Download Miller Electric DS-64M Swingarc Specifications

OM-1 588
161 875L
October 1999
Miller
Processes
MIG
H
(GMAW) Welding
Pulsed MIG
The Power ofBlue.
Flux Cored
(GMAW-P)
(FCAW) Welding
Description
H
Wire Feeder
(Use
DS-64M
with
CC/CV Power Sources)
Swingarc
I
12 and 16 Foot
0
OWNERS
F
I
Visft
www
our
webs~te at
MiHerWelds
corn
MANUAL
0
From Miller to You
.
Thank you and
you
can
get the
you dont
Thats
congratulations on choosing Miller. Now
job done and get it done right. We know
have time to do it any other way.
why
when Niels Miller first started
building arc
sure
1929,
products offered
long-lasting value and superior quality. Like you, his
customers couldnt afford anything less. Miller products
had to be more than the best they could be. They had to
be the best you could buy.
welders in
he made
his
the
people that build and sell Miller products continue the
tradition. Theyre just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
Today,
~II~Wfl~
Working
This Owners
Miller
help
Manual is
products.
you protect
designed help you get the most out of your
Please take time to read the Safety precautions. They will
to
yourself against potential
hazards
on
the worksite. Weve
as hard as you do
every power source from
Miller is backed by the most
-
hassle-free warranty
business.
in
the
made installation and
operation quick and easy.
With Miller you can count on years of reliable
service with proper maintenance. And if for
iEiIIi1IIIi p
IREGISTERED
I
QUALITY SYSTEM
the unit needs
some reason
______________
Miller
is
equipment
the first welding
manufacturer in
the U.S.A. to be
the ISO 9001
registered to
Quality System
Standard.
repair,
theres
.
a
Troubleshooting section that will help you
figure out what the problem is. The parts list
will then help you to decide which exact part
you may need to fix the problem. Warranty and
service information for your particular model
are also provided.
Miller offers
a
Manual which
more
Technical
provides
detailed service and
parts information for your
unit. To obtain
a Technical
Manual, contact your local
distributor. Your distributor
can
also
Welding
supply you with
Process Manuals
sucha
GMA~
Miller Electric manufactures
of welders and
welding
For information
products,
on
a
full line
related
other
equipment.
quality Miller
contact your local Miller distributor
to receive the latest full line
individual
catalog
or
catalog sheets. To locate your nearest
distributor call 1-800-4-A-Miller.
V.P.
TABLE OF CONTENTS
SECTION 1
EMF Information
SECTION 1
1-1.
cause
in
birth defects
and,
some
cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)
READ BEFORE USING
1-5.
1-3.
This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
-
1-4.
1-2.
a WARNING
SAFETY PRECAUTIONS
-
Symbol Usage
Arc Welding Hazards
Additional Symbols for Installation, Operation,
Principal Safety Standards
1-1.
1-2.
1-3.
1
1
and Maintenance
-
Signification des symboles
Dangers relatifs au soudage a arc
Dangers supplØmentaires en relation
normes
1-5.
Information
sur
2-1.
5
5
avec
Iinstallation,
Ies
champs electromagnØtiques
9
Specifications
9
3-6.
3-7.
Control Box Connections
3-8.
14-Pin
3-9.
Motor Start Control
3-10.
Removing Safety
3-3.
3-4.
3-5.
9
10
10
11
12
13
14
14
Plug Information
15
Collar And
Adjusting
15
Boom
16
3-11. Gun Recommendation Table
Type, Size, And Feed Speed Capability
Installing And Threading Welding Wire
3-12. Wire
3-13.
Table
16
17
18
SECTION 4- OPERATION
18
4-2.
Operational Terms
Pulse Welding Terms
4-3.
Front Panel Control&
19
4-4.
Side And Rear Panel Controls
20
4-1.
18
SECTION 5- SETTING SEQUENCE PARAMETERS
5-1.
Parameters In A
Sequence
SECTION 6
Dual Schedule Pair
Selecting
6-2.
Dual Schedule Switch
7-1.
7-2.
7-3.
Diagrams
USING THE OPTIONAL DATA CARD
-
9-2.
9-3.
9-4.
9-5.
9-6.
9-7.
9-8.
22
22
23
24
Installing Data Card
Displays
25
24
Card
26
SYSTEM SETUP
-
System Setup Display
Program
Program
Program
Program
Program
Program
Program
Program
SECTION 10
10-1.
21
24
Parameters
SECTION 9- STANDARD PULSE WELDING PROGRAMS
9-1.
21
Data Card Terms
SECTION 8
8-1.
Program
SETTING DUAL SCHEDULE PARAMETERS
-
6-1.
SECTION 7
-
1
-
2
3
4
5
6
7
8
-
-
-
-
-
-
-
27
Steel
27
Steel
27
Steel
27
Stainless
28
Stainless
28
Nickel
28
Alloy
Silicon Bronze
CONTROL
SharpArc
Adjusting SharpArc Control
SETTING
Selecting
26
27
Steel
And
SECTiON 10- TEACH POINTS
28
.29
29
30
10-1. Teach
30
10-2.
31
10-3.
Using 15 Points
Teach Using 4 Points
Redefining Teach Points
SECTiON 11
-
MAINTENANCE AND TROUBLESHOOTiNG
32
34
11-1. Routine Maintenance
34
11-2. Error
35
11-3.
36
Displays
Troubleshooting
SECTiON 12- ELECTRICAL DIAGRAM
38
SECTION 13- PARTS LIST
40
WARRANTY
OM-1588
8
9
INTRODUCTION
Installing Swivel Into Pipe Post
Installing Control Box And Adjusting Tilt
Installing Boom And Reel Support
Installing Wire Guide Extension
Equipment Connection Diagram
Connecting Weld Cables And Gas Hoses
3-2.
le fonctionnement
8
de sØcuritØ
SECTION 3- INSTALLATION
3-1.
5
7
Principales
-
3
LIRE AVANT UTILISATION
et Ia maintenance
1-4.
SECTION 2
3
4
CONSIGNES DE SECURITE
-
1
.
SECTION 1
SAFETY PRECAUTIONS
-
READ BEFORE USING
-
som
Symbol Usage
1-1.
Means
4A
A
Watch
Warning!
Out!
There
hazards with this
Marks
1-2.
possible
are
procedure! The possible
adjoining symbols.
shown in the
hazards
are
This group
ELECTRIC
special safety message.
a
~ Means Note~
A
not
safety
of
symbols
means
Watch
Warning!
The
symbols
shown below
are used throughout this manual
identity possible hazards. When you
symbol, watch out, and followthe related instructions
safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1 -4. Read and
follow all Safety Standards.
see
the
A Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
If earth
with
grounding
of the
another electrode from
Use only well-maintained
parts
it
directly
in contact with the work,
ground,
workpiece
is
required, ground
cable.
separate
a
Do not touch electrode if you
or
a
are
different machine.
equipment. Repair or replacedamaged
according to manual.
at once. Maintain unit
Wear
a
Keep
all
safety
harness if
and
panels
Clamp work
or
cable with
worktable
as near
above floor level.
working
covers
good
securely
in
place.
metal-to-metal contact to workpiece
the weld
as
practical.
Insulate work
ELECTRIC SHOCK
can
kill.
clamp when not connected
any metal object.
contact with
Do not connect
live
electrical parts can cause fatal
shocks or severe burns. The electrode and work
circuit is electrically live whenever the output is on.
The input power circuit and machine internal
circuits are also live when power is on. In semiautomatic or
automatic wire welding, the wire, wire reel, drive roll housing, and all
metal parts touching the welding wire are electrically live. Incorrectly
installed or improperly grounded equipment is a hazard.
Touching
Do not touch live electrical
Wear
hole-free
dry,
Insulate
work
or
Do not
insulating gloves
big enough
ground.
a
and
required
use
for the
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before
touching any parts.
remote
ground
this
output control if present
equipment according
on
to its
Manual and national, state, and local codes.
-
making input connections,
-
attach
proper
grounding
double-check connections.
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
-
-
Turn off all
equipment
when not in
If ventilation is poor,
use an
Read
Safety
Material
the
Do not
use
worn,
manufacturers
drape
cables
over
your
body.
or
and gases. Breathing
be hazardous to your
can
use
exhaust at the
arc
to
approved air-supplied respirator.
Data
Sheets
(MSDS5)
instructions for metals, consumables,
and
the
coatings,
cleaners, and degreasers.
a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
Do not weld in locations
operations.
form highly
poorly spliced cables.
near
degreasing, cleaning,
The heat and rays of the arc
toxic and irritating gases.
Do not weld
cadmium
use.
damaged, undersized,
behazardouS~
head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or
remove welding fumes and gases.
on
can
or
spraying
react with vapors to
coated metals, such as galvanized, lead, or
unless the coating is removed from the
plated steel,
weld area, the
Do not
can
Work in
Always verify the supply ground check and be sure that input
power cord ground wire is properly connected to ground terminal
in disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
conductor first
these fumes and gases
health.
Keep your
welding process.
input power or stop engine before installing or
equipment. Lockout/tagout input power according
OSHA 29 CFR 191 0.147 (see Safety Standards).
