
s’assurer que l’endroit ne présente pas de danger.
D Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
D Se protéger et d’autres personnes de la projection d’étincelles et
de 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 Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
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 Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-
peurs inflammables (vapeur d’essence, par exemple).
D Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
lées.
D En cas de non utilisation, enlever la baguette d’électrode du porte-
électrode ou couper le fil à la pointe de contact.
D Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans
revers, des chaussures hautes et un couvre chef.
D Avant de souder, retirer toute substance combustible de vos po-
ches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
DES PIECES DE METAL ou DES SALETES peuvent provoquer des blessures dans les yeux.
D Le soudage, l’écaillement, le passage de la pièce à la brosse en
fil de fer, et le meulage génèrent des étincelles et des particules
métalliques volantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES ACCUMULATIONS DE GAZ
t
a
n
u
-
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 confi-
nés ou se servir d’un respirateur d’adduction
d’air homologué.
LES CHAMPS MAGNETIQUES peuvent affecter des implants médicaux.
D Porteur de simulateur cardiaque ou autre im-
plants médicaux, rester à distance.
D Les porteurs d’implants doivent d’abord consulter leur médecin
avant de s’approcher des opérations de soudage à l’arc, de soudage par points, de gougeage, du coupage plasma ou de chauffage par induction.
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
dage, les manipuler avec précaution.
gaz font normalement partie du procédé de sou-
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 station-
naire 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 suffi-
samment de personnes pour soulever et déplacer les bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécurité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLOSION.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D Ne pas installer l’appareil à proximité de pro-
duits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.
LA CHUTE DE L’APPAREIL peut
blesser.
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’assu-
rer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.
L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; re-
specter 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 Les étincelles risquent de causer un incendie − éloigner toute sub
stance inflammable.
LES ÉTINCELLES VOLANTES risquent de provoquer des blessures.
D Porter un écran facial pour protéger le visage e
les yeux.
D Affûter l’électrode au tungstène uniquement à l
meuleuse dotée de protecteurs. Cette manœuv
re est à exécuter dans un endroit sûr lorsque l’o
porte l’équipement homologué de protection d
visage, des mains et du corps.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les
circuits imprimés.
D Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistati-
ques pour stocker, déplacer ou expédier des
cartes de circuits imprimes.
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.
OM-1500-14 Page 7
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres per-
sonnes ou toute pièce mécanique en engageant le fil de soudage.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir fermés et verrouillés les portes, pan-
neaux, 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.
LIRE LES INSTRUCTIONS.
D Lisez le manuel d’instructions avant l’utilisation
ou la maintenance de l’appareil.
D N’utiliser que les pièces de rechange recom-
mandées par le constructeur.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
D Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs.
D Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’ap-
pareil.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D L’énergie électromagnétique risque de provo-
quer des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement commandé par ordinateur tel que
les robots.
D Veiller à ce que tout l’équipement de la zone de soudage soit
compatible électromagnétiquement.
D 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).
D Veiller à souder à une distance de 100 mètres de tout équipe-
ment électronique sensible.
D Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
D En cas d’interférences après avoir pris les mesures précéden-
tes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
2-4. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des
cancers et des malformations congénitales ou autres
problèmes de procréation. Se laver les mains après manipulation.
Pour les moteurs à essence :
Pour les moteurs diesel :
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.
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-1500-14 Page 8
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).
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).
National Electrical Code, NFPA Standard 70, de National Fire Protection Association, P.O. Box 9101, 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, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (téléphone : 703-788-2700, site Internet :
www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, de
Canadian Standards Association, 5060 Mississauga, Ontario, Canada
2-6. 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 :
L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site
Internet : www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, de American National Standards Institute,
11 West 43rd Street, New York, NY 10036-8002 (téléphone :
212-642-4900, site Internet : www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association,
P.O. Box 9101, Quincy, MA 02269-9101 (téléphone : 617-770-3000,
site Internet : www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux−−le télépho-
ne de la région 5, Chicago, est 312-353-2220, site Internet :
www.osha.gov).
1. Garder les câbles ensemble, les torsader, les scotcher, ou les
recouvrir d’une housse.
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 implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
OM-1500-14 Page 9
OM-1500-14 Page 10
3-1. Specifications
SECTION 3 − INTRODUCTION
Type of Input
Power
24 Volts AC
Single-Phase
10 Amperes
50/60 Hertz
Maximum Height With 4 ft (1.2 m) Post 17 ft (5.2 m) 21 ft (6.4 m)
Vertical Lift Of Boom Horizontal to 60° Above Horizontal Horizontal to 60° Above Horizontal
Welding Power
Source Type
Constant Voltage (CV)
DC With 14-Pin And
Contactor Control
Wire Feed Speed
Range
Standard: 50 To 780 ipm
(1.3 To 19.8 mpm)
Optional High Speed: 92
To 1435 ipm
(2.3 To 36.5 mpm)
12 ft (3.7 m) Boom (DS-12) 16 ft (4.9 m) Boom (DS-16)
Wire Diameter
Range
.023 To 1/8 in (0.6
To 3.2 mm)
Max Spool Weight:
60 lb (27 kg)
Welding Circuit
Rating
100 Volts,
750 Amperes, 100%
Duty Cycle
SECTION 4 − INSTALLATION
4-1. Installing Swivel Into Pipe Post
! Do not remove Safety Collar
5
4
2
1
3
until instructed to.
1 Swingpak Base or CBC Cart
2 Pipe Post With Base
3 Steel Bolt
Secure as shown using as a mini-
mum 1/2 in diameter SAE grade 5
steel bolts.
4 Swivel Assembly
Insert into pipe post. Lubricate
swivel.
5 Safety Collar
Weight
12 ft (3.7 m):
207 lb (94 kg)
16 ft (4.9 m):
280 lb (127 kg)
Tools Needed:
3/4 in
152 268-B
OM-1500-14 Page 11
4-2. Installing Control Box And Adjusting Tilt
1
2
4
3
Tools Needed:
3/8 in
1 Weld Control
2 Bracket
3 Screw
Bracket and screws are installed
onto bottom of control at factory.
4 Swivel
Loosen screws. Place control on
swivel and slide forward. Tighten
5
7
screws.
5 Tilt Bracket
6 Rear Pivot Screw
6
7 Front Screw
Loosen rear pivot screw. Remove
front screw. Pivot control downward to desired viewing angle. Replace and tighten front screw. Tighten pivot screw.
4-3. Installing Boom And Reel Support
4
5
6
803 192
1 Swivel Plates
2 Yoke
Remove hardware from swivel
plates and yoke.
