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
DS-74DX12, and DS-74DX16
File: MIG (GMAW)
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TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − 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
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TABLE OF CONTENTS
SECTION 9 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SECTION 10 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
OPTIONS AND ACCESSORIES
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _2007−04
7
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
. Indicates special instructions.
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 ex-
plained in the text.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid the
hazards.
NOTICE − Indicates statements not related to personal injury.
1-2. Arc Welding Hazards
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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
groundedreceptacle outlet.
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
follow all Safety Standards.
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When making input connections, attach proper grounding conduc-
tor first − double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Only qualified persons should install, operate, maintain, and
repair this unit.
Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
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Turn off all equipment when not in use.
During operation, keep everybody, especially children, away.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
ELECTRIC SHOCK can kill.
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Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
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
Do not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be
present.
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
groundedequipment is a hazard.
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Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
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Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on
unit.
Additionalsafety 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 unavoid-
able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomaticDC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
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Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
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Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
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Do not connect more than one electrode or work cable to any
single weld output terminal.
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SIGNIFICANT DC VOLTAGE exists in inverter-type
welding power sources after removal of input
power.
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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.
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Do not touch hot parts bare handed.
Allow cooling period before working on gun or
torch.
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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).
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To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
OM-1500-14 Page 1
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Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
Use only correct fuses or circuit breakers. Do not oversize or by-
pass them.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
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Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
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If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
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Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
ing air is safe.
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.
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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.
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Wear approved safety glasses with side
shields even under your welding helmet.
Do not weld on coated metals, such as galvanized, lead, or
cadmiumplated 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.
BUILDUP OF GAS can injure or kill.
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Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use
approved air-supplied respirator.
ARC RAYS can burn eyes and skin.
MAGNETIC FIELDS can affect Implanted
Medical Devices.
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.
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Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
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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).
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ImplantedMedical 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.
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Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
NOISE can damage hearing.
Noise from some processes or equipment can
damagehearing.
Wear protective clothing made from durable, flame-resistant mate-
rial (leather, heavy cotton, or wool) and foot protection.
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Wear approved ear protection if noise level is
high.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
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.
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.
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Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder − explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
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Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
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Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
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Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
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Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
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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).
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Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
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Use the right equipment, correct procedures, and sufficient num-
ber of persons to lift and move cylinders.
Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
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
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1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
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Do not install or place unit on, over, or near
combustiblesurfaces.
Do not install unit near flammables.
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Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
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Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
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Have only qualified persons remove doors, panels, covers, or
guards for maintenance as necessary.
Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
FALLING UNIT can cause injury.
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Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
READ INSTRUCTIONS.
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Read Owner’s Manual before using or servic-
ing unit.
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Use only genuine replacement parts from the
manufacturer.
OVERUSE can cause OVERHEATING
H.F. RADIATION can cause interference.
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Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
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High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
Have only qualified persons familiar with
electronic equipment perform this installation.
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Do not block or filter airflow to unit.
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FLYING SPARKS can cause injury.
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The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
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Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
If notified by the FCC about interference, stop using the
equipmentat once.
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Have the installation regularly checked and maintained.
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Sparks can cause fires — keep flammables away.
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.
STATIC (ESD) can damage PC boards.
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Put on grounded wrist strap BEFORE handling
boards or parts.
ARC WELDING can cause interference.
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Use proper static-proof bags and boxes to
store, move, or ship PC boards.
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Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
MOVING PARTS can cause injury.
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Be sure all equipment in the welding area is
electromagneticallycompatible.
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Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
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To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
WELDING WIRE can cause injury.
Be sure this welding machine is installed and grounded
according to this manual.
D
Do not press gun trigger until instructed to do
so.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
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.
D
OM-1500-14 Page 3
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1-4. California Proposition 65 Warnings
For Gasoline Engines:
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.)
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproduc-
tive harm.
For Diesel Engines:
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
reproductiveharm. Wash hands after handling.
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
1-5. Principal Safety Standards
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
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 Protec-
tion, 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, web-
Recommended Safe Practices for the Preparation for Weldingand Cut-
ting 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).
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, P.O. Box 9101, Quincy, MA 02269-9101 (phone:
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendentof 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).
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
CanadianStandards Association, Standards Sales, 5060 Mississauga,
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
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.
Welding current, as it flows through welding cables, will cause electro-
magnetic 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 power-
frequency 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.
4. Keep welding power source and cables as far away from opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as possi-
ble.
About Implanted Medical Devices:
ImplantedMedical 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 recom-
mended.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-1500-14 Page 4
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2007−04
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 des instructions spécifiques.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan-
gers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
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.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
2-2. Dangers relatifs au soudage à l’arc
(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 re-
commandée.En outre, ne pas travailler seul !
Les symboles représentés ci-dessous sont utilisés dans ce ma-
nuel 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 Sec-
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’alimentationselon la norme OSHA 29 CFR 1910.147 (voir nor-
mes de sécurité).
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.
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
D
Seul un personnel qualifié est autorisé à installer, faire fonc-
tionner, entretenir et réparer cet appareil.
Pendant le fonctionnement, maintenir à distance toutes les
personnes,notamment les enfants de l’appareil.
D
D
En effectuant les raccordements d’entrée, fixer d’abord le conduc-
teur de mise à la terre approprié et contre-vérifier les connexions.
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est
sous tension lorsque le courant est délivré à la
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.
sortie. Le circuit d’alimentation et les circuits internes de la machine
sont également sous tension lorsque l’alimentation est sur Marche.
Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de
commande du rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement installé ou mis
à la terre de manière incorrecte ou impropre constitue un danger.
D
D
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
sante ou mal épissés.
D
D
Ne pas enrouler les câbles autour du corps.
D
D
Ne pas toucher aux pièces électriques sous tension.
Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
Porter des gants isolants et des vêtements de protection secs et
sans trous.
D
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
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.
Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide dou-
blée.
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
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
champ les pièces endommagées. Entretenir l’appareil
conformémentà ce manuel.