When
work cable to any
or
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
if
this
install and
electrode
Welding produces fumes
or
Disconnect
Properly
one
FUMESAND GASES
AC output in damp areas, if movement is confined,
danger of falling.
output is required,
Owners
than
body protection.
unit.
servicing
more
output terminal.
ground using dry insulating mats
prevent any physical contact with the
to
Use AC output ONLY if
If AC
weld
workpiece to prevent
to
parts.
use
there is
single
yourself from work and
or covers
S
possible
hazards.
Consult symbols and related instructions below for necessary
actions to avoid the hazards.
related.
to avoid the hazard. The
to
Out!
SHOCK, MOVING PARTS, and HOT PARTS
Arc Welding Hazards
to call attention to and
A
_nd_4/98
area
is well
ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
OM-1588 Page 1
ARC RAYS
bum eyes and skin
can
BUILDUP OF
Shut off
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
GAScan injure
shielding gas supply when
not in
Always ventilate confined spaces
approved air-supplied respirator.
awelding helmetfitted with a proper shade of filterto protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
kill.
or
use.
or
use
.
Wear
HOT PARTS cancausesevere burns.
with side shields under your
approved safety glasses
Wear
helmet.
Do not touch hot parts bare handed.
protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
Allow
Use
before
cooling period
working
on
gun
or
torch.
protective clothing made from durable, flame-resistant
(leather and wool) and foot protection.
Wear
material
MAGNETIC FIELDS can affect pace nakers.
WELDING can cause fire or explosion.
Pacemaker
wearers
keep away.
Wearers should consult their doctor before
closed
Welding
on
drums,
pipes,
containers,
such as tanks,
them to blow up. Sparks
can fly off from the welding arc. The flying sparks,
hot workpiece, and hot equipment can cause fires
and burns. Accidental contact of electrode to metal objects can
cause sparks, explosion, overheating, orfire. Check and be surethe
area is safe before doing any welding.
Protect
yourself
or
and others from
Do not weld where
flying sparks
flying sparks
can
Remove all flammables within 35 ft
this is not
possible, tightly
going near arc welding, gouging,
welding operations.
can cause
cover
NOISE
fire,
and
Be
that
welding
aware
can cause
fire
Do not weld
on
keep
a
(10.7 m) of the welding arc.
approved covers.
extinguisher nearby.
ceiling, floor, bulkhead,
equipment
can
Wear
approved
ear
protection
if noise level is
high.
CYLINDERS can
partition
or
explode
if
damaged.
the hidden side.
on
closed containers such
as
tanks, drums,
as
or
welder to thaw frozen
close to the
welding
when not in
gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the welding
process, be sure to treat them carefully.
Protect
off
welding
wire at
compressed gas cylinders from excessive heat,
slag, open flames, sparks, and arcs.
mechanical shocks,
Install
or cut
cylinders in an upright position by securing to a stationary
or cylinder rack to prevent falling or tipping.
support
Keep cylinders away from any welding
use.
protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Never
Remove any combustibles, such as a butane
from your person before doing any welding.
Never weld
Wear oil-free
lighter or matches,
can
injure
eyes.
drape
Never allow
Use
FLYING METAL
a
a
welding
welding
on a
torch
over a
or
approved safety glasses with side
shields even under your welding helmet.
other electrical circuits.
gas cylinder.
electrode to touch any
pressurized cylinder
-
cylinder.
explosion
will result.
only
shielding gas cylinders, regulators, hoses,
fittings designed for the specific application; maintain them
associated parts in good condition.
correct
Turn face away from valve outlet when
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear
.
area as
pipes.
Remove stick electrode from holder
Shielding
pipes,
(see
to AWS F4.1
to
tip
or
If
prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
contact
processes
fire
on a
Connect work cable to the work
use
some
damage hearing.
them with
they are properly prepared according
Safety Standards).
Do not
damage hearing.
can
Noise from
strike flammable material.
unless
practical
spot
and hot metal.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Watch for
or
Keep protective cap in place
use or connected for use.
over
Read and follow instructions
associated
equipment,
valve
opening cylinder
except
when
and
and
valve.
cylinder is in
compressed gas cylinders,
publication P-i listed in Safety
on
and CGA
Standards.
.
OM-1588
Page
2
I -3.
And Maintenance
Symbols For Installation, Operation,
Additional
MOVING PARTS
FIRE OR EXPLOSION hazard.
Do not install
unit on, over,
place
or
Do not install unit
is
building wiring
properly sized, rated,
and
flammables.
sure
injury.
can cause
eye to lift unit
lifting
cylinders,
gear, gas
fans.
guards
power supply system
H.F. RADIATiON
Use
as
to handle this unit.
protected
FALUNG UNIT
such
all doors, panels, covers, and
closed and securely in place.
Keep
near
be
-
cause injury.
Keep away from moving parts
or near
combustible surfaces.
Do not overload
can
or
NOT
only,
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
Have only qualified persons familiar with
electronic equipment perform this installation.
any other accessories.
Use equipment of adequate
capacity
interference.
can cause
running
to lift and
support unit.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
The
is
user
promptly
responsible
having a qualified electrician
problem resulting from the
for
correct any interference
installation.
OVERUSE
Allow
can cause
cooling period;
Reduce current
starting
to weld
Do not block
or
STATIC (ESD)
Put
or
on
handling
OVERHEATING
follow rated
reduce
duty cycle.
duty cycle
grounded
boards
or
wrist
at once.
the FCC about interference,
regularly
stop using
the
checked and maintained.
doors and
panels tightly shut,
Keep high-frequency
keep spark gaps at correct setting, and use grounding and
shielding to minimize the possibility of interference.
source
filter airflow to unit.
damage PC
by
Have the installation
before
again.
can
If notified
equipment
boards.:
BEFORE
strap
parts.
ARC WELDING
static-proof bags and
store, move, or ship PC boards.
Use proper
can cause
interference.
boxes to
energy can interfere with
electronic equipment such as
Electromagnetic
sensitive
computers and computer-driven equipment
MOVING PARTS
can cause
such
injury.
Keep away from moving parts.
Keep away from pinch points such
as
robots.
all equipment in the welding
electromagnetically compatible.
Be
as
To reduce
drive
possible,
rolls.
sure
WELDING WIRE
can cause
injury
possible interference, keep weld cables as short as
together, and down low, such as on the floor.
welding operation
equipment.
Be
sure
according
Do not press gun
trigger until
instructed to do
is
close
Locate
tronic
area
this
welding
100 meters from any sensitive elec
machine
is installed
and
grounded
to this manual.
If interference still occurs, the user must take extra measures
as moving the welding machine, using shielded cables,
so.
such
point gun toward any part of the body,
people, or any metal when threading
welding wire.
using
Do not
line
filters,
or
shielding
the work
area.
other
1-4
Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49. 1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten
dent of Documents, U.S. Government Printing Office, Washington,
Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-i, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
Safe
and
Code for Safety in Welding and Cutting, CSA Standard Wi 17.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1 R3.
of Containers That Have Held Hazardous Substances,
American Welding Society Standard AWS F4.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
Protection, ANSI Standard Z87.1,from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Code, NFPA Standard 70, from National Fire
Association, Batterymarch Park, Quincy, MA 02269.
Cutting And Welding Processes, NFPA Standard SiB, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
D.C. 20402.
Recommended Safe Practices for the
Preparation
for
Welding
Cutting
National Electrical
Protection
Safe Practices For
Occupation
And Educational
Eye
And Face
OM-i588
Page
3
EMF Information
1-5
And The Effects Of Low
Frequency
1.
Keep
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
2.
Arrange
3.
Do not coil
Considerations About
Welding
Electric And
Fields
Magnetic
years of research, a special blue ribbon committee of the National
Research Council concluded that: ~The body of evidence, in the
committees judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding
To
magnetic
cables to
or
together by twisting
one
drape
or
taping
side and away from the
cables around your
Keep welding power
practical.
source
Connect work
to
and cables
them.
operator.
body.
as
far away from opera-
tor as
5.
clamp
workpiece
as
close to the weld
as
possible.
About Pacemakers:
cutting.
or
reduce
4.
cables close
fields in the
workplace,
use
the
following
Pacemakerwearersconsultyourdoctorfirst. If cleared byyourdoctor,
following the above procedures is recommended.
then
procedures:
.
.
OM-1588
Page
4
SECTION 1
CONSIGNES DE SECURITE
UTI LISATION
-
LIRE AVANT
-
som
SignificatIon
1-1.
symboles
Signif~e Mise en garde! Soyezvigilant! Cette procedure
prØsente des risques de danger! Ceux-ci sont identifies
par des symboles adjacents aux directives.
4~
A
des
Identifie
message de sØcuritØ
un
~
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant! IIy a des
risques de danger relies aux CHOCS ELECTRIQUES, aux PIECES EN
particulier.
MOUVEMENTetaux PIECESCHAUDES.
Reportez-vousauxsymboles
etauxdirectives ci-dessous afinde connaItre les
~
Signifie
nest
Øviter tout
pas relatif A Ia sØcuritØ.
