1 - Miller Electric

Transcription

1 - Miller Electric

December 1985
IMPORTANT
Read
and
understand
the
FORM: OM-1523F
entire
Effective With Serial No. JF923259
contents of both this manual and the power source
manual used with this unit, with special emphasis
the safety material throughout both manuals,
before installing, operating, or maintaining this
on
equipment.
This unit and these instructions
MODEL
for
use only by persons trained and experienced in the
safe operation of welding equipment. Do not allow
untrained persons to install, operate, or maintain
this unit. Contact your distributor if you do not fully
are
SWINGARC DIGITAL -2 12
SWINGARC DIGITAL -216
understand these instructions.
OWN ERS
MANUAL
*
miliEu
MILLER ELECTRIC MFG. CO.
718 S. BOUNDS ST, P.O. Box 1079
APPLETON, WI 54912 USA
PRINTED IN U.S.A.
LIMITED WARRANTY
fr
EFFECTIVE: FEBRUARY 25. 1985
This warranty supersedes all previous MILLER warranties and is ex
clusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY
~
tions hereof,
~
~
~
warrants
~
~
its
to
-
Miller Electric
Subject to the terms and condiMfg. Co., Appleton, Wisconsin
Distributor/Dealer that all
new
and
unused
Equipment furnished by Miller is free from defect in workmanship and material as of the time and place of delivery by Miller.
No warranty is made by Miller with respect to engines, trade
accessories or other items manufactured by others. Such
engines, trade accessories and other items are sold subject to
All
the warranties of their respective manufacturers, if any
.
by their manufacturer for one year from
date of original purchase, except Tecumseh engines which
engines
~
have
are
a two
warranted
year warranty,
as specified below, Millers warranty does not apply
components having normal useful life of less than one Ill
year, such as spot welder tips, relay and contactor points,
MILLERMATIC parts that come in contact with the welding
Except
In the case of Millers breach of warranty or any other duty
with respect to the quality of any goods, the exclusive remedies
therefore shall be, at Millers option (1) repair or (2) replacement
or, where
authonzed in
writing by
Miller in
appropriate
cases,
(3)
~
the reasonable cost of repair or replacement at an authorized
Miller service station or (41 payment of or credit for the purchase
price (less reasonable depreciation based upon actual use) upon
risk and expense. MILLERs
return of the goods at Customers
option of repair or replacement will be FOB., Factory, at
Appleton, Wisconsin, or F.O.B., at a MILLER authorized service
facility, therefore, no compensation for transportation costs of
any kind will be allowed. Upon receipt of notice of apparent
defect or failure, Miller shall instruct the claimant on the warranty
claim procedures to be followed.
to
,~/
wire
1~
not result from
,~
~
required to honor warranty claims on warEquipment in the event of failure resulting from a defect
within the following periods from the date of delivery of Equipment to the original user:
including nozzles
and nozzle insulators where failure does
defect in workmanship
or
material.
ranted
wekiing guns, feeder/ guns and
All other Millermatic Feeders
3. Au
~
4.
5.
Replacement
6.
Batteries
provided that
or
plasma torches... 90 days
repair parts, exclusive
of labor
..
1 year
60 days
6 months
Miller is notified in
writing
within
thirty (30) days
of the date of such failure.
~
AS
TO
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX
CLUDED AND DISCLAIMED BY MILLER.
~rr components
~: ~rin~r
WARRANTY, GUARANTY OR REPRESENTA
PERFORMANCE, AND ANY REMEDY FOR
BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION,
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,
CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
TION
Miller shall be
~
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED
~1TMr
EXPRESSLY PROVIDED BY MILLER IN
INTENDED
ARE
PRODUCTS
FOR
ULTIMATE
PURCHASE
COMMERCIAL/INDUSTRIAL
BY
USERS AND FOR OPERATION BY PERSONS TRAINED AND
IN
MAINTENANCE OF
EXPERIENCED
THE
USE AND
WELDING EQUIPMENT AND NOT FOR CONSUMERS OR
CONSUMER USE. MILLERS WARRANTIES DO NOT EXTEND
EXTEND
MILLERS WAR RAN11 ES TO~NY CONSUMER.
EXCEPT
WRITING,
AS
MILLER
(~f~
Feb.23,1987
ERRATA SHEET
FORM:OM-1523F
j
After this manual was printed, refinements in
appearing later in this manual.
AMENDMENT TO SECTION 3
Amend Section 3
Delete
Add
-
c. to
Complete Steps
Add Section 3
WARNING
-
k of Subsection B.
Assembly, Step 2. Post Support
thru g in Subsection 2. Post
Amend Subsection B.
Complete Steps
INSTALLATION
-
Subsection B. Assembly to read
c
c
to data
1. LOCATION AND ASSEMBLY
Steps h, i, j, and
Step 1
equipment design occurred. This sheet lists exceptions
Assembly, Steps 3c.
as
follows:
Support
and 4c. to read
as
follows:
Support
hA. SAFETY COLLAR REMOVAL
RELEASE OF SPRING PRESSURE WITHOUT BOOM ATTACHED
can cause
serious personal
__________
injury and equipment damage.
Perform installation exactly as outlined in the following step-by-step instructions.
Do not remove safety collar until instructed to do so.
Retain safety collar for future disassembly use.
A
safety collar is provided on top of the post to maintain spring pressure and prevent vertical movement during in
required whenever the boom is disassembled or relocated. To remove the safety collar, pro
stallation. The collar is
ceed
as
follows:
1.
Grasp bar and pull boom down slightly. The boom should be pulled down only far
which is applied to the safety collar.
2.
Remove the safety collar, and retain for future
enough
to remove
the pressure
use.
3. The boom should now balance in any position from horizontal to 60 degrees above horizontal. If the boom does
not balance properly, proceed to Section 3-12.
-
TROUBLESHOOTING
See page 2 for circuit diagram.
Dia.
Part
Replaced
Mkgs.
No.
With
8-
C57
031 677
007 742
8-
R51,54,55,57,63,67,
68,75,82,89
R81 .84
035 827
035
035
039
039
092
88-
R53
R63,79
035 827
039 106
SN1
Description
CAPACITOR, electrolyte 10 uf 35 volts
827
RESISTOR
825
332
106
648
RESISTOR, carbon film 0.25 watt 1 K ohm
RESISTOR, carbon film 0.25 watt 15K ohm
RESISTOR,carbonfilm0.25watt470 ohm
RESISTOR, carbon film 0.25 watt zero ohm (part of
110 158
071642 circuitcard)
SNUBBER, poly metfilm 0.5 uf 200VDC 100 ohm (Eff
(qtychg)
w/JG056098)
digit represents page no digits following dash represents item no.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
**First
-
Quantity
1
10
2
1
2
15
1
I
C)
0
-S C) C
3
i:tl
~L~i.T
~Ov
A5~
Cii
SwrI
'L J /1fl~
~fLil
cD
1201HYt f~\oai~JMOT R
1L
;~
I.TSV.~
DCJ
PLO.
I
6LR4~!(
I
66W
_
SWING ONLY
PIG
CT
PC
PCTI
ic<~
~ f2~HTL!~1-I~A_~.1 .-_ …~(
S
CR,
~
127
t~1~1~.
it
C
a
ET
CPA
No.
14
F
BAR
PLGS
RE
<
CR6 ~
~
p
k
_
RCa
51
LEFT
3
~~~CPs
PURGE
_. _ ~4g~
¶~RVSWE
flIGH~MOTE ~
6
-
L_~ :4~87L~:i:~lI~
-~
Lt.
if~
_
TR~EI~OTE
GAS
LI6 PLAID
.1
1
SOLENID
J,1J2
BURNACPIS REMOVE INSTAL
LEE
SOY
P
CDA
R:TIf~5.L
I~I ~
TO
~i
~
4b_o~
PURGE
_I!!]
1~
Ii~
V
6534782 ~
SOLENID LSEIFDTE
~
I
GAS
36
Efectiv
Models
PCI
L;H~c~C~PI LEFT&RICH OPTINAL RESPC
Serial
With
305
2
53
Diagr m
JG05698
P
j
WI5 PLC
No.
C~
T
261
<RIGHT CONTA R <CONTR(L
Cp2
C-hO
Circuit
Qs~
L
I
As;
ARC
404
For
Diagr m
Circuit
1.
II
A
T
7
RI
Figure
RIGHT I NCH
S2~
33
75
~
AC~
661
<
<
AC
ISV
I
0
(31 (6) ~1
(D
PLC23 > ~
Ii,,
3>
-.
SWINGARC
BAR ~
2>~
I
A>
I
I
~LC1a LE r
L
TRIGER
ONLY
250
-~ : ~ILJ
5r
~
ARC
INC ONLY
SW
PLG7~ > ~. . )~_ J7C13
~
-
~ 2>~ 3>~1T(O RIGHT TRIGE
i
Dec. 5,1986
FORM: OM-1523F
ERRATA SHEET
After this manual
appearing
was
printed, refinements
Amend Section 3
Delete
Add
in
to data
later in this manual.
-
Steps h, i, j,
Step ic.
1.
Complete Steps
c
and k of Subsection B.
Add Section 3
WARNING
c
-
as
~
follows:
Support
Assembly, Steps 3c. and 4c.
1 1A.
~~
Assembly, Step 2. Post Support
Amend Subsection B.
ALE ~
~UU~ TO ~C~~frR
LOCATION AND ASSEMBLY
Subsection B. Assembly to read
to
Complete Steps
INSTALLATION
-
to read as
follows:
Support
SAFETY COLLAR REMOVAL
RELEASE OF SPRING PRESSURE WITHOUT BOOM ATTACHED
can cause
serious
person&I
__________
injury and equipment damage.
Perform installation exactly as outlined in the following step-by-step instructions.
Do not remove safety collar until instructed to do so.
stallation: The collar is required whenever the boom is disassembled or relocated. To remove the safety collar, pro
ceed as follows:
A
1.
Grasp bar and pull boom down slightly. The boom should be pulled down only far enough
2.
Remove the
3.
The boom should
not
safety collar,
and retain for future
to remove
use.
now balance in any position from horizontal to 60 degrees above horizontal. If the
balance properly, proceed to Section 3-12.
See page 2 for circuit
-
diagram.
Dia.
Part
Replaced
No.
With
8-
C57
031 677
007 742
CAPACITOR, electrolyte 10 uf 35 volts
8-
R51,54,55,57,63,67,
68,75,82,89
R81 ,84
035 827
035 827
035 825
RESISTOR (qtychg)
8-
R53
035 827
039 332
8-
R63,79
039 106
039 106
110 158
RESISTOR,carbonfilm0.25wattl5Kohm
RESISTOR,carbonfilm0.25watt470ohm
SNUBBER, poly metfilm 0.5 uf 200VDC 100
SN1
Quantity
Description
1
10
2
1
2
ohm (Efl
w/JG056098)
**FirSt
boort~~does
TROUBLESHOOTING
Mkgs.
**
the pressure
-
1
-n cc c
3 CD
C-)
CD
C1) C
7+ 0
cc
3
~
06,15
MOT R
~
05PELI MEASUR
1PM- WIT,
0
ESCPI
:~
LiLT /~V L
*1
ALE All
No.
~OU~R
II.
MEASURD 107 51
FOAMS POINT RESP CT
WAVE VOLTAGES
300
C-hO
,
E~
A
TO
404
'
'
COM N WIT,
~
~ZEi~
RC,G~1 o
6015
~
Diagr m
AC
A
SW
Circuit
~Th
3
CR1
27
~
2P
~5R~
COTIAR
JG05698
CR2
0
P
CA4
2
0
w,
No.
F
I
0
Serial
ROtp
-
2
~CR3
300
il.
~~CR3
REMOTE
~O_1
RIGHT
60
SOLENID SRIIcDHrE
CR5
FIji
REMOTE
GAS
~
_ 7~f~CW RCI~
Jjtflp
LEFT
TI
0 50
R:TF/:5fl1
IC,3
OUR08CDS REMOVE INSTAL
~i_ _
SPIGOT
~
TO
OPTINAL
~EFl ITESP C
R9A~
CR50
i3,
~6RC4
~~DI
A
D~OCS
501 , SlEIFDTE 432.1
MET R
K)1
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.3437
._ L ~
ASET~ 1,50
~5
~,Y
T
IC
L
I
L~J
CASO
TI
0
!
CT3
~>
2> I>
53
L5O
052
RIG~IT
>~>~
r
OS,
~;-~.)~ LIT_li ,NGARC
SW
620 ~ RET 8015
~>
I
For
Diagr m
Circuit
1.
6!
~
Models
A
J~
_
Efectiv
A
34
GAS
With
INGARC ONLT
~> 8H15
SW
r
lEAP
0
3>~Af RIGHT TR,6EG
L
I
L
~
~
CT
ON
-
7
Figure
May29,
ERRATA SHEET
After this manual
appearing
was
in
printed, refinements
FORM: OM-1523F
1986
to data
later in this manual.
-
INSTALLATION
-
-~
Amend Section 3
-
1.
~
LOCATION AND ASSEMBLY
~
Delete
Add
Steps h, i, j, and k
Step ic.
to Subsection B.
Complete Steps
c
Complete Steps
WARNING
c
-
Assembly
Assembly, Step 2.
to
read
Amend Subsection B.
Add Section 3
of Subsection B.
as
Post
Support
~
I
£J~ ~
follows:
Support
Assembly, Steps 3c. and 4c.
to
read
as
follows:
thru g in Subsection 2. Post Support
hA. SAFETY COLLAR REMOVAL
RELEASE OF SPRING PRESSURE WITHOUT BOOM ATFACHED
can cause
serious
personal
__________
equipment damage.
Perform installation exactly as
injury
and
outlined in the
following step-by-step
safety collar until instructed to do
Do not
remove
instructions.
so.
stallation. The collar is required whenever the boom is disassembled or relocated. To remove the safety collar, pro
ceed as follows:
A
1.
Grasp bar and pull boom down slightly. The boom should be pulled down only far enough
2.
Remove the
safety collar, and retain for future
to remove
the pressure
use.
3. The boom should now balance in any position from horizontal to 60 degrees above horizontal. If the boom does
not balance properly, proceed to Section 3-12.
-
TROUBLESHOOTING
See page 2 for circuit diagram.
Dia.
Part
Replaced
**
Mkgs
No.
With
8-
R51,54,55,57,63,67,
68,75,82,89
R81 ,84
035 827
035 827
RESISTOR (qtychg)
035 825
039 332
RESISTOR,carbonfilm0.25watt470 ohm
SNUBBER, poly metfilm 0.5 uf 200VDC 100
8-
R53
8-
R63,79
035 827
039 106
SN1
039 106
110 158
Quantity
Description
10
2
ohm (Eff
w/JG056098)
**First
-
> 3 CD
m CD C
0
CD
C, C rt
0) CD 0) 3
MOT R kR-D IVE ROL S)
fl- i~EW() L-1_J
RUNIG
IPUMOTR
BOY
c
RESPCT MEASUR
WITH
MEASURD
FORMS POINT
RESPCT
WAVE VOLTAGES
COM N
3
6TS~I~1~1
T
~64~j
-
<
HL(~)
RIGHT
~D5R
No.
Serial
~
M
~T ~
_ ~<
H
25
SR
LEFT
CR3
TC05
R
PLO3
Id
CR3
JG05698
-~ 051
WAX
2
Circuit
~
~ PLG1I
RE
Diagr m
057
W
~
No.
~
T~
_ _~CR~1~
CONTA R CONTRL
I~
~
2O~
RIGHT
C-hO
A53
SW5HG~RC
WITH
ALL ALL
~
~
TO
404
I
C~,
WIl Y
~j2OWAC
IC
EXCPT POINT
AT
A53
:~
At
3D0
I
#71
E1
H
~__
i~i
T
TO
_ ~T
I I~I
0-540 ONLY
PL1
IC5
With
MV-
1
HEIR
I
REMOTE
-
RU
RIGHT
Efectiv
I
a
SIDE
PURGE RIGHT
CRS
.fi1
I
H
60
~1
I~ 1~4~I
CR2
I
I
I
Ia
I
I
381
I
k
311
__
pu~oe SIDE
LE r
RC,R
5
JISJ2
OURNACES REMOVE INSTAL
REMOTE
LEFT
ID
PLO
:lX54L
Models
-
A50
-
~
-
For
RC11
C2
TO
F
CR1
RUNBACE* Z~f~tW ~R
GAS HG
H
I I
on2
I
SOlENID TUbE
101t~
231 RIGHT
I
I
~
r
I
21
RUN6ACI* esj. ~ fcW *LEFTIRGY OPTINAL RESPC
LEFT
I
r
PLGH
RC4
H
~R
5
L~
-
I
~1 III ~
39
~
3232
US
SOLENID SLEIFDTE
4
4
38
GUS
~MH~
RCR~
1 0~ 9R-CD
,)55
ID
11
fl~ ,,
3437
36
55
ByRCS ,,
H
~
dl
,
H
L
0
RCS
H
AC
~
TO
~
32
Z
cR~scR: 5~
AC
33
RIGHT I- NCA
I
CRS
CR3
-~ : ~ILJ
35~
L'..
I
~
51
53
050
052
PLGD
CR~
~
U
AR
>I~
EVA
AC
Hz
ISV
I
0
as Ca) m
a)
CONTU R CONTRL~
AIS~ LEFT
>Lj RC2-~
RIO ~VT REX BRA
3> ~> I>
I
I
PLGIB LEFV
L
SWINGARC ONLY
TRIGER
~1
ARC
TC)3
PLO134
BRA OLE )FVT
SWING ONLY
2>
r
VITO
3>
I
RIGRT TRIG ER
MET
C
F5$~2T ,2__
R
054
ER~J
F
PLG9I5, L~_J
SW
ONLY
ISV
Diagr m
Circuit
1.
-
7
Figure
TABLE OF CONTENTS
Page No.
Section No.
SECTION 1
1
1
-
-
-
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1 -3. Arc
1
-
2
-
-
-
-
INTRODUCTION
1. General Information And
Safety
2.
Receiving-Handling
3. Description
SECTION 3
3
1
7
11
Welding
4. Standards Booklet Index
SECTION 2
2
2
1
1. Introduction
2. General Precautions
-
-
.
-
-
-
-
3-12. BoomAdjustments
3-13. Motor Control Connection
3-14. Gun Trigger Connections
3-15. Weld Cable Connection
3-16. 115 Volts/Contactor Control Connections
3-17. AdjustmentOfHubTension
3-18. PulleyAdjustment
3-19 Remote Control Connections
-
-
4
-
-
3.
4.
4 -5.
4
4
4
-
-
-
5
5
5
-
-
-
Remote Control Receptacles And Switches
Purge Buttons
Jog Switches
6. Inches Per Minute Meter
7. Reset Circuit Breaker
8. Burnback Controls
SECTION 5
-
6
1.
2.
6
6-3.
6
4.
6
5.
-
-
-
-
SECTION 7
-
Fuse
Brush Inspection & Replacement
Drive Shaft Inspection And Maintenance
-
22
22
22
22
22
23
23
24
24
24
24
25
TROUBLESHOOTING
7-1. General
7
22
22
22
22
MAINTENANCE
Inspection And Upkeep
Cleaning Of Drive Rolls
-
15
15
16
16
16
16
18
18
19
19
20
20
20
20
21
21
21
SEQUENCE OF OPERATION
1. Welding Wire Threading
2. Gas Metal-Arc Welding
3. Shutting Down
SECTION 6
14
15
OPERATOR CONTROLS
4-1. PowerSwitch
4
2. Wire Speed Controls
4
13
INSTALLATION
1 Location And Assembly
3-2. DriveMotor
3 -3. Installation Of Wire Support
3
4. Reinstallation Of Hub Assembly
3
5. Installation Of Wire Reel
3-6. Installation Of Spool-Type Wire
3 -7. Installation Of Reel-Type Wire
3
8. Drive Roll And Wire Guide Installation
9. Water Control Kit Connections
3
3-10. WeldingGunConnections
3-11. Shielding Gas Connections
SECTION 4
13
13
2. Troubleshooting Chart
25
25
SECTION 1
SECTION 1
-
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
REGLES DE SECURITE POUR LE FONCTIONNEMENT DU POSTE DE SOUDAGE A LARC
-
1-1. INTRODUCTION
We learn
by experience.
