SteelMax ARC Runner Operator's Manual

112 Inverness Circle East Suite F Englewood, CO 80112 1– 87STEELMAX, FAX 303 – 690 – 9172 www.steelmax.com [email protected] OPERATOR’S MANUAL A AR RC C R Ruunnnneerr WELDING CARRIAGE

1.1. Application ................................................................................................................. 3 1.2. Technical data............................................................................................................ 4 1.3. Equipment included ................................................................................................... 5 1.4. Dimensions ................................................................................................................ 6 1.5. Design ....................................................................................................................... 7 2. SAFETY PRECAUTIONS .................................................................................................. 8 3. STARTUP AND OPERATION...........................................................................................10 3.1. Preparing ..................................................................................................................10 3.2. Connecting to welding circuits ...................................................................................11 3.3. Positioning at the worksite ........................................................................................12 3.4. Starting .....................................................................................................................14 3.5. Programming ............................................................................................................14 3.6. Welding procedure ....................................................................................................16 3.7. Operating ..................................................................................................................17 3.8. Using oscillator (accessory) ......................................................................................18 3.9. Troubleshooting ........................................................................................................21 4. MAINTENANCE ...............................................................................................................22 5. ACCESSORIES ................................................................................................................23 5.1. Oscillator ...................................................................................................................23 5.2. Torch clamps ............................................................................................................25 5.3. Rods .........................................................................................................................26 5.4. Torch holders ............................................................................................................27 5.5. Torch extension arm .................................................................................................29 5.6. Guide arms ...............................................................................................................30 5.7. Dual torch mount .......................................................................................................35 5.8. Flexible guide set ......................................................................................................36 5.9. Guide adjustment tool ...............................................................................................38 5.10. 76 mm cross slide ...................................................................................................39 5.11. Display protection shield .........................................................................................40 5.12. Fall arrester .............................................................................................................40 5.13. Stainless steel wheels .............................................................................................41 6. 115–230 V EXPLODED VIEWS AND PARTS LIST ..........................................................42 7. 42 V EXPLODED VIEWS AND PARTS LIST ....................................................................47 8. 115–230 V WIRING DIAGRAM .........................................................................................52 9. 42 V WIRING DIAGRAM ..................................................................................................53 10. DECLARATION OF CONFORMITY ...............................................................................54 11. QUALITY CERTIFICATE ................................................................................................55 12. WARRANTY CARD ........................................................................................................56

3 1. GENERAL INFORMATION 1.1. Application The ARC Runner is a welding carriage designed to make continuous or stitch butt and fillet welds. The carriage allows MIG/MAG torches with the handle diameter of 16–22 mm (0.63–0.87’’). It is fixed by permanent magnets and can work in the following welding positions: PA/1F/1G, PB/2F, PC/2G, PD/4F, and PE/4G. Accessories allow, for instance, welding with oscillation, using torches with the handle diameter larger than 22 mm, using two torches at the same time, and guiding the carriage along outside edges, lap joints and templates, walls low or with holes, and on ceilings, pipes, and tanks.

4 1.2. Technical data Voltage 1~ 115–230 V, 50–60 Hz 1~ 42 V, 50–60 Hz (60 V DC) Power 25 W Welding position (according to EN ISO 6947 and AWS/ASME) Horizontal PA / 1F / 1G PB / 2F PC / 2G PD / 4F PE / 4G Vertical PF / 3F / 3G (with optional oscillator) PG / 3F / 3G (with optional oscillator) Minimum path curve radius 1500 mm (5 ft) Torch type MIG/MAG Torch diameter 16–22 mm (0.63–0.87’’) Maximum torch reach 80 mm (3.15’’) Maximum allowed cable weight Horizontal work 12 kg (27 lbs) Vertical work 8 kg (18 lbs) Minimum workpiece thickness 5 mm (0.20’’) Ground clearance 5 mm (0.20’’) Horizontal pulling force 220 N (48 lbs) Vertical pulling force 150 N (33 lbs) Cross slide adjustment range 0–35 mm (0–1.38’’, up-down, left-right) Guide arm adjustment range 0–75 mm (2.95’’) Horizontal speed 0–120 cm/min (0–47.2 in/min) Vertical speed 0–110 cm/min (0–43.3 in/min) Noise level Less than 70 dB Weight 14 kg (31 lbs)

5 1.3. Equipment included 1 Carriage 1 unit 2 Foam-filled cardboard box 1 unit 3 Cable anchor 1 unit 4 Short rod torch holder with clip 1 unit 5 3 m (10 ft) power cord 1 unit 6 6.5 m (21 ft) arc ignition cable 1 unit 7 4 mm hex wrench 1 unit – Operator’s Manual 1 unit 1 2 3 4 5 6 7

6 1.4. Dimensions 411 mm (16.2’’) 368 mm (14.5’’) 447 mm (17.6’’)

7 1.5. Design Lug for fall arrester Arc ignition socket Control panel Cross slide Oscillation socket Guide arm Power switch Limit switch Magnet ON/OFF lever LCD display Knob F1 Knob F2 Arc ignition switch (TEST / O / I) Travel direction switch (Left / O / Right) Speed adjustment knob