D
D
Se servir d’une source électrique à courant électrique UNIQUE-
MENT si le procédé de soudage le demande.
D
D
Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
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.
S’assurer que tous les panneaux et couvercles sont correctement
en place.
D
D’autres consignes de sécurité sont nécessaires dans les condi-
tions suivantes : risques électriques dans un environnement
humideou si l’on porte des vêtements mouillés ; sur des structures
métalliquestelles 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
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
D
Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage.
OM-1500-14 Page 5
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Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur quand on a
coupé l’alimentation.
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 peu
provoquer leur éclatement. Des étincelles peuven
D
Arrêter les convertisseurs, débrancher le courant électrique et
déchargerles condensateurs d’alimentation selon les instructions
indiquées dans la partie Entretien avant de toucher les pièces.
être projetées de l’arc de soudure. La projection d’étincelles, des pièce
chaudes et des équipements chauds peut provoquer des incendies e
des brûlures. Le contact accidentel de l’électrode avec des objet
métalliquespeut provoquer des étincelles, une explosion, un surchauf
fement ou un incendie. Avant de commencer le soudage, vérifier e
s’assurer que l’endroit ne présente pas de danger.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
D
Ne pas toucher à mains nues les parties
chaudes.
D
Prévoir une période de refroidissement avant de
travailler à l’équipement.
D
Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusementavec des protections homologués.
D
Ne pas toucher aux pièces chaudes, utiliser les outils recomman-
dés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
D
D
D
Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
LES FUMÉES ET LES GAZ peuvent être
dangereux.
Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
Le soudage génère des fumées et des gaz. Leur
inhalationpeut être dangereux pour votre santé.
D
D
D
Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
D
D
Eloigner votre tête des fumées. Ne pas respirer les fumées.
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.
Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
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 nor-
mes de sécurité).
D
D
Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
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 dégrais-
seurs.
D
D
Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-
peurs inflammables (vapeur d’essence, par exemple).
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 provo-
quant des risques d’électrocution, d’étincelles et d’incendie.
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
D
D
Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
lées.
D
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 for-
mer des gaz hautement toxiques et irritants.
En cas de non utilisation, enlever la baguette d’électrode du porte-
électrode ou couper le fil à la pointe de contact.
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.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revête-
ment 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
revêtementset tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
D
D
D
D
D
D
Avant de souder, retirer toute substance combustible de vos po-
ches telles qu’un allumeur au butane ou des allumettes.
Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
LES RAYONS DE L’ARC peuvent pro
voquer des brûlures dans les yeux e
sur la peau.
Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intense
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
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.
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).
DES PIECES DE METAL ou DES SA-
LETES peuvent provoquer des bles-
sures dans les yeux.
D
D
Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
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
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
métalliquesvolantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.
Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
D
Porter des vêtements confectionnés avec des matières résistan-
tes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.
D
OM-1500-14 Page 6
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D
D
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.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
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
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.
Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
LES CHAMPS MAGNETIQUES peuv-
ent affecter des implants médicaux.
D
D
Ne jamais placer une torche de soudage sur une bouteille à gaz.
D
Porteur de simulateur cardiaque ou autre im-
plants médicaux, rester à distance.
Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D
Les porteurs d’implants doivent d’abord consulter leur médecin
avant de s’approcher des opérations de soudage à l’arc, de sou-
dage par points, de gougeage, du coupage plasma ou de chauf-
fage par induction.
D
D
Ne jamais souder une bouteille pressurisée − risque d’explosion.
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.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D
D
D
D
Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
D
Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Utiliser les équipements corrects, les bonnes procédures et suffi-
samment de personnes pour soulever et déplacer les bouteilles.
Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endomma-
gée, elle peut exploser. Du fait que les bouteilles de
gaz font normalement partie du procédé de sou-
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 sécu-
rité.
dage, les manipuler avec précaution.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLO-
SION.
LES ÉTINCELLES VOLANTES ris-
quent de provoquer des blessures.
D
Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D
Porter un écran facial pour protéger le visage et
les yeux.
D
Ne pas installer l’appareil à proximité de pro-
duits inflammables.
D
Affûter l’électrode au tungstène uniquement à la
meuleuse dotée de protecteurs. Cette manœuv-
re est à exécuter dans un endroit sûr lorsque l’on
porte l’équipement homologué de protection du
visage, des mains et du corps.
D
Ne pas surcharger l’installation électrique − s’assurer que
l’alimentationest correctement dimensionnée et protégée avant
de mettre l’appareil en service.
D
Les étincelles risquent de causer un incendie − éloigner toute sub-
stance inflammable.
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.
Utiliser un équipement de levage de capacité
suffisante pour lever l’appareil.
LES CHARGES ÉLECTROSTATI-
QUES peuvent endommager les
circuits imprimés.
D
D
Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
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.
D
Utiliser des pochettes et des boîtes antistati-
ques pour stocker, déplacer ou expédier des
cartes de circuits imprimes.
L’EMPLOI EXCESSIF peut SUR-
CHAUFFER L’ÉQUIPEMENT.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
Prévoir une période de refroidissement ; re-
specter le cycle opératoire nominal.
D
Ne pas s’approcher des organes mobiles.
Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
D
Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D
D
Ne pas obstruer les passages d’air du poste.
OM-1500-14 Page 7
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LES FILS DE SOUDAGE peuvent
provoquer des blessures.
LE RAYONNEMENT HAUTE FRÉ-
QUENCE (H.F.) risque de provoquer
des interférences.
D
Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D
Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipe-
ments de radio−navigation et de communica-
tion, les services de sécurité et les ordinateurs.
D
Ne pas diriger le pistolet vers soi, d’autres per-
sonnes ou toute pièce mécanique en enga-
geant le fil de soudage.
D
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installa-
tion.
DES ORGANES MOBILES peuvent
provoquer des blessures.
D
D
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’ap-
pareil.
D
S’abstenirde toucher des organes mobiles tels
que des ventilateurs.