Learning safety through personal experience, like a
child touching a hot stove is harmful, wasteful, and un
wise. Let the experience of others teach you.
1-1. INTRODUCTION
Contrairement a lappren
tissage de Ia vie, lapprentissage de Ia sØcuritØ par ex
pØrience personnelle, comme lenfant qui touche un
poŒle chaud, est dangereux, imprudent et inutile.
lnstruisez-vous donc de lexpØrience dautrui.
Safe practices developed from experience in the use of
welding and cutting are described in this manual.
Research, development, and field experience have
evolved reliable equipment and safe installation, opera
tion, and servicing practices. Accidents occur when
equipment is improperly used or maintained. The
reason for the safe practices may not always be given.
Some are based on common sense, others may require
Des mØthodes de sØcuritØ issues de lexpØrience du
et du coupage sont dØcrites dans le manuel. La
recherche, le progres et lexpØrience dans ce domaine
ont dØveloppØ un materiel fiable et des mØthodes de
sØcuritØ pour linstallation, le fonctionnement et lentre
tien. Des accidents se produisent lorsque le materiel est
inadØquatement utilisØ ou entretenu. La raison de ces
mØthodes de sØcuritØ peut ne pas Øtre toujours donnØe.
Certaines sont fondØes sur le sens commun, dautres
demanderont a Łtre expliquØes par des livres techni
ques. II est plus sage de suivre les rŁgles.
technical volumes to explain. It is wiser
rules.
to
follow the
Read and understand these safe practices before at
tempting to install, operate, or service the equipment.
Comply with these procedures as applicable to the par
ticular equipment used and their instruction manuals,
for personal safety and for the safety of others.
Failure
these safe practices may cause
serious injury or death. When safety becomes a habit,
the equipment can be used with confidence.
to
observe
These safe practices are divided into two Sections:
1
General Precautions, common to arc welding and
-
-
soudage
Lisez et comprenez
ces
mØthodes de sØcuritØ avant
dessayer dinstaller, de faire fonctionner ou de rØparer
Pour votre sØcuritØ personnelle et celle
lappareil.
dautrui, conformez-vOus a ces rŁgles et aux manuels
dinstructions.
Manquer dobserver ces mØthodes de sØcuritØ pourrait
entrainer des blessures graves ou mŁme a mort. Quand
Ia sØcuritØ devient iine habitude, le materiel peut alors
Œtre utilisØ en toute confiance.
Ces mØthodes de sØcuritØ sont divisØes en deux sec
1
tions:
Precautions generales,
communes
au
soudage et au coupage a larc, et 2 Soudage a larc
(et coupage) (uniquement).
-
-
cutting;
and 2
-
Arc
Welding (and Cutting) (only).
Reference standards: Published Standards on safety are
also available for additional and more complete pro
cedures than those given in this manual. They are listed
in the Standards Index in this manual. ANSI Z49.1 is the
most
complete.
The National Electrical
Code, Occupational Safety and
Health Administration, local industrial codes, and local
inspection requirements also provide a basis for equip
ment
installation,
Normes de rØfØrence: Des publications des normes
amØricaines de sØcuritØ sont aussi a votre disposition
modes opØratoires plus complets que
pour dautres
ceux du present manuel. Elles sont donnØes dans rln
dex des Normes de ces regles de sØcuritØ. ANSI Z49-1
est Ia plus complete.
les codes provinciaux et
de IACNOR,
donnent aussi les exigences pour une in
stallation, une utilisation et un entretien sUrs.
Les
use, and service.
1-2.
1-2. GENERAL PRECAUTIONS
Different
arc
and fluxes
welding processes, electrode alloys,
produce different fumes, gases,
can
and radiation levels. In addition to the information
in this manual, be sure to consult flux and elec
trode manufacturers for specific technical data
and precautionary measures concerning their
material.
PRECAUTIONS GENERALES
Plusieurs procØdØs du soudage a larc, des Ølec
trodes allies, et lee flux peuvent produire des
de
et
niveaux
rayonnemant
vapeurs,
gaz,
diffØrents. Pour tout renseignement supplØmen
taire a ce manuel, consultez aussi lea fabricants
des electrodes et des flux afin dobtenir
lee
renseignements techniques spØcifiques et lee
de
mesures
precaution concernant leurs
matriaux.
A.
A.
codes
municipaux
Prevention des brUlures
Burn Prevention
Portez des vŒtements de
protective clothing gauntlet gloves designed
welding, hat, and high safety-toe shoes. Button
shirt collar and pocket flaps, and wear cuffless trousers
to avoid entry of sparks and slag.
Wear
use
-
for
in
safety goggles or glasses with side
appropriate filter lenses or plates
(protected by clear cover glass). This is a MUST for
welding or cutting, (and chipping) to protect the eyes
spØcialement dØsignØs
protection des garits a crispin
soudage, Un casque et
-
pour le
des chaussures de sØcuritØ. Boutonne~ le col de votre
chemise et les pattes de vos poches, et portez des pantalons sans revers pour Øviter que des Øtincelles et du
laitier ne sy introduisent.
Wear helmet with
shields underneath,
Portez un masque avec lunettes de sØcuritØ ou avec
Øcrans latØ-raux de protection, des lunettes filtrantes ou
des couvre-lentilles (protØgØs par un verre clair). Pour le
soudage ou le coupage (et le burinage), il est
OM-1 523
Page
1
from radiant energy and flying metal. Replace cover
glass when broken, pitted, or spattered. See 1-3A.2.
Avoid
oily
or
never
A
ignite them.
electrode stubs and
be handled without gloves.
workpieces
Hot metal such
should
clothing.
may
greasy
spark
as
Medical first aid and eye treatment. First aid facilities
and a qualified first aid person should be available for
each shift unless medical facilities are close by for, im
mediate treatment of flash burns of the eyes and skin
burns.
Ear
plugs should
be worn when working on overhead or
confined space. A hard hat should be worn when
others work overhead.
in
OBLIGATOIRE de protØger ses yeux contre lØnergie de
rayonnement et les Øclats de metal. Remplacez le verre
protecteur lorsqud est brisØ, piquØ ou qui~ a recu des
projections. Voir 1 .3A.2.
Evitez de porter des habits imprØgnØs dhuile
Une Øtincelle pourrait les enflammer.
ou
de
graisse.
Ne manipulez jamais sans gants un metal chaud tel que
des chutes dØlectrode et des piŁces a souder.
Premiers soins et traitement des yeux: Tout atelier
devrait avoir a sa disposition un poste de premiers soins
ainsi quune personne compØtente, a moms quur, ser
vice medical ne soit a proximitØ pour soigher immediate
ment les brGlures des yeux et de Ia peau.
a
Flammable hair preparations should not be used by per
sons
intending
B.
to weld or cut.
Severe
discomfort, illness
that
with
or
lorsque
Les personnes devant souder
death
vous
travaillez
au
espace restreint. Portez un casque
personnes travaillent au plafond.
un
ou
couper
ne
employer des preparations inflammables
Toxic Fume Prevention
fumes, vapors, heat,
Portez des bouche-oreilles
plafond ou dans
lorsque dautres
doivent pas
pour Jeurs
cheveux.
can
result from
oxygen enrichment or depletion
(or cutting) may produce. Prevent them
B.
Prevention des gax
toxiques
or
welding
adequate ventilation
as described in ANSI Stan
dard Z49.1 listed 1 in Standards index. NEVER ventilate
with oxygen.
Les gaz, les vapeurs, Ia chaleur, un enrichissement ou
manque doxygŁne
peuvent entralner un malaise,
une maladie ou mŒme Ia mort. RemØdiez-y par Ia ven
tilation dØcrite dans Ia Norme ANSI Z49.1 paragraphe 1
de llndex des Normes. NE ventilez JAMAIS a lox
un
ygene.
Lead
cadmium
zinc
mercury -, and beryllium
and similar materials, when welded (or cut) may
-,
-,
-,
-
bearing
produce harmful concentrations of toxic fumes.
Ade
quate local exhaust ventilation
must be used, or each
the operator must wear an
air-supplied respirator. For beryllium, both must be us
ed.
person in the
area as
well
as
En soudant
mercure
et
ou en
coupant, les plomb, cadmium, zinc,
beryllium
ou
autres matØriaux
semblables
peuvent crØer des concentrations nocives de gaz toxi
ques. On doit avoir recours a une ventilation aspirante
du local, ou alors toute personne sur les lieux,
de mŒme que le soudeur, doit porter un masque a ad
duction dair.
On doit employer los deux pour le
adequate
beryllium.
Metals coated with or containing materials that emit
toxic fumes should not be heated unless coating is
removed from the work surface, the area is well ven
tilated,
or
the operator
wears an
Work in
air-supplied respirator.
a confined space only while it is
tilated and, if necessary, while wearing an
being ven
air-supplied
respirator.
Gas leaks in a confined space should be avoided.
Leaked gas in large quantities can change oxygen con
centration dangerously. Do not bring gas cylinders into
a confined space.
Leaving confined space, shut OFF gas supply at sourceS
prevent possible accumulation of gases in the space
if downstream valves have been accidently opened or
to
left open. Check to be
re-entering it.
sure
that the space is safe before
Vapors from chlorinated solvents can be decomposed
by the heat of the arc (or flame) to form PHOSGENE, a
highly toxic gas, and other lung and eye irritating pro
ducts. The ultraviolet (radiant) energy of the arc can
decompose trichloroethylene and per
also
vapors to form phosgene. DO NOT
where solvent vapors can be drawn into
or cutting atmosphere or where the radiant
chloroethylene
WELD
the
or cut
welding
Les mØtaux enrobØs
Page
2
composes de matØriaux Ømet
doivent pas Œtre chauffØs a
de Ia surface a
ne soit tØ
que
travailler, que le local ne soit bien ventilØ, ou que le
soudeur ne porte un masque a adduction dair.
moms
toxiques
lenrobage
ne
Ne travaillez dans un espace restreint que sil est bien
ventilØ et, si nØcessaire, portez un masque a adduction
dair.
On doit Øviter les fuites de gaz dans un espace restreint.
Les fuites de gaz en grande quantite peuvent
transformer dangereusement Ia concentration dox
ygŁne. Namenez pas de bouteilles de gaz dÆns un
espace restreint.
En quittant un espace restreint, FERMEZ le robinet
dalimentation de gaz de Ia bouteille. Ainsi on pourra
rentrer en toute sØcuritØ dans Ia piŁce, mŒme si les
robinets ~aval
ont ete ouverts par accident, ou si on los
a laissØs ouverts.
Les vapeurs de dissolvants chlorØs peuvent Œtre dØcom
posØes par Ia chaleur de larc (ou de Ia flamme) et
former du PHOSGENE, gaz trŁs toxique, et dautres
produits irritant les poumons et les yeux~ LØnergie
ultra-violette de larc peut aussi dØcomposer les vapeurs
de trichloroØthylŁne et de perchloroethylŁne pour
former du phosgŁne. NE SOUDEZ PAS ou no coupez
pas dans des endroits o
dans
vent Œtre attirØes
OM-1 523
ou
tant des gaz
les vapeurs do dissolvants peu
ou do
latmosphŁre do soudago
energy can penetrate to
of
minute
amounts
atmospheres containing
trichioroethylene or
even
per
chioroethylene.
coupage et o lenergie de rayonnement pout pØnØtrer
dans des atmospheres contenant des quantitØs memo
de
minuscules
trichloroethylene ou de per
chloroØthylene.
Fire and Explosion Prevention
C.
C.
Causes of fire and explosion are: combustibles reached
by the arc, flame, flying sparks, hot slag or heated
material; misuse of compressed gases and cylinders;
and short circuits.
BE AWARE THAT flying sparks or falling slag can pass
through cracks, along pipes, through windows or
doors, and through wall or floor openings, out of sight
of the goggled operator. Sparks and slag can fly 35 feet.
To prevent fires and
explosion:
Keep equipment clean and operable, free of oil, grease,
and (in electrical parts) of metallic particles that can
cause
short circuits.
explosions
Les causes dincendie
et dexplosion
sont les com
bustibles atteints par larc, Ia flamme, les Øtincelles, le
laitier chaud ou les matØriaux chauffØs, le mauvais
emploi des gaz comprimØs et des bouteilles ainsi que les
courts-circuits.
Sachez que les Øclats dØtincelles ou Ia chute du laitier
dans les fissures, le long des
peuvent sinfiltrer
tuyauteries, par les fenØtres et les portes et par les
couvertures des murs ou du sol, sans que le soudeur
portant des lunettes ne les voie. Les Øtincelles et les
35 pieds.
scones peuvent voler jusqu
Pour prØvenir les incendies et les explosions: Veillez a ce
que votre appareil soit propre et en Øtat de marche,
dØnuØ dhuile et de graisse, et de particules de metal sur
les piŁces Ølectriques qui pourraient entrainer des
courts-circuits.
If combustibles are in area, do NOT weld or cut. Move
the work if practicable, to an area free of combustibles.
Avoid paint spray rooms, dip tanks, storage areas, yen
tilators. If the work cannot be moved, move com
bustibles at least 35 feet away out of reach of sparks
and heat; or protect against ignition with suitable and
snug-fitting, fire-resistant
covers or
shields.
Si des combustibles se trouvent a proximitØ, ne soudez
pas, ne coupez pas. Si possible, dØplacez votre travail
loin des combustibles. Evitez les ateliers de peinture au
pistolet, les cuves dirnmersion, les entrepts, les yen
tilateurs. Si cela nest pas possible, placez les com
bustibles a au moms 35 pieds des Øtincelles et de Ia
chaleur et protØgez-les des Øtincelles avec des couver
tures ou des Øcrans protecteurs adequats, bien ajustØs
et
opposite sides should
welded
on (or cut). Walls, ceilings, and floor near
not be
work should be protected by heat-resistant covers or
Walls
Prevention des incendies at des
touching combustibles
on
ignifugØs.
shields.
doit pas souder (ou couper) le ctØ opposØdes
touchant les combustibles. Les murs, plafonds et
planchers proches du travail doivent Œtre protØgØs par
des couvertures ou Øcrans protecteurs ignifuges.
Fire watcher must be standing by with suitable fire ex
tinguishing equipment during and for some time after
Un surveillant doit se tenir a proximitØ avec un materiel
de lutte contre lincendie adØquat, pendant et quelque
temps aprŁs le soudage ou le coupage si:
welding
or
On
ne
murs
cutting if:
a.
a.
appreciable combustibles (including building
b.
construction) are within 35 feet
appreciable combustibles are further than 35
can be ignited by sparks
openings (concealed or visible) in
b.
feet but
c.
walls
within
35
feet
may
floors
expose
or
c.
com
sparks
combustibles adjacent to walls, ceilings,
roofs, or metal partitions can be ignited by
bustibles to
d.
radiant
or
d.
conducted heat.
permit should be obtained before operation to
supervisors approval that adequate precautions
Hot work
ensure
have been taken.
After work is done, check that
glowing embers, and flames.
area
is free of
sparks,
An empty container that held combustibles, or that can
produce flammable or toxic vapors when heated, must
never be welded on or cut, unless container has first
as described in AWS Standard A6.O,
listed 3 in Standards index.
been cleaned
This includes:
a
solvent
or
thorough steam or caustic cleaning (or
water washing, depending on the corna
quantites apprØciables de combustibles
(y compris une construction en chantier) se
trouvent a moms de 35 pieds.
Des quantites apprØciables de combustibles
sont a plus de 35 pieds mais peuvent Œtre
Des
enflammØes par des Øtincelles.
Des ouvertures (cachØes ou visibles) sur les
planchers ou les murs a moms do 35 pieds
peuvent exposer des combustibles aux
Øtincelles.
combustibles adjacents aux
Les
murs,
plafonds, toits ou cloisons mØtalliques peu
vent Œtre enflammØs par une chaleur rayon
nante ou transmise.
Avant de commencer, avisez le contremaItre pour quil
sassure que les precautions adØquates soient prises.
Une fois le travail terminØ, vØrifiez quiI ny alt pas
dØtincelles, de cendres ardentes ou de flammes dans le
local.
souder ni couper sur un recipient
combustibles, ou pouvant produire
des vapeurs inflammables ou toxiques a Ia chauffe, a
moms que le recipient nait ØtØ lavØ au prØalable, corn
dØcrit dans Ia Norme AWS A6.O, figurant au
me
paragraphe 3 de llndex des Normes.
On
ne
ayant
dolt
jamais
contenu des
Cela comprend: un nettoyage a fond a Ia vapeur ou au
caustique (ou un lavage avec dissolvant ou eau solon Ia
solubilitØ du combustible) suivi dune
purge et dune
in
OM-1523
Page 3
solubility) followed by purging and inerting
nitrogen or carbon dioxide, and using protective
equipment as recommended in A6.O. Waterfilling just
below working level may substitute for inerting.
jection dazote ou de gaz carbonique, en utilisant un
Øquipement de protection comme recommandØ dans
A container with unknown contents should be cleaned
(see paragraph above). Do NOT depend on sense of
est inconnue
bustibles
with
lA6-O. LatmosphŁre inerte peut ºtre remplacØe par un
niveau deau arrivant au-dessous du travail a effectuer.
Vous devez layer
smell
or
sight
to determine if it is safe to weld or cut.
Hollow
castings or containers must be
welding or cutting. They can explode.
vented before
Explosive atmospheres. Never weld or cut where the air
may contain flammable dust, gas, or liquid vapors (such
as
gasoline).
D.
recipient dont Ia
nature de contenu
souder
ou
le couper
toute sØcuritØ.
en
Vous devez
pratiquer
pients creux
exploser.
avant de les souder ou couper:
un
event
sur
les
ou rØci
ils peuvent
piŁces
Atmospheres explosives: Ne soudez ni ne coupez
jamais dans des Iieux oCi lair peut contenir des
poussiŁres, gaz ou vapeurs liquides inflammables (tels
que lessence).
Compressed Gas Equipment
Standard precautions. Comply with precautions in this
manual, and those detailed in CGA Standard P-i,
PRECAUTIONS FOR SAFE HANDLING OF COM
PRESSED GASES IN CYLINDERS, listed 6 in Stan
dards index.
1.
un
(voir paragraphe ci-dessus). NE vous fiez
PAS a lodorat ou a Ia vue pour dire si lon peut le
Pressure
Regulators
D.
Gaz comprimØ
Precautions gØnØrales: Suivez les precautions de ce
manuel, et celles dØcrites a Ia Norme CGA P-i (PrØcau
tions de sØcuritØ pour a manipulation de gaz comprimØs
des Normes.
en bouteilles), paragraphe 6 de Ilndex
1.
DØtendeurs de
pression
La soupape de sretØ dun dØtendeur est destinØe a pro
seulement le dØtendeur de Ia surpression. Elle na
pas pour but de protØger les boyaux et le chalumeau: on
protege ceux-ci par des soupapes de retenue concues
specialement pour cette fonction.
tØger
Regulator relief valve is designed to protect only the
regulator from overpressure; it is not intended to pro
tect any downstream equipment. Provide such protec
tion with
one or more
relief devices.
Never connect a regulator to a cylinder containing gas
other than that for which the regulator was designed.
Remove
faulty regulator from service immediately for
repair (first close cylinder valve). The following symp
toms indicate a faulty regulator:
if gas leaks externally.
if delivery pressure continues to rise
Excessive Creep
with downstream valve closed.
Leaks
-
-
Faulty Gauge if gauge pointer does not move off stop
pin when pressurized, nor returns to stop pin after
-
pressure release.
Repair. Do NOT attempt repair. Send faulty regulators
for repair to manufacturers designated repair center,
where special techniques and tools are used by trained
personnel.
2.
Cylinders
Cylinders must be handled carefully to prevent leaks
and damage to their walls, valves, or safety devices:
Avoid electrical circuit contact with cylinders including
third rails, electrical wires, or welding circuits. They can
produce short circuit arcs that may lead to a serious ac
cident. (See i-3C.)