Dangers relatifs
1-2
A
NOTA
au
soudage a
Les symboles prØsentØs ci-aprŁs sont utilisØs tout au long du
present manuel pour attirer votre attention et identifier les
risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnØes atm dØviter tout
danger. Les consignes de sØcuritØ prØsentØes ci-aprŁs ne font
vent Œtre confiØs
A
Au coursde
qu
reparations
qualifiees.
et les
lutilisation, lentretien
Linstallation,
des personnes
a
ne
avec
en
Ia
piŁce a souderou
quand
place
facon
travaille
on
hauteur.
en
tous les panneaux et
a obtenir
capots.
bon contact mŁtal-mŁtal
un
latable detravail, le
plus prŁs possible de Ia
soudure.
Isoler Ia
pince de masse quand pas mis a Ia piŁce pour Øviter
objet metallique.
le contact
peut tuer
Ily
toucher les
harnais de sŁcuritŁ
Fixer le cable de retour de
doi
contact avec des
piŁces Łlectriques peut
provoquer une electrocution ou des blessures graves.
LŁlectrode et le circuit de soudage sont sous tension
des que lappareil est sur ON. Le circuit dentrØe et les
circuits internes de lappareil sont Øgalement sous
tension ace moment-l. Ensoudagesemi-automatique ouautomatique,
le fil, le dŁvidoir, le logement des galets dentraInement et les piŁces
mØtalliques en contact avec le fil de soudage sont sous tension. Des
matØriels mal installØs ou mal mis a Ia terre prØsentent un danger.
jamais
un
Maintenir solidement
avec tout
UN CHOC ELECTRIQUE
Ne
prendre pour
manuel.
ce
Porter
lutilisation, tenirtoute personne a lØcartet plus par
simple
a
Nutiliser quun materiel en bon Øtat. RØparer ou remplacer sur-le
champ les piŁces endommagŁes. Entretenir lappareilconformØment
ticuliŁrement les enfants.
Un
mesures
danger.
Iarc
que rØsumer Iintormation contenue dans les normes de sØcuritØ
ØnumØrØes a Ia section 1-4. VeuiHez lire et respecter toutes ces
normes de sØcuritØ.
A
fre 4/98
_nd
DU COURANT CONTINU IMPORTANT dans les
a
convertisseurs
tion
aprŁs
Ia
suppression
de Ialimenta
Ølectrique.
ArrŁter les convertisseurs, dŁbrancher le
courant
electrique,
et dŁ
selon les instructions
charger les condensateurs dalimentation
indiquees dans Ia partie entretien avant de
toucher les
piŁces.
piŁces Ølectriques sous tension.
protection secs ne comportant
Porter des gants et des vŒtements de
pas de trous.
de Ia piŁce et de Ia terre au moyen de tapis ou dautres
moyens isolants suffisamment grands pour empŒcher le contact phy
sique Łventuel avec Ia piŁce ou Ia terre.
Sisoler
Ne pas
se
humides, dans
Se seivir dune
procØdØ
de
se
es
source
source
soudage
Si lutilisation
saire,
courant Ølectrique dans les
endroits confines ou l o on risque de tomber.
servir de
dune
Ølectrique
Ølectrique
courant
electrique
zones
-~
=5
source
Ølectrique
courant
~
Eloigner votre tŒte des fumŁes. Ne pas
les fumŁes.
_____________
Ølectrique
lappareil
savŁre
en
est
nØces
Øquipe.
-
raccordŁ ala
borne deterre du sectionneurou que Ia fiche du cordon est raccordŁe
a une prise correctement mise a Ia terre.
terre du cordon dalimentation
est bien
En effectuant les raccordements dentrŁe fixer dabord le conducteur
de mise a Ia terre approprie et contre-vŁriller les connexions.
Verifier
frŁquemment le cordon dalimentation pour voir sil nest pas
endommagØ oudŁnudØ remplacer le cordon immŁdiatement sil est
endommagŁ un cable dŁnudØ peut provoquer une electrocution.
Mettre lappareil hors tension quand on ne Iutilise pas.
Ne pas utiliser des cables uses, endommagŁs, de grosseur insuffi
sante ou mal ŁpissØs.
-
-
Ne pas enrouler les cables autour du corps.
Si Ia piŁce soudŁe doit Œtre mise a laterre, le faire directement avec
cable distinct.
Ne pas toucher lŁlectrode
terre ou une electrode
quand
on est en
contact avec Ia
piŁce,
A
I
Le soudage gŁnŁre des fumŁes et des gas. Leur
inhalation peut Łtre dangereux pour votre sante.
UNIQUEMENT si le
servir de Ia fonction de tØlØcommande Si
que le fil de
~ tredangereuL.
le demande.
Couperialimentation ou arrŒterle moteuravantde procØderlinstal
lation, a a reparation ou a lentretien de lappareil. DŁverrouiller
lalimentation selon Ia norme OSRA29 CFR 1910.147 (voir normes
de sŁcuritØ).
Installer et mettre a laterre correctement cet appareil conformØment
et aux codes nationaux, provinciaux et
son manuel dutilisation
municipaux.
Verifier et sassu
Toujours verifier Ia terre du cordon datimentation
rer
LES FIJMEES ET LES GAZ peuvent
~
lintŁrieur,
veau
ventiler Ia
zone
respirer
etlou utiliser un echappement au ni
des fumŁes et des gaz de soudage.
de larc pour lŁvacuation
Si Ia ventilation est insuffisante, utiliser
tion dair homo!oguŁ.
un
respirateur
a alimenta
Ure les spŁcificationsde sŁcuritŁ des matŁriaux (MSDSs) et les ins
tructions du fabricant concernant les mŁtaux, les consommables,
les
revŒtements, les nettoyants
et les
dŁgraisseurs.
espace fern,Ł seulement sil est bien ventilŁ ou
en portant un respirateur a alimentation dair. Demander toujours a
un surveillant dOment formŁ de se tenir a proximitŁ. Des fumŁes et
des gaz de soudage peuvent dŁplacer lair et abaisser le niveau
doxygŁne provoquant des blessures ou des accidents mortels.
Travailler dans
Sassurer
un
que lair de
respiration
ne
prŁsente
aucun
danger.
Ne pas souder dans des endroits situŁs a proximitØ dopØrations de
degraissage, de nettoyage ou de pulvŁrisation. La chaleur et les
rayons de larc peuvent reagir en presence de vapeurs et former
des gaz hautement toxiques et irritants.
Ne pas souder des mŁtaux munis dun revŒtement, tels que lacier
galvanise, plaque en p10mb ou au cadmium a moms que le revŒte
ment nait ŁtŁ enlevŁ dans Ia zone de soudure, que lendroit soil
bien ventilŁ, et si nŁcessaire, en portant un respirateur a alimenta
tion dair. Les revŒtements et tous les mŁtaux renferniant ces ØlØ
ments peuvent degager des fumŁes toxiqueS en cas de soudage.
un
Ia
provenant dune autre machine.
OM-1 588
Page
5
LES RAVONS DEL~ARC peUvent pro
:.~quer des bfl~tureSdans les yeux et
surla P~1
des brlures
pendant
le
.1.
I
.:,
de Iarc du procØdØ de soudage
gØnŁre des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer
dans es yeux et sur Ia peau. Des Øtincelles sont projetØes
Le
LES ACCUMULATIONS EDE GAz ris
rayonnement
soudage.
quentde provoquerdØs blessures:u
rnŒmelamort.
CJ
Fermer Ialimentation
non
Veiller
toujours a bien aØrer
rateur dadduction
Porter un casque de soudage muni dun Øcran defiltre appropriØ pour
protØger votre visage et vos yeux pendant le soudage ou pour regar
der (voir ANSI Z49. 1 et Z87. 1 ØnumØrØ dans les normes de sØcuritØ).
Porter des protections
approuves
Utiliser des Øcrans
des barriŁres pour
ou
ne
pas
Porter des vŒtements de protection constituØ dans une matiŁre dura
au feu (cuir ou lame) et une protection des pieds.
m
~EJ
~
LE SOUDAGE
incendie u
peut provoquerun
explosion.
souda~e
effectuØ
Se protØger et dautres
metal chaud.
personnes de
ment passer dans dautres
des ouvertures.
a
projection dØtincelles
des Øtincelles
zones en
traversant de
SurveillertoutdŁclenchementdincendieettenirun
mite.
soudage effectuŁ
peut dØclencher
un
Ne pas effectuer le
Brancher le cable
sur un
incendie de lautre
soudage
chaudes a mains
une
le
pØriode
pistolet
ou
de refroidissement avant
Ia torche.
cardiaques.
Les
porteurs dun stimulateur cardiaque doivent
consulter leur mØdecin avant de
operations de soudage a arc,
soudage par points.
des
de
sapprocher
de gougeage
Cu
Le bruit des processus at des
IouIe.
Porter des
ou
ctØ.
provoquant des risques dØlec
Des bouteilles de gaz protecteur contiennent du gaz
haute pression. Si une bouteille est endomma
gee, elle peutexploser. Du fait qua las bouteilles degaz
font normalement partie du procØdŁ de soudage, es
dŁgeler
des conduites ge
utilisation, enlever Ia baguette dØlectrode du porte
couper le fil a Ia pointe de contact.
Porter des vØtements de protection dØpourvus dhuile tels que des
gants en cuir, une chemise en matØriau lourd, des pantalons sans re
vers, des chaussures hautes et un couvre chef.
non
Avant de souder, retirer toute substance combustible de
telles quun allumeur au butane ou des allumettes.
vos
poches
peUventblesser
NTES
tes yeux~
precaution.