3 Boom
Set boom into swivel as shown.
4 Yoke Pin
3
7
2
Install pin through yoke. Install cotter pin and spread ends.
5 Bolt
Install bolt, washers, and nut. Tight-
en hardware, and back bolt off one
half turn.
6 Locking Knob
Install locking knob but do not
tighten.
7 Reel Support
Install reel support.
Tools Needed:
OM-1500-14 Page 12
1
3/8, 3/4 in
ST-153 170-A
4-4. Installing Wire Guide Extension
1
1 Wire Guide Fitting
2 Bolt
3 Monocoil Liner
4 Wire Guide Extension
Tighten bolt to secure liner in wire
4
3
2
guide fitting. Do not overtighten bolt
and crush liner.
Repeat procedure for opposite
side.
Tools Needed:
3/8 in
ST-152 383
OM-1500-14 Page 13
4-5. Equipment Connection Diagram
1
2
3
4
5
12
1 Welding Power Source
2 Remote 14 Connection
3 Negative (−) Weld Output
Cable
4 Positive (+) Weld Output
Cable
5 Workpiece
6 Weld Control
7 Boom
8 Gun
9 Swivel
10 Pipe Post And Base
11 Gas Hose
12 Gas Supply and Regulator
(Customer Supplied)
. Shielding gas pressure not to
exceed 100 PSI (689 kPa).
11
6
7
10
9
8
OM-1500-14 Page 14
803 195
4-6. Control Box Connections
AJ
E
F
1
1 Interconnecting Cables
2 Interconnecting Cable
Receptacles
3 14-Pin Cord
2
4-7. 14-Pin Plug Information
Pin* Pin Information
A 24 volts ac with respect to socket G.
I
G
F
*The remaining pins are not used.
B
L
NH
C
M
D
E
AJ
K
B Contact closure to A completes 24 volts ac contactor control circuit.
G Circuit common for 24 volts AC circuit.
C +10 volts dc input from power source to wire feeder with respect to socket D.
D Remote control circuit common.
E 0 to +10 volts dc output 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.
3
803 197-A
OM-1500-14 Page 15
4-8. Removing Safety Collar And Adjusting Boom
4
5
2
1
3
1 Locking Knob
Tighten knob to prevent boom
movement. Loosen knob to allow
boom movement. Change knob position to limit upward movement.
Pull boom down slightly and remove safety collar. Boom should
balance in any position from horizontal to 60 degrees above horizontal. If necessary, adjust boom
as follows:
2 Threaded Rod
3 Jam Nut
Loosen jam nut and turn threaded
rod until boom balances. Tighten
jam nut. Be sure several full threads
are through yoke to prevent boom
falling.
4 Yoke
5 Safety Collar
Retain safety collar for use in disas-
sembling or moving boom.
4
3
2
Tools Needed:
1-1/8 in
Rod
Increasing Spring
Pressure For A Heavy
Gun
Rod
Decreasing Spring
Pressure For A
Lighter Gun
4-9. Gun Recommendation Table
Process Gun
GMAW − Hard or Cored Wires Roughneck C-Series Guns: 300, 400, 500, And
FCAW − Self-Shielding Wires FC-1260 Or FC-1150
600 Amp.
4-10. Wire Type, Size, And Feed Speed Capability Table
Motor Speed Wire Type Wire Size Feed Speed Capability
Standard All .023 To 5/64 in (0.6 To 2 mm) 50 To 780 ipm (1.3 To 19.8 mpm)
ST-142 599-C
Standard All 3/32 To 7/64 in (2.4 To 2.8 mm) 50 To 700 ipm (1.3 To 17.8 mpm)
Standard All 1/8 in (3.2 mm) 50 To 300 ipm (1.3 To 7.6 mpm)
Optional High
Speed
OM-1500-14 Page 16
All .023 To 5/64 in (0.6 To 2 mm) 92 To 1435 ipm (2.3 To 35.6 mpm)
4-11. Installing And Threading Welding Wire
Tools Needed:
Pressure
Adjust
Install wire spool. Adjust tension nut so
wire is taut when wire
feed stops.
Pressure
Indicator
Scale
3/16, 5/64 in
3/8, 15/16 in
Install wire guide.
Install drive rolls.
NONCONDUCTIVE
SURFACE
No Wire Slip Wire Slips
. Be sure that outlet cable has proper
size liner for the welding wire size.
When installing gun, position liner
extending from outlet wire guide as
close as possible to drive rolls without touching.
Install gun. Lay gun cable out straight. Cut off
end of wire. Push wire through guides up to
drive rolls; continue to hold wire. Press Jog
button to feed wire out gun.
Pressure
Adjust
Drive Rolls
Gun Cable
End Of Liner
NONCONDUCTIVE
SURFACE
. For soft wire or small diameter stainless
steel wire, reduce drive roll pressure on
the rear roll to half that of the front rolls.
803 196 / 152 648-A / 803 020 / 802 966 / Ref. 137 391-A / 802 954 / Ref. S-0627-A
. To adjust drive roll pressure, hold nozzle
about 2 in (51 mm) from nonconductive
surface and press gun trigger to feed wire
against surface. Tighten knob so wire
does not slip. Do not overtighten. If contact tip is completely blocked, wire should
slip at the feeder (see pressure adjustment above). Cut wire off. Close cover.
OM-1500-14 Page 17
4-12. Setting Internal DIP Switches
. When DIP switch positions are changed, the
unit must be turned Off and then On again in
order for the new settings to be active. DIP
switches are only read on power up.
1 DIP Switch S1
2 DIP Switch S4 (Not For Customer Use)
DIP switch S1 allows the user to make a num-
ber of choices affecting unit operation.
w Defining Motor Speed (S1-7 & 8)
Switches 7 and 8 allow the user to define
whether the motor in use is standard speed
(50-780 inches per minute), or high speed
(92-1435 inches per minute).
. Setting DIP switches allows the feeder to
display the proper wire speed. Setting
the DIP switches will not change the
speed range of the motors.
1
O
12345678
N
. In the DIP switch S1 illustrations,
the elevated slider on each switch
2
Position Settings And Results For DIP Switch S1
78
7 Off, 8 Off = Standard
speed motor (50-780 inches per minute, or 1.2-19.8
meters per minute)
78
7 Off, 8 On = High speed
motor (92-1435 inches per
minute, or 2.3-36.4 meters
per minute)
is shown in white. For example,
the switches above are all in the
Off position.