Ne montez jamais un dØtendeur sur une bouteille conte
different de celui pour lequel le dØtendeur a
ØtØ conu.
nant un gaz
Enlevez immØdiatement un dØtendeur dØfectueux pour
le faire rØparer (dabord,
fermez le robinet de (a
bouteille). Les symptomes suivants dØnotent Ia dØfec
tuositØ du dØtendeur:
si le gaz fuit extØrieurement.
Fuites
Ascension excessive si Ia pression de debit continue a
monter, le robinet du chalumeau Øtant fermØ.
Si (aiguille du manomŁtre ne
ManomŁtre dØfectueux
sØcarte pas de Ia goupille de butØe lors do Ia mise en
preSsion, ou ne revient pas sur Ia goupille aprŁs lØchap
pement de Ia pression.
-
-
-
Reparation. NESSAYEZ PAS de rØparer vous-mºmes.
Envoyez les dØtendeurs dØfectueux a rØparer aux
ateliers do reparation agrØØs du fabricant, OCi des techni
ques et des outils spØciaux sont utilisØs par un person
nel formØ.
2.
Bouteilles
Les bouteilles doivent Œtre
manipulØes avec soin pour
a leurs parois, robinets ou
systŁmes de sOretØ. Evitez quun circuit Ølectrique soit
en contact avec les bouteilles, y compris les rails de con
tact, los fils Ølectriques ou los circuits de soudage. Cela
pourrait crØer des arcs courts-circuits pouvant entralner
prØvenir les fuites
ou
degts
des accidents graves (Voir 1.3C.).
DOT marking must be on each cylinder. It is an
assurance of safety when the cylinder is properly
ICC
or
handled.
OM-1 523
Page 4
bouteille doit porter los inscriptions ICC ou
DOT. Cest un gage de sØcuritØ pourvu que Ia bouteille
soit bien manipulØe.
Chaque
Identifying gas content. Use only cylinders with name
of gas marked on them; do not rely on color to identify
gas content. Notify supplier if unmarked. NEVER
alter name, number, or other markings
illegal and hazardous.
DEFACE
or
cylinder.
It is
on a
Empties: Keep valves closed, replace caps securely;
mark MT; keep them separate from FULLS and return
promptly.
Prohibited
use.
Never
cylinder
use a
or
other than its intended use, NEVER
roller.
its contents for
as
a
support
Identification du gaz: Nutilisez que les bouteilles mdi
nature du gaz; ne vous fiez pas a Ia couleur
pour reconnaItre (a nature du gaz. Adressez-vous a
votre fournisseur si cela nest pas indique.
quant Ia
NEFFACEZ
modifiez
ou
ne
numØros ou autres indications
est
illegal
JAMAIS les noms,
une bouteille. Cela
sur
dangereux.
et
Vides: Maintenez les robinets fermØs, replacez bien les
chapeaux; inscrivez Vides;
sØparez-les des Pleines
et retournez-les rapidement.
or
Emploi interdit: Nutilisez une bouteille ou son contenu
ce a quoi elle est destinØe, mais JAMAIS corn-
que pour
Locate
or secure
cylinders
so
they
cannot be knocked
over.
Passageways and work areas. Keep cylinders clear of
areas where they may be struck.
Transporting cylinders. With a crane, use a secure sup
port such as a platform or cradle. Do NOT lift cylinders
off the ground by their valves or caps, or by chains,
slings, or magnets.
Do NOT expose cylinders to excessive heat, sparks,
slag, and flame, etc. that may cause rupture. Do not
allow contents to exceed 130F. Cool with water spray
where such exposure exists.
Protect cylinders particularly valves from bumps, falls,
falling objects, and weather. Replace caps securely
when moving cylinders.
me
support
ou
rouleau.
Placez les bouteilles pour quelles ne tombent
quun dØtendeur (et un boyau) est monte
placez les ou attachez-Ies debout.
pas. Lors
sur
elles,
Passages et Iieux de travail. Enlevez Ies bouteilles dun
endroit oCi lon pourrait les frapper.
Transport des bouteilles. Avec une grue, utilisez un sup
port fiable tel quune
plate-forme ou un cadre. NE
SOULEVEZ PAS des bouteilles du sal par leur robinet
ou chapeau, ou avec des chaines, Ølingues ou aimants.
NEXPOSEZ
PAS les bouteilles a une chaleur excessive,
au laitier et aux flammes, etc., pouvant
causer leur
rupture. Le contenant ne doit jamais
dØpasser 55C. Refroidissez en pulverisant de Ieau si
nØcessaire.
aux
Øtincelles,
les bouteilles et particuliŁrement les soupapes
chocs, les chutes, les chutes dobjets et Ia
temperature. Remettez bien les chapeaux lorsque vous
dØplacez les bouteilles.
ProtØgez
contre les
Stuck valve. Do NOT
cylinder valve that
your supplier.
a
Mixing
use a
can not
hammer
be
or
wrench
gases. Never try to mix any gases in
Never refill any
to open
opened by hand. Notify
cylinder.
a
cylinder.
Cylinder fittings should
never
be modified
or
exchang
ed.
Robinet coincØ. NUTILISEZ PAS un marteau ou une
clØ mØtallique pour ouvrir un robinet de bouteille que
lon ne peut pas ouvrir a Ia main. Avisez votre four
nisseur.
MØlange
dans
3.
Prohibited
use.
Never
specified
use
gas. A
hose other than that
general
gases.
tubing splices. Use only standard
splice hose.
No copper
brass fit
long runs to prevent kinks and abuse. Suspend
hose off ground to keep it from being run over, stepped
on, or otherwise damaged.
Avoid
Coil
3.
Boyau
Utilisation interdite. Nutilisez
que celui
Use ferrules or clamps designed for the hose (not or
dinary wire or other substitute) as a binding to connect
hoses to fittings.
to
excess
des gaz
designed
hose identification rule
is: red for fuel gas, green for oxygen, and black for inert
tings
Nessayez jamais de mØlanger
bouteille.
Ne rechargez jamais une bouteille. Les ØlØments de Ia
bouteille ne doivent jamais Œtre modifies ou remplacØs.
Hose
for the
de gaz.
une
hose to prevent kinks and
tangles.
jamais
un
boyau
autre
gaz indiquØ. La regle gØnØrale
didentification est: rouge pour les gaz combustibles,
et noir pour les gaz inertes.
vert pour loxygene,
appropriØ
au
Utilisez des bagues ou colliers appropriØs au boyau (et
non dii fil ordinaire ou autre substitution) pour brancher
les boyaux a lappareillage.
Nutilisez pas des raccords en cuivre. Nutilisez que des
accessoires standard en laiton pour raccorder un boyau.
Utilisez
noeuds
petite longueur de boyau. Cela Øvitera les
lusure prØmaturØe. Suspendez le boyau au
dessus du sol pour Øviter quil ne soit ØcrasØ, piØtinØ ou
une
et
endommagØ.
Protect hose from
sparks, slag, and
Examine hose
damage by sharp edges, and by
open flame.
regularly for leaks, wear, and loose con
pressured hose in water; bubbles in
Enroulez le surplus de boyau pour Øviter les noeuds et
emmØlements. Evitez que le boyau ne soit endommagØ
par des tranchants, Øtincelles, laitier et flamme nue.
nections. Immerse
dicate leaks.
OM-1523 Page 5
Repair leaky or worn hose by cutting
ing (1-2D3). Do NOT use tape.
4.
area out
and splic
Proper Connections
Clean cylinder valve outlet of impurities that may clog
orifices and damage seats before connecting regulator.
Except for hydrogen, crack vave momentarily, pointing
outlet away from people and
a clean lintless cloth.
sources
of
ignition. Wipe
with
Match regulator to cylinder. Before connecting, check
regulator label and cylinder marking agree, and
that the regulator inlet and cylinder outlet match.
NEVER CONNECT a regulator designed for a particular
gas or gases to a cylinder containing any other gas.
that the
Tighten
connections. When
assembling threaded
con
CGA adapter (available from your sup
and regulator, if one is required.
plier)
Use two wrenches to tighten adapter marked RIGHT
and LEFT HAND threads.
between
Pressurizing Steps:
Drain regulator of residual gas through suitable vent
before opening cylinder (or manifold valve) by turning
adjusting screw in (cockwise). Draining prevents ex
cessive compression heat at high pressure seat by
allowing seat to open on pressurization. Leave adjusting
screw engaged slightly on single-stage regulators.
Stand to side of regulator while opening cylinder valve.
Open cylinder valve slowly so that regulator pressure in
When gauge is pressurized (gauge
creases slowly.
reaches regulator maximum) leave cylinder valve in
following position: For oxygen, and inert gases, open
fully to seal stem against possible leak. For fuel gas,
open to less than one turn to permit quick emergency
shutoff.
Use pressure charts (available from your supplier) for
safe and efficient, recommended pressure settings on
regulators.
Check for leaks on first pressurization and regularly
there-after. Brush with soap solution (capful of Ivory
Liquid* or equivalent per gallon of water). Bubbles in
dicate leak. Clean off soapy water after test; dried soap
is combustible.
E.
User
Responsibilities
Remove leaky or defective equipment from service im
mediately for repair. See User Responsibility statement
in equipment manual.
*Trademark of Proctor & Gamble
OM-1 523
Page 6
4.
Branchements corrects
Avant de brancher le dØtendeur, nettoyez Ia sortie du
robinet de Ia bouteille des impuretØs qui peuvent
obstruer les orifices et endommager les sieges. Sauf
pour lhydrogŁne, ouvrez momentanØment le robinet,
en
Øloignant
flammables.
Ia sortie des personnes et des sources in
Essuyez avec un tissu propre et non
graisseux.
Appareillez le dØtendeur
a Ia bouteille. Avant de bran
que Ia marque du dØtendeur et Ia
descrip
tion de Ia bouteille concordent, et que lorifice dentrØe
du dØtencieur et Iorif ice de sortie de Ia bouteille aillent
ensemble. NE BRANCHEZ JAMAIS un dØtendeur
concu pour un gaz special (ou des gaz spØciaux) a une
bouteille contenant dautres gaz.
a
cylinder
Regulator outlet (or hose) connections may be iden
tified by right hand threads for oxygen and left hand
threads (with grooved hex on nut or shank) for fuel gas.
5.
Reparation. Coupez Ia partie percØe ou usØe, et rac
cordez (1-2D3). NUTILISEZ JAMAIS de ruban adhØsif.
cher, vØrifiez
nections, clean and smooth seats where necessary.
Tighten. If connection leaks, disassemble, clean, and
retighten using properly fitting wrench.
Adapters. Use
VØrifiez rØguliŁrement les fuites, lusure
et les rac
cordements lØches. Plongez le boyau sous pression
dans de leau; les bulles indiqueront les fuites.
Serrez les branchements. Lorsque vous assemblez des
branchements filetØs, nettoyez et polissez les sieges ou
cest nØcessaire. Serrez. Si les branchements perdent,
dØmontez-les, nettoyez et resserez avec une clef adØ
quate.
si besoin est, un adaptateur CGA
chez votre fournisseur) entre Ia bouteille et le
dØtendeur. Avec deux clefs, serrez ladaptateur filetØ A
DROITE et A GAUCHE.
Adaptateurs. Placez,
(en
vente
On pout reconnaItre les branchements de sortie du
dØtendeur (ou boyau) a laide du filetage a droite pour
loxygene et a gauche (identifiØ par un Øcrou cannelØ)
pour les gaz combustibles.
5.
DØmarches de mise
en
pression
Purgez le dØtendeur de rØsidu de gaz avant douvrir Ia
bouteille (ou le robinet de canalisation) en serrant Ia vis
de rØglage (dans le sens des aiguilles dune montre).
Cette operation permet au siege de haute pression de
souvrir a Ia mise en pression, supprimant ainsi toute
surchauffe de compression. Maintenez Ia vis de reglage
des dØtendeurs a simple dØtente lØgŁrement engagee.
Avant douvrir le robinet de Ia bouteille, assurez-vous
que les boyaux sont branches et quo les soupapes aval
sont fermØes.
Tenez-vous latØralement au dØtendeur en ouvrant le
robinet de Ia bouteille. Ouvrez-le lentement pour que Ia
pression du dØtendeur monte progressivement. Lorsque
le manomŁtre est mis sous pression (indique le max
imum) le robinet do Ia bouteille de gaz inerte ou dox
ygene devra Œtre ouvert a fond pour assurer lØtanchØitØ
et celui de Ia bouteille de gaz combustible ouvert de
moms dun tour pour pouvoir le reformer rapidement en
cas
durgence.
RØfØrez-vous aux tableaux de pression (distribuØs par
fournisseur) pour un reglage recommandØ de
pression sr et efficace sur les dØtendeurs. VØrifiez les
fuites a Ia premiere mise en pression puis rØguliŁrement,
brossez avec une solution savonneuse (un bouchon
dlvory Liquid* ou semblable par gallon deau). Les
bulles indiquent une fuite. Enlevez Ieau savonneuse
aprŁs examen; le savon sec est inflammable.
votre
*Marque do Commerce do
Proctor & Gamble
F.
Leaving Equipment Unattended
Close gas supply at
source
E.
ResponsabilitØs de lusager
Otez immØdiatement les parties percØes ou dØfec
ResponsabilitØs de lUsager du manuel
de lappareil.
and drain gas.
tueuses. Voir les
G.
Rope Staging-Support
Rope staging-support should not be used for welding
cutting operation; rope may burn.
1-3. ARC WELDING
Comply with
1-1, 1-2, and this section. Arc Welding,
is a safe process, but a careless operator
The equipment carries high currents
-
invites trouble.
at
significant
Sparks fly,
arc is very bright and hot.
fumes rise, ultraviolet and infrared energy radiates,
weldments are hot, and compressed gases may be us
ed. The wise operator avoids unnecessary risks and pro
tects himself and others from accidents. Precautions
are described here and in standards referenced in index.
Burn Protection
Comply
with
precautions
Appareil laissØ
Fermez lalimentation
precautions in
properly done,
voltages. The
A.
F.
or
in 1-2.
The
welding arc is intense and visibly bright. Its radia
can damage eyes, penetrate lightweight clothing,
reflect from light-colored surfaces, and burn the skin
and eyes. Skin burns resemble acute sunburn, those
from gas-shielded arcs are more severe and painful.
DONT
GET BURNED; COMPLY WITH PRECAU
G.
sans
surveillance
de gaz a Ia
Liens et supports
source et
purgez.
temporaires
Pour vos travaux de soudage ou de coupage, nutilisez
pas de Ia corde comme soutien, elle est inflammable.
1-3. SOUDAGE
A
LARC
Conformez-vous
-
aux
prØcautionsdes paragraphesl.1 etl.2decettesection.
soudage a Iarc bien exØcutØ est sr, mais tin
negligent est un danger. Le poste de soudage
Le
soudeur
courants ØlevØs sous de fortes tensions.
est trŁs vif et chaud. Les Øtincelles volent, les
transporte des
Larc
vapeurs montent, Ienergie ultra-violette et infrarouge
rayonnent, les soudures sont chaudes, et des gaz corn
primes peuvent Œtre utilisØs. Le soudeur prudent Øvite
les risques inutiles, se protege et protege autrui contre
les accidents. Les precautions sont dØcrites ici et dans
les normes donnØes dans llndex.
tion
TIONS.
1.
Protective
Clothing
Wear
long-sleeve clothing (particularly for gas-shielded
arc) in addition to gloves, hat, and shoes (1-2A). As
necessary, use additional protective clothing such as
leather jacket or sleeves, flame-proof apron, and fireresistant leggings. Avoid outergarments of untreated
cotton.
Bare skin protection. Wear dark, substantial clothing.
Button collar to protect chest and neck and button
pockets
2.
to
prevent entry of
Eye and Head Protection
arc.
Protection contra lea brlures
Conformez-vous aux precautions du paragraphe 1.2.
Larc de soudage est intense et visiblement vif. Son
rayonnement petit blesser les yeux, traverser les habits
lØgers, se rØflØchir sur les surfaces claires, et brCiler Ia
peau et les yeux. Les brUlures de Ia peau ressemblent a
un gros coup de soleil. Celles darcs sous gaz protecteur
sont plus graves et plus douloureuses. NE VOUS
SUIVEZ LES PRECAUTIONS.
BRULEZ PAS
-
1.
VŒtements de
protection
Portez des vŒtements a manches longues (surtout pour
larc en atmosphere inerte) avec gants, masque et
chaussures (1.2A.).
Si nØcessaire portez en plus une veste ou des manches
cuir, un tablier et des guŒtres ignifugØs. De
prØfØrence ne portez pas de vŒtements en coton non
traitØ.
en
sparks.
Protect eyes from exposure to
electric arc without protection.
A.
NEVER look at
an
or shield containing a filter plate shade
12 or denser must be used when welding. Place
over face before striking arc.
Protection de Ia peau. Portez des vŒtements Øpais
foncØs. Boutonnez le col pour proteger Ia poitrine et le
cou, et boutonnez les poches pour prØvenir linfiltration
dØtincelles.
Welding helmet
no.
Protect filter
plate with
a
clear
cover
plate.
Cracked or broken helmet or shield should NOT be
worn; radiation can pass through to cause burns.
Cracked, broken,
IMMEDIATELY.
broken, pitted,
or
or
loose filter
Replace
spattered.
plates
clear
replaced
plate when
2.
Protection des yeux et de Ia tŒte
Evitez que vos yeux soient
JAMAIS tin arc electrique
exposØs a larc. NE regardez
sans protection.
vous soudez, portez tin Øcran ou masque avec
filtrant teintØ N 12 ou plus foncØ. Mettez-le sur le
visage avant damorcer larc.
Lorsque
verre
must be
cover
ProtØgez
le
verre
filtrant dun
couvre-verre
clair.
NE
PORTEZ PAS un masque fendu ou brisØ; le rayonne
ment petit sinfiltrer et causer des brQlures.
Les
verres
filtrants fendus, brisØs
ou
lØches doivent Œtre
remplacØs IMMEDIATEMENT. Remplacez tin couvre
verre brisØ, piquØ ou tachØ par des projections.
OM-1523 Page 7
Flash
goggles
the helmet to
with side shields MUST be
give
some
worn under
the eyes should
the face before an arc is
protection
to
the helmet not be lowered over
struck. Looking at an arc momentarily with
eyes
(particularly
a
unprotected
high intensity gas-shielded arc) can
retinal burn that may leave
in the field of vision.
cause a
area
3.
a
permanent dark
Vous devez portez des lunettes a Øcrans IatØraux sous le
masque pour protØger les yeux dansle cas oCi le masque
de
ne serait pas abaissØ sur le visage avant Iamorcage
larc. Regarder momentanØment un arc sans protection
(principalement un arc en atmosphere inerte a haute in
tensitØ) peut brCiler Ia rØtine et laisser un point sombre
permanent dans le champ de vision.
3.
Protection of Nearby Personnel
Enclosed
welding
For
area.
production welding,
Protection du
Local de
a
personnel
soudage fermØ. Pour
a
proximitØ
le
sudage
de
produc
enclosed bay is best. In open areas,
separate
the operation with low-reflective, nonsurround
combustible screens or panels. Allow for free air circula
tion, particularly at floor level.
baie
fermee. Dans les locaux ouverts, entourez les travaux
dØcrans ou panneaux peu rØflØchissants et ininflam
mables. Laissez lair circuler librement, particuliŁrement
au niveau du sol.
Viewing the weld. Provide face shields for all persons
who will be looking directly at the weld.
Donnez des masques aux personnes
directement Ia soudure.
room or
Others
flash
working in
goggles.
area.
See that all persons
Before starting to weld, make
bay doors are closed.
B.
sure
that
are
wearing
screen
flaps
tion, ii
sØparØe
ou une
qui regarderont
Autres personnes travaillant sur les Iieux. Veillez a ce
que toutes Ies personnes portent Ies lunettes de protec
tion.
or
Avant dattaquer
Ia soudure, assurez-vous
rebords dØcran ou les portes soient fermØs.
que
les
Toxic Fume Prevention
B.