Proteger les bouteilles de gaz comprimŁ dune chaleur excessive,
des chocs mŁcaniques, du laitier, des flammes ouvertes, des Øtin
le passage de Ia piŁce
fil defer, et le meulage gŁnŁrent
desØtincellesetdes particules mŁtalliquesvolan
en
pØriode de refroidissement des soudures,
elles
risquent
du laitier.
Øcrans latØraux
cu un
arcs.
Placer les bouteilles debout en les fixant dans un support station
naire ou dans un porte-bouteilles pour les empŒcher de tomber ou
de se renverser.
ØloignŁes des circuits de soudage ou autres cir
Tenir les bouteilles
cuits electriques.
Ne
jamais placer
Une electrode de
une
torche de
une
soudage
ne
soudage sur une bouteille a gaz.
jamais entrer en contact avec
doit
bouteille.
jamais
souder
Ne pas tenir Ia tŒte
bouteille.
soudage, lØcaillement,
avec
avec
une
bouteille
pressurisØe
-
risque dexplosion.
Utiliser seulement des bouteilles de gaz protecteur, rØgulateurs,
tuyaux et raccords convenables pour cette application specifique;
les maintenir ainsi que les ŁlŁments associØs en bon etat.
_____
Porter des lunettes de sØcuritØ
manipuler
Ne
DES PARTICIJLES VOL
a Ia brosse
sous
celles et des
pour
oreilles si
Si des BOUTEILLES sont endomma
gØes, elles pourront exploser.
separation
Ia
soudage
protections approuvØs pour les
trop ØlevØ.
affecter
le niveau sondre est
sur
en
equipements peut
extincteurproxi
ou
Le
PrØvoir
dutiliser
petites fissures et
piŁce le plus prŁs possible de Ia zone de sou
transport du courant sur une longue distance par
sur
Ne pas utiliser le poste de
lees.
projeter
parties
peuvent tomber
plafond, plancher, paroi
pour Øviter le
des chemins inconnus Øventuels
trocution et dincendie.
dage
de
pro
et de
sØcuritØ).
tes. Pendant Ia
PI¨CES CHAUDESpØuvent
dabord
des conteneurs fermØs tels que des
reservoirs, tambours, ou conduites, a moms quils naient ØtŁ prØpa
rØs correctement conformŁment a AWS F4.i (voir les normes de
de
respi
Porteurs de stimulateur cardiaque, restez a distance.
DØplacertoutes les substances inflammables a une distance del 0,7
m de larcde soudage. En cas dimpossibilitØ les recouvrirsoigneuse
ment avec des protections homologuØs.
Des Øtincelles et des matØriaux chauds du soudage peuvent facile
cas
servir dun
LE BRUIT peut affecter louIe.
Ne pas souder dans un endroit l o
sur des substances inflammables.
En
ou se
affecter les stimulateurs
sur
provo9uerleurØclatement.
electrode
espaces confines
LES CHAMPS MAGN TIQUES peuvent
une
des conteneurs fermØs tels
que des reservoirs, tambours ou des conduites peut
Des Øtincelles peuventØtre
projetees de larc de soudure. La projection dØtincel
les, des piŁces chaudes et des Øquipements chauds peut provoquer des
incendies et des brlures. Le contact accidentel de lØlectrode avec des
objets mØtalliques peut provoquer des Łtincelles, une explosion, un
surchauffement Cu Ufl incendie. Avant de commencer le soudage,
verifier et sassurer que lendroit ne presente pas de danger.
Le
Le
es
flues
ble, resistant
(~.
de
homologue.
Ne pas toucher des
re
Iarc.
garder
cas
Øclair
protØger des tiers de
lØblouissement; demander aux autres personnes de
en
voquer des brOlures graves.
trop ØlevØ.
et de
dair
DES
pour les oreilles Si le niveau sondre est
du gaz protecteur
utilisation.
en
face de Ia sortie
Maintenir le chapeau de protection
dutilisation ou de branchement de
en
Ia soupape, sauf
bouteille.
sur
a
ouvrant Ia soupape de Ia
en cas
Lire et suivre les instructions concernant les bouteilles de gaz corn
les Łquipements associØs et les publications P-i CGA Ønu
mØrØes dans les normes de sØcuritØ.
prime,
Øcran facial.
.
OM-1588
Page
6
1-3.
Dangers supplØmentairesefl relation
avec
Iinstallation, le fonctionnement
etla maintenance
DES ORGANES MOBILES
provoquerdes blessures.
Risque DINCENDIE OU
DEXPLOSION.
Ne pas
sur, au-dessus
de surfaces infliammables.
placer lappareil
proximitØ
ou
Rester a lØcart des organes mobiles
a
MaintenirfermØsetfixementen place les portes,
panneaux, recouvrements et dispositifs de
lappareil a proximitØ de produits inflammables
pas surcharger linstallation electrique sassurer que lalimen
-
protØgØ
le
comme
ventilateur.
Ne pas installer
Ne
tation est correctement dimensionnØ et
lappareil en service.
peuvent
protection.
avant de mettre
LE RAVONNEMENT HAUTE FRE
QUENCE (HF.) risque de provoquer
LA CHUTE DE LAPPAREIL
des interferences.
peut
blesser.
Lerayonnementhautefrequence peutprovoquer
avec les Øquipements de ra
dio-navigationetde communication, lesservices
des interferences
Utiliser lanneau de levage uniquement pour sou
lever lappareil, NON PAS les chariot, es bouteil
les de gaz ou tout autre accessoire.
dune
capacitØ appropriØe
engin
pour
lappareil.
En utilisant des fourches de levage pour dØplacer lunitØ, sassurer
que lesfourches sont suffisamment longues pour dØpasser du ctØ
oppose de lappareil.
Utiliser
un
soulever
de sØcuritØ et les ordinateurs.
Demander seulement a des personnes qualifiees familiarisØes
avec des Øquipements Ølectroniques de faire fonctionner installa
tion.
Lutilisateur est tenu de faire
qualifie
corriger rapidement par
les interferences resultant de linstallation.
Si le FCC
signale des interferences, arrŒter
un
Ølectricien
immØdiatement
lappa
reil.
Effectuer
L~EMPLOI EXCESSIF peut
SURCHAUFFER
rØguliŁrement
le contrle
correcte et utiliser une terre et et un
PrØvoir une pØriode de refroidissement, respec
ter le cycle opØratoire nominal.
RØduire le courant ou le cycle
recommancer le soudage.
ELECTROSTATIQUES
Ia connexion avec Ia barrette de terre
avant de manipuler des cartes ou des pieces.
pochettes et des boites antistatiques
expØdier des
cartes de
DES :ORGANES M9BILES peuvent
:pmvoquer:des blesŁures..
Ne pas
sapprocher
des organes mobiles.
Ne pas sapprocher des points de coincement
tels que des rouleaux de conimande.
LES FILS DE SOUDAGE peuvent pro
~
vquer;des bIessUrØS.:~I
LØnergie
ØlectromagnØtique
Veiller a
Ne pas
le fil de
gachette
avant den
avoir
pistolet vers soi, dautres per
piŁce mecanique en engageant
soudage.
diriger
le
sonnes ou toute
inter
risque
de
robots.
lequipement de Ia zone de soudage soit com
patible ØlectromagnØtiquement.
Pour rØduire Ia possibilitØ dinterfØrence, maintenir les cables de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
Veiller a souder a une distance de 100 metres de tout Øquipement
electronique sensible.
Veiller a ce que ce poste de soudage soit pose et mis a Ia terre
Ce
que tout
conformØment a
ce
mode
demploi.
En cas dinterfØrences aprØs avoir pris les mesures prØcØdentes, 1
incombe a lutilisateur de prendre des mesures supplØmentaires
telles que le dØplacement du poste, lutilisation de cables blindØs,
lutilisation de flltres de ligne ou Ia pose de protecteurs dans Ia zone
de travail.
LES CHAMPS MAGNETIQUES peuvent
affecter lØs :stimulateurs cardiaques.
Porteurs de stimulateur
Ne pas appuyer sur Ia
recu linstruction.
es
provoquer des interferences pour lØquipement
Ølectronique sensible tel que les ordinateurs et
tØquipement commandØ par ordinateur tel que
es
Etablir
ou
pour rØduire
LE SOUDAGE A LARC
risque de
provoquer des interferences.
primes.
Utiliser des
blindage
opØratoire avant de
peuvent endommager lescircuits im
pour stocker, dØplacer
circuits imprimes.
de installation.
fØrences Øventuelles.
Ne pas obstruer les passages dair du poste.
LES CHARGES
et lentretien
Maintenir soigneusement fermØs es portes et les panneaux des
sources de haute frØquence, maintenirles Øclateurs une distance
L~EQUIPEMENT.
cardiaque,
restez a dis
tance.
Les porteurs dun stimulateur cardiaque doivent
dabord consutter leur mØdecin avant de sappro
cher des operations de soudage a larc, de gou
geage
ou
de
soudage par points.
OM-1 588
Page
7
1-4
Principales
normes
de securite
Safetyin Welding and Cutting, norme ANSI Z49. 1, de American
ding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safetyand Health Sandards,
Wel
Safe
Superintendent
Printing Office, Washington, D.C.