8 2. SAFETY PRECAUTIONS 1. Before starting, read this Operator’s Manual and complete proper occupational safety and health training. 2. Use the carriage only in applications specified in this Operator’s Manual. 3. The carriage must be complete and all parts must be genuine and fully functional. 4. The specifications of the power source must conform to those specified on the rating plate. 5. Connect the carriage into a properly grounded power source. 6. Never carry the carriage by the cords or arc ignition cable. Never pull them because this may damage them and result in electric shock. 7. Untrained bystanders must not be present near the carriage. 8. Before starting, ensure the correct condition of the carriage, power source, cords, arc ignition cable, plugs, control panel, and wheels. 9. Keep the carriage dry, and never expose it to rain, snow, or frost. 10. Keep the work area well lit, clean, and free of obstacles. 11. Never use near flammable liquids or gases, or in explosive environments. 12. Make sure that the rubber of the wheels is clean and not damaged. 13. Never remove the cover of the wheels. 14. Remove objects attracted to the chassis by the magnet. 15. Transport and position the carriage by using the carrying handle and only when the magnet ON/OFF lever is set to ‘O’. 16. Position the carriage on the ferromagnetic workpiece so that the wheels are in contact with the surface and no contact is between the surface and chassis. 17. Do not stay below the carriage placed at heights. 18. Plug the cords and arc ignition cable only when the power switch is set to ‘O’. 19. Keep the sockets clean. Do not use compressed air for cleaning. 20. Install only MIG/MAG torches whose handle diameter is the same as the diameter of the torch holder in use. 21. Do not position the torch more than 80 mm (3.15’’) outward from the left or right side of the carriage. 22. Keep the torch cables from coming in contact with the surface. They must be suspended to reduce the load of the carriage. Use only cables whose weight is not more than 12 kg (27 lbs) for horizontal work and 8 kg (18 lbs) for vertical work.

9 23. Never work on curves with convex or concave radius less than 1500 mm (5 ft). 24. At heights, use a fall arrester to protect the carriage from falling. 25. Always use eye protection (helmet, shield, and screen), hearing protection, gloves, and protective clothing during work. Do not wear loose clothing. 26. Before every use, inspect the carriage to ensure it is not damaged. Check whether any part is cracked or improperly fitted. Make sure to maintain proper conditions that may affect the operation of the carriage. 27. Never try to manually stop the travel. To stop, set the travel direction switch to ‘O’. 28. Maintain only when the carriage is unplugged from the power source. 29. Repair only in a service center appointed by the seller. 30. If the carriage falls from any height, is wet, or has any other damage that could affect the technical state of the carriage, stop the work and promptly send the carriage to the service center for inspection and repair. 31. Never leave the carriage unattended during work. 32. Remove from the worksite and store in a secure and dry place when not in use.

10 3. STARTUP AND OPERATION 3.1. Preparing Use the carrying handle to transport the carriage to the worksite. Then, set to ‘O’ all switches (power, travel direction, and arc ignition switch) and the magnet lever. Fig. 1. View from the back side Connect the carriage to the power source, insert the torch into the torch holder, and then secure it with the screws with the 4 mm hex wrench. Next, insert the torch cable into the cable anchor, secure it with the knobs, and then fix the anchor in the required position with the lever. Precise torch position adjustment knobs Knobs securing the cable in the anchor Lever securing the cable anchor Screws securing the torch in the holder Levers securing the torch position and angle Screws securing the guide arm Carrying handle

11 3.2. Connecting to welding circuits The carriage can control two torches by using the arc ignition cable plugged into the arc ignition socket. To do this, according to the diagram shown in Fig. 2 connect any blue-jacketed wire to any terminal of the welding circuit. Then, connect the second blue-jacketed wire to the second terminal of the same circuit. To control the second torch, connect the green-jacketed wires to the terminals of the second welding circuit. Fig. 2. Connecting the arc ignition cable to welding circuits To make sure that the arc ignition cable is connected correctly, turn on the power of the carriage, and then set the arc ignition switch to the position TEST. This should enable the arc for a while. blue blue Welding circuit 1 green green Welding circuit 2

12 3.3. Positioning at the worksite The guide arms must be positioned so that the carriage is in constant contact with the workpiece. They can be set by a constant step (interval adjustment), or continuously after they are swapped (continuous adjustment). To set them properly when the carriage travels to the left, use the 4 mm hex wrench to loosen the screws securing the right guide arm. Next, move out the right arm about 10 mm (0.4’’) or one groove more than the left arm (Fig. 3), and then retighten the screws. Fig. 3. Proper positioning of the guide arms The roller assemblies may be installed at the other end of the guide arms Interval adjustment Travel direction Continuous adjustment Swap the guide arms to change between methods of adjustment Grooves Moving out the right arm by one groove Lug for fall arrester

13 To position the carriage closer to the workpiece, use the 3 mm hex wrench to unscrew the roller assemblies. Next, install them at the other end of the guide arms, and then swap the guide arms (Fig. 3). Switch the magnet ON/OFF lever from left (‘O’) to right (‘I’). This will change the clamping force from minimum to maximum. Loosen the levers to adjust the position and angle of the torch. Use two knobs at the cross slide to precisely set the torch position. At heights, attach a fall arrester (not included) to a lug (Fig. 3) to prevent the carriage from falling. This will avoid possible injury to the operator in case the carriage loses the clamping. Do not stay below the carriage placed at heights.

14 3.4. Starting Plug the power cord into the power source and set the power switch to ‘I’ to turn on the power. Then, an initial screen with the current firmware number appears, and the carriage checks for an oscillator connected to the oscillation socket. If the oscillator is connected, appears. After the control system is loaded, the main menu from Fig. 4 appears. Fig. 4. Example of the main menu Press and hold the knob F1 for about 3 seconds to go into the configuration menu and set the welding parameters. 3.5. Programming The ARC Runner welding carriage allows defining up to 40 welding programs. After going into the configuration menu, proceed as described in Fig. 5 to move among the parameters from Tab. 1. Fig. 5. Configuration menu Current operating state Program number Unit of speed Value of speed Name of parameter. Rotate the knob F1 to change among parameters listed in Tab. 1. Value of parameter. Rotate the knob F2 to change the value by the higher step indicated in Tab. 1. Press and rotate the knob F2 to change the value by the lower step. Unit of parameter. Can be changed from the setting.