Comply with precautions
Suivez les precautions du paragraphe 1.2B. LØchappe
ment du moteur de Ia gØnØratrice doit §tre ventilØ a Iair.
extØrieur. Loxyde de carbone peut tuer.
Fire and Explosion Prevention
Comply with precautions
Prevention des gaz toxiques
in 1-2B.
Generator engine exhaust must be vented to the outside
air. Carbon monoxide can kill.
C.
vaut mieux utiliser une salle
C.
Prevention des incendies et des explosions
in 1-2C.
rated capacity. Do
Equipments
welding equipment. It may overheat
overload
not
cables and
arc
cause a
Suivez les precautions 1.2C. Puissance nominale de
Iappareil. Ne surchargez pas le poste de soudage a
larc. Cela peut surchauffer les cØbles et causer un in
cendie.
fire.
Loose cable connections may overheat
fire.
or
flash and
Les branchements lches
faire des Øtincelles et
ou
de cable peuvent surchauffer
incendie.
causer un
cause a
Never strike
an
arc
on
vessel. It creates a brittle
rupture or lead to such
a
cylinder
area
a
that
or
other pressure
violent
can cause a
rupture later under rough
Namorcez
jamais un arc sur une bouteille ou autre rØci
pression. Cela crØerait un point de rupture
entraInant a plus ou moms longue ØchØance Iexplosion
pient
sous
du reservoir.
handling.
D.
Compressed Gas Equipment
Comply with precautions in 1-2D.
E.
Shock Prevention
Exposed hot conductors or other bare metal in the
welding circuit, or in ungrounded, electrically-HOT
equipment can fatally shock a person whose body
DO NOT STAND, SIT, LIE,
a conductor.
LEAN ON, OR TOUCH a wet surface when welding,
without suitable protection.
becomes
OM-1 523 Page 8
D.
Gaz comprime
Suivez les
E.
precautions
Prevention des
1.2D.
dØcharges Ølectrlques
Des conducteurs charges ou metal nu incorporØs au cir
cuit de soudage ou a un appareil chargØ sans mise a Ia
terre peuvent donner une decharge fatale a Ia personne
dont Ie corps devient conducteur. NE SOUDEZ PAS
DEBOUT, ASSIS, COUCHE, PENCHE sur une surface
humide ni en contact avec une telle surface sans protec
tion appropriØe.
against shock:
To protect
Keep body and clothing dry. Never work in damp area
adequate insulation against electrical shock.
Stay on a dry duckboard, or rubber mat when damp
without
be avoided. Sweat, sea water, or
and an electrically HOT
ness or sweat can not
moisture
between
body
reduces the body surface
or grounded metal
part
electrical resistance, enabling dangerous and possibly
lethal currents to flow through the body.
-
-
Pour vous proteger contre les decharges Ølectriques,
maintenez votre corps et vŒtements secs. Ne travaillez
jamais dans un endroit humide sans isolation dØquate
contre les decharges Ølectriques.
Lorsque vous ne
pouvez Øviter Ihumidit~ ou Ia sueur, placez-vous sur un
caillebotis sec ou un tapis en caoutchouc. La sueur,
leau de mer, ou lhumiditØ entre le corps et une piŁce
CHARGEE, ou une piŁce de metal a Ia masse, rØduisent
Ia rØsistance electrique de Ia surface du corps, permet
tant lentrØe de courants dangereux, voire mortels.
1.
1.
the
Grounding
welding equipment is grounded according to
the National Electrical Code, and the work is grounded
according to ANSI Z49.1 Safety In Welding And Cut
ting, a voltage may exist between the electrode and
any conducting object. Examples of conducting objects
include, but are not limited to, buildings, electrical
tools, work benches, welding power source cases,
workpieces, etc. Never touch the electrode and any
metal object unless the welding power source is
When
Mise a Ia terre de
arc
Lorsque lappareil de soudage a Iarc
suivant Ia
est
in
norme
National Electrical
mise a Ia terre suivant Ia
Welding
IØlectrode
and
installing, connect the frames of each unit such
welding power source, control, work table, and
water circulator to the building ground. Conductors
must be adequate to carry ground currents safely.
Equipment made electrically HOT by stray current may
shock, possibly fatally. Do NOT GROUND to electrical
conduit, or to a pipe carrying ANY gas or a flammable li
When
as
as
oil
or
fuel.
Three-phase connection. Check phase requirements of
equipment before installing. If only 3-phase power is
available, connect single-phase equipment to only two
wires of the 3-phase line. Do NOT connect the equip
ment ground lead to the third (live) wire, or the equip
a dangerous condi
ment will become electrically HOT
tion that can shock, possibly fatally.
-
Before
welding,
conductors
are
ground for continuity. Be sure
touching bare metal of equipment
check
frames at connections.
If
a
line cord with
a
ground
lead is
provided with
switchbox, connect
the
the
equipment for connection to a
ground lead to the grounded switchbox. If a threeprong plug is added for connection to a grounded
mating receptacle, the ground lead must be connected
to the ground prong only. If the line cord comes with a
three-prong plug, connect to a grounded mating recep
tacle. Never remove the ground prong from a plug, or
use a plug with a broken off ground prong.
2.
Electrode Holders
3.
use
holders with
protruding
screws.
mise a Ia terre
et Ia masse
ANSI Z49.1 ~Safety
tension peut exister entre
norme
Cutting, une
objet conducteur. Certaines
de
ces
ob
seulement), des
outils Ølectriques, des Øtablis, des
bªtiments,
chassis de postes de soudure, des piŁces douvrage,
jets
sont
etc. Ne
par
des
exemple
(mais
pas
jamais touchez IØlectrode
ou
des
objets
en
mis le poste de soudure a larrŁt.
metal avant davoir
A Iinstallation, branchez les chassis de chaque ØlØment
(source de courant, commande, Øtabli et circuit deau) a
Ia terre. Les conducteurs doivent pouvoir conduire es
courants telluriques en toute sØcuritØ. Lappareil chargØ
par les courants vagabonds peut donner une dØcharge
risquant dŒtre mortelle. t~JE BRANCHEZ PAS VOTRE
PRISE DE TERRE a une conduite Ølectrique, ou a
tuyau de gaz ou de liquide inflammable tel que lhuile
un combustible.
un
ou
Connexion triphasØe. Avant Iinstallation
vØrifiez Ia
phase nØcessaire a lappareil. Si seul le triphasØ est
disponible, ne branchez lappareil monophasØ qua deux
des fils de Ia ligne triphasØe. NE BRANCHEZ PAS le
conducteur de terre de lappareil au troisiŁme fil (sous
tension), autrement Iappareil serait chargØ: condition
dangereuse pouvant donner une dØcharge fatale.
Avant le soudage, vØrifiez si Ia prise de terre est
uniforme. En branchant, assurez-vos
que les con
ducteurs touchent le metal nu du chassis de lappareil.
Lorsquun
appareil doit
fret dalimentation,
a celui-ci.
Si
Œtre alimentØ a partir dun cof
le conducteur de terre doit Œtre reliØ
fiche a troisbroches pour Ia
terre qua Ia broche
de terre. Si le cordon dalimentation a une fiche a trois
broches, reliez-Ie a une prise femelle tripolaire reliØe a Ia
terre. Nenlevez jamais Ia broche de terre dune fiche ou
nutilisez jamais une fiche dont Ia broche de terre serait
brisØe.
vous
terre,
2.
Fully insulated electrode holders should be used. Do
NOT
est
Code,
et un
off.
quid such
lappareil
Equipment
ne
avez en
plus
une
branchez le conducteur de
Pince-Ølectrodes
Utilisez des pince-Ølectrodes bien isolØes. NUTILISEZ
PAS des pince-Ølectrodes avec vis saillantes.
Connectors
3.
Fully insulated lock-type connectors should
join welding cable lengths.
Connecteurs
be used to
Utilisez des connecteurs a verrouillage bien isolØs pour
assembler de longs cØbles.
OM-1523 Pege9
4.
Cables
4.
Frequently inspect cables for wear, cracks and damage.
IMMEDIATELY REPLACE those with excessively worn
or damaged insulation to avoid possibly
lethal shock
from bared cable. Cables with damaged areas may be
taped to give resistance equivalent to original cable.
-
Keep cable dry, free of oil ar(d grease, and protected
from hot metal and sparks.
5.
Terminals And Other Exposed Parts.
VØrifiez frØquemment lusure, les fissures et laltØration
des cables. REMPLACEZ IMM~DIATEMENT ceux dont
lisolation serait trop usØe ou altØrØe pour prØvenir les
dØcharges mortelles provoquees par un cØble dØnudØ.
Vous pouvez enrouler les parties endommagees de
ruban adhØsif en Øpaisseur suffisante pour donner une
rØsistance de cable neuf. Maintenez les cØbles secs,
dØpourvus dhuile et de graisse et mettez-les a labri du
metal chaud at des Øtincelles.
5.
Terminals and other exposed parts of electrical units
should have insulating covers secured before operation.
6.
Cables
Electrode
TŒtes de cØbles at autres parties dØnudØes
Avant Ia mise en marche, las tØtes de cables at autres
parties dØnudØes dun appareil Ølectrique doivent Œtre
munies de leurs couvrefils isolants.
Electrode
6.
a.
Equipment
with output on/off control (con
tactor)
a
Appareil
.
ØquipØ
dune
commande
mar
che/arrOt (contacteur)
Welding
metal
power
sources
for
use
with the gas
En gØnØral, les postes do soudure utilisØs
welding (GMAW), gas tungsten
arc welding (GTAW) and similar processes
normally are equipped with devices that per
mit on-off control of the welding power out
put. When so equipped the electrode wire
becomes electrically HOT when the power
source switch is ON and the welding gun
arc
pour le
gazeuse
a larc
sous protection
electrode fusible (GMAW), ou
avec electrode tungstene (GTAW) et des
procŁs semblables sont ØquipØs dune corn
mande marche/arrOt de Ia puissance de sor
tie. Lorsque linterrupteur est en position
MARCHE
et linterrupteur du pistolet est
fermØ, Ia fil dØlectrode devient chargØ. Na
touchez jamais le fil electrode ou tout autre
objet conducteur faisant contact avec le cir
cuit dØlectrode sans couper le courant au
poste de soudure.
switch is closed. Never touch the electrode
wire or any conducting object in contact
with the electrode circuit unless the welding
power source is off.
b.
Equipment
without output on/off control
b. Appareil non-ØquipØ dune commande
che/arrŒt (sans contacteur)
(no contactor)
Welding power
metal
sources
used with shielded
Las
7.
Safety
Devices
Before installation, inspection, or service, of equip
ment, shut OFF all power and remove line fuses (or lock
or red-tag switches) to prevent accidental
turning ON of
power. Disconnect all cables from welding power
source, and pull all 115 volts line-cord plugs.
Do not open power circuit or change polarity while
welding. If, in an emergency, it must be disconnected,
guard against shock burns, or flash from switch arcing.
postes
de
soudage a Iarc
7.
Safety devices such as interlocks and circuit breakers
should not be disconnected or shunted Out.
mar
soudure utilisØs pour Ia
enrobØe
avec electrode
(SMAW) et des procŁs semblabes peuvent
Œtre non-ØquipØs dune
commando rnar~
che/arrOt tie Ia puissance de sortie. Lorsque
linterrupteur est en position MARCHE
devient chargØ.
lØlectrode
Ne touchez
jamais IØlectrode sans couper le courant au
poste de soudure.
welding (SMAW)
and similar pro
cesses may not be equipped with welding
power output on-off control devices. With
such equipment the electrode is electrically
HOT when the power switch is turned ON.
Never touch the electrode unless the
welding power source is off.
arc
soudage
avec
Dispositif de sØcuritØ
La dispositif de sØcuritØ-verrouillage at coupe-circuit
doit pas Łtre dØbranchØ ou dØshuntØ.
ne
Avant linstallation, linspection ou Ia reparation do lap
pareil, mettez lalimentation sur ARRET et enlevez les
fusibles gØnØraux (ou verrouillez les interrupteurs) pour
Øviter une remise en MARCHE accidontelle. DØbran
chez tous los cØbles de Ia source do courant ainsi quo los
prises des cordons dalimentation en 115 volts.
Lors du
et ne
soudage, nouvrez pas le circuit dalimentation
changez pas Ia polaritØ. SiI est dØbranchØ au
Leaving equipment unattended. Always shut OFF and
disconnect all power to equipment.
cours
dune
Power disconnect switch must be available
Appareil laissØ sans surveillance. Mettez
ARR ET et dØbranchez lappareil.
welding
power
OM-1523 Page 10
source.
near
the
decharge
urgence, faites attention
ou aux
aux
brGlures do
jaillissements dØtincelles.
toujours
sur
F.
Protection For Wearers Of Electronic Life
Linterrupteur
Support Devices (Pacemakers)
imitØ de Ia
Magnetic fields from high currents can affect
pacemaker operation. Persons wearing electronic life
support equipment (pacemaker) should consult with
their doctor before going near arc welding, gouging, or
spot welding operations.
For more in.
1-4. STANDARDS BOOKLET INDEX
formation, refer to the following standards or their latest
-
revisions and comply
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
as
applicable:
ANSI Standard Z49.1, SAFETY IN WELDING
AND CUTTING obtainable from the American
Welding Society, 550 Le Jeune Ad, P.O. Box
351040, Miami, FL 33135.~
HEALTH IN ARC
WELDING AND GAS WELDING AND CUTTING
obtainable from the Superintendent of
Documents, U.S. Government Printing Office,
Washington, D.C. 20402.
NIOSH,
SAFETY
se trouver
a prox.
Protection pour toute personne portant des
appareils Ølectroniques de sauvetage (ap
pareil pour le reglement de battement de
coeur)
Inducteurs do courant OlevØ peuvent nuire le fonction
foment dun appareil pour le reglement do battement
de coeur. Toute personne portant un appareil Ølec
tronique de sauvetage (appareil pour le reglement do
battement do coeur), devrait consulter un docteur avant
dapprocher toute operation de soudage a Iarc, a Ia
gouge ou a point.
1-4.
INDEX
do
Pour plus
do IACNOR
amØricaines suivantes:
DES
NORMES
renseignements, rØfØrez-vous
ou aux normes
-
aux normes
AND
OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the U.S. Govern
ment Printing Office, Washington, D.C. 20402.
ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018.
ANSI Standard Z41 .1, STANDARD FOR MENS
SAFETY -TOE FOOTWEAR obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018
ANSI Standard Z49.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PRO
CESSES obtainable from the American National
Standards Institute, 1430 Broadway, New York,
NY 10018.
AWS Standard A6.O, WELDING AND CUT
TING CONTAINERS WHICH HAVE HELD COM
BUSTIBLES obtainable from the American
Welding Society, 550 Le Jeune Rd., P.O. Box
351040, FL 33135.
FUEL GAS
Standard 51, OXYGEN
SYSTEMS FOR WELDING AND CUTTING ob
tainable from the National Fire Protection
Association, 470 Atlantic Avenue, Boston, MA
02210.
NFPA
F.
darrŒt doit toujours
de courant.
source
1.
ANSI Standard Z49.1, SAFETY IN WELDING
AND CUTTING distribuØ par IAmerican Welding
Society, 550 Le Jeune Rd., P.O. Box 351040
Miami, FL 33135
2.
NIOSH, SAFETY AND HEALTH IN ARC
WELDING AND GAS WELDING AND CUTTING
distribuØ par le Superintendent of Documents,
U.S. Government Printing Office, Washington
D.C. 20402
3.
OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, distribuØ par U.S. Department of
Labor, Washington D.C. 20210
4.
ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION distribuØ par IAmerican
National Standards Institute, 1430 Broadway,
New York, NY 10018
5.
ANSI Standard Z41.1, STANDARD FOR MENS
TOE FOOTWEAR distribuØ par Iad
SAFETY
dresse donnee en 4.
-
6.
ANSI Standard Z49.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PRO
CESSES distribuØ par Iaddresse donnee en 4.
7.
AWS Standard A6.O, WELDING AND CUT
TING CONTAINERS WHICH HAVE COM
BUSTIBLES distribuØ par Iaddresse donnee en
8.
FUEL GAS
NFPA Standard 51, OXYGEN
SYSTEMS FOR WELDING AND CUTTING
distribuØ par Ia National Fire Protection Associa
tion, 470 Atlantic Avenue, Boston, MA 02210
9.
NFPA Standard 70-1978, NATIONAL ELEC
TRICAL CODE distribuØ par Iaddresse donnØe
en 8
10.
NFPA Standard 51B, CUTTING AND WELDING
PROCESSES distribuØ par Iaddresse donnØe en
-
NFPA Standard 70.1978, NATIONAL ELEC
TRICAL CODE obtainable from the National Fire
Protection Association, 470 Atlantic Avenue,
Boston, MA 02210.
NFPA Standard 51 B, CUTTING AND WELDING
PROCESSES obtainable from the National Fire
Protection Association, 470 Atlantic Avenue,
Boston, MA 02210.
-
8
OM-1523 Page 11
11.
CGA Pamphlet P-i, SAFE HANDLING OF COM
PRESSED GASES IN CYLINDERS obtainable
from the Compressed Gas Association, 500 Fifth
Avenue, New York, NY 10036.
12.
13.
11.
CGA Pamphlet P-i, SAFE HANDLING OF COM
PRESSED GASES IN CYLINDERS distribuØ par
Ia Compressed Gas Association, 500 Fifth
Avenue, New York, NY 10036.
CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING obtainable from the
Canadian Standards Association, Standards
Sales, 178 Rexdale Boulevard, Rexdale, Ontario,
Canada M9W 1 R3.
12.
CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING distribuØ par Ia Cana
dian Standards Association, Standards Sales,
178
Rexdale
Boulevard, Rexdale, Ontario,
Canada M9W 1R3.
NWSA
13.
NWSA
WELDING
booklet,
SAFETY
BIBLIOGRAPHY distribuØ par Ia National
Welding Supply Association, 1900 Arch Street
Philadelphia, PA 19103.
14.
American Welding Societe Standard AWSF4.1
Recommended Safe Practices for the Prepara
tion for Welding and Cutting of Containers and
Piping That Have Held Hazardous Substances,
distribuØ par IAmerican Welding Societe, 550 Le
Jeune Rd., P.O. Box 351040, Miami, FL 33135
15.
ANSI Standard Z88.2 Practice For Respiratory
Protection
distribuØ par lAmerican
National
Standards Institute, 1430 Broadway, New York,
NY 10018.
WELDING
booklet,
SAFETY
BIBLIOGRAPHY obtainable from the National
Welding Supply Association,
Philadelphia, PA 19103.
14.
American
1900 Arch Street,
Welding Society Standard AWSF4.1
Recommended
Safe Practices for the Prepara
tion for Welding and Cutting of Containers
and
Piping That Have Held Hazardous Substances,
obtainable from the American Welding
Society,
550 Le Jeune Rd., P.O. Box 351040,
Miami, FL
33135.
15.
ANSI Standard Z88.2 Practice for Respiratory
Protection obtainable from the American Na
tional Standards
York, NY 10018.
OM-1523
Page
12
Institute, 1430 Broadway, New
SECTION 2
INTRODUCTION
-
Model
Horizontal To 60
Maximum Height (W/4 Ft. Post)
At Full Lift Of Boom
17 ft. (5.2 m)
(Patented)
50,
.
Weight
Figure
21 ft. (6.4 m)
2
or
60.
Net
210 lbs.
330 lbs.
Net
275 lbs.
(95 kg)
(150 kg)
(125 kg)
-
1.
1. GENERAL INFORMATION AND SAFETY
Ship
Ship
415 lbs.
(188 kg)
Specifications
A third signal word, IMPORTANT highlights instruc
______________,
tions which need special emphasis to obtain the most
efficient operation of this equipment.
General
Information presented in this manual and
labels, tags, and plates
on
the unit
on
pertains
to
various
equip
ment design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
followed for safe and effective use of this equipment.
B.