803 198
OM-1500-14 Page 18
4-13. Power Source Selection Menu
Non-CE Model Shown
1
Program
Start
Crater
Pre/Postflow
Sequence Setup
* * Power Source
Deltaweld 452 dELT 452 Vmin =10 Vmax =38
Deltaweld 302 dELT 302 Vmin =10 Vmax =32
Deltaweld 652 dELT 652 Vmin =10 Vmax =44
Dimension 302 dIM 302 Vmin =10 Vmax =32
Dimension 452 dIM 452 Vmin =10 Vmax =38
Dimension 652 dIM 652 Vmin =10 Vmax =65
Dimension 1000 dIM 1000 Vmin =10 Vmax =60
XMT 304 XMT 304 Vmin =10 Vmax =35
XMT 456 XMT 456 Vmin =10 Vmax =38
Invision 354MP I354 MP Vmin = 10 Vmax =35
Invision 456MP I456 MP Vmin = 10 Vmax =38
Invision 456P I456 P Vmin =10 Vmax =38
PHOENIX 456
SUMMIT ARC 1000 SUM 1000 Vmin =25 Vmax =44
** For any power sources not listed, pick a matching voltage range, or see Sec 4-12 to
set Vmin and Vmax.
Volts Time (sec)
Wire Speed Amps
Adjust
Upper Display
Trigger Hold
Dual Schedule
Lower Display
2
Voltage Range
PHX 456 Vmin =10 Vmax =38
1 Upper Display
2 Lower Display
. When the feeder is turned on,
the Power Source Selection
Menu allows the operator to select a default power source.
Selecting a default power
source, automatically sets the
correct Vmin and Vmax settings for adjusting the output
voltage of the power source.
First Time Feeder Is Turned On
The feeder automatically goes into
the Power Source Selection Menu.
The feeder displays “dELT” on the
Upper Display and “452” on the
Lower Display, meaning that a Deltaweld 452 is the default power
source, and has a voltage range of
10V as Vmin and 38V as Vmax.
At power up, the operator has three
seconds to select a default power
source from the list shown on the
display. Operator may scroll
through the list of power sources by
using the Adjust control. After selecting a power source the operator
has three seconds to change to a
different power source or begin
welding. After making a power
source selection, the operator may
press the Program Button to avoid
having to wait the three seconds.
When turning off the feeder, the default power source will be retained.
If voltage settings have already
been set with the Vmin and Vmax in
the Auxiliary Menu, selecting a default power source with the Power
Source Selection Menu overrides
the Vmin and Vmax voltage settings.
Next Time Feeder Is Turned On
The feeder will display the last selected default power source. The
operator has three seconds to select another power source, or press
the Program Button to exit the Power Source Selection Menu.
Disabling The Power Source
Selection Menu
Once the default power source has
been selected the Power Source
Selection Menu may be disabled
using the Auxiliary Menus. See
Section 5-12.
OM-1500-14 Page 19
SECTION 5 − OPERATION
5-1. 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.
5-2. Power Switch
1 Power Switch
5-3. Left/Right Select Switch
1
1
803 193
1 Left/Right Select Switch
Pressing the Left/Right Select
switch allows the operator to
choose which side of the units’ controls will operate.
. Engaging the Left or Right
Gun Trigger also allows the
operator to enable the controls on that side of the unit.
803 194
OM-1500-14 Page 20
5-4. Jog/Purge Switch
2
1 Jog/Purge Switch
2 Adjust Control
1
Pressing the Jog/Purge switch allows the operator to jog wire without energizing the weld
power or gas valve circuit.
• The unit provides the ability to jog the wire
feeder by means of the gun trigger or the
Jog/Purge switch. If the welding arc does
not initiate in 3 seconds after the gun trigger
is activated, the unit will perform a jog operation for a maximum of two minutes. If the gun
5-5. Front Panel Controls
See
Section
5-6
Program
trigger is still activated after two minutes, the
jog operation is terminated to prevent complete despooling of the wire, in the case of
a damaged gun.
• The unit displays the “ERR TRIG“ message
to inform the operator that the trigger is activated.
• Jog speed can be adjusted by the Adjust
control when the unit is jogging wire. The
Volts Time (sec)
803 194
unit displays jog speed when the unit is being jogged.
• Jogging can also be accomplished by
pressing the Jog/Purge button.
• Pressing the Jog/Purge button also allows
the operator to purge gas lines before welding and to preset gas pressure at the
regulator.
See
Section
5-7
See
Section
5-8
Wire Speed Amps
Start
Crater
Pre/Postflow
Sequence Setup
See
Section
5-11
Adjust
See
Section
5-10
Dual Schedule
Trigger Hold
See
Section
5-9
OM-1500-14 Page 21
5-6. Program Push Button
1
2
5-7. Upper Display
. To set the correct voltage range for a particular power
source, see Section 4-13 for power source selection menu,
or Section 5-12 for V-Min And V-Max adjustments.
Program
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.
3 Program Push Button LED
3
The LED lights to indicate the Program push button is active.
1
4
1 Upper Display
The upper display shows voltage 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.
3 Upper Display Push Button LED
The upper display push button LED illumi-
Volts Time (sec)
5
nates to indicate that information displayed
can be changed by the Adjust control.
4 Volts LED
5 Time LED
The LEDs below the display illuminate to in-
dicate which value is being shown.
At any time while welding, the unit permits
the adjustment of the weld sequence voltage
and overrides the display of 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 dis-
3
2
play push button repeatedly until welding
time is the active parameter in the upper
display. At idle, the upper display toggles
between showing weld voltage or weld
time, with subsequent presses of the upper display push button.
• The unit defaults to displaying welding
voltage when a welding sequence display
mode is first entered.
• If the weld sequence has a time set (as in
spot time), after the weld program is completed, ERR TRG 1 will be displayed to indicate the weld program is complete. Release trigger to clear error.
OM-1500-14 Page 22
5-8. Lower Display
1
4
3
2
Wire Speed Amps
5
1 Lower Display
The lower display shows wire speed or
amperage. The unit displays and adjusts only
preset wire speed at idle. When the unit is in a
welding state, actual wire speed is displayed
for the active welding sequence.
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
5-9. Setup Push Button
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.
• If the unit is in a welding state that does not
involve feeding wire, the unit displays the
weld sequence wire speed. At any time during welding, the weld sequence wire speed
can be adjusted and overrides the preset
wire speed display. In other words, if the Ad-
3
4
Trigger Hold
Dual Schedule
1
Setup
just control is activated while welding, the
unit displays and permits adjustment of the
weld sequence wire feed speed regardless
of the active welding sequence.
• When the unit is displaying amperage, the
Amps LED illuminates. Amperage is only
displayed if the unit is in a welding state and
the amperage is above a minimum value of
25 Amps.
• The display will read dashes for amperage
readings below the amperage threshold,
prior to arc initiation.