15 Parameter Value Description 0–130 cm/min 0–52 in/min [step: 1 or 0.1] Speed of the carriage. 1–250 cm 1–100 in [step: 1 or 0.1] Length of the single weld. 0–100 cm 0–40 in [step: 1 or 0.1] Space between welds. If set to zero, ‘crater fill’ and ‘backweld’ are reset and the carriage works in the continuous welding mode. 0–3 s [step: 0.1] Time of filling the crater. Inactive if ‘skip’ set to zero, which is indicated by the sign. YES NO Function of the welding source to lower the current of the arc while filling the crater. Time of filling the crater must be set higher or equal to the time of the current lowering that is set at the welding source. 0–2 cm 0–2 in [step: 0.1] Length of the backweld. Shorter or equal to ‘weld length’. Inactive if ‘skip’ set to zero, which is indicated by the sign. 0–1000 cm 0–400 in infinity [step: 10 or 1] Longer or equal to the sum of ‘weld length’ and ‘skip’. If set to infinity, the program executes until the carriage is stopped manually. cm in Unit used in the menu. 1–40 Pressing knob F2 saves the current configuration under the indicated program number. 1–40 Pressing knob F2 loads the configuration saved under the indicated program number. ENGLISH POLISH SPANISH FRENCH PORTUGUESE TURKISH GERMAN RUSSIAN Language of the menu. Tab. 1. Settings available in basic version of ARC Runner

16 To change the language of the menu, go to setting by rotating the knob F1 to the right and then rotate the knob F2 to choose among the available languages. After the rest of the parameters from Tab. 1 is set, go to , choose a program number by rotating the knob F2, and press the knob to save the current values under this number. The action is confirmed by showing message for a short time. To load a previously saved program, proceed as described, but from setting. Then, to go back to the main menu (Fig. 4), press the knob F1 and hold it for 3 seconds. If the chosen parameters are not saved, they will be active only until the current program number is changed in the main menu. 3.6. Welding procedure Fig. 6 shows a graphic description of the welding procedure that starts with the speed value shown in the main menu when selecting a travel direction. The first stage involves producing the weld, after which the carriage fills the crater (stage 2) for the chosen time. Next, the carriage performs the backweld (stage 3) and then moves to the starting point of the next weld (stage 4). This process is repeated until the carriage reaches the value of the total length. Fig. 6. Visualization of the welding procedure according to parameters from Tab. 1 (stage 1) (stage 3) Starting point of the first weld (stage 2) (stage 4) Final point of the welding procedure

17 3.7. Operating Set the power switch to ‘I’ to turn on the carriage. To control the torch via the carriage, set the arc ignition switch to ‘I’. With state shown on the main menu (Fig. 4) the current program can be changed by pressing and rotating the knob F2. Use the speed adjustment knob to change the current welding speed. Right rotation increases the speed by the step of 0.1, and left rotation decreases the speed by the same step. Use the travel direction switch to select a direction of travel. The carriage will start moving according to the chosen program parameters. The indication of the current operating mode will show on the display during program execution. The carriage speed can be changed during work with the speed adjustment knob. The new speed will be saved only if the current program does not change in the meantime. The carriage stops after reaching the total length and message shows on the display. Then, set the travel direction switch to ‘O’ to go into the main menu. After the work is finished, use the power switch to turn off the power, and then unplug the carriage from the power source. If the arc ignition switch is set to ‘I’, the torch will start welding promptly after selecting a travel direction.

18 3.8. Using oscillator (accessory) 3.8.1. Installing Install the oscillator according to the following instructions. • Remove the torch holder 1. • Remove the torch holder plate 2 by unscrewing screws 3 with 4 mm hex wrench. • Unscrew the cap 4. • Fix the arm 5 to the oscillator 6. • Fix the oscillator 6 to the bracket 7 with two M5x20 screws 8. • Fix the bracket 7 to the cross slide 10 with two M5x16 screws 9. • Fix the oscillator plug 11 to the oscillation socket 12. • Fix the low torch holder 13 to the oscillator arm 5. 4 2 3 1 8 7 9 12 10 6 11 5 13

19 3.8.2. Welding with oscillation If the oscillator is connected to the ARC Runner welding carriage, several new settings will appear in the menu (Tab. 2). Welding with oscillation is performed in the standard manner; however, produced welds form a shape similar to the shape shown in Fig. 7 instead of the straight line from Fig. 6. Parameter Value Description 0–100% [step: 10% or 1%] Relative amplitude of the oscillation. 0–100% [step: 10% or 1%] Relative speed of the oscillation. The higher the speed, the shorter the oscillation period. 0–5 s [step: 1 or 0.1] Dwell time in the top position of the oscillation. 0–5 s [step: 1 or 0.1] Dwell time in the bottom position of the oscillation. YES NO Choosing YES locks the capability of changing dwell times during welding. Tab. 2. Additional settings available with connected oscillator Fig. 7. Graphic description of the oscillation parameters from Tab. 2 Starting point of the weld Final point of the weld 1 /

20 3.8.3. Operating The ARC Runner welding carriage with connected oscillator is operated similarly to operating without the oscillator. During welding with the oscillator, the menu indicated in Fig. 8 is shown on the display. Fig. 8. Menu shown during welding with the oscillator If parameter is set to YES, pressing the knob F1 or F2 during work will not trigger any action. Otherwise, the delay parameters will show on the display and can be adjusted online (Fig. 9). Fig. 9. Menu for changing the oscillator dwell times Rotation of the knob F1 changes the oscillation amplitude by 1%. Rotation of the knob F2 changes the oscillation speed by 1%. Rotation of the knob F2 changes the delay 2 by 0.1 s. Pressing the F2 switches from showing delay 2 to oscillation speed. Rotation of the knob F1 changes the delay 1 by 0.1 s. Pressing the F1 switches from showing delay 1 to oscillation amplitude.

21 3.9. Troubleshooting Problem Cause Solution Dark LCD display after powering. Malfunction of the power cord, power switch, power supply unit, or controller. Contact service center for inspection and repair. Anomalies on the LCD display. Values illegible. Malfunction of the display or power supply unit. Contact service center for inspection and repair. Carriage reached the obstacle at the front. Remove the obstacle blocking the travel or choose the opposite travel direction. Carriage reached the obstacle at the rear. Remove the obstacle blocking the travel or choose the opposite travel direction. Too fast switching between left and right travel direction. Set the travel direction switch to ‘O’. 1. Travel direction switch not set to ‘O’ when powering. 2. Displayed during travel indicates a malfunction of the travel direction switch or travel direction identification circuit of the controller. 1. Set the travel direction switch to ‘O’. 2. Contact service center for inspection and repair.