Above
Compression Spring Is Designed To Balance
Boom At Any Angle. Pressure Adjustment Is
Provided To Hold The Boom At Any Desired
Angle Or To Limit The Vertical Lift At 40,
Counterbalance
A.
16 ft. (4.9 m)
3600
Vertical Lift
-
I
12 ft. (3.7 m)
Length
Swing
2
Dual 16
50-780 l.P.M. (1 .27-19.8 m)
Speed Range
Boom
I
Dual 12
2
2. RECEIVING
HANDLING
Prior to installing
this equipment, clean all packing material from around
the unit and carefully inspect for any damage that may
have occurred during shipment. Any claims for loss or
damage that may have occurred in transit must be filed
-
-
-
by the purchaser with the carrier. A copy of the bill
lading will be furnished by the manufacturer on re
of
Safety
quest if occasion to file claim arises.
operation, maintenance, and
troubleshooting of arc welding equipment requires
practices and procedures which ensure personal safety
and the safety of others. Therefore, this equipment is to
be installed, operated, and maintained only by qualified
The
installation,
persons in accordance with this manual and all ap
codes such as, but not limited to, those listed at
the end of Section 1
Safety Rules For Operation Of
plicable
-
Arc
Welding
Power Source.
Safety instructions specifically pertaining to this unit ap
pear throughout this manual highlighted by the signal
words WARNING and CAUTION which identify
When
requesting information concerning this equip
ment, it is essential that Model Description and/or
Stock Number and Serial (or Style) Numbers of the
equipment be supplied.
2
-
3.
digital
DESCRIPTION
-
This unit is
a
boom mounted
wire feeder. The wire feeder is of the constant
wire feed speed type which feeds wire alternately from
two welding guns. It is designed to be used in conjunc
tion with 1 or 2 constant potential welding power
sources.
___________
different levels of hazard.
a patented design allowing both vertical lift
swing. Cables are routed through the boom from
the feeder control to the wire drive assembly.
The boom is
WARNING
statements include
installation, operating,
procedures or practices which if not
carefully followed could result in serious personal injury
and maintenance
or
loss of life.
CAUTION statements include installation, operating,
and maintenance procedures or practices which if not
carefully followed could result in minor personal injury
____________
or
damage
to this
and
The wire feeder is a heavy duty wire feeding unit which
maintains constant wire feed speed regardless of line or
load variations. It contains all the controls and equip
ment needed to supply welding wire and shielding gas
to the
welding
guns.
equipment.
OM-1 523
Page 13
SECTION 3
3
-
1. LOCATION AND ASSEMBLY
A.
INSTALLATION
-
WARNING FALLING BOOM can cause serious
personal injury and equipment damage.
(Figure 3-1)
Location
Securely
mount unit to a structure that can sup
port the weight of the unit when the boom is in
A suitable location for this unit will allow room for the
boom to swing horizontally in the desired arc, and to
the horizontal
pivot upward to the desired angle. Proper placement
will also provide sufficient cleance from obstruction at
the wire support end of the unit when the boom swings.
The structure to which the unit is being installed should
be of sufficient construction to support the weight of
the unit when the boom is in the horizontal position.
B.
1.
Assembly
2.
Post
a
.
Support (Optional)
Uncrate and
WARNING FALLING BOOM
can
cause
serious
remove
all
packing material
from the unit.
b
.
Mount post support to the desired structure.
WARNING
Existing Support (Customer Supplied)
position.
FALLING BOOM
can
cause
serious
Securely mount unit to a structure that can sup
port the weight of the unit when the boom is in
the horizontal position.
___________
Use 2-1/2 in. (63.5 mm) diameter, Schedule 40
pipe (wall thickness of 0.203 in. or 5.2 mm) as
support pipe for 12 foot (3.7 m) booms.
Use 5 in. (127 mm) diameter, Schedule 40 pipe
(wall thickness of 0.258 in. or 6.6 mm)
pipe for 16 foot (4.9 m) booms.
a
.
Uncrate and
from the unit.
remove
all
as
support
c
.
Remove
from the
WARNING
yoke pin, nut, washers
yoke and swivel plates.
OF
RELEASE
SPRING
and bolt
PRESSURE
WITHOUT BOOM A11ACHED can cause serious
Perform installation exactly as outlined in step-b y
packing
material
step instructions be/ow.
Do not remove safety collar until instructed to do
so.
b.
Mount post support to the desired structure.
S
Retain safety collar for future
disassembly
use.
Yoke Pin
Hole In Yoke
Yoke
Cotter Pin
Screw
Lock Washer
Wire
Support
Plates
Support
18-081 753
Figure 3
OM-1623 Page 14
-
1. Base And Boom Assembly
d
.
a.
Place bearing on top of post and insert
swivel into post.
Place the boom base plate in between the
two swivel
plates.
Slide washer onto bolt and insert through
hole. Slide washer onto bolt and install nut
onto bolt. Tighten nut; then back off nut 1/2
f.
a
h
.
pin through yoke, hole, and install
pin through pin.
Insert
ter
the
Connect
assembly
as
welding
guns
instructed in
Manual for the desired
to
b
welding
cot
drive
Owners
guns.
Grasp bar and pull boom down slightly. The
boom should be pulled down only far
enough to remove the pressure which is ap
plied to the safety collar.
i.
Remove the safety
future adjustments.
j.
collar and
retain for
Swingpak
remote
all
packing
material
base.
can
serious
cause
Mount welding power source on Swingpak base
before mounting Swingarc.
.
c
.
Uncrate and remote all
from the Swingarc Unit.
packing material
Complete Steps c-k in Subsection 2. Post
Support.
CAUTION
the
the
and
WARNING: FALLING BOOM
turn.
g.
Uncrate
from the
.
EXCESSIVE FRICTION
can
damage
equipment.
Periodically lubricate swivel to prevent wear.
Excessive lubrication is not required or recommended.
3
2.
-
with
DRIVE MOTOR
-
The drive motor is
provided
which must be removed prior to the
operation of the wire feeder. The vent screw can be
removed through the hole provided in the motor shroud
(see Figure 3-6).
a vent screw
CAUTION PRESSURE IN WIRE DRIVE MOTOR
GEAR BOX will damage motor.
_________
k.
The boom should now balance in any posi
tion from horizontal to 60 degrees above
horizontal. If the boom does not balance
properly, proceed to Section 3-12.
CAUTION
EXCESSIVE FRICTION
can
damage
equipment.
Periodically lubricate swivel to prevent wear.
Remove vent
Warranty is void if
to operation.
3
-
screw
prior
the vent
to
operation.
screw
is not removed
3. INSTALLATION OF WIRE SUPPORT.
prior
(Figure
3-li
1.
Remove the securing
screws
and lock washers
from the swivel base.
3.
Base
Support (Optional)
chased with the
to
the floor.
FALLING BOOM
can
cause
For mounting base support use, as a minimum,
1/2 in. (12.7mm) diameter, S.A. E. grade 5 bolts.
equivalent strength, non-corrosive bolts if
unit is mounted in an extremely damp environUse
b.
C.
Insert securing
tighten.
Uncrate and
from the unit.
remove
all
packing
part
Complete Steps c-k in Subsection 2. Post
equipment.
Periodically
Base
follows:
b.
Fiber Washer
Brake Washer
c.
Hub
d
Brake Washer
Fiber Washer
.
.
e.
g
h
damage
lubricate swivel to prevent wear.
Swingpak
as
Slide the following items onto the spindle sup
port shaft in order given:
f.
can
-
material
Support.
4.
or
assembly(s)
a
FRICTION
with lock washers and
OF HUB ASSEMBLY
If it should become necessary to replace
all of the hub assembly(s), reinstall the new hub
(Figure 3-2)
Fasten base support to the floor.
CAUTION: EXCESSIVE
screws
the holes in the
3 -4. REINSTALLATION
1.
ment.
.
3.
over
serious
___________
a
Lift the wire support in place
swivel base.
an
fastening the base support
WARNING
2.
optional base support was pur
unit, mounting holes are provided for
IMPORTANT If
2.
Keyed Washer
.
.
Spring
Flat Washer
Rotate hex nut onto support shaft. Hex nut
should be rotated only until a slight drag is felt
while turning hub.
(Optional)
OM-1 523
Page 15
3 -6. INSTALLATION
OF
SPOOL-TYPE
WIRE
(Figure 3-2)
ring.
1.
Remove the retaining
2.
Slide the spool of wire onto the hub so that the
wire will feed off the top of the spool. The spool
turns in a clockwise direction.
3.
Rotate the spool until the hole in the spool aligns
with the pin in the hub. Slide the spool onto the
hub until it seats against the back flange of the
Washer
hub.
Replace the retaining ring.
4.
3
-
REEL-TYPE
OF
INSTALLATION
7.
WIRE
(Figure 3-3)
Lay the wire
1.
Retaining
or
reel (see
Figure 3-3) flat
18-081 754
Figure 3
2. Wire
Loosen the four wing nuts
wire reel.
3.
Pull the four fingers out until they
toward the center of the reel.
INSTALLATION
OF
WIRE
REEL
The following procedures for
the installation of the wire reels are applicable to the left
and/or right sides.
(Optlonal)(Flgure 3-3)
on
the wire onto the
reel
can
be rotated
the four
bot
in a
turns
over
fingers. Ensure that the wire feeds off the
5.
-
Install
4.
table
fingers of the
the
2.
Support And Hub Assembly
Depress the two spring loaded stops on the re
taining ring and slide the retaining ring into pro
per position on the hub. Release the two stops.
3.
3
-
on a
floor.
of the
reel. The
counterclockwise direction.
tom
-
5.
reel
Rotate the four fingers back to their proper posi
tion. Tighten the four wing nuts.
1.
Remove the
2.
Slide the wire reel onto the hub. Rotate the wire
reel until the hub guide pin Is seated in the reel.
3 -8. DRIVE ROLL AND WIRE GUIDE INSTALLA
TION (FIgures 3-4 & 3-5)
Upon intitlal installation, or
as a result of changes in wire size and type, it is
necessary to install the required drive rolls and wire
3.
Replace the retaining ring.
guides.
retaining ring.
-
IMPORTANT: Base selection of drive rolls upon the
following
Wire Reel
recommended usages:
V-Groove rolls for hard wire.
2. U-Groove rolls for soft and soft shelled cored wires.
3. U-Cog rolls for extremely soft shelled wires (usually
hard surfacing types).
4. Split V-Knurled rolls for hard shelled cored wires
(se/f-shielding and C02 shielded types).
5. Drive roll types may be mixed to suit particular re
quirements (example: V-knurled roll in combination
with U-groove).
1.
I Nuts
Hub Guide
Pin
Hub
Having selected the appropriate drive rolls and wire
guides proceed to the following Installation instructions.
A.
DrIve Roll InstallatIon
(FIgures 3-4 b 3-5)
1.
Loosen pressure adjustment knob
and pivot it free of cover.
2.
Pivot gear
3.
Loosen and
each gear.
cover
(Figure 3-4)
away to expose pressure gear.
18-081 758
Figure 3
OM-1 623
Page 16
-
3. Reel Installation
remove
the three
securing
screws on
Anti-Wear Guide
Liner
Inlet Wire Guide
Gun/Feeder Connector
Securing
Split Drive
Knob
Rolls
Gear
Securing
Bolt
One
Drive Roll
Figure 3
4.
-
4.
TB.081 810.8
Drive Rolls Installation
For one piece drive rolls: Slide a drive roll onto
the drive gear and pressure gear with holes align
ed and secure with screws.
For
split drive rolls: Align holes on each side of
split drive rolls, insert a securing screw and slide
drive roll onto the drive gear and pressure gear
with screw in line with one of the threaded holes.
a
Insert
remaining
screws
and
tighten.
IMPORTANT One-Piece drive rolls are of the double
usage type. When the grooves become worn, reverse
each drive roll, locating the unused groove in position to
feed the wire.
Split drive rolls are of the double usage type. When the
knurled groove of the drive rolls becomes worn, the split
halves may be reversed so that the unused edges will
now provide a new knurled groove.
IMPORTANT
To ensure proper gripping action of
U-Cog drive rolls, both rolls should be installed showing
slots on the side or both should show the side without
slots. Also, it is necessaty to line up the blunted teeth
TAO81 756.A
Figure 3
-
5.
U-Cog
Drive Rolls Installation
______________
on
the pressure gear roll directly over the spaces bet
the teeth on the drive gear roll (see Figure 3-5).
I W~I Zs1:~ fi~1 ~ Wire
guides should be installed so
guide is as close to the drive roll as
possible without touching.
that the
tip
of the
ween
c
B.
inlet Wire Guide
1.
For .030-5/64 in. (.8-2.0 mm) wire.
a
.
.
(Figure 3-4)
Insert liner into inlet wire
guide
2.
and
secure
Loosen the inlet wire guide
assembly.
For 3/32-1/8 in. (2.4-3.2 mm) wire.
a
.
Remove anti-wear guide(s) from inlet wire
guide.
with setscrew.
b.
Insert guide assembly into drive
Secure by tightening screw.
securing
screw.
b.
Loosen the inlet wire
guide securing
screw.
OM.1523
Page
17
IMPORTANT
Wire guides should be installed
tiP of the guide is as close to the drive roll
so
Lockout/tagging procedures
consist of
line
padlocking
_____________
that the
Insert the inlet wire guide into drive
assembly as illustrated in Figure 3-4. Secure
by tightening screw.
c.
d
as
Install
.
guide
anti-wear guide(s) onto
and secure with setscrew.
disconnect switch in open position, removing fuses
from fuse box, or shutting off and red-tagging circuit
breaker or other disconnecting device.
Work
IMPORTANT Drive roll alignment has been factor,
set, but if readjustment is necessary rotate the drive
gear securing bolt thereby moving the drive roll in or out
of the desired position. The drive roll on the pressure
gear will locate itseff on the wire when the gear cover is
replaced and the gears mesh together.
CAUTION OVERHEATING
damage
can
performed by qualified
2.
Remove control box wrapper.
3.
Locate terminal
4.
per
strip 1 T inside control box.
Right Side Only: To supply water on the right
Right Gun trigger is depressed,
side when the
lead No. 6 from terminal A
to terminal C.
move
on
terminal
strip iT
Left Side Only: To supply water on the left side
when the Left Gun Trigger is depressed, move
lead No. 6 from terminal A on terminal strip 11 to
(Optional) CONNEC
terminal E.
of
Gas
Either side: To supply water on either side when
the appropriate gun trigger is depressed, move
Metal-Arc
_________
Welding gun
S
If using
internal parts to be
inlet wire
______________
3 -9. WATER CONTROL KIT
TIONS
on
sons.
gun.
lead No. 6 from terminal A
terminal K.
a water cooled gun and recirculating
coolant system, do not make connections from
the coolant pump to water valve; instead, make
5.
connections directly from the coolant system to
on
terminal strip 1 Ito
Replace wrapper.
gun hoses.
3
A.
-
10. WELDING GUN CONNECTIONS
Installation Of Water Hoses
Water coolant is
supplied
either one gun or both guns
utilizing one water solenoid and the same input, output,
and return hoses. The solenoid is energized when the
POWER switch is placed in the ON position.
Connect
to
hose from the water supply to the Water in
the rear of the control. This fitting has a
put fitting
left-hand thread. The water supply hose routed through
the boom connects to the Water fitting at the front of
the control.
a
A.
Outlet Wire Guides
The outlet guide is
IMPORTANT:
each gun
1.
(Figure 3-4)
provided as part of
assembly.
Loosen
the
gun/feeder
connector
securing
knob(s).
at
IMPORTANT
Wire
guides should be installed
so
_____________
that the
tip of the guide is
as
close to the drive roll
as
When water is
adapter to the
required for
appropriate
one gun only, connect the
weld terminal on the drive
assembly and connect the water return hose to this
adapter. If water is required for both guns, connect the
2.
return hose Y
assembly to an adapter at each weld
terminal. The water return hose is routed through the
boom. Connect this hose to an appropriate disposal.
3.
B.
the
appropriate
1.
Shut
gun
unit
down
and
disconnect
from
line
voltage.
_________ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Disconnect input power to the wire feeder
or
employ lockout/tagging procedures on the
welding power source before internally inspecting
servicing.
OM-1 623 Page 18
from
the
gun/feeder
connector
securing
B.
Weld Cables
(Figure 3-6)
provided in the drive assembly for con
corresponding
gun weld cables (see Figure 3-6). Connect the Left Gun
weld cable (if so equipped) to the boom weld cable on
the left side of the drive assembly and the RIght Gun
Two holes
are
boom weld cables and the
weld cable (if so equipped) to the boom weld cable
the right side of the drive assembly.
WARNING
or
the
Tighten
necting the
trigger is depressed.
gun/feeder connector(s)
knob(s).
Electrical Reconnection Of Water Solenoid
The control is shipped connected to supply water when
the POWER switch is in the ON position. The water
solenoid circuitry can be modified to supply water when
Insert the
gun(s) which includes the installed outlet
guide(s), into the drive assembly opposite the
respective inlet wire guide(s) as illustrated in
Figure 3-4.
C.
The
on
Shielding Gas
shielding
nected to the
gas hose from each gun is to be
appropriate
con
has hose which extends out
H
of the motor end of the boom. Connect the gas hose
from the Left Gun to the hose labeled LEFT GAS and
the gas hose from the Right Gun to the other gas hose.
Reducing bushings are provided to accept 5/8-18 L.H.
fittings. If the reducing bushings are removed, 7/8-14
L.H.
fittings
be accomodated.
can
3-11. SHIELDING
GAS
CONNECTIONS-A
divided-hose assembly is supplied with the unit for mak
ing connections to the Shielding Gas input fittings at
the rear of the control from one shielding gas source.
These fittings have a right-hand thread.
IMPORTANT If
a
different
shielding
gas is
required
______________
for each
welding gun,
a
separate hose
nected from each
shielding gas source
propriate input fitting at the control.
Vent Screw
Access Hole
be
can
con
the ap
to
The gas hoses, routed through the boom, connect to
the appropriate Shielding Gas output fittings at the
front on the control.
3-12. BOOM ADJUSTMENTS
A.
(Figure 3-7)
Weight Lift Adjustment
TA-081 811
ITiI~a~lk~(e~
Figure 3
-
6. Gun Weld Cable Connections
FALLING BOOM
can
serious
cause
Maintain full threads on adjustment rod through
the yoke.
IMPORTANT
Integral gas input fittings are provided
assembly for guns utilizing this type of con
nection (see Figure 3-6). If the gas hoses which extend
out of the motor end of the boom are provided with fit
tings, cut the fittings off and push the hoses onto the
appropriate barbed fittings on the drive assembly. See
the appropriate welding gun Owners Manual for in
structions on making this connection.
______________
on
tile drive
D.
Gun
Yoke
Jam Nut
Trigger
Two four-contact
receptacles
extend out of the motor
end of the boom for connecting the gun trigger plugs to
the control. Connect the Left Gun to the gun trigger
receptacle labeled LEFT TRIGGER, and the Right Gun
TA-081 757
the other gun trigger receptacle by inserting the plugs
fully into the receptacles and rotating collars clockwise.
to
ELECTRIC SHOCK can kill.
Do not touch either electrode wire when either
gun trigger is closed.
WARNING
_________
wire and all metal parts in contact with it carry
weld current when the welding power source contactor
is energized. When one welding power source is utiliz
Welding
ed, both electrode wire will be electrically energized
when either gun trigger is depressed.
E.
Water (If
Applicable)
If water coolant is required for one gun only, connect
the gun water input hose to the water output hose at
the motor end of the boom. (If water is required for both
guns, the water output hose from the control divides at
the motor end of the boom to accept connections from
both gun water input hoses). Connect the water return
hose from the gun to the adapter at the appropriate
weld terminal
on
the drive
assembly.
Figure 3
-
7.
Boom Adjustments
The amount of weight which the boom can retract into
the upright position when released can be varied by ad
justing the jam nut and adjustment rod located at the
base of the boom. If heavier guns are installed on the
end of the boom thereby making it necessary to in
crease the amount of weight that the boom can lift,
loosen the jam nut and rotate the adjustment rod so that
adjustment rod threads into the yoke. When the proper
adjustment is obtained, tighten the jam nut against the
base of the yoke. If lighter guns are used with the Sw
ingarc, rotate the adjustment rod so that the adjustment
rod threads out of the yoke.