Gases in
Cylinders,
CGA
Pamphlet
de sØcuritØ en soudage, coupage etprocØdØs connexes, norCSA Wi 17.2, de lAssociation canadiennede normalisation, vente
de normes, 178 Rexdale Boulevard, flexdale (Ontario) Canada M9W
1R3.
mi FL 33126
1430
Code, NFPA Standard 70, de Ia National Fire Pro
Batterymarch Park, Quincy, MA 02269.
tection Association,
sur
.
me
tion,
fnformation
Compressed
RŁgles
Recommended Safe Practice for the Preparation for Welding and Cut
ting of Containers That Have Held Hazardous Substances, norme
AWS F4. 1, de American Welding Society, 550 N.W. Lejeune Rd, Mia
1-5.
of
OSHA 29 CFR 1910, du
of Documents, U.S. Government
20402.
National Electrical
Handling
P-i, de Ia Compressed Gas Association, 1235 Jefferson Davis High
way, Suite 501, Arlington, VA 22202.
les
Safe Practices ForOccupationAnd Educational EyeAnd Face Protec
ANSI Z87.1, de lAmerican National Standards Institute,
New York, NY 10018.
norme
Broadway,
Cutting and Welding Processes, norme NFPA SiB, de Ia National
Protection Association, Batterymarch Park, Quincy, MA 02269.
Fire
champs ØlectromagnØtiques
DonnØes
Afin de rØduire les
des
de
sur le soudage electrique et sur les effets, pour lorganisme,
champs magnØtiques basse frequence
soudage, pendant son passage dans es cables de sou
dage, causera des champs electromagnetiques. II y a eu et il y a
encore un certain souci a propos de tels champs. Cependant, aprŁs
avoir examine plus de 500 etudes qui ont ØtØ faites pendant une pe
1
Garder les cables ensembles en les torsadant
attachant avec du ruban adhØsif.
2
Mettre tous
3
Ne pas courber pas et
Le courant de
node de recherche de 17 ans, un comitØ special ruban bleu du
National Research Council a conclu: Laccumulation
de preuves, sui
jugement du comitØ, na pas dØmontrØ que lexposition aux
champs magnØtiques et champs Ølectriques a haute frequence reprØ
sente un risque a Ia sante humaine.
Toutefois, des etudes sont
toujours en cours et les preuves continuent a Œtre examinØes. En at
tendant que es conclusions finales de Ia recherche soient Øtablies, il
vous serait souhaitable de rØduire votre exposition aux champs Ølec
tromagnØtiques pendant le soudage ou le coupage.
champs ØlectromagnØtiques dans Ienvironnement
travail, respecter les consignes suivantes
es
cables du ctØ
ne
oppose
de
les
ou en
IopØrateur.
pas entourer pas
es
cables autour de
votre corps.
4
Garder le poste de
de
soudage
et les cables le
plus
loin
possible
vous.
vant le
5
Relier
pince
a
de
masse
le
plus prŁs possible
de Ia
zone
de
soudure.
Consignes
relatives
aux
stimulateurs
cardiaques
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur docteur. Si vous Œtes dØclarØ apte par votre docteur, il
est alors recommandØ de
respecter
les
consignes
ci-dessus.
.
.
OM-1 588
Page
8
SECTION 2- INTRODUCTION
Specifications
2-1.
Type
of
Source
Amperes
50/60 Hertz
Wire Diameter
Wire Feed
Speed
Range
Type
Range
.023 To 1/8 in (0.6
To 3.2 mm)
Standard: 50 To 780
To 19.8 mpm)
Constant Voltage (CV)
DC For GMAW Or
Constant Voltage (CV) /
Constant Current (CC) DC
For GMAW-P
All Need 14-Pin And
24 Volts AC
Single-Phase
10
Power
Welding
Input
Power
ipm (1.3
Optional High Speed:
ipm (2.3 To
36.5 mpm)
Max
Weight
Welding Circuit
Rating
12 ft
100 Volts,
Amperes,
100% Duty Cycle
16 ft
Spool Weight:
(27 kg)
60 lb
92 To 1435
(3.7 m):
(94 kg)
207 lb
750
280 lb
(4.9 m):
(127 kg)
Contactor Control
12 ft
Maximum
Height
With 4 ft
(1.2 m)
(3.7 m)
17 ft
Post
Vertical Uft Of Boom
Horizontal to 60
16 ft
Boom
(4.9 m)
21 ft
(5.2 m)
Above Horizontal
Boom
(6.4 m)
Above Horizontal
Horizontal to 60
SE CTION 3- INSTALLATION
3-1.
Installing Swivel
Into
Pipe
Post
5
4
1
Swingpak
2
Pipe
3
Steel Bolt
Secure
mum
Base
or
CBC Cart
Post With Base
shown
as
using
as a
mini
1/2 in diameter SAE grades
steel bolts.
4
Swivel
Insert
Assembly
into
pipe post.
Lubricate
swivel.
2
5
Safety
A
Do
Collar
not
remove
until
instructed to.
3
Tools Needed:
~
3/4in
ST-152 382
OM-1 588
Page
9
3-2.
Installing Control
Box And
Adjusting
Tilt
I
1
Swivel Plates
2
Yoke
Remove
plates
.
hardware
and
Set boom into swivel
as
shown.
Yoke Pin
4
Install
ter
swivel
Boom
3
3
from
yoke.
pin
5
pin through yoke. Install
and spread ends.
cot
Bolt
7
Install
bolt,
washers,
Tighten hardware,
4
one
half turn.
6
Locking
Install
and
nut.
and back bolt oft
Knob
locking
knob but do
not
tighten.
6~
7
Reel
Support
Install reel
support.
2
Tools Needed:
~:==~
3/8, 3/4
in
ST-153 170
OM-1588
Page
10
3-4.
Installing
Wire Guide Extension
1
Wire Guide
2
Bolt
Fitting
3
Monocoil Liner
4
Wire Guide Extension
Tighten bolt to secure liner in wire
guide fitting. Do not overtighten
bolt and crush liner.
Repeat procedure for opposite
side.
4
Tools Needed:
EI~ZJ1i
3/8 in
ST-152 383
OM-1 588
Page
11
3-5.
Equipment Connection Diagram
300/400 Ampere Model
CC/CV lnverter Welding
Power Source
I
Use settings shown for both
pulse MIG welding and MIG
welding.
2
450
Ampere Model CV
Welding Power
Inverter
Source
3
14-Pin Cord
4
Positive
Weld Cable
(+)
5
Negative (-)
Be
sure
Weld Cable
cables
weld
are
sized
properly for peak amperage if
pulse welding (see welding power
source Owners
Manual).
PULSED
~MIG~
UFT~ARC,~p~
SCRATCH
~CK
V-SENSE
PANEL
Workpiece
7
Voltage Sensing
(Optional Use)
8
Gun
Lead
Be
sure gun is rated for peak am
perage if pulse welding. Install ac
cording to its Owners Manual.
0
9
REMOTE
INDUCTANCE/DIG
6
V/A CONTROL
Wire Feeder
For connections
see
Gas
Section 3-7.
10
Shielding
11
Supplied
12
Gas Hose From Boom
Y
Supply
Adapter
ST-8O1 806 / Ref. ST-175 086 / Ref. ST-iSO 311-8
OM-1588 Page 12
3-6.
Connecting
Weld Cables And Gas Hoses
The weld cables and
hoses extend lOft
shielding gas
(3 m) from the
boom.
Route
weld
through
reed
cables from
relays,
if
boom
applicable.
If the welding power source or gas
supply are further from the boom,
extend cables
or
1
Weld Cable
2
Insulated
Bolt
Use electrical
3
as
follows:
Sleeving
together
welding power
sleeving
hoses
weld
from
cables
source
and boom.
tape and
insulated
to cover connection.
Shielding
Gas Hose
Connect hose to gas supply or ex
tension hose. The hose from the
has
boom
5/8-18
right-hand
threads.
Tools Needed:
5/8in
Ret. ST-801 806 / Ref. 5T-152 800-A
OM-1588
Page
13
3-7.
Control Box Connections
Optional
Reed
Connection
2
Wire Feed Motor And Gas
Valve Control
3
Relay
Receptacle
.
Wire Feed Motor And Gas
Valve Control
Plug
From
Boom
4
14-Pin Cord
5
Volt Sense Lead
(Optional
Use)
6
0
Gun
Trigger Plug
From Boom
0
p
ST-800 177-A / Ref. ST-800 17S
14-Pin
3-8.
Plug Information
Pin Information
24 volts
ac
with respect to socket G.
Contact closure to A
Circuit
common
+10 volts dc
completes
24 volts
ac
contactor control circuit.
for 24 volts AC circuit.
output
to remote control with
Remote control circuit
common.
0 to +10 volts dc
command
input
Voltage feedback;
signal
respect
to socket D.
from remote control with
0 to +10 volts dc, 1 volt per 10
arc
respect
to socket D.
volts.
Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes.
CC/CV Select (+24 V
Inductance
*The
remaining pins
are
=
CV)
(0-10 V)
not used.
.
OM-1588
Page
14
Motor Start Control
3-9.
change wire feed starting speed
proceed as follows:
To
Turn Off wire feeder and
power
welding
source.