22 4. MAINTENANCE Daily: 1. Clean the chassis and wheels. 2. Clean the rollers of the guide arms and make sure that the rollers rotate freely. 3. Clean the torch nozzle. Replace if damaged. Monthly: 1. Check whether the knobs and the switches work as intended. Replace if loose or damaged. 2. Inspect cables, cords, and hoses. Replace if damaged. 3. Tighten screws if loose.

23 5. ACCESSORIES 5.1. Oscillator Allows welding with oscillation. Can be installed either vertically to use a short rod low torch holder with clip (included) or horizontally to use a torch holder with clip (in standard). Oscillation type Pendulum (maximum 11°) Oscillation amplitude at r=150 mm (5.9’’) 1–30 mm (1–100%) Oscillation speed at oscillation amplitude of 10 mm (0.4’’) and zero dwell time on ends 7–164 cycles/min (1–100%) Dwell time on ends 0–5 s Maximum torque 5 Nm (3.7 lb·ft) Power 12 W Weight 2.6 kg (5.7 lbs) To obtain the proper shape of oscillation, the axis of the oscillator’s output shaft must cross with the axis of the torch. Part number: ZSP-0477-24-00-00-0 (includes: short rod low torch holder with clip)

25 5.2. Torch clamps 5.2.1. 16–22 mm torch clamp Allows using a torch with the handle diameter of 16–22 mm (0.63–0.87’’). 5.2.2. 16–22 mm torch clip Allows using a torch with the handle diameter of 16–22 mm (0.63–0.87’’). Use the 4 mm hex wrench to tighten the torch in the clip. 5.2.3. 22–35 mm torch clamp Allows using a torch with the handle diameter of 22–35 mm (0.87–1.38’’). Part number: ZRZ-0466-19-00-00-0 Part number: ZRZ-0466-04-01-00-0 Part number: ZCS-0476-06-01-00-0

26 5.3. Rods 5.3.1. Short rod Provides a 120 mm (4.72’’) reach. 5.3.2. Long rod Provides a 240 mm (9.45’’) reach. Part number: WLK-0476-20-01-00-0 Part number: WLK-0466-04-10-00-0

27 5.4. Torch holders 5.4.1. Short rod torch holder with clamp Allows using a torch with the handle diameter of 16–22 mm (0.63–0.87’’). 5.4.2. Short rod torch holder with clip Allows using a torch with the handle diameter of 16–22 mm (0.63–0.87’’). Use the 4 mm hex wrench to tighten the torch in the clip. 5.4.3. Short rod low torch holder with clip Allows using a torch with the handle diameter of 16–22 mm (0.63–0.87’’). Use the 4 mm hex wrench to tighten the torch in the clip. Part number: UCW-0476-20-00-00-0 Part number: UCW-0476-27-00-00-0 Part number: UCW-0476-06-00-00-0

28 5.4.4. Long rod torch holder with clamp Allows using a torch with the handle diameter of 16–22 mm (0.63–0.87’’). 5.4.5. Long rod torch holder with clip Allows using a torch with the handle diameter of 16–22 mm (0.63–0.87’’). Use the 4 mm hex wrench to tighten the torch in the clip. Part number: UCW-0466-22-00-00-0 Part number: UCW-0466-04-00-00-0

29 M5x16 M5x10 Part number: PRD-0466-43-00-00-0 5.5. Torch extension arm Extends the reach of the torch. Use the 4 mm hex wrench to unscrew the M5x10 screws fixing the cross slide. Next, use the same screws to fix the cross slide at the end of the arm as shown in the figure. Then, use M5x16 screws to fix the arm to the carriage.

30 5.6. Guide arms 5.6.1. Edge following guide arms Allow guiding the carriage along outside edges. Use the 4 mm hex wrench to unscrew the standard guide arms and install the new guide arms. Part number (2 units): PRW-0476-21-00-00-1

31 5.6.2. Adjustable guide arms Allow guiding the carriage along lap joints and templates. Use the 4 mm hex wrench to unscrew the standard guide arms and install the new guide arms. Part number (2 units): PRW-0476-22-00-00-1

32 5.6.3. Magnet guide arms Allow guiding the carriage on ceilings. Use the 4 mm hex wrench to unscrew the standard guide arms and install the new guide arms. Part number (2 units): PRW-0476-52-00-00-1

33 5.6.4. Low guide arms Allow guiding the carriage along low walls. Use the 4 mm hex wrench to unscrew the standard guide arms and install the new guide arms. To position the carriage closer to the workpiece, use the 3 mm hex wrench to unscrew the roller assemblies. Next, install them at the other end of the guide arms, and then swap the guide arms. Part number (2 units): PRW-0476-54-00-00-1

34 5.6.5. High guide arms Allow guiding the carriage along walls with holes. Use the 4 mm hex wrench to unscrew the standard guide arms and install the new guide arms. Part number (2 units): PRW-0476-55-00-00-1

35 5.7. Dual torch mount Allows using a second torch. Use the 5 mm hex wrench to unscrew the M6x20 screws and washers fixing the carrying handle. Next, use the same screws and washers to fix the mount to the carriage. Part number: PDT-0466-40-00-00-1

36 5.8. Flexible guide set Allows guiding the carriage on planes along a straight line, and on pipes and tanks. A single flexible guide is 1.85 m (6 ft) long, and its minimum curve radius is 1 m (3.3 ft). The holding force of a magnet block placed on a 5 mm (0.2’’) thick ferromagnetic surface is 90 N (20 lbs) up to a temperature of 100°C (212°F). At 180°C (356°F) the force decreases to 54 N (12 lbs). Connect two guides with the 3 mm hex wrench and M5x16 screws to form a butt or lap joint. Next, use the 4 mm hex wrench to remove the standard guide arms and install the new guide arms. Flexible guide (1 unit): PRW-0466-50-01-01-0 Magnet block set: BLO-0466-68-00-00-0 (includes: 10 magnet blocks and 22 screws M5x16) Butt joint Lap joint Guide arms (2 units): PRW-0476-50-01-00-1