B.
Locking
Knob
By rotating the Locking knob, located on the side of the
swivel plate, in a clockwise direction, the boom may be
held in any desired position. Rotating the Locking Knob
in a counterclockwise direction will permit the boom to
free travel. Changing the position of the Locking Knob
OM-1523 Page 19
to the other threaded holes
provided along the side of
the swivel plate, limits the lift of the boom to 50 degrees
or 40 degrees respectively during free travel.
3-13. MOTOR CONTROL CONNECTION (Figure
A receptacle is provided for connecting the
motor control plug to the control. Align keyways and in
sert the plug from the control end of the boom into the
3-8)
-
receptacle and
3-14. GUN
rotate collar clockwise.
CONNECTIONS
TRIGGER
(FIgure
receptacles, labeled TRIGGER, are pro~iided
on the front panel of the control for making gun trigger
control connections. The gun trigger control cables ex
4-1)
-
Align keyways and insert the 115 volts/contactor con
trol plug into the Left 115 Volts/Contactor Control
receptacle and rotate collar clockwise. Insert the 115
volts power plug into the 115 volts ac receptacle on the
welding power source and rotate clockwise. Insert con
tactor control plug into the welding power source con
tactor control receptacle and rotate clockwise. Store
the remaining contactor control cable.
WARNING
kill.
and all metal parts in contact with it carry
Welding wire
trigger control receptacle on the Left control and
the other gun trigger control plug into the receptacle on
the Right control and rotate collars clockwise.
is
gun
Two weld
CABLE CONNECTION
cables extend out of the control end of the boom for
making secondary connections to the welding power
sources. The end of each weld cable is equipped with a
terminal for a 1/2 in. (12.7 mm) stud. Connect weld
cables to the desired POSITIVE output terminal on the
can
Do not touch either electrode wire when either
gun switch is closed.
tend out of the control end of the boom. Insert the gun
trigger control plug, labeled LEFT TRIGGER, into the
3-15. WELD
ELECTRIC SHOCK
_________
Two
energized. When
one
welding
power
source
is utiliz
ed, both electrode wires will be electrically energized
when either gun trigger is depressed.
B.
Using Two Welding Power Sources
applicable welding
-
power
source.
Through minor modification, the contactor control cir
cuitry of the wire feeder can be adapted to operate two
welding power sources, that is, the left gun trigger
governing contactor control to one welding power
source and the right gun trigger governing contactor
control to the other. Two contactor control cables are
with the unit for making connections to the
contactor control circuitries in the welding power
supplied
Left 115 Volts/
Contactor Control
DVC Switching
Relay Receptacle
sources.
~ ELECTRIC SHOCK can kill.
or
employ lockout/tagging procedures on the
we/ding power source before internally inspecting
or servicing.
Lockout/tagging procedures consist of padlocking line
from fuse box, or shutting off and red-tagging circuit
Work on internal parts to be performed by qualified per
sons.
Gas
Input
Fitting
Right Contactor
Receptacle
Control
1.
Remove the wrapper from the control box.
2.
Locate terminal
3.
Disconnect lead No. 39 from terminal K on ter
minal strip iT and reconnect it to terminal E.
4.
Replace
5.
Align keyways and insert the contactor control
plug into the Right Contactor Control receptacle
strip iT inside control
box.
TA-046 105
Figure 3-8. Rear Panel ConnectIons
I kd~Z
welding power source is used,
cables from the wire feeder to the
. V ~ If one
connect the weld
we/ding
power source
terminal
as
High
or
Low POSITIVE output
desired.
wrapper.
and rotate the threaded collar clockwise. Insert
contactor plug into the right welding power
source contactor control receptacle and rotate
3-16. 115 VOLTS/CONTACTOR CONTROL CON
NECTIONS (Figure 3-8)
clockwise.
A.
Using One Welding Power Source
6.
The contactor control circuitry in this wire feeder is con
nected to operate both guns from one welding power
Align keyways and insert the 115 volts/contac
tor control plug into the Left 115 Volts/Contac
tor
Control receptacle and rotate collar
c!ockwise. Insert the 115 volts power
source.
plug
into
OM-1523 Page 20
I
~
~
-~----
--.~---..~
the 115 volts ac receptacle on the welding power
source and rotate clockwise. Insert contactor
control plug into the welding power source con
tactor control receptacle and rotate clockwise.
wires (0.030-5/64 in. or 0.8-2.0 mm), have pulley shaft
in upper holes. For larger diameter wires (3/32-1/8 in.
or 2.4 to 3.2 mm), have pulley shaft in lower holes. If a
pulley adjustment is necessary because of
change, proceed as follows:
3-17. ADJUSTMENT OF HUB TENSION (Figure
Check the hub tension by slowly pulling the wire
3-2)
toward the feed roll. The wire should unwind freely, but
the hub tension should be sufficient to keep the wire
3-18. PULLEY ADJUSTMENT (Figure 3-1)
WARNING
.
ELECTRIC SHOCK
can
kill.
Do not touch five electrical parts.
Shut down the welding power source and wire
feeder and be sure that they cannot be accidental
ly energized
before
adjusting pulley(s).
The boom pulleys can be adjusted up or down to pro
vide the minimum bend in the wire. For small diameter
SECTION 4
-
wire size.
Retract wire and
2.
Loosen nuts
3.
Move shaft to desired hole: Upper hole for fine
diameter wires, lower hole for larger diameter
wires.
4.
Tighten
5.
Thread
taut
dingly.
wire size
1.
-
and prevent backlash when the wire feeding
ceases. If adjustment is required, loosen or tighten the
hex nut on the end of the spindle support shaft accor
change
a
to new
securing pulley shaft
nuts to secure
welding
wire
to boom.
pulley shaft.
according
to Section 5-1.
3-19. REMOTE CONTROL CONNECTIONS (Figure
Left and Right Remote Control receptacles are
4-1)
provided for connecting remote or optional equipment
to the wire feeder. Align keyways and insert the plug
from the remote or optional equipment into the ap
propriate remote control receptacle and rotate collar
-
clockwise.
OPERATOR CONTROLS
Right Jog Switch
Right
Wire
Speed Control
Right Pilot Light
Circuit Breaker
Power Switch
Right Remote
Control Switch
Right
Control
Gas
Remote
Receptacle
Fitting
TA-046 104
Figure 4
-
1. Control
Components
OM-1 523
Page 21
4
1. POWER SWITCH (FIgure 4-1)
Placing the
POWER switch on the control in the ON position will
-
-
apply 115 volts ac to the unit and thereby place It in an
operational condition, ready to feed wire and permit
shielding gas to flow from either gun. Placing the
POWER switch in the OFF position will shut the
the Left wire at the Left WIRE SPEED control setting
and the Right JOG switch permits jogging of the right
wire at the Right WIRE SPEED control setting without
energizing the welding circuits or the corresponding
shielding
4
wire/feeder down.
-
2. WIRE SPEED CONTROLS
(Figure 4-1) The
provide the means of
which welding wire is fed into
-
ten turn WIRE SPEED controls
determining the rate at
the weld. Rotating the Left WIRE SPEED controlin a
clockwise direction will increase the rate at which wire is
fed from the Left Gun. Rotating the Right WIRE SPEED
control In a clockwise direction will increase the rate at
which wire is fed from the Right Gun.
4 -3. REMOTE CONTROL RECEPTACLES AND
SWITCHES (Figure 4-1)
The Remote Control recep
tacle and switches are provided for use in conjunction
with certain optional controls. When an optional control
is connected across a Remote Control receptacle, the
corresponding switch must be in the REMOTE position.
If no optional controls are utilized, the Remote Control
switches must be in the STANDARD position.
-
6. INCHES
PER
MINUTE
METER
(Figure
This meter displays the wire speed in inches per
minute. When the control is turned on, the meter
displays the wire speed set by the Right WIRE SPEED
control. If it is necessary to set the Left WIRE SPEED,
actuate the Left JOG switch momentarily. The meter
will then display the setting of the Left WIRE SPEED
-
4-1)
4
gas valves.
-
control.
speed
During welding the meter displays actual wire
by the WIRE SPEED control for the gun in
as set
use.
4
7.
RESET
CIRCUIT
BREAKER
(Figure
The circuit breaker provides protection to the
feeder motor. In the event the motor should be placed
in an overload condition, the breaker would trip and
suspend all output. Should this breaker trip, the RESET
button would have to be manually depressed in order to
reset the circuit breaker.
-
4-1)
-
4
7. BURNBACK CONTROLS (Optional)
The
burnback circuitries in this control provide a means of
keeping the welding wires from sticking to the
workpiece after the corresponding gun switches are
released. The Left BURN BACK control keeps weld cur
rent present on the left welding wire and the Right
BURNBACK control keeps weld current present on the
right welding wire from 0 to 15 cycles after the cor
responding wire has stopped feeding. This delay action
permits the welding wires to burn back to a point where
they neither stick to the workpiece nor the contact
tubes. If welding wire sticks to the contact tube, rotate
the
BURN BACK
control
corresponding
counterclockwise.
If welding wire sticks to the
workpiece, rotate the corresponding BURNBACK con
trol clockwise.
-
4
4. PURGE BUTTONS (Figure 4-1)
The PURGE
buttons are momentary contact switches. The Left
PURGE button will energize the Left Gas Solenoid and
purge the shielding gas line of the Left Gun. The Right
PURGE button will energize the Right Gas Solenoid and
purge the shielding gas line of the Right Gun. The
PURGE buttons also allow the shielding gas regulator(s)
to be adjusted without energizing the welding circuit.
-
-
5. JOG SWITCHES (FIgure 4-1)
The JOG swit
ches are spring-loaded toggle switches. When ac
tivated, either switch completes the circuit to the motor
4
-
-
without having to depress the corresponding gun trig
ger switch. The Left JOG switch permits jogging of the
SECTION 5
6
-
-
-
SEQUENCE OF OPERATION
1.
1. WELDING WIRE THREADING
WARNING ELECTRIC SHOCK can kill; MOVING
PARTS can cause Injury.
Keep clear of pinch points.
Install the wire
(reel-type
structed in Section 3-8
side.
or
or
spool-type)
3-7
on
as
in
the desired
_________
Do not
energize welding power
feeder until instructed to do so.
The
are
welding wire and all metal parts
energized while welding.
source
or
2.
wire
Cut off any portion of the free end of the wire
which is not straight. Ensure that the cut end is
free from rough surfaces to permit proper
feeding.
in contact with it
3.
Route the wire through the wire guide tube on
the side of the boom, over the wire pulley, and to
the drive
CAUTION WELDING WIRE can cause
puncture
4.
__________
wounds; HOT SURFACES
Do not activate gun
can
burn skin.
trigger until instructed
to
do
so.
Do not point gun toward any part of the body
other personnel when threading welding wire.
Allow gun
to cool before
OM-1 523 Page 22
7
~.
.~.
touching.
assembly.
If necessary because of wire size change,
boom pulley(s) for minimum wire bend
ding to Section 3-18.
adjust
accor
or
5.
Loosen the knob
on
the drive roll pressure ad
justment, pivot the pressure adjustment free of
the cover, and pivot the pressure gear assembly
away until it is in an open position.
6.
Feed the wire through the inlet wire guide, past
the drive rolls, and on into the outlet wire guide.
Feed approximately 4 inches (102 mm) of wire
into the outlet wire guide.
2.
Rotate the Right WIRE SPEED control until the
desired setting is displayed on the Inches Per
Minute meter.
3.
Momentarily depress the
3-8), pivot the gear
cover
7.
8.
9.
desired setting is displayed
Minute meter.
away from the drive gear and
rotate the pressure gear one tooth.
4.
the pressure adjustment knob in a
clockwise direction until the drive rolls are tight
against the welding wire. Do not overtighten.
If
a
JOG
switch.
the Inches Per
on
remote control is to be used on either or both
sides,
Pivot the gear cover closed making sure the
teeth on the pressure gear mesh with the teeth
on the drive gear. The welding wire must also be
in the grooves of the drive rolls.
Pivot the pressure adjustment knob until the
washer on the pressure adjustment is seated on
top of the gear cover.
Left
Rotate the Left WIRE SPEED control until the
IMPORTANT: If when the gear cover is closed, the
U-Cog drive rolls are not aligned properly (see Section
make
connection
Remote Control
the
to
appropriate
receptacle(s)
and place the cor
responding Remote Control switch(s) in the
REMOTE positon. if no remote controls are us
ed, place both Remote Control switches in the
STANDARD position.
5.
Place the POWER switch
ON
the control in the
on
position.
Turn
Further adjustment to attain desired clamping
pressure can be made after the welding power
source and the wire feeder are put into opera-
6.
Energize
the
welding
7.
Turn
the
shielding
8.
Depress the PURGE buttons for
9.
Hold the
on
power source(s).
gas at the source(s).
one
minute.
tion.
10.
Draw the gun cable out
straight.
10.
11.
Repeat Steps 1-10
the
on
the
12.
Energize
13.
Place the control POWER switch in the ON
welding
power
15.
source.
Depress the Right JOG switch until welding wire
approximatey one inch (25.4 mm) out of
Right Gun tip. Weld current will not be pre
extens
sent on the wire.
RAYS. SPARKS, AND HOT
burn eyes and skin; NOISE can
WARNING ARC
_________
SURFACES
can
damage hearing.
Wear correct eye, ear, and body protection.
FUMES AND GASES can seriously harm your
health.
Use enough ventilation to keep fumes and gases
from the
breathing
the gun handle. Gas will
feed if drive roll
pressure adjustment knob 1/2 turn clockwise.
Repeat until slippage stops. Do not overtighten
posi
Depress the Left JOG switch. This will run the
welding wire through the Left Gun without plac
ing weld current on the wire. Release the Left
JOG switch when welding wire extends approx
imately one inch (25.4 mm) out of the gun tip.
the
on
pressure is properly adjusted to prevent slippage.
If wire slippage is noticed, tighten the drive roll
knob.
tion.
14.
Depress the trigger
start to flow and wire will start to
side.
opposite
tip of the desired gun approximately
1/2 inch (13 mm) from the workpiece.
zone.
See Section 1
Safety Rules For Operation Of Arc
Welding Power Sources for basic welding safety infor
-
mation.
WARNING:
ELECTRIC SHOCK
can
kill.
____
Do not touch five electrical pans.
Do not touch welding wire or any metal part in
contact with it while welding.
Welding wire and all metal parts in contact with it carry
is energized. When one welding power source is utiliz
ed, both electrode wires will be electrically energized
when either gun
trigger
is depressed.
5 -3. SHUTTING DOWN
gas at the source(s).
1.
Turn off the
2.
Place the POWER switch
OFF position.
3.
Turn off all associated
L~~U~E
shielding
HIGH
SHIELDING GASES
Shut off gas
the control in the
equipment.
CONCENTRATION
can
supply
on
OF
harm health or kill.
when not in use.
5 -2. GAS METAL-ARC WELDING
1.
Make all necessary connections
Section 3 of this manual.
as
instructed in
OM-1523 Page 23
SECTION 6
-
IMPORTANT: Every 6 months inspect the labels on
this unit for legibility. All precautionary labels must be
maintained in a clearly readable state and replaced
when necessary. See the Parts List for part number of
MAINTENANCE
6 -4. BRUSH INSPECTION
(Figures 6-1 & 6-2)
1.
precautionary labels.
1. INSPECTION
UPKEEP
Usage and
shop conditions will determine the frequency and type
of maintenance. Inspect equipment as follows:
-
AND
ELECTRIC SHOCK
can
kill;
WELDING WIRE can cause puncture wounds; HOT
SURFACES can burn skin.
Disconnect unit from input power before internal
ly inspecting
or
servicing.
Allow gun and unit to cool befose touching.
Do not activate gun trigger while performing
maintenance on gun.
ELECTRIC SHOCK
can
kill.
_______
Do not touch five electrical parts.
-
L~~U~L
REPLACEMENT
Shut unit and associated equipment off.
WARNING
O
8
or
employ lockout/tagging procedures on welding
power source before internally inspecting or ser
vicing.
Lockout/tagging procedures consist of padlocking line
from fuse box, or shutting of and red-tagging circuit
Work
on
internal parts to be
performed only by qualified
persons.
1.
Make
is shut down.
2.
Open brush cap by sliding screwdriver under
catch and lifting. Remove brush cap.
2.
Inspect gun for broken areas; cracks and loose
parts: tighten, repair, and replace as required.
3.
Grasp spring retaining bracket with long-nose
pliers.
4.
Push spring retaining bracket in lightly and move
towards brush. This should release the spring
assembly and it can be removed.
Carefully
3.
welding
sure
remove
power
source
any weld spatter
or
foreign
accumulate around the nozzle
hardwood stick, never a metal tool.
matter which may
orifice. Use
a
Repair or replace, as required, all hose and cable;
give particular attention to frayed and cracked in
4.
sulation and
areas
where it enters
Brush Box
equipment.
.Brueh
5.
Remove grease and grime from components;
moisture from electrical parts and cable.
6.
Blow out the gun wire guide liner with compress
ed air when changing wire. This will remove any
metal chips and dirt that may have accumulated.
6
2. CLEANING OF DRIVE ROLLS
Occasionally
it will become necessary to clean the wire groove on the
drive rolls. This cleaning operation can be performed
with a wire brush.
Pigtail
1Ao48fl8
Figure 8-1. View Of Spring Assembly And Brush
When Brush Cap Is Opened
-
-
HIGH ROTATIONAL SPEED may
to drive rolls.
Do not allow drive rolls to rotate at high speed if
compressed air is used for cleaning the drive roll
5.
6.
Pull brush out
If the brushes
using brush pigtail.
are
less than 1/4 in. (6.4 mm)
long, replacement is necessary. Disconnect the
brush pigtail from the brush box tab and remove
WARNING
_________
cause
damage
brush.
7.
Connect
new
brush
pigtail
to brush box tab.
assembly.
8.
To clean the wire grooves it will be necessary to discon
nect unit from line power before removing the drive
roll(s) (see Section 3-8 for removal and installation in
structions).
properly maintain the drive
build-up of wire particles which will
decrease the efficiency of the wire feeding operation.
10.
Using long-nose pliers, insert spring assembly
beside brush sliding the spring retaining bracket
along the brush box wall. The spring retaining
a
The control is protected
8
3. FUSE (Figure 4-1)
from damage due to an internal short or excessive
overload by fuse Fl. Should Fl open, the control would
-
-
completely inoperative.
OM-1623 Page 24
slot in brush box. Ensure
come into contact with a
Insert brush into brush box. Ensure that the low
end of the bevel on the top of the brush is
towards the spring.
IMPORTANT Failure to
be
pigtail through
9.
______________
rolls can result in
Route
that the pigtail will not
metal surface.
-
brackłt hooks
lustrated in
on
the
Figure 6-2.
brush box wall
as
Il
Brush Box
Tab
TA-046 226
2.
Disconnect
3.
Remove drive gears in both drive roll
4.
Remove motor gear guard.
5.
Remove
6.
Remove drive shafts and
welding
right
guns.
drive roll
housings.
housing.
large
spur drive gear.
CAUTION SOLVENTS CONTAINING PHENOL
OR FORMIC ACID can damage plastic gears.
Do not use so/vent containing phenol or formic
acid.
________
Figure 6-2. View Of Spring Assembly
And Brush
From Armature End Of Motor
11.
If the spring retaining bracket is in place, it will be
against the brush box wall when the pliers are
7.
Clean clutch/bearings inside gear and the drive
shafts. Dry thoroughly, and grease.
8.
Reinstall drive shafts in spur drive gears and drive
roll housing and secure housing to mounting
released.
12.
Ensure that the spring is in the proper
illustrated in Figure 6-1.
13.
Replace and latch the brush cap.
14.
Reconnect power to all
position
as
bracket. Do not
9.
equipment
and
resume
Reinstall drive gears on drive shafts. Check for
alignment of drive roll housing on drive
shaft by rotating drive gears in the direction of
wire travel. If the drive gear does not turn freely,
proper
operation.