D
Maintenirfermés et verrouillés les portes, pan-
neaux, recouvrements et dispositifs de protec-
tion.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D
D
Seules des personnes qualifiées sont autorisées à enlever les
portes, panneaux, recouvrements ou dispositifs de protection
pour l’entretien.
D
L’énergie électromagnétique risque de provo-
quer des interférences pour l’équipement élec-
tronique sensible tel que les ordinateurs et l’é-
quipement commandé par ordinateur tel que
les robots.
Remettreles portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
D
Veiller à ce que tout l’équipement de la zone de soudage soit
compatibleélectromagnétiquement.
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).
Veiller à souder à une distance de 100 mètres de tout équipe-
ment électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précéden-
tes, il incombe à l’utilisateur de prendre des mesures supplé-
mentairestelles que le déplacement du poste, l’utilisation de câ-
bles blindés, l’utilisation de filtres de ligne ou la pose de protec-
teurs dans la zone de travail.
LIRE LES INSTRUCTIONS.
D
Lisez le manuel d’instructions avant l’utilisation
ou la maintenance de l’appareil.
D
D
D
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 distan-
ce correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
2-4. Proposition californienne 65 Avertissements
Pour les moteurs à essence :
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 mal-
formations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Les gaz d’échappement des moteurs contiennent des pro-
duits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.
Pour les moteurs diesel :
Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimi-
ques dont l’État de Californie reconnaît qu’ils provoquent des
cancers et des malformations congénitales ou autres
problèmesde procréation. Se laver les mains après manipu-
lation.
Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie com-
me provoquant des cancers et des malformations
congénitalesou autres problèmes de procréation.
OM-1500-14 Page 8
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2-5. Principales normes de sécurité
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).
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 Protec-
tion, 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).
RecommendedSafe Practices for the Preparation for Welding and Cut-
ting 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).
:
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).
National Electrical Code, NFPA Standard 70, de National Fire Protec-
tion 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 Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de U.S. Government Printing Office, Superin-
tendent 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).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 4221 Walney Road, 5th Floor, Chan-
tilly, VA 20151 (téléphone
www.cganet.com).
:
703-788-2700, site Internet
:
Code for Safety in Welding and Cutting, CSA Standard W117.2, de
CanadianStandards Association, 5060 Mississauga, Ontario, Canada
2-6. Information EMF
Considérationssur le soudage et les effets de basse fréquence et des
champs magnétiques et électriques.
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.
Le courant de soudage, pendant son passage dans les câbles de sou-
dage, causera des champs électromagnétiques. Il y a eu et il y a encore
un certain souci à propos de tels champs. Cependant, après avoir exa-
miné 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
magnétiqueset 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
souhaitablede réduire votre exposition aux champs électromagnéti-
ques pendant le soudage ou le coupage.
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 induc-
tion. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
Pour réduire les champs magnétiques sur le poste de travail, appliquer
les procédures suivantes :
OM-1500-14 Page 9
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OM-1500-14 Page 10
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SECTION 3 − INTRODUCTION
3-1. Specifications
Type of Input
Power
Welding Power
Source Type
Wire Feed Speed
Range
Wire Diameter
Range
Welding Circuit
Rating
Weight
Standard: 50 To 780 ipm
(1.3 To 19.8 mpm)
.023 To 1/8 in (0.6
To 3.2 mm)
12 ft (3.7 m):
207 lb (94 kg)
100 Volts,
750 Amperes, 100%
Duty Cycle
24 Volts AC
Single-Phase
10 Amperes
50/60 Hertz
Constant Voltage (CV)
DC With 14-Pin And
Contactor Control
Optional High Speed: 92
To 1435 ipm
Max Spool Weight:
60 lb (27 kg)
16 ft (4.9 m):
280 lb (127 kg)
(2.3 To 36.5 mpm)
12 ft (3.7 m) Boom (DS-12)
17 ft (5.2 m)
16 ft (4.9 m) Boom (DS-16)
21 ft (6.4 m)
Maximum Height With 4 ft (1.2 m) Post
Vertical Lift Of Boom
Horizontal to 60° Above Horizontal
Horizontal to 60° Above Horizontal
SECTION 4 − INSTALLATION
4-1. Installing Swivel Into Pipe Post
Do not remove Safety Collar
until instructed to.
5
4
1
2
3
Swingpak Base or CBC Cart
Pipe Post With Base
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.
2
3
5
Safety Collar
1
Tools Needed:
3/4 in
152 268-B
OM-1500-14 Page 11
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4-2. Installing Control Box And Adjusting Tilt
1
2
3
Weld Control
Bracket
Screw
Bracket and screws are installed
onto bottom of control at factory.
4
Swivel
1
Loosen screws. Place control on
swivel and slide forward. Tighten
screws.
5
2
5
6
7
Tilt Bracket
Rear Pivot Screw
Front Screw
6
Loosen rear pivot screw. Remove
front screw. Pivot control down-
ward to desired viewing angle. Re-
place and tighten front screw. Tight-
en pivot screw.
4
7
3
Tools Needed:
3/8 in
803 192
4-3. Installing Boom And Reel Support
1
2
Swivel Plates
Yoke
Remove hardware from swivel
plates and yoke.
3
Boom
Set boom into swivel as shown.
Yoke Pin
4
Install pin through yoke. Install cot-
ter pin and spread ends.
3
5
Bolt
7
Install bolt, washers, and nut. Tight-
en hardware, and back bolt off one
half turn.
6
Locking Knob
4
5
Install locking knob but do not
tighten.
7
Reel Support
6
Install reel support.
2
1
Tools Needed:
3/8, 3/4 in
ST-153 170-A
OM-1500-14 Page 12
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4-4. Installing Wire Guide Extension
1
2
3
4
Wire Guide Fitting
Bolt
Monocoil Liner
Wire Guide Extension
1
Tighten bolt to secure liner in wire
guide fitting. Do not overtighten bolt
and crush liner.