Remove wrapper.
1
2
Motor Board PCi
Motor Start Control Poten
tiometer R70
Turn
potentiometerclockwiseto in
time it takes the motor to
ramp up to speed. Remove protec
tive white rubber cap before mak
crease
ing adjustment. Adjust potentiome
using a small nonconduc
ter R70
tive screwdriver.
Reinstall wrapper.
Tools Needed:
Non-Conductive
-
___
c1j=o
1/4 in
ST-162 132/Ref. SA-183 121-B
3-10.
Removing Safety Collar
And
Adjusting
Boom
1
Locking
Tighten
Knob
knob
prevent boom
to
movement. Loosen knob to allow
boom movement. Change knob
position to limit upward movement.
Pull boom down
move
safety
slightly
and
re
collar. Boom should
balance in any position from hori
zontal to 60 degrees above hori
zontal. If necessary,
as follows:
2
Threaded Rod
3
JamNut
adjust
boom
Loosen jam nut and turn threaded
rod until boom balances. Tighten
nut.
Be sure several full
threads are through yoke to pre
vent boom falling.
2
jam
3
4
E
Yoke
safety collar for use in
assembling or moving boom.
Retain
0
dis
4
I
.3
Rod
2
Tools Needed:
1-1/8 in
Increasing Spring
Decreasing Spring
Pressure For A
Pressure For A
Heavy
Gun
Ughter Gun
ST-142 599-B
OM-1588
Page
15
3-11. Gun Recommendation Table
Process
GMAW-P
GMAW
FCAW
3-12. Wire
Motor
-
-
-
Hard
Hard
or
or
Gun
Cored Wires
Cored Wires
M25, M40, Or GA-50C
Wires
GA-4OGL Or GA-5OGL
Self-Shielding
Type, Size,
Speed
GW-500 Or GW-600
Wire
Type
And Feed
Speed Capability
Table
Wire Size
Feed
Standard
All
Standard
All
3/32 To 7/64 in (2.4 To 2.8 mm)
Standard
All
1/8 in (3.2 mm)
OpUon:l High
All
.023 To 5/64 in
.023 To 5/64 in
(0.6
(0.6
To 2
To 2
mm)
mm)
Speed Capability
50 To 780
ipm (1.3
To 19.8
mpm)
50 To 700
ipm (1.3
To 17.8
mpm)
50 To 300
ipm (1.3
To 7.6
92 To 1440
ipm (2.3
To 35.6
mpm)
mpm)
.
.
OM-1588
Page
16
Installing
3-13.
And
Threading Welding
Wire
r1~:~d *4
Tools Needed:
~
3/16,5/64in
~ 15/16,3/81n
Install wire spool.
Adjust tension nut so
wire
is
wire feed
taut
when
stops.
JO
4-
Install drive rolls.
-,
NONCONDUCTIVE
SURFACE
No Wire
UJ~ Be
that outlet cable has proper
size liner for the welding wire size.
When installing gun, position liner
extending from outlet wire guide as
to drive
Jog
Wire
Slips
0:7 Forsoft wire orsmall diameterstainless
steel wire, use 2 drive rolls and set drive
roll pressure from 0 to a maximum of 4
the pressure indicator scale (so that
only the inner spring is compressed).
on
to drive rolls without
possible
touching.
Install gun. Lay gun cable out straight. Cut
offend of wire. Push wire through guides up
as
SURFACE
Slip
sure
close
NONCONDUCTIVE
This setting will generally give the best
performance for these types of wires.
To
adjust
drive roll pressure, hold nozzle
about 2 in
(51 mm)
from nonconductive
surface and press gun trigger to feed wire
against surface. Tighten knob so wire does
slip. Do not overtighten. If contact tip is
completely blocked, wire should slip at the
feeder (see pressure adjustment above).
not
Cut wire off. Close
Repeat
cover.
for other side.
rolls; continue to hold wire. Press
button to feed wire out gun.
ST-152 564-B I Ref. ST-156 929 / Ref. SC-150 922 / Ref. ST-156 930/ S-0627-A
OM-1 588
Page
17
SECTION 4- OPERATION
4-1.
Operational
Note 1EI~
The
following
is
a
Terms
See Menu Guide for detailed
list of terms and their definitions
as
programming steps.
they apply
to this wire feeder:
General Terms:
Adaptive
Pulse
The wire feeder
Welding
less of
Cold Wire
change
automatically regulates pulse frequency
welding wire stickout.
to maintain a constant arc
length, regard
in
When weld amperage is not present, wire feeds for about three seconds at set wire feed speed.
Then the welding power source contactor deenergizes and wire continues to feed at the wire jog
Jog
speed.
Inductance
As inductance
Trim
Arc
increases,
arc on
time increases, and the weld
length adjustment in pulse welding. Increasing
placed by volts in MIG programs.
Synergic
The
the
puddle becomes
trim increases the actual
operator programs pulse parameters for a specific wire feed speed.
pulse parameters between these wire feed speed increments.
more
fluid.
length.
arc
Trim is
re
The wire feeder determines
Side Panel Terms:
Process Mode
Sequence
Is used to select the
type of process
to be
used, including Pulse, Adaptive Pulse,
Is used to select and program the weld sequences which include
and run-in.
Mode
or
Mig.
weld, crater, burnback, postflow,
preflow,
Dual Schedule Mode
Is used to select
a
Card Mode
Is used to select
use
Security
Only
Mode
functions with
rameter
4-2.
Pulse
Welding
pair
a
of programs that
of the
optional
can
be used
data card
data card. Allows
using
together.
storage
and retrieval
the lock feature for
capabilities.
restricting range
of program pa
.
changing.
Terms
1
Apk
Peak
=
Increasing Apk
Amperage
increases penetra
tion.
Vpk
Peak
=
Voltage
Arc
voltage during peak current
phase of the pulse waveform. This
determines
arc
length during
adaptive pulse welding.
3
/\
2
Abk
3
PPS
Background Amperage
=
Maintains
arc
=
Increasing
Amps
between
pulses.
Pulses Per Second
PPS increases travel
speed.
4
PWms
=
Pulse Width In
Milliseconds
1
2
Increasing
PWms increases bead
width.
Time
/
.
OM-1588
Page
18
Front Panel Controls
4-3.
2
3
8
7
4
4
6
5
5
ST-162 127
1
2
while welding, with
Display
Press button to
3
(see
Pulse is
default
Parameter Select Button
move > on
change value pointed to by>.
Active Side Indicator
5
Trigger
When 1PM is selected,
click causes wire feed
To weld without
turning control one
speed (1PM) to in
by
0.1.
When
click
Prg
# is
selected, turning control
change type
one
be set
light
Ught
on a
Light
per program ba
for programs
comes on
holding gun trigger through
cycle, press and release button to
feature on (indicator light turns on).
and release gun
trigger within three seconds after an arc has
been struck. To end weld cycle, press and
6
cycle, press
trigger.
Side Select Button
changed
The feeder remembers the last used pro
gram for each side and retums to that pro
gram when the active side is changed.
Button
Jog
Push to
out
causes
The program number cannot be
7
momentarily feed welding wire with
energizing welding circuit or shielding
gas valve.
Jog speed is varied using the Display Con
trol while Jog button is pressed. Default set
ting is 200 1PM.
8
out weld
To start weld
change
of
use
where this feature is active.
release gun
program number (Prg #) to in
crease/decrease by one.
can
sis. Indicator
turn
one.
When MPM is selected, turning control three
clicks causes wire feed speed (MPM) to in
crease
To
Hold Button And Indicator
Trigger Hold
crease/decrease by
setting.
4
Turning control one click causes Trim (arc
length) to increase/decrease by one or Volt
to increase/decrease by 0.1.
The gun trigger may be used to
active side of the feeder.
6).
process (Pulse, Adaptive Pulse, or MIG)
side panel controls (see Section 4-4).
display.
Display Control
Turn control to
a
exception of Dual Sched
Section
ule Mode
Purge
Button
Push to
without
lET
Jog
momentarily energize gas valve
energizing the welding circuit.
and
Purge only
work
on
the active
side of the feeder.
Holding the Jog and Purge buttons at the
time displays pulse parameters on
the side panel display and voltage on
front panel display.
same
OM-1 588
Page
19
4-4.
Side And Rear Panel Controls
1
Mode
2
Mode Select Button
Display
Press button to move> in
display.
Display
3
Parameter
4
Parameter Select Button
Press button to
move >
in
display.
5
Parameter Increase Button
6
Parameter Decrease Button
7
Power Switch
8
Circuit Breaker CB1
CB1 protects the wire feeder from
overload.
5
6
2
4
Ref. ST-162 128/ Ret. ST-i 62 133
.
.
OM-1 588
Page
20
SECTION 5
-
SETTING SEQUENCE PARAMETERS
OM-1 588
Page
21
SECTION 6- SETTING DUAL SCHEDULE PARAMETERS
6-1.
Selecting
Dual Schedule Pair
Dual Schedule is used with two
consecutive weld programs 1 & 2,
3&4, 5&6, or7&8.Anyprogram
type (MIG, Adaptive Pulse, or
_______
Pulse)
be combined in dual
can
schedule.
1
Side Panel
Use side
See
panel
Menu
Display
to turn feature on.