2
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 Set-
up push button LED flashes and the Trigger
Hold LED flashes.
• 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 status 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 5-12), 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.
• Trigger hold and dual schedule cannot be
used concurrently.
• 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.
• While in the Setup mode, the active program
can be adjusted without deactivating the
trigger hold Setup mode operation. If the
trigger is activated, Setup mode(s) is terminated.
OM-1500-14 Page 23
5-10. Adjust Control
1
5-11. Sequence Push Button
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.
Adjust
3
Start
Crater
Pre/Postflow
Sequence
. For more information on Setting
Sequence Parameters see Section 6-1.
• 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.
• The LED illuminates to indicate that a weld-
ing sequence display mode other than Weld
is activate. 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
2
1
• In the weld sequence display mode the Se-
• When the Sequence push button is pressed
Start
Time
Preflow
Time
Welding Sequence Diagram
the weld display mode is activated.
If zero time is programmed for a timed se-
quence except for Weld, that sequence will
be skipped.
quence 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 shown in the displays.
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 shown in
the displays.
Weld
Time
Crater
Time
Postflow
1 Sequence Push Button
2 Sequence Push Button LED
3 Welding Sequence LEDs
Time
• 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.
OM-1500-14 Page 24
5-12. Auxiliary Menus
1
2
Program
Volts Time (sec)
1 Program Display
2 Program Push Button
3 Sequence Push Button
4
5
7
4 Upper Display
5 Upper Display Push Button
6 Lower Display
7 Lower Display Push Button
8 Adjust Control
9 Setup Push Button
Wire Speed Amps
Start
Crater
Pre/Postflow
3
Sequence Setup
Adjust
5-12 Auxiliary Menus (Continued)
Reset To Factory Settings
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.
Auxiliary Menu
• An auxiliary menu is provided if both the Se-
quence 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 push
button and the Setup push buttons simultaneously.
V-Min And V-Max
• If the Setup push button is pressed, the unit
allows the setting of the manual override
power source min and max voltage preset
range. The minimum voltage is displayed in
the upper display and the lower display indicates “VMIN”. When the Setup push button
is pressed the unit displays the maximum
voltage setting of the welding power source.
The maximum voltage is displayed in the upper display and the lower display indicates
“VMAX”.
In both cases, the Adjust control is used to
specify the minimum and maximum voltage
settings of the welding power source. The settings correspond to arc voltage obtained at
minimum command and arc voltage obtained
at maximum command.
This method of setting “VMIN” and “VMAX”
may be used if the power source being used
is not listed in the Power Source Selection
Menu.
. If a default power source has already been
. The power source selection menu must
Power Source Selection Menu
• If the Setup push button is pressed, the unit
allows the Power Source Selection menu to
be disabled or enabled.
Trigger Hold
Dual Schedule
8
selected with the Power Source Selection
menu, setting “VMIN” and “VMAX” will
override the default power source settings.
be set to “OFF” when overriding the default “VMIN” or “VMAX” settings.
6
9
The upper display shows “PSS”. Lower display shows “On” or “Off”. The Adjust Control is
used to select either “On” or “Off”.
Arc Time
• If the Setup push button is pressed, the unit
displays arc time in hours.
Arc time is indicated by the Program display
showing “HR”. Arc time is shown in the lower
display.
Cycles
• If the Setup push button is pressed, the unit
displays the number of cycles.
Arc cycles are indicated by the Program display showing “CL”. The arc cycle count is
shown in the lower display.
Run-In
• If the Setup button is pressed, the unit allows
setting the run-in modes. The run-in modes
are program specific. 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 a
manual setting the run-in wire speed. Speed
may be adjusted from 10% to 100% of weld
wire speed.
Pressing the lower display button allows disabling of the run-in feature. When the lower
display indicates “OFF” run-in is disabled.
OM-1500-14 Page 25
5-12 Auxiliary Menus (Continued)
Burnback
• If the Setup push button is pressed, the unit
allows burnback time to be set.
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, like run-in settings, are program specific. The active program is displayed in the
Program display and can be adjusted (see
Section 5-6).
Trigger Hold Setup
• If the Setup push button is pressed, the unit
allows trigger hold delay time to be set.
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.
• 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.
• When the Setup push button is pressed
again, the menu repeats to the first menu
selection of run-in wire speed selection.
Trigger Program Select
• If the Setup push button is pressed, the unit
allows Trigger Program Select or Trigger
Dual Schedule to be enabled or disabled.
The upper display shows “TSEL”. Lower display shows “OFF” or “PROG” or “DUAL”. The
Adjust Control is used to select “OFF” or
“PROG” or “DUAL”.
Trigger Program Select (PROG) allows the
operator to select programs during preflow 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. Trigger Program Select cannot be used while welding or with Dual
Schedule.
(Example: If programs 1 and 3 have a minimum of 0.2 seconds of preflow time, clicking
the trigger will toggle between programs 1 and
3).
Trigger Dual Schedule Select (DUAL) allows
the operator to switch between paired schedules (programs 1−2, 3−4, 5−6, or 7−8) with the
gun trigger, but only while welding. This feature cannot be used with Trigger Hold or Dual
Schedule. To end the weld, the trigger must be
released for 0.4 seconds.
(Example: when welding with this feature enabled in program 1, if you release, re-trigger,
and hold again within <0.4 seconds, the active
program will switch to program 2. If the previous sequence is repeated the active program will switch back to program 1. This cycle
can be repeated for the entire weld).
Process Select
Process selection indicated by ”PROS” in the
upper display is set to either ”VOLT” or ”TRIM”
in the lower display. Each program can be selected be be a MIG program indicated by
”VOLT” or a pulsing program indicated by
”TRIM”.
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 feed speed
range lock ranges from 0 to 250 ipm. Locks are
program dependent and wire speed is independent from voltage or trim.
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
• If the Setup push button is pressed, the unit
allows OPT1 to be disabled or enabled.
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.
OPT2
• If the Setup push button is pressed, the unit
allows OPT2 to be disabled or enabled.
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.
Display Hold
Display hold indicated by ”DISP” in the upper
display is set to “OFF” or “HOLD” in the lower
display. When ”HOLD” is selected, the unit will
hold the last weld information for 5 seconds following weld termination. If any front panel
push button is pressed, or if the Adjust control
is activated, the display hold feature is terminated.