4
3
Repeat procedure for opposite
side.
2
Tools Needed:
3/8 in
ST-152 383
OM-1500-14 Page 13
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4-5. Equipment Connection Diagram
1
2
3
Welding Power Source
Remote 14 Connection
Negative (−) Weld Output
Cable
4
Positive (+) Weld Output
Cable
5
6
7
8
9
Workpiece
Weld Control
Boom
12
Gun
1
Swivel
10 Pipe Post And Base
11 Gas Hose
2
12 Gas Supply and Regulator
(Customer Supplied)
. Shielding gas pressure not to
exceed 100 PSI (689 kPa).
3
4
5
11
6
7
10
9
8
803 195
OM-1500-14 Page 14
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4-6. Control Box Connections
1
2
InterconnectingCables
Interconnecting Cable
Receptacles
3
14-Pin Cord
1
2
3
803 197-A
4-7. 14-Pin Plug Information
Pin*
Pin Information
A
B
G
C
D
E
H
F
24 volts ac with respect to socket G.
Contact closure to A completes 24 volts ac contactor control circuit.
Circuit common for 24 volts AC circuit.
J
A
K
I
B
C
L
H
N
+10 volts dc input from power source to wire feeder with respect to socket D.
Remote control circuit common.
M
E
G
D
F
0 to +10 volts dc output signal from wire feeder to power source with respect to socket D.
Voltage feedback; 0 to +10 volts dc, 1 volt per 10 arc volts.
Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes.
*The remaining pins are not used.
OM-1500-14 Page 15
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4-8. Removing Safety Collar And Adjusting Boom
1
Locking Knob
Tighten knob to prevent boom
movement. Loosen knob to allow
boom movement. Change knob po-
sition to limit upward movement.
Pull boom down slightly and re-
move safety collar. Boom should
balance in any position from hori-
zontal to 60 degrees above hori-
zontal. If necessary, adjust boom
as follows:
4
2
3
Threaded Rod
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.
5
4
Yoke
2
5
Safety Collar
Retain safety collar for use in disas-
semblingor moving boom.
1
3
4
3
2
Rod
Rod
Tools Needed:
Decreasing Spring
Pressure For A
Lighter Gun
Increasing Spring
Pressure For A Heavy
Gun
1-1/8 in
ST-142 599-C
4-9. Gun Recommendation Table
Process
Gun
GMAW − Hard or Cored Wires
Roughneck C-Series Guns: 300, 400, 500, And
600 Amp.
FCAW − Self-Shielding Wires
FC-1260 Or FC-1150
4-10. Wire Type, Size, And Feed Speed Capability Table
Motor Speed
Standard
Wire Type
Wire Size
Feed Speed Capability
All
All
All
.023 To 5/64 in (0.6 To 2 mm)
3/32 To 7/64 in (2.4 To 2.8 mm)
1/8 in (3.2 mm)
50 To 780 ipm (1.3 To 19.8 mpm)
50 To 700 ipm (1.3 To 17.8 mpm)
50 To 300 ipm (1.3 To 7.6 mpm)
Standard
Standard
Optional High
Speed
All
.023 To 5/64 in (0.6 To 2 mm)
92 To 1435 ipm (2.3 To 35.6 mpm)
OM-1500-14 Page 16
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4-11. Installing And Threading Welding Wire
Tools Needed:
3/8, 15/16 in
3/16, 5/64 in
Install wire spool. Ad-
just tension nut so
wire is taut when wire
feed stops.
Pressure
Adjust
Pressure
Indicator
Scale
Install wire guide.
Pressure
Adjust
Drive Rolls
Install drive rolls.
Gun Cable
End Of Liner
NONCONDUCTIVE
SURFACE
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 with-
out touching.
. For soft wire or small diameter stainless
steel wire, reduce drive roll pressure on
the rear roll to half that of the front rolls.
. 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 con-
tact tip is completely blocked, wire should
slip at the feeder (see pressure adjust-
ment above). Cut wire off. Close cover.
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.
803 196 / 152 648-A / 803 020 / 802 966 / Ref. 137 391-A / 802 954 / Ref. S-0627-A
OM-1500-14 Page 17
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4-12. Setting Internal DIP Switches
1
2
DIP Switch S1
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
(92-1435inches 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.
. 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
O
N
1
2
3
4
5
6
7
8
. In the DIP switch S1 illustrations,
the elevated slider on each switch
is shown in white. For example,
the switches above are all in the
Off position.
2
803 198
Position Settings And Results For DIP Switch S1
7
8
7 Off, 8 Off = Standard
speed motor (50-780 inch-
es per minute, or 1.2-19.8
meters per minute)
7
8
7 Off, 8 On = High speed
motor (92-1435 inches per
minute, or 2.3-36.4 meters
per minute)
OM-1500-14 Page 18
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4-13. Power Source Selection Menu
1
2
Upper Display
Lower Display
Non-CE Model Shown
1
. When the feeder is turned on,
the Power Source Selection
Menu allows the operator to se-
lect a default power source.
Selecting
a
default power
source, automatically sets the
correct Vmin and Vmax set-
tings for adjusting the output
voltage of the power source.
Program
Volts
Time (sec)
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 Del-
taweld 452 is the default power
source, and has a voltage range of
10V as Vmin and 38V as Vmax.
Wire Speed
Amps
2
Start
Trigger Hold
Crater
Pre/Postflow
Dual Schedule
At power up, the operator has three
seconds to select a default power
source from the list shown on the
display. Operator may scroll
throughthe list of power sources by
using the Adjust control. After se-
lecting 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 de-
fault power source will be retained.