Guide
detailed
for
programming steps.
2
Front Panel
Press front
Display
panel parameter select
button to select program number.
3
Front Panel
4
Dual Schedule Switch
Section
Display
Control
(See
6-2)
U7 Switch type is set in
System
Setup.
5
Welding
Gun
Trigger
Selecting dual schedule program A
or B is done by using Display Con
trol, dual schedule switch,
or
gun
trigger (depending
setup).
on
When program B is
active,
Display Control
click clock
one
wise to select another
pair
system
turn
of dual
schedule programs.
~
Programs
can
be
rearranged
in desired order using the data
card. See Section 7.
2
Display
Control
V
>Prg
2
Dual
B
Display
Control
I>Prg
Dual
OM-1 588
Page
22
31
Al
.
Dual Schedule Switch
6-2.
Diagrams
1
Momen 2P
(Momentary-Contact
2-Pole
Switch)
2
1
1
1
2
2
>
3
2
>
>
4
(Maintained-Contact
Switch)
(Maintained-Contact
Switch)
Maint 1 P
1-Pole
2
>
>
Maint 2P
2-Pole
Trigger
scheduling after estab
welding arc.
Allows dual
lishing
A
3
2
-1
>
O
a
A
3
U~ If trigger is
>
~
77
/
used
schedule switch,
is disabled.
for
dual
Trigger
Hold
(_--0B
B
4
4
4
3
I
I
I
Adapter
p
TR~
I
IBO
>>
>
>>~
>
3
3
>>
I
I
p
TR
___
3
>
A\~
4
4
>
PM-i 588
Page
23
SECTION 7- USING THE OPTIONAL DATA CARD
7-1.
Data Card Terms
CARD SCREEN TERMS
WRITE
Programs
To Card
>Wr
i
t e
Read
Delete
Done
READ
Programs
From Card
PULSE MIG TERMS
PPS
Amperage
(Pulses Per
Second)
PWms
~
(Pulse Width In
Milliseconds)
-r
Apk (Peak
Amperage)
~~~1
Abk
Time
(Background
Amperage)
.
SA-158 435
7-2.
Installing
Data Card
1
Label
label to data card. Write pro
gram information on label.
Apply
2
Data Card
3
Card Slot
For Blank Data Card:
Insert card into slot. Toformat card,
3~
turn On power. Select Card from
menu. Data card formats when unit
enters Card mode.
2
For Power Source Data Card:
Insert card into slot. Turn On pow
Push Parameter Select button
within 3 seconds and the 8 pro
er.
1
grams and setup information are
read into the wire feeder memory.
Unit is
Wait
front
ready
to use when Please
disappears
panel display.
message
from
.
ST-156 266-B
OM-1 588
Page
24
7-3.
Card
Displays
1f7 See Menu Guide for detailed
programming steps. Security
mode only functions with a
data card.
1
Card
2
Moving
Display
Line
Moving line is
be changed.
Sequence
3
under value that
can
Write
Dual Schd
>Card
Security
Pr
Transfers program data from unit
to card. The program card can hold
up to 32 programs. When writing to
ess
Below
the
card, the next available pro
gram number is automatically
as
signed.
Side Panel
Parameter
Select Once
4
Read
Transfers program data from card
to unit.
5
Delete
Deletes program data from card.
6
Done
4
Exits card
display.
5
OM-1588
Page
25
SECTION 8- SYSTEM SETUP
8-1.
System Setup Display
Note ~
DISPLAY SETflNG
*
>System
>Range
*
Parameters
See Menu Guide for detailed
NOTES
Select the process the
welding
Welding
minimum and maximum
for
power
source
When on, restricts
>Mig Type
Default is Off. Set to On
Default is
source
power
Set values to match
pulse welding.
>Access$
>Voltage
programming steps.
of
use
setup
only for
14-pin receptacle.
is able to do.
welding
voltage
power
values
source
are
needed.
always
values
Amperage
are
required
ranges.
screens.
older CV
welding
Use V. Sense when
power
source
without
than 50 ft
more
voltage
(1 5m) of
feedback at 14-socket
weld cable is used
receptacle.
(including gun
cable
length).
>Arc Start~
Use Hot Start
only
with Inverter Model
welding
power
source
and
large
diameter wires. The
arc
starts in CV and
switches to CC.
>Dual Schedule
See Section 6-2.
>Trigger
When on,
trigger
can
be used to switch between programs that have at least 0.2 seconds of
preflow
time pro
grammed.
>Remote
When on,
a
dual schedule switch
panel display>
can
be used to
change
Volts
or
Trim, 1PM,
or
Prg depending
>Arc Time
Displays
>Wire Feed
Choose to
>Memory
No Reset: allows
accumulated
display
arc
time and
where the front
cycles.
inches per minute
operator
or
meters per minute and motor
to exit memory reset
type, but installed
parameter without resetting any
motor must match selection.
data.
Program Reset: unit defaults to original factory setting for the last active program. Setup
change. If setup card is in card slot, program will be loaded from card.
System
on
is.
Reset: unit defaults to
original factory settings
for all programs and
information does not
setup excluding System and Arc Time. If
setup card is in card slot, program will be loaded from card.
Total Reset: unit defaults to
original factory settings
for all programs and setup
including System
and Arc Time. If
setup card is in card slot, program will be loaded from card.
*
>ShutdoWn
When on, the system
age is sensed.
>Teach
Default is 15
>Gas Flow
Setting
>Software
Know this when
Automatically
Can be used
--
points,
immediately
but
can
must be Meter Off if
talking
shuts down if
be set to 4
option
no arc
points.
is not installed.
with service
personnel.
set if power source data card is used.
only when optional data card is inserted.
Selection does not appear on display when MIG Only is System choice.
Must remain set to Meter Off if option is not installed to prevent system
OM-1 588
Page
26
error.
voltage
is sensed. When off, wire feeds
even
if
no arc
volt
SECTION 9- STANDARD PULSE WELDING PROGRAMS
Note ~
Apk
=
PPS
Peak
=
Amperage, Vpk
factory set programs.
interpolations from the
9-1.
Program
Wire
Size/Type: .035
=
Peak
Pulses Per Second, PWms
=
Voltage,
Abk
If selection is set for
4
Background Amperage,
(milliseconds). Four teach points were use d for
fifteen teach points, the remaining points are
=
Pulse Width
taught points.
1 -Steel
Gas: Ar
-
CO2
or
Ar
-
Oxy /40 CFH (19 L/m)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
700/17.8
440
36.7
160
180
2.9
400/10.2
385
32.4
108
126
2.3
200/5.1
335
28.7
61
81
2.0
100/2.5
328
27.4
37
47
1.7
9-2.
Wire
Program
Size/Type:
2
-
Steel
Gas: Ar
.045
-
CO2
or
Ar
-
Oxy /
40 CFH
(19 L/m)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
700 / 17.8
518
35.0
195
205
3.6
400/10.2
466
31.3
147
158
2.9
200/5.1
412
28.5
93
106
2.4
100/2.5
375
26.5
50
66
2.2
9-3.
Wire
Program
Size/Type:
3
-
Gas: Ar
.052
-
CO2
or
Ar
-
Oxy /
40 CFH
(19 L/m)
PWms
1PM / MPM
Apk
Vpk
Abk
625 / 15.9
560
39.3
200
229
3.6
400/10.2
525
36.2
148
189
3.5
200/5.1
475
31.7
102
131
2.7
100/2.5
445
29.6
50
80
2.4
Wire
Program
Size/Type:
4
-
COMMENTS
Steel
PPS
9-4.
COMMENTS
COMMENTS
Steel
Gas: Ar
.062
-CO2
or
Ar
-
Oxy /
40 CFH
(19 Urn)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
400/10.2
550
36.8
200
195
4.1
300/7.6
510
36.3
145
175
3.8
200/5.1
480
31.6
110
155
3.2
100/2.5
460
28.7
69
94
2.6
COMMENTS
OM-1 588
Page
27
9-5.
Wire
5
Program
Size/Type:
-
Stainless
Gas: Ar
.035
-
He
-
CO2 /40 CFH (19 L/m)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
700/17.8
403
33.9
132
191
2.8
400 /10.2
318
31.6
87
146
2.4
200/5.1
295
28.5
53
94
1.9
100/2.5
280
26.0
32
45
1.8
9-6.
Wire
6
Program
-
Stainless
Gas: Ar
Size/Type: .045
.
He
-
CO2 /
40 CFH
(19 L/m)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
700/17.8
480
39.0
200
227
3.2
400 / 10.2
425
32.4
155
185
2.5
200/5.1
360
28.0
100
115
2.0
100 / 2.5
350
26.2
40
70
2.0
9-7.
Wire
Program
.035
Size/Type:
7
-
Nickel
Nickel
Gas: Ar
Alloy
-
He / 40 CFH
(19 L/m)
Vpk
PPS
PWms
350
34.5
130
144
3.7
400/10.2
310
30.0
80
105
3.3
200/5.1
280
27.5
48
55
2.9
100/2.5
260
25.1
28
36
2.5
Apk
700/17.8
9-8.
Wire
Program
Size/Type:
.035
8
-
COMMENTS
Alloy
Abk
1PM / MPM
COMMENTS
COMMENTS
.