Software Revision Level
• If the Setup push button is pressed, 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, indicated by “OFF”
in the lower display. The user may enter a numerical password between 0 and 999 by turning the Adjust control. When the user re−en-
ters the auxiliary menu, the password code
must be selected to gain access to the auxiliary menu. A failed attempt return 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. Pressing the Program,
Sequence, upper display, and Set−up push
buttons simultaneously, the counter can be reset in the weld screen. 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 will allow the user to reset the unit to the factory defaults, indicated by “WIPE” in the upper display. Resetting the unit will also turn off the
password code feature.
OM-1500-14 Page 26
SECTION 6 − SETTING SEQUENCE PARAMETERS
6-1. Sequence Parameters In A Program
Sequence Parameters
Volts IPM Seconds
1. Preflow 0-9.9
. For more information on
Sequence Push Button see
Section 5-11.
If time is set to zero in Weld
sequence, welding continues until
gun trigger is released.
If time is set to zero in any timed
sequence except Weld, the
sequence is skipped.
2. Run-In
3. Start
4. Weld
5. Crater
6. Burnback
7. Postflow
X = Setting available.
X
XX
X
X
X
Weld Time
0.00-5.00XX
0-100.0
0-5.00
0-0.25
0-9.9
Preflow
Trigger
Pressed
Preflow
Time
Start
Start
Time
Crater
Time
Burnback
Time
Postflow
Time
Time
Burnback
WeldRun-In
Trigger
Released
PostflowCrater
Sequence
End
OM-1500-14 Page 27
SECTION 7 − SETTING DUAL SCHEDULE PARAMETERS
7-1. Optional Dual Schedule Switch Diagrams
1 Maint 2P (Maintained-Contact
1
11
22
3A
4B
A
TR
2
DSS-8DSS-9
B
1
2
3
4
2-Pole Switch)
2 Maint 1P (Maintained-Contact
1-Pole Switch)
. Will not function with trigger
hold and dual schedule. A
DSS-9 is recommended for
this application.
Notes
OM-1500-14 Page 28
7-2. Diagnostics
3
1
2
Left Side Motor Control Board PC101
ERR
COM1
ERR
TRG1
ERR
TCH1
1 LED3 On Right Side Motor
Control Board PC1
2 LED3 On Left Side Motor
Control Board PC101
3 LED4 On Dual Board PC70
. There is a two-position DIP
switch S1 located on motor control boards PC1 and PC101.
These switches are factory-set
in the off position and must remain in that position for the unit to
operate correctly.
803 063-A
ERR
MTR1
. Note: The error messages
are shown on the upper
and lower displays to indicate specific errors. Explanations are in the text
below:
Right Side Motor Control Board PC1
Dual Board PC70
Error Indications
Error conditions are indicated by LED3 on
PC1, PC101, and LED4 on PC70. To view
LEDs, turn Off unit, remove wrapper, and turn
unit On.
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.
Indicates a communication error.
ERR
COM2
Indicates a communication error.
Indicates a trigger
error.
ERR
TRG2
Indicates a trigger
error.
ERR
Indicates a
COM3
1 blink = Communication Error
2 blinks = Trigger Error
3 blinks = Tach Error
4 blinks = Motor Error
• The communication error occurs 2.5 sec-
onds after a loss of communication between the motor and the Front Panel board
or Dual board. The user may continue to
weld with this error.
• The trigger error occurs if the user has the
trigger held for more than two minutes without striking an arc (providing current override is not enabled), 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.
communication
error.
Indicates a
tachometer error.
ERR
TCH2
Indicates a
tachometer error.
• The tach error occurs 2 seconds after the
loss of tachometer feedback. The user may
continue to weld with this error. The motor
speed is regulated through the monitoring of
voltage and current.
• The motor error indicates that the motor
has been drawing too much current for too
long.
Indicates a motor
error.
ERR
MTR2
Indicates a motor
error.
OM-1500-14 Page 29
7-3. Diagnostics For User Defined Options
1 Front Panel
2 Front Panel Board PC20
User Defined Shutdown Error
Messages (Additional hardware
1
required for these to be functional)
If OPT1 and/or OPT2 are enabled
without additional hardware setup,
the following error messages will be
displayed on the front panel meters.
OPT1 and/or OPT2 must be disabled.
. Refer to Section 5-12 for cor-
2
rect setup procedures.
803 198
ERR
OPT1
Indicates a User Defined
Option Error
ERR
OPT2
SECTION 8 − MAINTENANCE & TROUBLESHOOTING
8-1. Routine Maintenance
. Maintain more often
during severe conditions.
3 Months
Replace
unreadable
labels.
Clean and
tighten
weld
terminals.
! Disconnect power
before maintaining.
Repair or
replace
cracked
weld
cable.
Replace
cracked
parts.
6 Months
Blow out or vacuum
inside. During heavy
service, clean
monthly.
OM-1500-14 Page 30
Check
14-pin cord.
Or
Check gas
hose and
fittings.
Check gun
cable.
Clean
drive rolls.
8-2. Troubleshooting
Trouble Remedy
! Disconnect power before troubleshooting.
Wire feeds, shielding gas flows, but electrode wire is not energized.
Wire feeder is on, meter(s) do not light
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.
Motor runs slowly. Check for correct input voltage.
Wire does not feed until trigger is pulled,
but continues to feed after trigger is released, and trigger hold is not on.
Gas valve in feeder is rattling loudly
along with possible erratic or slow wire
feed speed.
Check interconnecting cord connections. If secure, check cord for continuity and repair or replace (see
Sections 4-5 and 4-6).
Check and reset circuit breaker at welding power source.
Check gun trigger connection. See gun Owner’s Manual.
Check gun trigger. See gun Owner’s Manual.
Readjust hub tension and drive roll pressure (see Section 4-11).
Change to correct size drive roll (see Table 10-1).
Clean or replace dirty or worn drive roll.
Incorrect size or worn wire guides.
Replace contact tip or liner. See gun Owner’s Manual.
Remove weld spatter or foreign matter from around nozzle opening.
Have Factory Authorized Service Agency check drive motor or motor control board PC1.
Check for a short between welding gun trigger leads and weld cable. Repair short or replace welding gun.
Check for a short between welding gun trigger leads and weld cable. Repair short or replace welding gun.
Wire feeder power is on, displays light
up, but unit is inoperative.
Check welding gun trigger leads for continuity, and repair leads or replace gun.
OM-1500-14 Page 31
SECTION 9 − ELECTRICAL DIAGRAM
OM-1500-14 Page 32
Figure 9-1. Circuit Diagram
204 144-C
OM-1500-14 Page 33
. Hardware is common and
not available unless listed.