Sequence
Adjust
Setup
Upper Display
Voltage Range
* * Power Source
Lower Display
Deltaweld 452
Deltaweld 302
Deltaweld 652
Dimension 302
Dimension 452
Dimension 652
Dimension 1000
XMT 304
dELT
dELT
dELT
dIM
452
302
652
302
452
652
1000
304
456
MP
Vmin =10
Vmax =38
Vmax =32
Vmax =44
Vmax =32
Vmax =38
Vmax =65
Vmax =60
Vmax =35
Vmax =38
Vmax =35
Vmax =38
Vmax =38
Vmax =38
Vmax =44
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =10
Vmin =25
If voltage settings have already
been set with the Vmin and Vmax in
the Auxiliary Menu, selecting a de-
fault power source with the Power
Source Selection Menu overrides
the Vmin and Vmax voltage set-
tings.
dIM
dIM
dIM
XMT
XMT
I354
I456
I456
PHX
SUM
XMT 456
Next Time Feeder Is Turned On
Invision 354MP
Invision 456MP
Invision 456P
PHOENIX 456
SUMMITARC 1000
The feeder will display the last se-
lected default power source. The
operator has three seconds to se-
lect another power source, or press
the Program Button to exit the Pow-
er Source Selection Menu.
MP
P
456
1000
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
** For any power sources not listed, pick a matching voltage range, or see Sec 4-12 to
set Vmin and Vmax.
OM-1500-14 Page 19
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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
Sequence
Feeding wire without contactor or gas valve being energized.
A portion of the weld program, such as preflow, run-in, start, weld, crater, burnback, and postflow.
A group of sequences that make up a weld cycle.
Weld Program
5-2. Power Switch
1
Power Switch
1
803 193
5-3. Left/Right Select Switch
1
Left/Right Select Switch
Pressing the Left/Right Select
switch allows the operator to
choose which side of the units’ con-
trols will operate.
. Engaging the Left or Right
Gun Trigger also allows the
operator to enable the con-
trols on that side of the unit.
1
803 194
OM-1500-14 Page 20
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5-4. Jog/Purge Switch
1
2
Jog/Purge Switch
Adjust Control
2
1
803 194
Pressing the Jog/Purge switch allows the op-
erator to jog wire without energizing the weld
power or gas valve circuit.
trigger is still activated after two minutes, the
jog operation is terminated to prevent com-
plete despooling of the wire, in the case of
a damaged gun.
unit displays jog speed when the unit is be-
ing jogged.
• Jogging can also be accomplished by
pressing the Jog/Purge button.
• 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 opera- • Jog speed can be adjusted by the Adjust
tion for a maximum of two minutes. If the gun
• The unit displays the “ERR TRIG“ message
to inform the operator that the trigger is acti-
vated.
• Pressing the Jog/Purge button also allows
the operator to purge gas lines before weld-
ing and to preset gas pressure at the
regulator.
control when the unit is jogging wire. The
5-5. Front Panel Controls
See
Section
See
Section
Program
See
Section
Volts
Time (sec)
Wire Speed
Amps
Start
Dual Schedule
Trigger Hold
Crater
Pre/Postflow
Sequence
Adjust
Setup
See
Section
See
Section
See
Section
OM-1500-14 Page 21
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5-6. Program Push Button
1
Program Display
The number of the active program
is displayed.
2
Program Push Button
Press button to activate program
select feature. To change the pro-
gram number, press the Program
push button and rotate the Adjust
control.
1
2
Program
3
Program Push Button LED
3
The LED lights to indicate the Pro-
gram push button is active.
5-7. Upper Display
. To set the correct voltage range for a particular power
3
2
1
4
Volts
Time (sec)
5
1
Upper Display
nates to indicate that information displayed
can be changed by the Adjust control.
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 up-
per display push button.
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.
4
5
Volts LED
Time LED
The LEDs below the display illuminate to in-
dicate which value is being shown.
• The unit defaults to displaying welding
voltage when a welding sequence display
mode is first entered.
At any time while welding, the unit permits
the adjustment of the weld sequence voltage
and overrides the display of actual arc volt-
age.
2
Upper Display Push Button
Press and hold button to adjust or display
weld time. Release button to display voltage.
• If the weld sequence has a time set (as in
spot time), after the weld program is com-
pleted, ERR TRG 1 will be displayed to in-
dicate the weld program is complete. Re-
lease trigger to clear error.
• 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
Upper Display Push Button LED
The upper display push button LED illumi-
OM-1500-14 Page 22
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5-8. Lower Display
3
2
1
4
Wire Speed
Amps
5
1
Lower Display
to indicate that information displayed can be
changed by the Adjust control.
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.
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.
4
5
Wire Speed LED
Amps LED
• 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 LEDs below the display illuminate to indi-
cate which value is being shown.
2
Lower Display Push Button
• 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 dur-
ing welding, the weld sequence wire speed • The display will read dashes for amperage
can be adjusted and overrides the preset
wire speed display. In other words, if the Ad-
Press button to choose between wire speed or
amperagefunctions.
3
Lower Display Push Button LED
readings below the amperage threshold,
prior to arc initiation.
The lower display push button LED illuminates
5-9. Setup Push Button
3
4
Trigger Hold
2
Dual Schedule
1
Setup
1
Setup Push Button
the trigger hold status or press the lower dis- • When the Setup button is pressed a second
play push button. If trigger hold is turned On,
the trigger hold LED illuminates and stays
On.
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.
Press button to choose between trigger hold
or dual schedule functions.
2
3
4
• When the Setup button is pressed, the Set-
up push button LED flashes and the Trigger
Hold LED flashes.
Setup Push Button LED
Trigger Hold LED
Dual Schedule LED
• When trigger hold is On, the user must
press and hold the trigger for a predefined
amountof time (the trigger hold delay time−
ger hold function to be active. To shut off the
weld when trigger hold is On, the user must
press and release the trigger.
• Pressing the Setup button again exits the
Setup mode. The dual schedule LED stops
flashingto indicate the dual schedule status
is Off.
• The flashing LED indicates that the unit is in
the trigger hold display mode. In this mode
the upper display indicates HOLD and the
• 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 termi-
nated.