38 5.9. Guide adjustment tool Allows the guide to be positioned parallel to an outside edge or a groove. Fix the magnets to the guide, and position the guide on the workpiece along the direction of welding. Loosen the levers and put the tool onto the first magnet, resting the side of the pilot pin on an outside edge or placing the tip of the pilot pin in a groove. Then, lock the levers in this position and pull the further part of the guide off the workpiece (1). Next, start moving the tool along the guide (2) to clamp the successive magnets to the workpiece. Part number: UST-0466-53-00-00-0 1 2

39 5.10. 76 mm cross slide Extends either up-down or left-right adjustment range from 0–35 mm (0–1.38’’) to 0–76 mm (0–3’’). Use the 4 mm hex wrench to remove the standard cross slide and install the new cross slide. Part number: ZSP-0466-46-00-00-1

40 5.11. Display protection shield Protects the display from dirt. Use the 2.5 mm hex wrench to unscrew the top screws of the panel, and use them to tighten the shield. 5.12. Fall arrester Protects the carriage from falling. The length of the line is 10 m (33 ft). Part number: OSL-0476-23-00-00-0 Part number: URZ-000001

41 5.13. Stainless steel wheels Allow working in horizontal position on a preheated plate. As shown in the figure, use the 2.5 mm hex wrench to remove the cover and use the 3 mm hex wrench to remove four wheels. Install in reverse order. Part number (1 unit): KOL-0476-57-00-00-0

42 6. 115–230 V EXPLODED VIEWS AND PARTS LIST 4 3 12 5 11 13 14 6 24 21 2 22 25 8 20 19 18 17 16 23 15 10 7 9 1 4 3 12 5 11 13 14 6 24 21 2 22 25 8 20 19 18 17 16 23 15 10 7 9 1

43 ITEM PART NUMBER DESCRIPTION Q-TY 1 KBL-0466-17-00-00-0 START-STOP ARC IGNITION CABLE 6.5 M (20 FT) 1 2 PWD-0466-18-00-00-0 POWER CORD 230V (CEE) 1 2 PWD-0466-21-00-00-0 POWER CORD 230V (AU) 1 2 PWD-0466-23-00-00-0 POWER CORD 120V (UK type G) 1 2 PWD-0466-16-00-00-0 POWER CORD 120V (USA) 1 2 PWD-0466-24-00-00-0 POWER CORD 3x1.5 – WITHOUT PLUG 1 3 PRW-0476-04-00-02-0 LEFT GUIDE ARM ASSY 1 4 PDT-0466-55-00-00-0 CABLE ANCHOR ASSY 1 5 UCW-0476-27-00-00-0 SHORT ROD TORCH HOLDER WITH CLIP ASSY 1 6 KLC-000007 4 MM HEX WRENCH 1 7 TRM-0219-06-16-00-0 CLAMP PLATE I 1 8 KST-0466-55-01-00-0 ANCHOR CLAMPING BLOCK 1 9 NKR-000121 KNURLED NUT M6 2 10 RKJ-000036 HANDLEVER M6-32 1 11 ZCS-0476-06-01-00-0 TORCH CLIP ASSY 1 12 WLK-0476-20-01-00-0 SHORT ROD ASSY 1 13 TLJ-0419-04-02-03-0 INSULATION SLEEVE 1 14 RKJ-000036 HANDLEVER M6-32 1 15 SRB-000177 HEX SOCKET HEAD CAP SCREW M5x22 2 16 PDK-000036 ROUND WASHER 5.5 4 17 OSL-0466-06-02-00-0 ROLLER COVER 2 18 RLK-0221-01-19-00-0 GUIDE ARM ROLLER 2 19 TLJ-0419-06-03-00-0 ROLLER SLEEVE 2 20 TLJ-0476-04-02-00-0 GUIDE ARM SLEEVE 2 21 RAM-0476-04-01-00-2 GUIDE ARM 2 22 WKR-000473 HEX SOCKET BUTTON HEAD SCREW M5x30 2 23 SRB-000123 HEX SOCKET HEAD CAP SCREW M6x35 1 24 NKR-0466-55-02-00-0 ANCHOR NUT 1 25 PRW-0476-04-00-01-0 RIGHT GUIDE ARM ASSY 1

44 13 17 91 40 7 3 43 26 57 14 53 51 75 58 68 73 39 21 66 76 86 83 81 8 9 89 77 44 82 30 32 73 24 59 35 64 22 61 20 10 38 56 34 27 50 48 1 16 20 55 54 31 12 60 11 47 72 19 45 46 23 29 36 80 78 88 33 41 79 42 85 87 84 49 25 63 18 28 37 4 5 52 62 74 6 2 68 67 69 71 70 92