3
4
2
SECTION 10 − PARTS LIST
10
Fig 10-5
9
8
7
5
6
11
1
Fig 10-2
31
13
Fig 10-3
14
2
16
31
14
2
15
17
15
18
19
12
20
21
22
23
24
25
OM-1500-14 Page 34
Figure 10-1. Main Assembly
30
Fig 10-4
29
28
27
26
Fig 10-4
803 189-C
Quantity
Item
No.
Dia.
Mkgs.
Part
No.
Description
Model
DS-12 DS-16
Figure 10-1. Main Assembly
1 See Note Control Box, (Fig 10-2) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 201 319 Cable, Interconnecting (consisting of) 2 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 201 320 Cable, Interconnecting (consisting of) 0 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG37,38,137,138 047 636 Connector & Pins 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
079 739 Connector, Circ Clamp Str Rlf Sz 17-20 Amp 206322-2 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
163 520 Cable, Port No. 18/14 8/C (order by ft) 17Ft 21Ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 139 600 Hose, Gas 2 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 139 599 Hose, Gas 0 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 600 324 Cable, Weld Cop Strd No. 4/0 (order by ft) 26Ft 30Ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 602 243 Washer, Flat Stl Std .375 8 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 602 213 Washer, Lock Stl Split .375 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 601 872 Nut, Stl Hex Full .375-16 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 080 947 Bracket, Spring Retaining 1 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 151 626 Bracket, Spring Retaining 0 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 132 053 Screw, Cap Stl Hexhd .375-16 X 1.500 Lg 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 Fig 10-5 Support, Hub & Reel 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 ♦149 838 Pipe Post, 4ft W/Base Or 1 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 ♦149 839 Pipe Post, 6ft W/Base 1 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 ♦078 264 Pipe Post, 4ft W/Base Or 0 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 ♦079 216 Pipe Post, 6ft W/Base 0 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 ♦075 078 Pipe Post, 4ft W/O Base Or 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 ♦079 217 Pipe Post, 6ft W/O Base 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 Fig 10-3 Boom Assembly 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 RC37,137 047 637 Connector & Sockets (consisting of) 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG45,145 131 203 Housing Plug + Pins, (service kit) 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG44,144 167 640 Housing Plug Pins + Skts (service kit) 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG46,146 115 090 Housing Plug + Pins, (service kit) 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 203 314 Cable,Trigger 20 In Boom/Detach (consisting of) 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
115 094 Housing Plug+Skts,(service kit) 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
080 328 Rcpt W/Skts,Free Hanging 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
079 531 Conn,Circ Cpc Clamp Str Rlf Size 11 .453od 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
604 571 Cable,Port No 18 4/C Type sjo nprn jkt re 2Ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 605 227 Nut, Nyl Hex Jam .750npst 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 GS1,101 228 035 Valve, 34VDC 1way .750-14 Thd 2mm Orf 100PSI 2 2. . . . . . . . . . . . . . . . . . . . . . . . . .
PLG4,104 136 810 Housing Plug + Skts (service kit) 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 139 813 Cover, Protector Motor 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 139 816 Panel, Encl Cover 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 159 647 Insulator, Motor Clamp 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 159 646 Clamp, Motor Base 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 159 360 Insulator, Screw Machine 8 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 156 243 Clamp, Motor Top 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 145 639 Strip, Buna N Compressed Sheet .062 X 4.000sq 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 134 834 Hose, Sae .187 Id X .410 Od (order by ft) 3Ft 3Ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 208 944 Drive Assy,Wire Rh Vertical 4 Roll W/Clamp&tach (Fig 10-4) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . .
26 ♦208 945 Drive Assy,Wire Rh Vert 4 Roll Hi−speed W/Cl&tach (Fig 10-4) 1 1. . . . . . . . . . . . . . . . . . . . . . .
27 157 295 Guide, Monocoil 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 604 612 Screw, Set Stl Sch 8-32 X .125 Cup Point 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 082 050 Liner, Monocoil Inlet Wire 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 201 776 Drive Assy,Wire L Vertical 4 Roll W/Clamp&tach (Fig 10-4) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . .
30 ♦201 777 Drive Assy,Wire L Vert 4 Roll Hi−speed W/Cl&tach (Fig 10-4) 1 1. . . . . . . . . . . . . . . . . . . . . . .
149 322 Clamp, Hose .405−.485clp 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 211 989 Fitting, W/Screen 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
♦ OPTIONAL
Note: When ordering Control Box contact factory service department for proper number.
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-1500-14 Page 35
. Hardware is common and
not available unless listed.
24
23
25
22
21
20
8
1
2
4
3
7
6
5
18
8
19
9
10
17
12
13
11
14
9
15
16
803 200
Figure 10-2. Control Box
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure 10-2. Control Box (Figure 10-1 Item 1)
1 204 722 Wrapper, Feeder 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
134 464 Label,Warning General Precautionary Static&wire Fe 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 206 764 Panel, PC Card Front (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 200 153 Overlay, Front Panel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 PC21 200 693 Circuit Card Assy,Switches 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 PC20 210 683 Panel, Pc Card Display W/Program 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 S1 111 997 Switch, Rocker Spst 10A 250vac On-Off Visi Red Rock 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 PC70 220 903 Circuit Card Assy, Dual W/Program 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 PC1,101 217 898 Circuit Card Assy, Motor Control W/Program 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 030 170 Bushing,Snap−in Nyl .750 Id X 1.000 Mtg Hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 000 527 Blank, Snap−in Nyl .875 Mtg Hole Black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 047 838 Blank,Snap−in Nyl 1.000 Mtg Hole Black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 201 228 Cable, Power 16.5ft 8/c 2-14ga 6-18ga (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 139 041 Strain Relief 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 163 519 Cable, Port 16.5 Ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 079 739 Conn, circ cpc clamp str rlf 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 PLG12 141 162 Housing Plug+Pins, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG52 174 823 Housing Plug Pins+Skts, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG74 115 093 Housing Plug+Skts, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 RC40,140 047 637 Housing Rcpt+Skts,(service kit) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG34,134 136 810 Housing Plug+Skts, (service kit) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG35,135 131 204 Housing Plug+Skts, (service kit) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG36,136 115 094 Housing Plug+Skts, (service kit) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 010 494 Bushing, Snap−in Nyl 1.375 Id X 1.750 Mtg Hole 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quantity
OM-1500-14 Page 36
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure 10-2. Control Box (Continued)
18 134 201 Stand-Off Support, PC Card .312/.375w/Post&lock .43 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 204 721 Enclosure, Control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 206 765 Panel, Front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 206 771 Nameplate, Miller Lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 S2,102 200 295 Switch, Rocker Spdt 15A 12V (On)−Off−(On) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 S100 201 641 Switch, Rocker Spdt 15A 12V (On)−Off−(On) W/leds 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 213 134 Knob, Encoder 1.670 Dia x .250 Id Push On W/Spring 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 207 745 Nameplate, Miller Switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dia.