• If a weld time is programmed, trigger hold is
disabled.
lower display indicates the trigger hold sta- • Trigger hold and dual schedule cannot be
tus On/Off. Use the Adjust control to change used concurrently.
OM-1500-14 Page 23
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5-10. Adjust Control
1
Adjust Control
The Adjust control is used to
change various sequence parame-
ters, and to select various se-
quences. Refer to the section for
the function in question for informa-
tion related to using the Adjust con-
trol.
1
Adjust
5-11. Sequence Push Button
1
2
3
Sequence Push Button
Sequence Push Button LED
Welding Sequence LEDs
Start
3
Crater
Pre/Postflow
Weld
Time
2
1
Start
Time
Crater
Time
Preflow
Time
Postflow
Time
Sequence
Welding Sequence Diagram
the weld display mode is activated.
• 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 ab-
breviation PRE, to inform the operator that
preflow time is displayed. If the upper dis-
play push button is pressed, the Adjust con-
trol can be used to adjust preflow.
. For more information on Setting
If zero time is programmed for a timed se-
quence except for Weld, that sequence will
be skipped.
• The Sequence push button allows the
selection of welding sequences. Five weld-
ing 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 se-
quence is active.
• In the weld sequence display mode the Se-
quence push button LED is Off. When the
Sequence push button is pressed, the Se-
quence push button flashes and the Start
LEDs flash. In this condition, the unit is in the
Start sequence display mode, and Start se-
quence parameters are shown in the dis-
plays.
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 second time, the Crater sequence LED
flashes. The Sequence push button LED re-
mains flashing. In this condition, the unit is
in the Crater sequence display mode, and • When the Sequence push button is pressed
Crater sequence parameters are shown in
the displays.
• 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 se-
quence display modes are terminated and
a fourth time, the unit returns to the welding
sequence display mode.
OM-1500-14 Page 24
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5-12. Auxiliary Menus
1
2
3
4
5
6
7
8
9
Program Display
Program Push Button
Sequence Push Button
Upper Display
4
Upper Display Push Button
Lower Display
Lower Display Push Button
Adjust Control
5
7
1
Setup Push Button
2
Program
Volts
Time (sec)
Wire Speed
Amps
6
Start
Trigger Hold
Crater
Pre/Postflow
Dual Schedule
9
3
Sequence
Adjust
Setup
8
5-12 Auxiliary Menus (Continued)
Reset To Factory Settings
power source min and max voltage preset
The upper display shows “PSS”. Lower dis-
range. The minimum voltage is displayed in play shows “On” or “Off”. The Adjust Control is
A reset menu is displayed if the following four
push buttons are pressed simultaneously:
Program, Sequence, upper display, and Set-
up. The upper display indicates “WIPE” . The
lower display indicates “OFF”. The lower push
button is active indicating that the Adjust con-
trol 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.
the upper display and the lower display indi-
cates “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 up-
per display and the lower display indicates
“VMAX”.
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.
In both cases, the Adjust control is used to
specify the minimum and maximum voltage
settings of the welding power source. The set-
tings correspond to arc voltage obtained at
minimumcommand and arc voltage obtained
at maximum command.
Cycles
• If the Setup push button is pressed, the unit
displays the number of cycles.
Arc cycles are indicated by the Program dis-
play showing “CL”. The arc cycle count is
shown in the lower display.
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.
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.
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.
. If a default power source has already been
selected with the Power Source Selection
menu, setting “VMIN” and “VMAX” will
override the default power source set-
tings.
Pushing the Setup push button will step
through the menu. Pushing the sequence
push button will step through the menu in re-
verse.
The upper display indicates “RUNI”. The
lower display indicates “AUTO”, meaning the
factory set automatic run-in speed is se-
lected.
. The power source selection menu must
be set to “OFF” when overriding the de-
fault “VMIN” or “VMAX” settings.
. The auxiliary menu may be exited at any
time by pressing both the Sequence push
button and the Setup push buttons simul-
taneously.
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.
Power Source Selection Menu
V-Min And V-Max
• If the Setup push button is pressed, the unit Pressing the lower display button allows dis-
• If the Setup push button is pressed, the unit
allows the setting of the manual override
allows the Power Source Selection menu to abling of the run-in feature. When the lower
be disabled or enabled.
display indicates “OFF” run-in is disabled.
OM-1500-14 Page 25
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5-12 Auxiliary Menus (Continued)
Burnback
programs may be used. Trigger Program Se- • If the Setup push button is pressed, the unit
lect cannot be used while welding or with Dual
Schedule.
allows OPT2 to be disabled or enabled.
• If the Setup push button is pressed, the unit
allows burnback time to be set.
The upper display shows “OPT2”. Lower dis-
play shows “On” or “Off”. The Adjust Control is
used to select either “On” or “Off”.
(Example: If programs 1 and 3 have a mini-
mum of 0.2 seconds of preflow time, clicking
the trigger will toggle between programs 1 and
Burnback time and voltage can be specified
when the lower display indicates “BURN” and
the upper display indicates the burnback time 3).
or voltage. The Adjust control is used to set the
desired burnback time or voltage. Burnback
settings, like run-in settings, are program spe-
cific. The active program is displayed in the
Program display and can be adjusted (see
“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 se-
quence if shielding gas flow to the gun is inter-
rupted. 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 dis-
play “ERR” in the upper display and “OPT2” in
the lower display.
Trigger Dual Schedule Select (DUAL) allows
the operator to switch between paired sched-
ules (programs 1−2, 3−4, 5−6, or 7−8) with the
gun trigger, but only while welding. This fea-
ture cannot be used with Trigger Hold or Dual
Schedule.To end the weld, the trigger must be
released for 0.4 seconds.
Trigger Hold Setup
(Example: when welding with this feature en-
abled 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 pre-
vious sequence is repeated the active pro-
gram will switch back to program 1. This cycle
can be repeated for the entire weld).