6
tighten mounting bolts.
AND
SHAFT
INSPECTION
5. DRIVE
MAINTENANCE
Drive shaft cleaning and inspection
should be performed on a periodic basis, dependng on
the type and conditions of service. Inspect the drive
shafts for free movement by rotating the drive gears in
the direction of wire travel. If either drive gear does not
turn freely, clean the drive shafts and clutch assemblies
in the large spur drive gear and repack with a good
quality gear grease. Use the procedure outlined below
to remove the drive shafts. Where operating conditions
are severe, more frequent inspections should be made.
-
adjust
the
position
of the drive roll housing until
allowed free movement.
-
1.
Retract wire past drive
-
1. GENERAL
tion has been
drive
shaft
is
Tighten mounting bolts
and
recheck for the
movement.
10.
11.
Reinstall motor gear
Reconnect
welding
cover.
guns and rethread
welding
wire.
12.
Resume
operation.
housings.
SECTION 7
7
the
-
TROUBLESHOOTING
It is assumed that proper installa
made, according to Section 3 of this
-
manual, and that the unit has been
until this trouble developed.
functioning properly
trouble is not remedied after performing these pro
cedures, the nearest Factory Authorized Service Sta
tion should be contacted.
In all
malfunction, the manufacturers
should be strictly.followed.
of equipment
recommendations
cases
7 -2. TROUBLESHOOTING CHART
IMPORTANT Ensure
that all connections
to
the
______________
WARNING
ELECTRIC SHOCK
can
kill.
__________
Disconnect unit from input power and shut down
welding power
source
before
or servicing.
Troubleshooting of internal parts
by qualified persons.
internally inspecting
to
be
performed only
control and
all switches
Use this chart in conjunction with the circuit diagram
while performing troubleshooting procedures. If the
are
application
power
in the proper
before
and that
position for the we/ding
beginning troubleshooting pro
cedures.
CAUTION
_________
MAGNETS
ment
The following chart is designed to diagnose and provide
remedies for some of the troubles that may develop in
this unit.
welding
source are secure
DISASSEMBLY OF MOTOR FIELD
result in personal Injury or equip
can
damage.
Limit drive motor repairs to brush replacement.
The field magnets are very strong. If disassembly is at
tempted, injury to fingers and hands may result from a
magnet being drawn back into the motor. The field
magnets are matched sets and operation may be af
fected if the magnets are tampered with. Warranty is
void if the motor is tampered with.
OM-1523 Page 25
TROUBLE
PROBABLE CAUSE
Depressing gun trigger will
not energize wire feeder.
Electrode
wire
is
energized and shielding
POWER
wrong
switch
Si
in
SUGGESTED
CHECK
Place Si to ON
position.
AND/OR
REMEDY
position.
Replace Si.
not
gas
does not flow.
115
volts
input fuse
Fl
*
Replace
Fi.
open.
115 volts ac input plug PLG
17 is not secure., in receptacle.
Insert PLG 17 fully into 115
rotate plug clockwise.
vac
receptacle
Plug(s) PLG 14/15 from
gun trigger is not secure in
gun trigger control cable.
Insert PLG 14/15
fully into
locking ring.
gun
trigger control
Plug(s) PLG 2/13 from
trigger control cable is
Insert PLG 2/13 fully into TRIGGER receptacle
and rotate locking ring.
secure
gun
not
cable and rotate
and
in TRIGGER recep
tacle.
Circuit breaker CB1
Wire feeds, shielding gas
flows, but electrode wire is
not
energized.
tripped
115 Volts Contactor Conplug RC1 is not secure
trol
in contactor
receptacle
welding power
reset CB1 by depressing the button
the front panel of the control labeled RESET.
Manually
Insert RC1
fully
into
receptacle and
rotate
on
plug
clockwise.
on
source.
Control
cable
leads not secure on contac
tor plug terminals.
Secure leads to plug terminals.
Welding power
See
Contactor
source.
TROUBLESHOOTING Section
source instruction manual.
in
welding
power
Wire feeds
*Be
sure
OM-1 523
erratically.
replacement fuse is
Page 26
Pressure on drive rolls is insufficient.
Rotate pressure adjustment knob(s) clockwise in
1/4 turn increments until wire slippage stops.
Drive roll is too large for
wire size being used.
Change
Worn drive roll.
Replace drive roll. See Section 3-8.
Dirt in drive roll.
Clean drive roll
same
size, type, and rating.
to proper
as
size drive roll. See Section 3-8.
instructed in Section 6-2.
~
RUNIG
rPM-OTR
TO ..I1
AT
R.
:~
TO
~17
SPLGH
WIl!_<(
WITH
ALL ALL
Diagr m
9CW
R7
EXC PT POINT
J
c
No.
ROLSI
MEASURD
FORMS POINT RESP CT
WAVE VOLTAGES
COM N
300
C-098
WIlT
~
<
RESPCT MEASURE
WITH
198
S AD ONLY
C
AR
SWING ONLY
rcA~
~
CDI
Circuit
PLO?
RCTI
~5X
27
fi
~
~CR2
CONTA F CONTRL PLGI
~
557
I~i
O~i
23
p
~
1CUS
c
WI5
CR4 -1.1
lEVI
5
PC
SAM
2
305.
XI
i-CR3
:1
EF3
REMOTE
HEIR
NOV
RIGHT
~WGXTNDE
60
SOLENID SHIIGDHTE
~1~J~
7~~w
24~RIGHT
I
_J ~_ r
XC
1~GHT
CR3
CR~R2
GAS
6
BURNACPS R.EJMOIVEJ2 INSTAL
PC
REMOTE
CR50~
CRSOL
Diagr m
~
Circuit
I
~_ 1~
1.
LEFT
PLOW
5
J
IX
~
-
7
RC11
Figure
C2
I
BURNOACIYD H~ ~CW *LEFTRIGH OPTINAL RESPC
TO
2~1LEFT
3D
Ii
I
SC4
_~ALi
lip164~
I
I
432 F~-1
S
O
L
E
N
I
D
~ WATERSOLENIDLOPTI~LJ Q~j~-i~
ARCS
GIl
GAS
I
35
J
A
e~RC5
IX
q~,p
I
L
CR1
ci
I1LPLGI
A
F
A
H
.O~ ,
SIDE
LEFT
RCRA?1
,
~
ID
dl
IA
C
A
Er.ISDF~I2___
I
I
MET R
C
ITV
AC
ro
ST
0
RIGHT I NCh
0~
0
250
0
0
AC
~- CR5
7S~CR~j~Ifi~Ri
33
000
0
o
PLGl
AC
OH
PEG1?
~
>1:54 602
~CONTA RCONTRL 2>~WT 4>_B~ PLGia LEFT TRIGER
LEFT
~ILJ
16
0
BAY
I
L
INGARC ONLY
SW
~
,IL
CR3
H
CR547
1 50
3
PU~D52
PLO?
LT~J SWINGARC ONLY
PLGR
II
-,
C
AR
SWING ONLY
~
PLO134
BR B2Y lEVI
1> 2>
3>_MO L~ _RIGHT TRIGER
I
0
U, p-S C-S -v
P-S
BLK
Circuit
Figure 7
OM-1 523
Page
28
-
2. Circuit
Diagram For Tach.
Board
Diagram
No. A-094 456
December1985
FORM: OM-1523F
Effective With Serial No. JF923259
PARTS
LIST
1O7-D
TD-046
C
Fig
1
*45
53
36
thru
32
55
57
Asembly
Main
59
-
A
Figure
64 362
62
60
FigD
parts
for
list
parts
asembly.
in
No. this
71
0
UIP.) ca -U
S
Item
~
in
include
Quantity
Item
No.
Dia.
Part
Mkgs.
No.
Figure
1
PLG3
4
5
6
PLG1 1
7
8
9
PLG12
PLG1 7
10
11
12
PLG1
13
14
15
16
17
18
19
20
21
22
23
24
24
25
25
26
PLG2,13
27
28
29
PLG 14,15
30
31
31
32
32
33
34
35
36
37
38
39
40
40
PLG7
41
42
43
Description
A
2
3
Model
PLG8
Main
t046 174
079 531
079 878
079 535
049 455
039 635
099 522.
039 635
039 687
604 571
079 531
048 284
079 534
049 455
080 418
056 851
010 606
056 108
604550
073 433
044 858
073 432
051 297
047 684
047 685
049 012
048 618
079 878
079 535
079 531
605156
080 328
079 534
003 160
003 159
079 202
079 204
056 851
010 606
056 108
604 550
046 757
083 687
083 693
079 739
047 636
079 535
073 179
071 892
079 535
12
16
1
1
1
1
Assembly
CORD, contactor (consisting of)
CLAMP, cable
HOUSING PLUG & PINS (consisting of)
TERMINAL, male
CORD, No. 18/2c (order byft)
CONNECTOR BODY, twistlock 2P2W 20 amp 250 volts
CORD, control interconnecting (consisting of)
CONNECTOR BODY, twistlock 2P2W 20 amp 250 volts
CAP, twistlock grounded 2P3W, 15 amp 277 volts
CORD, No. 18/4c(orderbyft)
CLAMP, cable
HOUSING PLUG & SOCKETS (consisting of)
TERMINAL, female
HOSE ASSEMBLY, gas (consisting of)
FITTING, hose-brass barbed nipple3/16TBG
FITTING, hose-brass nut 5/8-16
FITTING, hose-brassferrule0.425IDx23/32
.
1
1
4
4
10 ft
10 ft
.
.
.
.
1
1
1
1
.
-
1
1
1
1
13 ft
13 ft
.
-
.
1
1
1
1
.
.
.
.
4
4
2 ft
2 ft
.
1
1
3
3
6
3
3
lift
lift
FITTING, brass barbed male 3/16 TBG x 1/4 NPT
FITTING, pipe Y short 1/8 NPT
FITTING, barbed male 3/16 TBG x 1/8 NPT
2
2
1
1
1
1
ADAPTER
1
1
.
.
.
.HOSE,No.1x3/161D(orderbyft)
-
.
.
-
.
.
(consisting of)
(consisting of)
right 16 ft (consisting of)
CORD,trigger-right2oft(consistingof)
CORD, trigger
CORD, trigger
CORD, trigger
-
-
left 16 ft
left 20 ft
-
6
1
1
1
1
1
1
4
4
2
l6ft
2
2Oft
.
.
.
TERMINAL, male
CLAMP, cable
.
.CORD,No.18/4c
.
RECEPTACLEW/SOCKETS,free-hanging(consistingof)
TERMINAL, female
HOSE, gas left 16 ft (consisting of)
HOSE, gas-left l9ft (consisting of)
HOSE, gas right 16 ft (consisting of)
HOSE, gas right 19 ft (consisting of)
FITTING, hose-brassbarbednipple3/16TBG
FITTING, hose-brass nut5/8-18 RH
FITTING, hose-brassferrule0.475 IDx23/32
HOSE, No.1 xO.187 ID (order byft)
CONTROL BOX (Fig B Pg 6)
CORD, motor l5ft (consisting of)
CORD, motor 19 ft (consisting of)
CLAMP, cable
TERMINAL, male
.
1
1
2
2
.
-
-
1
1
1
1
-
1
1
1
1
1
1
21 ft
1
.
.
.
.
17 ft
1
1
1
1
1
.
1
1
14
14
15 ft
19 ft
.
.
.
.
.
.
RECEPTACLE W/SOCKETS (consisting of)
.
TERMINAL, male
1
1
14
14
OM-1523 Page 2
Quantity
Item
Dia.
Part
No.
Mkgs.
No.
Figure
Model
Description
A
Main
079 706
080 415
080 940
078 992
078 993
077 455
600 323
600 742
079 628
080 947
Figure C
44
45
45
46
46
47
48
49
50
50
51
52
52
52
52
53
53
53
53
54
55
56
57
t079 591
t079
t078
t079
t075
t079
t075
t079
080
CLAMP,cable
CABLE, weld 26 ft left (consisting of)
CABLE, weld 30 ft left (consisting of)
CABLE, weld 26 ft right (consisting of)
CABLE, weld 30 ft right (consisting of)
TERMINAL, ring tongue 1/2 No. 3/o wire
CABLE, weld copper No. 3 (order by ft)
TERMINAL, ring tongue 3/8 stud No. 3/0 wire
BRACKET, spring-retaining
BRACKET, spring-retaining
BOOM (Pg 10)
-
.
76
77
78
79
80
aM-i 523 Page 3
30 ft
BASE,4ftor
-
-
:
-
-
1
1
1
1
1
1
1
4
2
1
2
1
1
1
4
2
.
072010
C50
D50
0C50
R50
R51
26 ft
.
-
73
74
75
1
.
214
264
216
390
215
078
217
Figure
~i6
Assembly (Contd)
BASE,6ft
BASE, 4 ft or
BASE,6ft
POST, support boom 4 ft (consisting of) or
POST, 6 ft. w/o base support boom (consisting of)
POST, support boom 4 ft (consisting of) or
POST, 6 ft. w/o base support boom (consisting of)
157
FITTING, grease 1/8 NPT
080 408 GEAR, spur steel 33 tooth 1/2 bore keyed
080412 GUARD, motor-gear
080419 SPACER,steell ODxl7/32IDx1/4
080 416 INSULATOR, housing
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
12
D
079 633
080 409
080 404
080 411
010910
602213
601 965
601 872
080 417
056068
047 553
080 802
080 283
080 282
*080 281
049 033
049 032
094 458
073 739
094 934
094 268
052 140
039 328
094 464
049 029
049 031
045 766
049 030
081 630
BUSHING,0.316IDx7/16x13/16x3/16
WIRE DRIVE & GEARS (Pg 12) (consisting of)
FITTING, hose brass barbed nipple 3/16 TBG
SHAFT, drive clutch
GEAR, spur drive
GUARD, drive gear
-
.
1
1
2
1
1
WASHER,flat-SAE3/8
4
4
WASHER,lock-split3/8
SCREW,cap-hexhd3/8-16x1
4
2
4
2
1
1
1
-
-
-
NUT, hex full 3/8-16
INSULATOR, housing
KEY,1/8x1/8x1/2
MOTOR ASSEMBLY (consisting of)
MOTOR, gear 1/8 hp 115 volts dc 2000 rpm (consisting of)
COVER, brush
SPRING, brush
.
.
.
.
.
.
.
BRUSH
SPACER, housing tachometer
CLAMP, strain relief
CIRCUIT CARD, tach (consisting of)
CAPACITOR, ceramid0.1 uf 50 voltsdc
DIODE, zener5.1 voIts400 MW.
IC, interface 963N51
-
.
-
.
.
.
.
.
.
.
.
.
.
.
.
RESISTOR, carbonfilm0.5watt33O ohm
RESISTOR, carbon film 0.25 watt 1 .5K ohm
CORD, tach 15 inches
HOUSING~ tachometer feedback
SHAFT, extension armature
OPTICAL ENCODER DISC
COVER, housing tachometer feedback
-
.
-
.
-
.
1
1
1
2
2
2
2
1
1
1
1
.
.
.
1
1
1
1
2
2
2
2
1
1
.CORD,motorl7 inch
1
1
1
1
1
1
1
1~
1
1
1
1
1
1
1
1
1
1
1
1
Quantity
Item
Dia.
Part
No.
Mkgs.
No.
Figure
81
82
A
Model
Description
Main
079 739
PLG9
047 636
079 535
.
.
.
I
12
16
Assembly (Contd)
CLAMP, cable
1
1
TERMINAL, male
1
1
14
14
.
*Recommended Spare Parts.
tParts For Optional Equipment.
Quantity
Dia.
Part
Mkgs.
No.
Model
Description
12
I
16
Parts For Optional Equipment
047 945
046
047
073
024
046
R7,9
WS1
+
+
046
046
046
035
010
079
602
056
+079
+008
000
000
000
080
081
000
000
080
081
048
045
047
023
980
562
366
531
532
533
534
601
295
573
934
296
773
657
571
570
572
BURNBACK CONTROL, left side (consisting of)
BURNBACK CONTROL, right side (consisting of)
TIMER, delay 20 mu sec/20 sec
POTENTIOMETER, 1 turn 2 watt 10K ohm
.
.
.
KNOB, pointer
WATER CONTROL KIT, one side (consisting of)
WATER CONTROL KIT, one side (consisting of)
WATER CONTROL KIT, both sides (consisting of)
WATER CONTROL KIT, both sides (consisting of)
VALVE, 115 volts ac 2 way 1/4 IPS port 1/8 orifice
.
.
.
.
.
1
1
1
1
1
1
1
1
1
1
HOSE,waterl5ft(kitforoneside)
1
HOSE,
HOSE,
water 20 ft
(kit for
(kit for
(kit for
(kit for
(kit for
(kit for
(kit for
499
water 12 ft
501
HOSE, water 20 ft
573
HOSE, water 25 ft
569
HOSE, water 29 ft
500
HOSE, water 25 ft
502
HOSE, water 29 ft
471 TOOL, extraction pin amp
503 LOCKING COVER
813 CABLE, extension 25 ft
.
1
2
-
.
1
2
-
.
1
1
FITTING, hose-brasselbowmale 1/4 NPTx5/8-18 LH
FITTING, pipe galvanized nipple L 1/4 NPT x 6
FITTING, pipe galvanized coupling 1/4 NPT
TUBING, plastic No. 4
ADAPTER, terminal water/electrode
FITTING, hose-brass bushing reducer 5/8-18 LH
HOSE, water lOft
-
.
1
1
1
.
.
1
.
.
.
.
.
side)
both sides)
both sides)
one side)
one side)
both sides)
both sides)
1
1
1
1
1
1
1
1
1
1
1
one
-
1
1
1
1
1
1
1
1
1
1
1
1
for these items.
+ + When using kit for both sides the quantity is 2 reqd.
OM-1523 Page 4
K
0
0
I
C
0
C.)
U.
I-
aM-i 523 Page 5
Item
No.
Dia.
Part
Mkgs.
No.
Figure B
1
2
3
4
R4,5
Si
CB1
5
6
7
8
9
10
CR3
CR1 ,2,5
R3
11
Ri
12
13
RC1
046 757
t047
070
603
011
011
080
027
079
095
101
634
856
233
991
148
811
844
033
080 388
079 497
030
601
048
079
651
219
283
535
Description
Quantity
Control Box (Fig A Pg 2 Item 37)
WRAPPER
1
electric shock etc
LABEL, warning
POTENTIOMETER, WW 10 turn 2 watt 10K ohm
SWITCH, toggle SPDT 10 amp 250 voltsac
CIRCUIT BREAKER, 1 pole 1 .5 amp 250 volts
SOCKET, relay 11 pin
CONNECTOR, 14 pin
SPRING, hoiddown relay
RELAY, enclosed 24 volts ac 4PDT
RELAY, enclosed 24 volts ac 3PDT
RESISTOR, WW fixed 25 watt 2000 ohm
-
LINK, jumper terminal block 20 amp
RECEPTACLE W/ PINS (consisting of)
-
1
2
1
1
3
1
1
1
3
1
1
4
1
4
TERMINAL, male
RC2,
i4
15
16
17
18
19
20
21
22
23
24
25
26
27
28
3,13
RC4,10
R2
048 282
079 534
048 144
047 100
056266
079 683
604 311
010 193
010 199
030 949
056 170
RECEPTACLE W/SOCKETS (consisting of)
TERMINAL, female
TERMINAL, male 1 pin plug keying (used with RC3)
PANEL, mounting receptacles
CONNECTOR, female 6 contact 7.5 amp
HEAT SINK, resistor
GROMMET, 1/4 ID x 3/8 mounting hole
TUBING, 3/8 OD x 18 ga wallx 1/4
TUBING, 0.275 ID x 0.048 wall x 1
HEAT SINK, rectifier
SHIELD, wire feeder
030941 RESISTOR, WWfixed 100 watt5 ohm
026 837 INSULATOR, terminal nylon
034 841 RELAY, 24 volts ac DPDT
054116 CONNECTOR, female 4 contact 10 amp
035914 RECTIFIER, integrated 30 amp 400 volts
-
-
-
-
CR4
RC18
SRi
RC7
29
30
31
32
33
34
PLG4,i0
35
36
GS1,2
RC5
Cl
37
38
39
40
Ti
41
42
43
44
45
46
iT
53,5
52,4
S6,7
047 637
079 534
047 123
071 642
073 730
031 692
006 426
056265
010 296
035601
010 141
079 573
046 754
602 934
036 135
038782
047 102
048 029
011 232
011 043
011 770
HOUSING RECEPTACLE & SOCKETS (consisting of)
TERMINAL, female
STAND-OFF, No. 4-40 x 2-5/8
CIRCUIT CARD, motor speed (Fig B1 Pg 8)
TERMINAL, header 22 pin
CAPACITOR, electrolytic 750 uf 200 volts dc
BRACKET, mounting capacitor
CONNECTOR, male 6 contact 10 amp 730 RMS
FITTING, hose brass male 1/4 NPT x 5/18-18 RH
VALVE, 115 volts ac 2 way 1/4 IPS 1/8 orifice
CLAMP, 1/4 dia
FITTING, pipe nipple L 1/4 NPT x 6
BRACKET, mounting gas/water
FITTING, pipe gaIvar~ized coupling 1/4 NPT
TRANSFORMER, control 115-24 volts ac
BLOCK, terminal 20 amp 10 pole
BRACKET, mounting relays
CLIP, retaining socket relay
SWITCH, push button SPDT
SWITCH, toggle DPDT multiple contact 6 amp 125 volts
SWITCH, toggle SPDT 5 amp 125 volts
-
-
-
-
-
-
-
-
-
3
4
2
1
2
1
1
6
2
1
1
1
3
1
1
1
1
14
4
1
1
1
1
2
4
2
1
2
1
2
1
1
1
1
2
2
2
OM-1 523 Page 6
Item
Dia.