45 ITEM PART NUMBER DESCRIPTION Q-TY 1 ZSP-0466-03-00-00-1 CROSS SLIDE ASSY 1 2 KUL-0466-13-00-00-0 LEVER BALL 1 3 ZSP-0476-01-00-00-0 DRIVE SYSTEM 1 4 GLK-0476-01-11-00-0 LEVER HOLDER 1 5 DZW-0476-01-12-00-0 LEVER 1 6 RKJ-0476-01-13-00-0 CARRYING HANDLE 1 7 PKR-0476-02-00-00-0 CONTROLLER HOUSING ASSY 1 8 PNL-0476-02-20-00-0 CONTROL PANEL ASSY 1 9 PLY-0476-03-00-00-0 TORCH HOLDER PLATE 1 10 WSP-0476-05-00-00-1 SLIDE BRACKET 1 11 SRB-0476-08-00-00-0 GUIDE ARM SCREW 4 12 USZ-0476-09-00-00-0 SEAL 1 13 PDK-000017 ROUND WASHER 5.3 4 14 PDK-000021 ROUND WASHER 6.4 4 16 WKR-000066 HEX SOCKET SET SCREW WITH CONE POINT M6x10 4 17 WKR-000092 HEX SOCKET BUTTON HEAD SCREW M4x10 6 18 WKR-000057 HEX SOCKET SET SCREW WITH FLAT POINT M6x6 1 19 SRB-000278 EYE BOLT M6 2 20 SRB-000075 HEX SOCKET HEAD CAP SCREW M5x10 8 21 SRB-000114 HEX SOCKET HEAD CAP SCREW M6x20 4 22 SRB-000083 HEX SOCKET HEAD CAP SCREW M5x16 4 23 WPS-0170-00-22-00-1 KEY 3x5x13 1 24 KRZ-0233-01-16-00-0 CAM 2 25 PDK-0233-01-21-00-0 DISTANCE WASHER 12.1x19x3 4 26 PDK-0233-01-23-00-0 WASHER 6.4x12x1.6 1 27 TLJ-0233-01-27-00-0 SLEEVE BEARING 9x16x10 1 28 TLJ-0233-01-28-00-0 SLEEVE BEARING 12x16x10 1 29 ZSP-0476-01-16-00-0 LIMIT SWITCH ASSY 1 30 KOL-0466-01-08-00-0 BEVEL GEAR z30 1 31 KRP-0476-01-01-00-1 BODY 1 32 WLK-0476-01-02-00-0 FRONT DRIVE SHAFT ASSY 1 33 WLK-0476-01-03-00-0 BACK DRIVE SHAFT ASSY 1 34 BLO-0476-01-04-00-0 MAGNET BLOCK ASSY 1 35 NPN-0476-01-05-00-0 CHAIN TENSIONER 1 36 RDK-0476-01-06-00-0 GEARBOX ASSY 1 37 KOL-0476-01-07-00-0 DRIVE WHEEL 4 38 OSL-0476-01-08-00-0 WHEEL GUARD RIGHT 1 39 OSL-0476-01-09-00-0 WHEEL GUARD LEFT 1 40 OSK-0476-01-10-00-0 SHAFT 1 41 LNC-0476-01-14-00-0 ROLLER CHAIN 1 42 ZSL-0476-01-15-00-0 POWER SUPPLY ASSY 1 43 NKR-000013 HEX NUT M4 2 44 NKR-000115 NUT M16x1.5 2 45 PRS-000005 EXTERNAL RETAINING RING 15z 2 46 KLK-000013 SPRING DOWEL PIN 4x16 2 47 OBJ-000002 HOLDER FOR FIXING LEADS 4 4 48 PRS-000018 INTERNAL RETAINING RING 28w 2 49 LOZ-000038 BALL BEARING 12x28x8 4

46 ITEM PART NUMBER DESCRIPTION Q-TY 50 PDK-000017 ROUND WASHER 5.3 4 51 PDK-000021 ROUND WASHER 6.4 1 52 PDK-000036 ROUND WASHER 5.5 4 53 PDK-000037 ROUND WASHER 6.5 1 54 PDK-000060 EXTERNAL TOOTH LOCK WASHER 4.3 2 55 WKR-000152 CROSS RECESSED COUNTERSUNK HEAD SCREW M4x16 1 56 WKR-000136 HEX SOCKET COUNTERSUNK HEAD SCREW M5x16 18 57 WKR-000097 HEX SOCKET COUNTERSUNK HEAD SCREW M5x12 1 58 SRB-000083 HEX SOCKET HEAD CAP SCREW M5x16 4 59 SRB-000061 HEX SOCKET HEAD CAP SCREW M4x10 2 60 WKR-000091 HEX SOCKET BUTTON HEAD SCREW M4x8 4 61 WKR-000092 HEX SOCKET BUTTON HEAD SCREW M4x10 10 62 SRB-000078 HEX SOCKET HEAD CAP SCREW M5x12 4 63 WKR-000290 HEX SOCKET BUTTON HEAD SCREW M6x12 1 64 USZ-0476-02-02-01-0 PANEL PLATE SEAL 1 65 MSK-0476-02-20-10-0 PANEL PLATE ASSY 1 66 MDL-0476-02-02-21-2 ELECTRONIC CONTROLLER ASSY 1 67 MDL-0476-02-02-30-1 ENCODER MODULE 1 68 PDK-000058 EXTERNAL TOOTH LOCK WASHER 3.2 7 69 WZK-0476-02-02-02-0 TRAVEL DIRECTION AND ARC IGNITION WIRE SET 1 70 OSL-000036 LEVER SWITCH COVER 2 71 PKT-000016 POTENTIOMETER KNOB 3 72* WZK-0476-02-07-00-0 POWER SWITCH WIRE SET 1 73 WKR-000181 CROSS RECESSED PAN HEAD SCREW M3x6 7 74 MDL-0476-02-02-22-2 DISPLAY MODULE 1 75 WZK-0466-02-09-00-0 POWER WIRE SET 1 76 PKR-0476-02-01-00-1 CONTROLLER HOUSING 1 77 DLW-000007 CABLE GLAND WITH STRAIN RELIEF PG11 1 78 SZP-0476-02-03-00-0 PIN 4 79 WZK-0476-02-04-00-0 ARC IGNITION SOCKET WIRE SET 1 80 WZK-0476-02-06-00-0 OSCILLATION SOCKET WIRE SET 1 81 NKR-000013 HEX NUT M4 1 82 NKR-000120 SOCKET CAP 1 83 PDK-000060 EXTERNAL TOOTH LOCK WASHER 4.3 2 84 PDK-000165 LOCK WASHER 12/19 1 85 PNK-000026 LEVER SWITCH 641H/3 1 86 WKR-000435 HEX SOCKET COUNTERSUNK HEAD SCREW M4x16 1 87 WKR-000287 HEX SOCKET BUTTON HEAD SCREW M3x10 4 88 ZLP-000025 PLUG M12 1 89 RKJ-000036 HANDLEVER M6-32 1 90* PWD-0476-10-00-00-0 GROUNDING WIRE 1 91 PDK-000045 SPRING WASHER 5.1 4 92 ZLP-000007 CAP 3 * not shown in the drawing