• 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
amountof time the trigger must be held for trig-
ger hold to work when the trigger is released
(the trigger hold function must be on). For ex-
ample, if a trigger hold delay time of 2.0 sec-
onds 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.
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 fol-
lowing weld termination. If any front panel
push button is pressed, or if the Adjust control
is activated, the display hold feature is termi-
nated.
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 se-
lected be be a MIG program indicated by
”VOLT” or a pulsing program indicated by
”TRIM”.
Software Revision Level
• If the Setup push button is pressed, the unit
displays the software version being used by
the interface PCB (PC20).
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 pro-
gram, 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 inde-
pendentfrom voltage or trim.
• When the Setup button is pressed again, the
• 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 trig-
ger 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.
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 nu-
merical password between 0 and 999 by turn-
ing the Adjust control. When the user re−en-
ters the auxiliary menu, the password code
must be selected to gain access to the auxilia-
ry 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 dis-
play . 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 re-
set 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 al-
low the user to reset the unit to the factory de-
faults, indicated by “WIPE” in the upper dis-
play. Resetting the unit will also turn off the
password code feature.
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 se-
lected.
• When the Setup push button is pressed
again, the menu repeats to the first menu
selection of run-in wire speed selection.
OPT1
• If the Setup push button is pressed, the unit
allows OPT1 to be disabled or enabled.
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 “OPT1”. Lower dis-
play shows “On” or “Off”. The Adjust Control is
used to select either “On” or “Off”.
The upper display shows “TSEL”. Lower dis-
play shows “OFF” or “PROG” or “DUAL”. The
Adjust Control is used to select “OFF” or
“PROG” or “DUAL”.
“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 dis-
play.
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 OPT2
OM-1500-14 Page 26
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SECTION 6 − SETTING SEQUENCE PARAMETERS
6-1. Sequence Parameters In A Program
. For more information on
Sequence Push Button see
If time is set to zero in Weld
sequence, welding continues until
gun trigger is released.
Sequence
Parameters
If time is set to zero in any timed
sequence except Weld, the
sequence is skipped.
Volts
IPM
Seconds
0-9.9
1. Preflow
2. Run-In
3. Start
4. Weld
X
X
X
X
X
X
X
X
0.00-5.00
0-100.0
0-5.00
5. Crater
6. Burnback
7. Postflow
0-0.25
0-9.9
X = Setting available.
Weld Time
Crater
Time
Burnback
Time
Start
Time
Preflow
Time
Postflow
Time
Time
Burnback
Sequence
Postflow
Run-In
Weld
Start
Crater
Preflow
End
Trigger
Released
Trigger
Pressed
OM-1500-14 Page 27
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SECTION 7 − SETTING DUAL SCHEDULE PARAMETERS
7-1. Optional Dual Schedule Switch Diagrams
1
2
Maint 2P (Maintained-Contact
2-Pole Switch)
1
2
Maint 1P (Maintained-Contact
1-Pole Switch)
1
2
DSS-9
1
DSS-8
1
. Will not function with trigger
hold and dual schedule. A
DSS-9 is recommended for
this application.
2
2
3
TR
B
A
3
4
A
4
B
Notes
OM-1500-14 Page 28
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7-2. Diagnostics
1
2
3
LED3 On Right Side Motor
Control Board PC1
2
3
LED3 On Left Side Motor
Control Board PC101
LED4 On Dual Board PC70
. There is a two-position DIP
switch S1 located on motor con-
trol boards PC1 and PC101.
These switches are factory-set
in the off position and must re-
main in that position for the unit to
operate correctly.
1
803 063-A
Left Side Motor Control Board PC101
ERR
ERR
ERR
TCH1
ERR
COM1
Indicates a com-
munication error.
TRG1
Indicates a trigger
error.
MTR1
Indicates a motor
error.
Indicates a
tachometer error.
. Note: The error messages
are shown on the upper
and lower displays to indi-
cate specific errors. Ex-
planations are in the text
below:
Right Side Motor Control Board PC1
ERR
ERR
ERR
ERR
COM2
Indicates a com-
munication error.
TRG2
Indicates a trigger
error.
TCH2
MTR2
Indicates a motor
error.
Indicates a
tachometer error.
Dual Board PC70
ERR
Indicates a
communication
COM3
error.
Error Indications
1 blink = Communication Error
2 blinks = Trigger Error
3 blinks = Tach 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.
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 num-
ber 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 commu-
nicationerror 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 se-
quence appears as a constant blink.
4 blinks = Motor Error
• The communication error occurs 2.5 sec-
onds after a loss of communication be-
tween the motor and the Front Panel board
or Dual board. The user may continue to
weld with this error.
• The motor error indicates that the motor
has been drawing too much current for too
long.
• The trigger error occurs if the user has the
trigger held for more than two minutes with-
out striking an arc (providing current over-
ride 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 er-
ror may be cleared by releasing the trigger.
OM-1500-14 Page 29
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7-3. Diagnostics For User Defined Options
1
2
Front Panel
Front Panel Board PC20
User Defined Shutdown Error
Messages (Additional hardware
required for these to be functional)
1
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 dis-
abled.
rect setup procedures.
2
803 198
ERR
ERR
OPT1
OPT2
Indicates a User Defined
Option Error
SECTION 8 − MAINTENANCE & TROUBLESHOOTING
8-1. Routine Maintenance
. Maintain more often
Disconnectpower
before maintaining.
during severe conditions.
3 Months
Clean and
tighten
Repair or
replace
cracked
weld
Replace
unreadable
labels.
weld
terminals.
cable.
Replace
cracked
parts.
Check
14-pin cord.
Check gas
hose and
fittings.
Check gun
cable.
6 Months
Blow out or vacuum
inside. During heavy
service, clean
Clean
drive rolls.
Or
monthly.