Mkgs.
Part
No.
Description
Harness Connectors/Receptacles
PLG6,106 115 094 Housing Plug+Skts, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG10,110 130 203 Housing Plug+Skts, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG72 115 092 Housing Plug+Skts, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG4,104 136 810 Housing Plug+Skts, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG11, 21,71,111 131 055 Housing Rcpt+Skts, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG1,77,78,79,101 202 592 Housing Plug+Skts, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG3,75,76,103 115 093 Housing Plug+Skts, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG51 174 824 Housing Plug Pins+Skts, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG7,27,67,107 115 091 Housing Plug+Skts, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG73 148 439 Housing Plug Pins+Skts, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG17,70 158 719 Housing Plug+Skts, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG117 165 404 Housing Rcpt+Skts, (service kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quantity
Quantity
OM-1500-14 Page 37
11
10
9
8
7
. Hardware is common and
not available unless listed.
12
18
13
14
26
15
19
27
16
28
17
15
20
25
212223
24
14
6
5
4
23
1
Figure 10-3. Boom Assembly
29
30
ST-142 306-H
OM-1500-14 Page 38
Quantity
Item
No.
Part
No.
Description
Model
DS-12 DS-16
Figure 10-3. Boom Assembly (Figure 10-1 Item 13)
1 010 313 Pin, Cotter Hair .072 X 1.437 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 010 910 Washer, Flat Stl Sae .375 6 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 079 622 Washer, Shld .381 Id X .750 Od 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 079 621 Pulley, V Sgl Grv 7.750dia X 8.000p X .625 Bore 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 079 667 Pipe, Plstc .500 X 133.750 2 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 080 812 Pipe, Plstc .500 X 181.750 0 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 079 632 Bolt, U Stl .250-20 X .875 Wide X 1.375 Deep 8 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 079 665 Guide, Wire 2 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 080 811 Guide, Wire 0 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 079 664 Guide, Wire Inlet 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 139 633 Liner, Monocoil 3/32-1/8 Wire X 15.687 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 159 999 Boom, Dual 1 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 160 513 Boom, Dual 0 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 080 947 Bracket, Spring Retaining 1 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 151 626 Bracket, Spring Retaining 0 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 073 742 Pin, Clevis .750 Od X 2.156 Lg 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 073 741 Clevis, .812 Yoke 6.062 Lg .750-16Thd 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 079 029 Nut, Stl Hex Full Fnsh .750-16 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 075 462 Shaft, Boom Counterbalance 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 602 250 Washer, Flat Stl Sae .750 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 079 020 Nut, Stl Hex Elastic Stop .750-16 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 155 335 Pipe, Blk 3.000 X .875 0 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 149 858 Spring, Cprsn 3.750 Od X .625 Wire X 36.000 1 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 151 625 Spring, Cprsn 3.750 Od X .640 Wire X 36.000 0 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 150 258 Retainer, Spring 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 024 605 Bearing, Ball Thr Sgl Row .750 X 1.625 X .625 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 075 101 Nut, Stl Hex Special .750-16 X 1.250 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 079 030 Washer, Lock Stl Ext Tooth .750 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 +174 754 Base, Swivel Boom (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
080 157 Fitting, Grease 1/8npt 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 174 688 Bracket, Mtg Control Tilt 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
142 804 Label, Swingarc Caution Heavy Spring 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
134 327 Label, Warning General Precautionary 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 073 666 Bolt, Mach Stl Hexhd .750-16 X 2.750 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 047 224 Knob, T-bar .500-13Thd 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 602 246 Washer, Flat Stl Std .500 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 010 493 Bushing, Snap-in Nyl .625 Id X .875mtg Hole 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 139 818 Guard, Motor Protector 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-1500-14 Page 39
. Hardware is common and
not available unless listed.
See Table 10-1 For
Drive Roll & Wire Guide Kits
16
22
14
17
18
19
20
21
15
7
6
5
4
3
2
1
36
35
34
33
32
31
8
9
12
10
11
37
38
39
40
28
29
30
13
26
27
14
24
25
22
23
Figure 10-4. Drive Assembly, Wire
Quantity
Item
No.
Dia.
Mkgs.
Part
No.
Description
Model
DS-12 DS-16
Figure 10-4. Drive Assembly, Wire (Figure 10-1 Items 26 and 30)
1 010 668 Screw, Cap Stl Sch .250-20 X 1.500 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 172 075 Carrier, Drive Roll W/Components 24 Pitch 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 149 962 Spacer, Carrier Drive Roll 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 149 486 Pin, Rotation Arm Rocker 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 163 282 Nut, .250-28 Stl 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 165 798 Spring, Pressure Arm Retaining 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 165 799 Washer, Flat .257 Id Stl 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 132 750 Arm, Pressure 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 150 520 Spacer, Rotation Pin 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 133 493 Ring, Retaining Ext .250 Shaft X .025thk 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 133 350 Pin, Hinge 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 M1,101 201 230 Motor, Gear 1/8hp 24vdc Standard Speed 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 M1,101 201 231 Motor, Gear 1/8hp 24vdc High Speed 0 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
153 491 Kit, Brush Replacement (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
153 492 Cap, Brush 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*153 493 Brush, Carbon 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
802 977-B
OM-1500-14 Page 40
Quantity
Item
No.
Dia.
Mkgs.
Part
No.