47 7. 42 V EXPLODED VIEWS AND PARTS LIST 2 4 3 12 5 11 13 14 6 24 21 22 25 8 20 19 18 17 16 23 15 10 7 9 1

48 ITEM PART NUMBER DESCRIPTION Q-TY 1 KBL-0466-17-00-00-0 START-STOP ARC IGNITION CABLE 6.5 M (20 FT) 1 2 PWD-0621-03-00-00-0 POWER CORD 42V 1 3 PRW-0476-04-00-02-0 LEFT GUIDE ARM ASSY 1 4 PDT-0466-55-00-00-0 CABLE ANCHOR ASSY 1 5 UCW-0476-27-00-00-0 SHORT ROD TORCH HOLDER WITH CLIP ASSY 1 6 KLC-000007 4 MM HEX WRENCH 1 7 TRM-0219-06-16-00-0 CLAMP PLATE I 1 8 KST-0466-55-01-00-0 ANCHOR CLAMPING BLOCK 1 9 NKR-000121 KNURLED NUT M6 2 10 RKJ-000036 HANDLEVER M6-32 1 11 ZCS-0476-06-01-00-0 TORCH CLIP ASSY 1 12 WLK-0476-20-01-00-0 SHORT ROD ASSY 1 13 TLJ-0419-04-02-03-0 INSULATION SLEEVE 1 14 RKJ-000036 HANDLEVER M6-32 1 15 SRB-000177 HEX SOCKET HEAD CAP SCREW M5x22 2 16 PDK-000036 ROUND WASHER 5.5 4 17 OSL-0466-06-02-00-0 ROLLER COVER 2 18 RLK-0221-01-19-00-0 GUIDE ARM ROLLER 2 19 TLJ-0419-06-03-00-0 ROLLER SLEEVE 2 20 TLJ-0476-04-02-00-0 GUIDE ARM SLEEVE 2 21 RAM-0476-04-01-00-2 GUIDE ARM 2 22 WKR-000473 HEX SOCKET BUTTON HEAD SCREW M5x30 2 23 SRB-000123 HEX SOCKET HEAD CAP SCREW M6x35 1 24 NKR-0466-55-02-00-0 ANCHOR NUT 1 25 PRW-0476-04-00-01-0 RIGHT GUIDE ARM ASSY 1

49 13 17 91 40 7 3 43 26 57 14 53 51 75 58 68 73 39 21 66 76 86 83 81 8 9 89 77 44 82 30 32 73 24 59 35 64 22 61 20 10 38 56 34 27 50 48 1 16 20 55 54 31 12 60 11 47 72 19 45 46 23 29 36 80 78 88 33 41 79 42 85 87 84 49 25 63 18 28 37 4 5 52 62 74 6 2 68 67 69 71 70 ITEM PART NUMBER DESCRIPTION Q-TY 1 ZSP-0466-03-00-00-1 CROSS SLIDE ASSY 1 2 KUL-0466-13-00-00-0 LEVER BALL 1 3 ZSP-0623-01-00-00-0 DRIVE SYSTEM 42V 1 4 GLK-0476-01-11-00-0 LEVER HOLDER 1 5 DZW-0476-01-12-00-0 LEVER 1 6 RKJ-0476-01-13-00-0 CARRYING HANDLE 1 7 PKR-0623-02-00-00-0 CONTROLLER HOUSING ASSY 42V 1

50 ITEM PART NUMBER DESCRIPTION Q-TY 8 PNL-0476-02-20-00-0 CONTROL PANEL ASSY 1 9 PLY-0476-03-00-00-0 TORCH HOLDER PLATE 1 10 WSP-0476-05-00-00-1 SLIDE BRACKET 1 11 SRB-0476-08-00-00-0 GUIDE ARM SCREW 4 12 USZ-0476-09-00-00-0 SEAL 1 13 PDK-000017 ROUND WASHER 5.3 4 14 PDK-000021 ROUND WASHER 6.4 4 16 WKR-000066 HEX SOCKET SET SCREW WITH CONE POINT M6x10 4 17 WKR-000092 HEX SOCKET BUTTON HEAD SCREW M4x10 6 18 WKR-000057 HEX SOCKET SET SCREW WITH FLAT POINT M6x6 1 19 SRB-000278 EYE BOLT M6 2 20 SRB-000075 HEX SOCKET HEAD CAP SCREW M5x10 8 21 SRB-000114 HEX SOCKET HEAD CAP SCREW M6x20 4 22 SRB-000083 HEX SOCKET HEAD CAP SCREW M5x16 4 23 WPS-0170-00-22-00-1 KEY 3x5x13 1 24 KRZ-0233-01-16-00-0 CAM 2 25 PDK-0233-01-21-00-0 DISTANCE WASHER 12.1x19x3 4 26 PDK-0233-01-23-00-0 WASHER 6.4x12x1.6 1 27 TLJ-0233-01-27-00-0 SLEEVE BEARING 9x16x10 1 28 TLJ-0233-01-28-00-0 SLEEVE BEARING 12x16x10 1 29 ZSP-0476-01-16-00-0 LIMIT SWITCH ASSY 1 30 KOL-0466-01-08-00-0 BEVEL GEAR z30 1 31 KRP-0476-01-01-00-1 BODY 1 32 WLK-0476-01-02-00-0 FRONT DRIVE SHAFT ASSY 1 33 WLK-0476-01-03-00-0 BACK DRIVE SHAFT ASSY 1 34 BLO-0476-01-04-00-0 MAGNET BLOCK ASSY 1 35 NPN-0476-01-05-00-0 CHAIN TENSIONER 1 36 RDK-0476-01-06-00-0 GEARBOX ASSY 1 37 KOL-0476-01-07-00-0 DRIVE WHEEL 4 38 OSL-0476-01-08-00-0 WHEEL GUARD RIGHT 1 39 OSL-0476-01-09-00-0 WHEEL GUARD LEFT 1 40 OSK-0476-01-10-00-0 SHAFT 1 41 LNC-0476-01-14-00-0 ROLLER CHAIN 1 42 ZSL-0623-01-01-00-0 POWER SUPPLY ASSY 42V 1 43 NKR-000013 HEX NUT M4 2 44 NKR-000115 NUT M16x1.5 2 45 PRS-000005 EXTERNAL RETAINING RING 15z 2 46 KLK-000013 SPRING DOWEL PIN 4x16 2 47 OBJ-000002 HOLDER FOR FIXING LEADS 4 4 48 PRS-000018 INTERNAL RETAINING RING 28w 2 49 LOZ-000038 BALL BEARING 12x28x8 4 50 PDK-000017 ROUND WASHER 5.3 4 51 PDK-000021 ROUND WASHER 6.4 1 52 PDK-000036 ROUND WASHER 5.5 4 53 PDK-000037 ROUND WASHER 6.5 1 54 PDK-000060 EXTERNAL TOOTH LOCK WASHER 4.3 2 55 WKR-000152 CROSS RECESSED COUNTERSUNK HEAD SCREW M4x16 1 56 WKR-000136 HEX SOCKET COUNTERSUNK HEAD SCREW M5x16 18 57 WKR-000097 HEX SOCKET COUNTERSUNK HEAD SCREW M5x12 1 58 SRB-000083 HEX SOCKET HEAD CAP SCREW M5x16 4 59 SRB-000061 HEX SOCKET HEAD CAP SCREW M4x10 2