OM-1500-14 Page 30
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8-2. Troubleshooting
Disconnect power before troubleshooting.
Remedy
Trouble
Wire feeds, shielding gas flows, but elec- Check interconnecting cord connections. If secure, check cord for continuity and repair or replace (see
Wire feeder is on, meter(s) do not light Check and reset circuit breaker at welding power source.
up, motor does not run, gas valve and
welding power source contactor do not
pull in.
Electrode wire feeding stops or feeds er- Check gun trigger connection. See gun Owner’s Manual.
ratically during welding.
Check gun trigger. See gun Owner’s Manual.
Clean or replace dirty or worn drive roll.
Incorrect size or worn wire guides.
Replace contact tip or liner. See gun Owner’s Manual.
Remove weld spatter or foreign matter from around nozzle opening.
Have Factory Authorized Service Agency check drive motor or motor control board PC1.
Motor runs slowly.
Check for correct input voltage.
Wire does not feed until trigger is pulled, Check for a short between welding gun trigger leads and weld cable. Repair short or replace welding gun.
but continues to feed after trigger is re-
leased, and trigger hold is not on.
Gas valve in feeder is rattling loudly Check for a short between welding gun trigger leads and weld cable. Repair short or replace welding gun.
along with possible erratic or slow wire
feed speed.
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
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204 144-C
OM-1500-14 Page 33
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Quantity
Model
DS-12 DS-16
Item
No.
Dia.
Mkgs.
Part
No.
Description
. 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
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. Hardware is common and
not available unless listed.
9
8
11
7
1
15
10
14
13
12
9
2
4
6
3
25
16
5
17
24
23
18
19
8
20
21
22
803 200
Figure 10-2. Control Box
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 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
OM-1500-14 Page 36
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
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.
Part
No.
Mkgs.
Description
Quantity
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
OM-1500-14 Page 37
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Quantity
Model
DS-12 DS-16
Item
No.
Part
No.
Description
. . . . . . 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
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. Hardware is common and
16
not available unless listed.
22
14
17
18
See Table 10-1 For
Drive Roll & Wire Guide Kits
19
20
21
22
15
23
7
8
6
14
9
5
12
10
4
11
13
3
2
1
24
25
37
38
39
40
36
35
34
26
27
28
32
33
29
31
30
802 977-B
Figure 10-4. Drive Assembly, Wire
Quantity
Model
DS-12 DS-16
Item
No.
Dia.
Mkgs.
Part
No.
Description
. . . 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
OM-1500-14 Page 40
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Quantity
Model
DS-12 DS-16
Item
No.
Dia.
Mkgs.
Part
No.
Description
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
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1
. Hardware is common and
2
not available unless listed.
3
4
5
6
7
8
13
7
6
12
9
10
11
ST-081 760-C
Figure 10-5. Support, Hub & Reel
Item
No.
Part
No.
Description
Quantity
. . . 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
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Table 10-1. Drive Roll and Wire Guide Kits
Wire Size
V-GROOVE
U-GROOVE
VK-GROOVE
UC-GROOVE
4 Roll
Kit
4 Roll
Kit
4 Roll
Kit
4 Roll
Kit
Drive
Roll
Drive
Roll
Drive
Roll
Drive
Roll
Metric
Fraction
.023-.025 in. 0.6 mm 150 993 149 518
151 024
151 025
087 130
053 695
.030 in.
0.8 mm 150 993 149 518
.035 in.
.040 in.
0.9 mm 150 993 149 518
1.0 mm 150 993 149 518
151 026
161 189
151 027
151 028
151 029
053 700
053 696
053 697
053 698
053 699
151 036
072 000
151 052 132 958
.045 in. 1.1/1.2 mm 150 994 149 519
.052 in. 1.3/1.4 mm 150 994 149 519
151 037
151 038
151 039
053 701
053 702
053 706
151 053 132 957
151 054 132 956
151 055 132 955
151 056 132 959
151 070 083 489
151 071 083 490
151 072 053 708
1/16 in.
1.6 mm 150 995 149 520
(.062 in.)
.068-.072 in. 1.8 mm 150 995 149 520
5/64 in.
2.0 mm 150 995 149 520
2.4 mm 150 996 149 521
2.8 mm 150 996 149 521
151 040
151 041
151 042
053 704
053 703
053 705
151 057 132 960
151 058 132 961
151 059 132 962
151 073 053 710
151 074 053 709
151 075 053 711
(.079 in.)
3/32 in.
(.094 in.)
7/64 in.
(.110 in.)
1/8 in.
(.125 in.)
3.2 mm 150 997 149 522
151 043
053 707
151 060 132 963
151 076 053 712
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.
S-0549-D
OM-1500-14 Page 43
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Notes
Start Your Professional
Welding Career Now!
Over 80,000 trained
since 1930!
400 Trade Square East, Troy, Ohio 45373
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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
guarantees or warranties expressed or implied.
Warranty Questions?
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.
*
Induction Heating Coils and Blankets, Cables, and
Non-Electronic Controls
APT & SAF Model Plasma Cutting Torches
Remote Controls
Call
1-800-4-A-MILLER
for your local
Miller distributor.
*
*
*
*
*
*
Accessory (Kits)
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas Covers
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.
Your distributor also gives
you ...
Miller’s True Blue® Limited Warranty shall not apply to:
Service
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.)
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
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.
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.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
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.
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.)
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.
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
*
*
*
*
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.
*
*
*
*
*
*
*
*
*
*
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
Grids
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,
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
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.
*
(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
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,
4. 6 Months — Batteries
5. 90 Days — Parts
*
MIG Guns/TIG Torches and Subarc (SAW) Guns
but may vary from province to province.
miller_warr 2007−01
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Owner’s Record
Please complete and retain with your personal records.
Model Name
Purchase Date
Distributor
Address
Serial/Style Number
(Date which equipment was delivered to original customer.)
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
To locate a Distributor or Service Agency visit
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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