Description
Model
DS-12 DS-16
Figure 10-4. Drive Assembly, Wire (continued)
184 136 Kit, Brush Holder 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 155 098 Kit, Cover Motor Gearbox (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
153 550 Cover, Motor Gearbox (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
155 099 Gasket, Cover 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
155 100 Screw, Cover 5 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
154 031 Spacer, Locating 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
133 493 Ring, Rtng Ext .250 Shaft Grv X .025Thk 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
203 642 Pressure Arm,R & Vert L 4 Roll (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
203 631 Pressure Arm,S/L & Vert S/R 4 Roll (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 203 461 Washer, Flat Indicator Spring Tension 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 182 415 Pin, Cotter Hair 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 203 640 Knob, W/Extension Short Pressure Arm 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 182 156 Spring, Cprsn 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 182 155 Spring 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 132 746 Bushing, Spring 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 203 633 Shaft, Spring 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 203 632 Carrier, Shaft 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 133 739 Washer, Flat Buna .375 Id X .625 Od X .062Thk 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 203 637 Knob, W/Extension Long Pressure Arm 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 PC51,151 201 225 Circuit Card, Digital Tach (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG5 131 204 Connector & Sockets 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
604 311 Grommet, Rbr .250 Id X .375Mtg Hole 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 132 611 Optical Encoder Disc 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
603 115 Weather Stripping, Adh .125 X .375 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 134 834 Hose, Sae .187 Id X .410 Od (order by ft) 2 Ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 149 959 Fitting, Brs Barbed M 3/16Tbg X .312-24 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 179 265 Adapter, Gun/Feeder Lh 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28 179 264 Adapter, Gun/Feeder Rh 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29 108 940 Screw, Cap Stl Hexwhd .250-20 X .750 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 604 538 Washer, Flat Stl Sae .312 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 151 437 Knob, Plstc T 1.125 Lg X .312-18 X 1.500 Bar 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 151 290 Screw, Hexwhd-Slt Stl Slffmg 10-32 X .500 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33 179 277 Cover, Drive Roll (consisting of) 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
196 956 Label, Warning Electric Shock And Pinch 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34 601 872 Nut, Stl Hex Full .375-16 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 602 213 Washer, Lock Stl Split .375 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36 602 243 Washer, Flat Stl .375 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37 601 966 Screw, Cap Stl Hexhd .375-16 X 1.250 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38 167 387 Spacer, Locating 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39 168 825 Drive, Pinion 40t 24p .376 Bore 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40 133 308 Ring, Retaining Ext .375 Shaft X .025Thk 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-1500-14 Page 41
1
2
3
4
5
6
7
. Hardware is common and
not available unless listed.
13
12
10
11
8
7
6
9
ST-081 760-C
Figure 10-5. Support, Hub & Reel
Item
No. Quantity
Part
No.
Description
Figure 10-5. Support, Hub and Reel (Figure 10-1 Item 10)
1 058 427 Ring, Retaining Spool 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 136 684 Nut, Stl Slflkg Hex Reg .625-11 W/Nyl Insert 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 605 941 Washer, Flat Stl .640 Id X 1.000 Od X 14ga Thk 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 010 233 Spring, Cprsn .970 Od X .120 Wire X 1.250 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 057 971 Washer, Flat Stl Keyed 1.500Dia X .125Thk 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 010 191 Washer, Fbr .656 Id X 1.500 Od X .125Thk 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 058 628 Washer, Brake Stl 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 058 428 Hub, Spool 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 080 393 Support, Reel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 ♦108 008 Reel, Wire 60 Lb (consisting of) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 124 900 Support, Reel Spool 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 +168 104 Retainer, Spool Support (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
166 594 Label, Caution Falling Wire Reel Can Cause Damage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 168 103 Nut, Spanner Retaining 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
♦ OPTIONAL
+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-1500-14 Page 42
Table 10-1. Drive Roll and Wire Guide Kits
Wire Size V-GROOVE
Inlet
Guide
Fraction
.023-.025 in. 0.6 mm 151 024 087 130
.030 in. 0.8 mm 151 025 053 695
.035 in. 0.9 mm 151 026 053 700 151 036 072 000 151 052 132 958
.040 in. 1.0 mm 161 189 053 696150 993 149 518
.045 in. 1.1/1.2 mm 151 027 053 697 151 037 053 701 151 053 132 957 151 070 083 489
.052 in. 1.3/1.4 mm 151 028 053 698 151 038 053 702 151 054 132 956 151 071 083 490
1/16 in.
(.062 in.)
.068-.072 in. 1.8 mm 151 056 132 959
Metric
150 993
150 993
150 993
150 994
150 994
1.6 mm 151 029 053 699 151 039 053 706 151 055 132 955 151 072 053 708
150 995
150 995
Guide
Intermediate
149 518
149 518
149 518
149 519
149 519
149 520
149 520
4 Roll
Kit Kit Kit Kit
Drive
Roll
U-GROOVE VK-GROOVE UC-GROOVE
4 Roll
Drive
Roll
4 Roll
Drive
Roll
4 Roll
Drive
Roll
5/64 in.
(.079 in.)
3/32 in.
(.094 in.)
7/64 in.
(.110 in.)
1/8 in.
(.125 in.)
Each Kit Contains An Inlet Guide, Intermediate Guide, And 045 233 Antiwear Guide With 604 612 Setscrew 8-32 x .125, Along
With 4 Drive Rolls.
2 Kits Required For Dual Models.
2.0 mm 151 040 053 704 151 057 132 960 151 073 053 710
2.4 mm 151 041 053 703 151 058 132 961 151 074 053 709
2.8 mm 151 042 053 705 132 962 151 075 053 711151 059
3.2 mm 151 043 053 707 151 060 132 963 151 076 053 712
150 995
150 996
150 996
150 997
149 520
149 521
149 521
149 522
S-0549-D
OM-1500-14 Page 43
Notes
g
g
g
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Effective January 1, 2007
(Equipment with a serial number preface of “LH” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.
1. 5 Years Parts — 3 Years Labor
* Original main power rectifiers
2. 3 Years — Parts and Labor
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Sources (Unless Otherwise Stated)
* Water Coolant Systems (Integrated)
* Intellitig
* Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
3. 1 Year — Parts and Labor Unless Specified
* Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources, Coolers, and
Electronic
Controls/Recorders
* Water Coolant Systems (Non-Integrated)
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Spot Welders
* Load Banks
* Arc Stud Power Sources & Arc Stud Guns
* Racks
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF
Models)
* Field Options
(NOTE: Field options are covered under True Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
* Bernard-Branded Mig Guns (No Labor)
* Weldcraft-Branded TIG Torches (No Labor)
* Subarc Wire Drive Assemblies
4. 6 Months — Batteries
5. 90 Days — Parts
* MIG Guns/TIG Torches and Subarc (SAW) Guns
guarantees or warranties expressed or implied.
* Induction Heating Coils and Blankets, Cables, and
Non-Electronic Controls
* APT & SAF Model Plasma Cutting Torches
* Remote Controls
* Accessory (Kits)
* Replacement Parts (No labor)
* Spoolmate Spoolguns
* Canvas Covers
Miller’s True Blue® Limited Warranty shall not apply to:
1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings, relays
or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
2. Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.
3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available,
but may vary from province to province.
miller_warr 2007−01
Owner’s Record
Please complete and retain with your personal records.
Model Name Serial/Style Number
Purchase Date (Date which equipment was delivered to original customer.)
Distributor
Address
City
State Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA © 2007 Miller Electric Mfg. Co.2007−01
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