51 ITEM PART NUMBER DESCRIPTION Q-TY 60 WKR-000091 HEX SOCKET BUTTON HEAD SCREW M4x8 4 61 WKR-000092 HEX SOCKET BUTTON HEAD SCREW M4x10 10 62 SRB-000078 HEX SOCKET HEAD CAP SCREW M5x12 4 63 WKR-000290 HEX SOCKET BUTTON HEAD SCREW M6x12 1 64 USZ-0476-02-02-01-0 PANEL PLATE SEAL 1 65 MSK-0476-02-20-10-0 PANEL PLATE ASSY 1 66 MDL-0476-02-02-21-2 ELECTRONIC CONTROLLER ASSY 1 67 MDL-0476-02-02-30-1 ENCODER MODULE 1 68 PDK-000058 EXTERNAL TOOTH LOCK WASHER 3.2 7 69 WZK-0476-02-02-02-0 TRAVEL DIRECTION AND ARC IGNITION WIRE SET 1 70 OSL-000036 LEVER SWITCH COVER 2 71 PKT-000016 POTENTIOMETER KNOB 3 73 WKR-000181 CROSS RECESSED PAN HEAD SCREW M3x6 7 74 MDL-0476-02-02-22-2 DISPLAY MODULE 1 75 WZK-0621-01-02-00-0 POWER WIRE SET 42V 1 76 PKR-0476-02-01-00-1 CONTROLLER HOUSING 1 77 DLW-000007 CABLE GLAND WITH STRAIN RELIEF PG11 1 78 SZP-0476-02-03-00-0 PIN 4 79 WZK-0476-02-04-00-0 ARC IGNITION SOCKET WIRE SET 1 80 WZK-0476-02-06-00-0 OSCILLATION SOCKET WIRE SET 1 81 NKR-000013 HEX NUT M4 1 82 NKR-000120 SOCKET CAP 1 83 PDK-000060 EXTERNAL TOOTH LOCK WASHER 4.3 2 84 PDK-000165 LOCK WASHER 12/19 1 85 PNK-000026 LEVER SWITCH 641H/3 1 86 WKR-000435 HEX SOCKET COUNTERSUNK HEAD SCREW M4x16 1 87 WKR-000287 HEX SOCKET BUTTON HEAD SCREW M3x10 4 88 ZLP-000025 PLUG M12 1 89 RKJ-000036 HANDLEVER M6-32 1 90* PWD-0476-10-00-00-0 GROUNDING WIRE 1 91 PDK-000045 SPRING WASHER 5.1 4 * not shown in the drawing

54 10. DECLARATION OF CONFORMITY EC Declaration of Conformity We PROMOTECH sp. z o.o. ul. Elewatorska 23/1 15-620 Białystok Poland declare with full responsibility that: ARC RUNNER WELDING CARRIAGE is manufactured in accordance with the following standards: • EN 12100 • EN 60745-1 • EN 60974-10 and satisfies safety regulations of the guidelines: 2004/108/EC, 2006/95/EC, 2006/42/EC. Person authorized to compile the technical file: Marek Siergiej, ul. Elewatorska 23/1, 15-620 Białystok Białystok, 4 March 2015 ___________________________ Marek Siergiej CEO

55 11. QUALITY CERTIFICATE Machine control card ARC RUNNER WELDING CARRIAGE □ 115–230 V □ 42 V Serial number ..................................................................... Electric test Type of test Result Name of tester Insulation electrical strength test (1000 V, 50 Hz) ................................... Date Continuity test of the protective earth system …........ Ω ................................... Signature Quality control ................................................. Adjustments, inspections Quality control .................................................

56 12. WARRANTY CARD WARRANTY CARD No........... .......................................................................... in the name of Manufacturer warrants the ARC Runner Welding Carriage to be free of defects in material and workmanship under normal use for a period of 12 months from the date of sale. This warranty does not cover wheels as well as damage or wear that arise from misuse, accident, tempering or any other causes not related to defects in workmanship or material. Date of production ......................................................................................................... Serial number ................................................................................................................ Date of sale ................................................................................................................... Signature of seller .......................................................................................................... 2.13 / 29 November 2017 WE RESERVE THE RIGHT TO MAKE CHANGES IN THIS MANUAL WITHOUT NOTICE