Part
No.
Mkgs.
No.
Description
Quantity.
.
..
.-
Figure B
47
48
49
50
51
52
53-.
54.
RC16,19
PL1,2
Fl
RC6
55
56
57
046 757
073 687
046 751
027 645
024 366
*073 426
012 617
059
028
081
031
139
598
798
643
Control Box
(Fig
A Pg 2 Item 37) (Contd.)
.
2
RECEPTACLE,4socketMS-3102A-14S-2S
CASE SECTION, front/bottom/back
LIGHT, indicator- red lens 125 voltsac
.
1
.
~
2
..
.
.....~
..
KNOB, pointer
FUSE, miniature glass sb blo 5 amp
HOLDER, fuse (consisting of)
2~
....
-
1
-
.i
.
..
.~
.CAP
TERMINAL, header 15 pin
METER, digital
CAPACITOR, ceramic 0.01 uf500voltsdc
NAMEPLATE (order by model & serial number)
.
1. ~:..
..,..
.
1
-~
..
I
:-~
1.:
.
Ref:
...
449-A
D-093
COMPONENTS TO BE REPLACED BY
QUALIFIED PERSONNEL ONLY
Figure Bi
-
Circuit -Card, Motor
Speed
*Recommended Spare Parts.
:
tWhen ordering a component originally displaying a precautionary label, the label should also be ordered.
.~
.
OMl523Page7
..
.
.
-.
;,
.
I
Dia.
Part
Mkgs.
No.
Figure B)
A50-53
C50
C51
C52,6 1
C53,62
C54
C55,
66-75,77
C56
C57
C60
C63,64
C65
Description
071 642
Circuit Card, Motor Speed (Fig B Pg 6 Item 30)
009
039
031
073
035
005
159
482
699
739
833
023
IC,Iinear358
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
ceramic 0.1 uf 50 volts
mylar 0.033 uf 100 volts dc
tantalum 2.2 uf 20 volts
031
073
031
035
044
031
643
549
677
561
602
721
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
ceramic 0.01 uf 500 volts dc
mylar 0.015 uf 200 volts
tantalum 5.6 uf 35 volts dc
mylar 4 uf 200 volts
polyfilm 0.47 uf 400 volts dc
4
electrolytic 100 uf 35 volts dc
095 033
RELAY, enclosed 24 volts
56-60
026 202
D55
1C50
080 910
081 800
037 200
037 824
039 355
030 839
DIODE, 1 amp 400 volts SP
DIODE, zener 15 volts 5 watt
IC, interface 2907
TRANSISTOR, 200 MA 40 volts NPN
THYRISTOR, SCR 7.4 amp 200 volts
TRANSISTOR, unijunction 15 MA 40 volts
035 827
052 138
RESISTOR, carbon film 0.25
RESISTOR, carbon film 0.25
035
030
039
039
049
RESISTOR, carbon film 0.25 watt lOOK ohm
POTENTIOMETER, cermet 15 turn 0.75 watt 50K ohm
RESISTOR, carbon film 0.25 watt 4700 ohm
RESISTOR, carbon film 0.25 watt 10 meg ohm
RESISTOR, carbonfilmO.25watt82Kohm
RESISTOR, carbon film 0.25 watt22K ohm
RESISTOR, carbon 0.5 watt 10 ohm
RESISTOR, carbon 0.5 watt 47 ohm
RESISTOR, carbon film 0.25 watt zero ohm
TRANSFORMER, pulse
IC, linear 78L08
IC, linear 78L12
SPRING, holddown relay
SOCKET, relay
HEAT SINK, rectifier
CR50
Quantity
ac
4PDT
1
1
2
2
1
12
1
2
1
2
1
1
D50-54,
Q50,53
Q51
Q52
R50
10
1
1
2
1
1
1
R51 ,53-55,57,
63,67,68,74,75,
81,82,85,89
R52,56,61
R58,62,65,
66,71,72,
76~90
R59
R60,87,88
R64
R70
R73,83
R77
R78
R79
R80
R85
R86
150
VR5O
VR51
039
052
039
039
035
030
030
092
085
081
047
079
091
037
884
007
335
331
015
328
142
108
106
886
937
090
648
399
799
272
844
861
261
watt 10K ohm
watt 20K ohm
-
14
3
8
1
3
1
1
2
1
1
1
1
1
1
13
1
1
1
1
1
1
OM.1523
Page 8
rn
(p
I,
I-
I-
~
I-
N
E
0
0
I-
UN
N
I0
a
rn
I
rn
a
N
N
OM-1523 Page 9
Quantity
Item
Model
Part
No.
No.
Description
Figure C
1
2
3
4
5
5
6
6
7
8
8
9
10
11
12
12
13
13
13
14
14
15
16
17
18
18
19
19
20
20
21
21
22
22
23
24
010313
079622
079621
079632
079667
080812
079665
080811
079664
007280
073742
045391
605538
045390
007279
073741
601 883
605884
079029
007995
075462
Figure Cl
079020
602250
010911
075 102
073663
024605
075 100
(Fig
26
27
28
29
29
30
31
32
33
34
When
ordering
a
PIN, cotter-hair 0.072
x
1.437
BUSHING, 0.622 ID x 0.075 OD x 0.501
PULLEY, V single groove
BOLT,U1-5/8highxl-1/8widexl/4
PIPE, 1/2 x 133-3/4
PIPE, 1/2 x181-3/4
GUIDE, wire
GUIDE, wire
4
4
2
8
2
4
4
2
10
2
2
1
1
2
2
2
2
2
2
1
1
2
1
1
1
-
1
1
2
-
1
1
2
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
ft
1
1
1
1
1
1
1
BOOM, dual 16 ft
WASHER, lock-split 3/8
BRACKET, hanger-gun
GUARD, motor-protector
SHAFT, pulley
originally displaying
1
1
1
SPACER, spring-boom
BEARING, thrust-boom
BASE, swivel-boom
BASE, swivel-boom
LABEL, warning electric shock etc
LABEL, caution heavy spring etc
LABEL, remove gearing vent etc
WASHER, fIat 1/2
KNOB,TBar
BOLT, hex-hd3/4-16x2-3/4
BOOM, dual 12
2
2
2
GUIDE, inlet
PIN, clevis 5/8-18 x 1-7/8
PIN, clevis3/4 ODx2.156
TUBING,3/8IDx3/32wa11x8
component
16
A Pg 3 Item 51)
CABLETIE
LINER, monocoil 3/32-1/8 wire x 9
CLEVIS
CLEVIS
NUT, hex jam 5/8-18
NUT, hex half 3/4-16 (top of shaft)
NUT, hex-full 3/4-16 (bottom of shaft)
SHAFT, boom-counter balance
SHAFT, boom-counter balance
SUPPORT, hub & reel (Pg 11)
NUT, hex-elastic stop 3/4-16
WASHER, flat SAE 3/4
WASHER, shield 3 inch square
BEARING, ball
BEARING, ball
NUT, 5/8-18 x 1-1/4 special
075 101 NUT, 3/4-16 x 1-1/4 special
602219 WASHER, lock-external tooth 5/8
079 030 WASHER, lock-external tooth 3/4
080449 SPRING,2ODxl lDxl2
080 723 SPRING, 3-3/8 OD x 37-3/4
075421
075 403
+072 091
+072 083
070634
079423
047702
602246
047224
073666
082 964
082 965
601872
602213
079631
079643
082970
25
25
+
Boom
12
4
4
4
4
2
1
2
2
1
2
a
precautionary label,
the label should also be ordered.
OM-1 523
Page 10
Item
No.
Part
No.
Figure Cl
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
080 393
010 191
058 628
058 428
057 971
010233
605 941
085 980
058 427
t056 416
604051
056312
056313
010224
601 880
056314
Quantity
Description
Support, Hub
& Reel
(Fig
C
Pg 10 Item 15)
SUPPORT, reel
WASHER, fiber 5/8 ID x 1-1/2 OD
WASHER, steel brake
HUB, spool
x
1/8
4
4
2
-
2
WASHER,flat-keyedl-1/2dia
SPRING, compression
2
2
2
2
WASHER, flat -41/64 ID x 1 OD
RING, retaining spool
REEL, wire (consisting of)(as reqd)
NUT, wing 1/2-13
FINGER, reel
STUD, steel 1/2-13 x 7
PIN, spring compression
NUT, hex-jam 1/2-13
-
-
4
4
4
-
4
REEL
1
325
6
7
8
1~
TC-081 760
Figure Cl
-
Support,
Hub 8 Reel
tParts For Optional Equipment.
OM-1 523 Page 11
Item
Part
No.
No.
Figure
D
1
082 036
2
082 050
3
604612
045 233
081 801
4
5
6
7
8
9
10
11
12
13
14
15
16
085 243
010231
085 244
085 242
010224
601 925
604741
079669
079634
080413
079772
604538
080403
028342
053 842
605518
079 626
010 193
048 336
602241
Description
Wire Drive & Gears
(Fig
A
GUIDE, inlet wire
LINER, monocoil inlet wire
SCREW, set socket hd 8-32
GUIDE, anti wear
-
Pg 3 Item 60)
1
1
x
1
1/8
1
1
WIRE DRIVE
(consisting of)
KNOB, adjust tension
SPRING, compression
1
1
WASHER, cupped 21/64 IDxl3/16
FASTENER, pinned
PIN, spring compression 3/16 x 1
SCREW, cap hex hd 1/4-20 x 1/2
PIN, cotter- hair0.042x15/16
LEVER, mounting pressure gear
PIN, hinge
RETAINER, bearing
-
-
-
KNOB
28
WASHER, flat- SAE5/16
HOUSING, adapter gun/feeder
BEARING, ball
GEAR, spur insulated w/bearing
SCREW, cap hex hd 1/4-20 x 1-1/4
SCREW, fiHister hd 10-32 x 7/8
TUBING, 3/8 OD x 18 ga wall x 1/4
COVER, stop
000418 SCREW, cap hex hd 1/2-20 x 1/2 self-locking
093 664 GEAR, spur
092 865 KEY,1/8x1/8x3/4
079 625 WASHER, spring 5/16 shakeproof
29
080410
17
18
19
20
21
22
23
24
25
26
27
Quantity
-
-
-
-
-
-
1
1
1
1
2
1
1
1
1
As Reqd.
1
1
1
1
6
1
1
1
1
2
2
GUARD, drive roll
IC-OBi 623-E
Figure D
-
Wire Drive & Gears
OM-1523 Page 12
IMPORTANT Base selection of drive rolls upon the following recommended
usages:
V-Groove rolls for hard wire.
2. U-Groove rolls for soft and soft shelled cored wires.
3. U-Cog rolls for extremely soft shelled wires (usually hard
surfacing types).
4. Split V-Knurled rolls for hard shelled cored wires (se/f shielding and
shielded
_______________
1.
5.
Drive roll types may be mixed to suit particular requirements
types).
C02
(example: V-knurled roll
in combination with
U-groove).
Wire Diameter & Type
Fraction
Decimal
Metric
023/.025
.023/.025
.6MM
.030
.030
.035
Kit No.*
Roll Drive
Inlet Wire
Part No.
Type
Guide
087 131
087 130
V-groove
056 192
.8MM
079 594
053 695
V-groove
056 192
.035
.9MM
079 595
053 700
V-groove
056 192
.045
.045
1.2MM
079 596
053 697
V-groove
056 193
.052
.052
1.3MM
079 597
053 698
V-groove
056 193
1/16
.062
1.6MM
079 598
053 699
V-groove
056 195
.035
.035
.9MM
044 749
072 000
U-groove
056 192
.045
.045
1.2MM
079599
053701
U-groove
056193
.052
.052
1.3MM
079 600
053 702
U-groove
056 193
1/16
.062
1.6MM
079 601
053 706
U-groove
056 195
5/64
079
2.0MM
079 602
053 704
U-groove
056 195
3/32
.094
2.4MM
079 603
053 703
U-groove
056 196
7/64
.110
2.8MM
079 604
053 705
U-groove
056 196
1/8
.126
3.2MM
079 605
053 707
U-groove
056 197
.035
.035
.9MM
079 606
079 726
V-knurled
056 192
.045
.045
1.2MM
079 607
079 728
V-knurled
056 193
.052
.052
1.3MM
079 608
079 727
V-knurled
056 193
1/16
.062
1.6MM
079 609
056 771
V-knurled
056 195
5/64
.079
2.0MM
079 610
056 773
V-knurled
056 195
3/32
.094
2.4MM
079 611
056 774
V-knurLed
056 196
7/64
.110
2.8MM
079 612
056 775
V-knurled
056 196
1/8
.126
3.2MM
079 613
056 776
V-knurled
056 197
.045
:045
1.2MM
083 318
083 489
U-cogged
056 193
.052
.052
1.3MM
083 317
083 490
U-cogged
056 193
1/16
.062
1.6MM
079614
053708
U-cogged
056195
5/64
.079
2.0MM
079 615
053 710
U-cogged
056 195
3/32
.094
2.4MM
079 616
053 703
U-cogged
056 196
7/64
.110
2.8MM
079 617
053 711
U-cogged
056 196
1/8
.126
3.2MM
079 618
053 712
U-cogged
056 197
Drive Roll & Wire Guide Kits
*When ordering replacement parts all kits listed with the exception of the V-KNURLED kits are one piece drive rolls.
Two drive rolls are required for the one piece drive kits and four drive rolls for the split V-knurled kits.
OM-1 523 Page 13
ACCESSORI ES
DUAL SCHEDULE SWITCHES
For use with Dual Schedule Controls.
DSS-8
For 10 ft. (3 m) gun.
Stock No. 079 691 (Field)
For 15 ft.
(4.6 m)
gun.
A two-position trigger switch which
attaches to the gun handle and is used
in place of the standard trigger.
DSS-9 DUAL SCHEDULE SWITCH
For 10 ft. (3 m) gun.
For 15 ft. (4.6 m) gun.
A two-position slide switch which at
taches to the gun handle and is used
to select the desired welding condi
tion. The standard gun trigger operates
the power
supply
DDSC Dual Schedule Control
Stock No. 041 483
Two welding conditions can be pro
grammed on one or both wires of
the Swingarc Digital units. Two DDSCs
are required when you wish to pro
gram two welding conditions on each
side of a Swingarc Digital 2. The
DDSC must be used in conjunction
with a DVC voltage control.
NOTE: Dig/ta/arc voltage controls are
listed in the catalog sheets for the
following power sources: Deltaweld~
series. Form DCI 16. 1; Intel//weld 650.
Form DCI 16.3; and Pulstar 450. Form
DCI 16.2.
Water Control Kit
For use with water-cooled gun. Consists
of solenoid valve, tube and fittings.
STOCK NO.
For 16 (4.9 m) Boom
SINGLE OR ONE
SIDE OF DUAL
046 533 (factory)
046 537 (field)
DUAL
046 534 (factory)
046 538 (field)
contactor.
LOCKING COVERS
To secure wire feed speed controls,
voltage controls and dual schedule
controls.
STOCK NO.
For 12 (3.7 m) Boom
SINGLE OR ONE
SIDE OF DUAL
046 531 (factory)
046 535 (field)
Adjustable Spool Carrier
Stock No. 096 074 (Factory)
Designed for use with 6 (1.8 m) pipe
post only. Replaces the standard spool
assembly allowing the spools or coils
of wire to be positioned lower for easier
loading and unloading. Not recom
mended for use with Swingarc mounted
on
CBC-8 cart.
PRC-2 POLARITY REVERSING
CONTROL
Stock No. 041 518
Control allows an operator to weld
with a different polarity on each
wire. Both will be electrically hot
but only one may be used.
When
operating in the same polar
the two wires are electrically
isolated. Only the wire being used
is energized. Both electrical isola
tion and polarity reversing cannot
ity,
be
accomplished
at the same time.
NOTE: PRC-2 must be used in con
a digital voltage control.
junction with
DUAL
046 532 (factory)
046 536 (field)
(For Both Sides)
DIGITAL 2
Wire feeder only
Wire feeder and
voltage control
Dual schedule control
STOCK NO.
NOTE: Not recommended when using
a recirculating system such as Radi
ator 1 or 2.
045 503
045 504
045 502
Two 045 502 required if dual schedule
is used on both sides of dual feeder.
NOTE: Locking covers are for field
installation only. Padlock not included.
Spool Adaptor
Stock No. 047 141
For use with 14 lb. (6.3 kg) spool
of Lincoln self-shielding wire.
Wire Reel Assembly
Stock No. 056 416
For 60 lb. (27 kg) coil of wire.
Mounting Bracket
Stock No. 080 939
Required to mount the PRC-2 control
on the Swingarc.
25 Ft. (7.6 m) Extension Cable
Stock No. 047 813
Connects to existing 10 ft. (3 m)
115 volt and contactor control cable.
Permits Swingarc to be located 35
ft. (10.7 m) from the power source.
An additional cable is necessary when ex
tending a feeder with a digital voltage
control.
Stock No. 041 607 for OW control.
OPTIONAL CONTROLS
TRIGGER HOLD CONTROLS
SPOT CONTROLS
the operator to make extended
welds without having to hold the
Allo~y
gun
trigger.
Burnback Control
Recommended for use with automa
tic setups to eliminate wire freeze
in the puddle at the completion of
the weld.
SINGLE
047 945 (factory)
047 946 (field)
TH-1 Stock No. 044 042
For single Swingarcs and
of duals.
TH-2 Stock No. 044 040
For both sides of the dual
one
side
CS-3A Stock No. 044 935
Provides to 5 seconds of spot weld
time in two ranges. Time starts with
depression of gun trigger switch.
Burnback control to .25 seconds.
NOTE: If spot control is desired on
both sides of a dual, two controls
Swingarc.
are
required.
Interface Control
Stock No. 045 031
To Lincoln and Hobart constant po
tential power sources requiring a
continuity set of contacts for con
tactor control.
Left
Right
047
047
046
046
DUAL
945 (factory)
946 (field)
023 (factory)
024 (field)
Pre-Flow/Post-Flow Timer Control
Stock No. 044 936
A 0 to 5 second adjustable timer to
control gas flow prior to arc initiation
and at completion of weld.
NOTE: If pre-flow/post-flow control
is required on both sides of a dual,
two controls are needed.

1 - Miller Electric

Transcription

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