Silicon Bronze
Gas:
SiBr
Argon /
40 CFH
(19 Urn)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
510/13.0
340
30.7
100
125
3.7
400/ 10.2
310
29.8
83
97
3.4
200/5.1
277
26.6
48
55
3.0
242
25.2
31
31
3.0
COMMENTS
.
OM-1 588
Page
28
SharpArcTM CONTROL
SECTION 10- SETTING
10-1.
Selecting And Adjusting SharpArc~ Control
1
Arc
is Arc
SharpArc
It is used to
and
arc
_________________
the
display.
width
arc cone
characteristics.
Use front
______________________
on
adjust
panel parameter
button to
move> to
Display
setting.
Control
select
select Arc. Use
to
adjust
Arc
SharpArc~ setting range is from 0
factory default is set at
zero
(0). When Arc value is
to 20. The
5 0
T ri
m
1PM
200
>Prg
1
increased toward 20, the arc cone
and the weld puddle
narrows
S t
0 3 5
becomes less fluid.
/
Parameter
Select
50
200
5 0
200
iL
Tr
rn
Prg
I
PM
>
Tr
im
Prg
lU
I
PM
A
01
>
r
c 2
01
Ref. S-0259
OM-1 588
Page
29
SECTION 11
11-1. Teach
TEACH POINTS
-
.
15 Points
Using
*4
L~
Apk
=
Peak
Amperage
A
Vpk
=
Peak
Voltage
E
Abk
=
Background Amperage
0
PPS
1PM / MPM
=
PWms
Pulses Per Second
Pulse Width
=
(Milliseconds)
780 / 19.8
750/19.1
700/17.8
650/16.5
600/15.2
550/14.0
500 / 12.7
450/11.4
Example Of A Synergic
Setting For 425 1PM With
400/10.2
All Teach Points Set At 50
1PM
(1.3 MPM)
350/8.9
Increments
300/7.6
250/6.4
200/5.1
150/3.8
100/2.5
50/1.3
100
180
210
240
270
300
330
360
370
420
10
18
21
24
27
30
33
36
37
42
Abk
10
20
30
40
50
60
70
80
90
100
110
120
130
PPs
20
55
80
105
130
160
185
210
235
260
290
315
340
Apk
Vpk
2
PWms
The teach mode allows the
user
to create
pulse programs. The teach mode
selection for 15 teach points gives a more
defined curve for a specific range. At each
teach point, the user can adjust five param
eters to shape the pulse waveform of the
weld output. The six parameters are: 1PM
(MPM), Apk, Vpk, Abk, PPS, and PWms.
custom
OM-1 588
Page
30
450
480
510
540
45
48
51
54
3
Apk, Vpk, Abk, PPS, and PWms acting
together provide the energy necessary to
burn off welding wire at a set wire feed
speed. The graph below shows that as wire
feed speed increases, energy increases
(Apk, Vpk, Abk, PPS, and PWms acting
synergically).
4
565
56
Apk
Vpk
140
200
Abk
365
400
PPS
5
PWms
Undersomeconditions,thewirefeederlim
its wire feed
speed
to maintain all
pulse pa-
rameterswithinthecapabilityofthesystem.
11-2. Teach
Using
4 Points
L~
Apk
=
Peak
Amperage
A
Vpk
=
Peak
Voltage
U
Abk
=
Background Amperage
0
PPS
=
Pulses Per Second
PM / MPM
PWms
=
Pulse Width
(Milliseconds)
780/19.8
750/19.1
700/17.8
650/16.5
600/ 15.2
550/14.0
500/12.7
450/11.4
Example Of A Synergic
Setting For 425 1PM With
400/10.2
Teach Points Set At
350/8.9
Intervals Of 100
200
(5.1),
700
400
1PM
(2.5),
(10.2), And
(17.8 MPM)
Increments
300 / 7.6
250/6.4
200/5.1
150/3.8
100 /2.5
50/1.3
300
330
360
370
420
27
30
33
36
37
42
Abk
10
20
30
40
50
60
70
80
90
100
110
120
130
PPS
20
55
80
105
130
160
185
210
235
260
290
315
340
user
to create
pulse programs. The teach mode
selection for 4 teach points gives the whole
welding range quickly. At each teach point,
the user can adjust five parameters to
shape the pulse waveform of the weld
output. The six parameters are: 1PM (MPM),
Apk, Vpk, Abk, PPS, and PWms.
custom
Abk
400
PPS
54
270
24
The teach mode allows the
200
540
51
240
21
2
140
365
510
48
210
18
PWms
Apk
Vpk
480
45
180
10
3
Apk, Vpk, Abk, PPS, and PWms acting
together provide the energy necessary to
burn off welding wire at a set wire feed
speed. The graph below shows that as wire
feed speed increases, energy increases
(Apk, Vpk, Abk, PPS, and PWms acting
synergically).
4
565
56
450
100
Apk
Vpk
5
PWms
Undersomeconditions,thewirefeederlim
its wire feed speed to maintain all pulse pa-
rameterswithinthecapabilityofthesystem.
OM-1 588
Page
31
11-3.
Redefining
Teach Points
IPMC
erminestheweld metal tie-
position
UT
Redefining
1PM Teach Point
rate.
Redefining 1PM is not normally
required unless special wire or
unusual
is
joint design
needed.
Trim
50
Prg
1PM
>4 5 0
~
Display Control
point value.
to
select teach
Press and hold Purge button while
turning Display Control to redefine
the pm teach point. For example:
there are teach points at 150, 200,
and 250 ipm; the teach point at 200
can be adjusted to a wire feed
speed of 151 to 249 ipm.
________________
Prg
1
2
Redefining
select
________________
Trim
>460
panel parameter
buttontomove >toselectlPM. Use
Arid
____________________
50
1
Pulse
_________________
Purge
Use front
1PM
Pulse
Vpk
Peak
-
Voltage
Arc
voltage during peak current
phase of the pulse waveform. This
determines
arc
length during
adaptive pulse welding.
3
Apk
4
Abk
Peak
-
Peak and
Pulse Parameters
depend
power
Amperage
Background Amperage
-
on
background amperage
welding
the range of the
source.
5
Pulses Per Second Of
PPS
20-400
6
PWms
-
-
Pulse Width Of
1.0-5.0 Milliseconds
panel controls to change
parameters. See Menu
Guide for detailed programming
Use side
pulse
steps.
2
After values
maintain
are
an arc
set, strike and
for five seconds.
Do this for each teach
point.
End weld
by releasing gun trigger,
by pulling gun out of weld. Re
peat for each custom teach point.
not
The
Trim
taught arc length represents
(arc length) setting of 50.
a
Once the teach
points are set, the
adjusts parameters be
teach points synergically.
wire feeder
tween
1PM
5
4
___y3
32.4
Vpk
385
Apk
Vpk
385
Apk
108
Abk
>385
Apk
>108
Abk
>126
PPS
108
Abk
126
PPS
2.3
PWms
400
32.4
___________
385
Apk
108
Abk
126
PPS
>2.3
PWms
___________
Ref
OM-1 588
Page
32
S-0259/Ref. ST-154 109
.
Date
Wire
Program Number_
Gas
SizejType_
Equipment
Used
-
Power Source
Serial Number___________________________
Serial Number
Wire Feeder
Gun Model_____________________ Weld Cable
Wire Manufacturer________________
1PM / MPM
Preflow
Run-In
_CFH(L/min)
Flowrate______
Vpk
Apk
-
Positive______
Negative
Mfg. Date_______________________________
Abk
PPS
PWms
COMMENTS
Seconds:________
TrimNolts:________ 1PM / MPM:___________________________________ Seconds:____________________________
Crater Volts:_____________________ 1PM I MPM:_____________________________ Seconds:_____________________________
Postf low
Seconds:________
OM-1588
Page
33
SECTION 12
-
MAINTENANCE AND TROUBLESHOOTING
.
12-1. Routine Maintenance
i~5~1~
A
Disconnect power before
maintaining.
Repair
replace
or
cracked
weld
cable.
Replace
cracked
parts.
a
Check
14-pin
cord.~
6 Months
Blow out
inside.
or vacuum
During heavy
service, clean
monthly.
OM-1 588
Page
34
A
Or
Check gas
hose and
fittings.
Check gun
cable.
12-2. Error
Displays
I
r
i
gge
~fIlfl
I
Release
r
2
00
No
Volt
Sensed
1Error
3
1
Memory
Prg
CRC
Error
Memory
Prg
Range
Error
Release
Error
Trigger
2
No Volt Sensed Error
The
arc
Display
voltage sense circuit is not
receiving feedback. Check voltage
Check
connections.
sensing
connections at 14-position plugs!
receptacles at the unit and welding
source.
power
Turn unit off and back
5
Display
This appears if the trigger is closed
when the unit power is turned on, or
if the trigger is stuck or defective.
after
on
correcting problem.
\
Tach
No
Sensed
1Er
If this
when
error
continues
to
it may
pulse welding,
occur
help
to
ror
3
Memory
CRC Error
Display
The data in the program indicated
is not the same data that was
Start
Arc
Stop
8
Mi
Ga
9
Ma
n
s
x
C F H
F
I
x
o w
C F H
Gas F
x
I
10
x
ow
\~
Gas
Lo
11
f R
Coo
12
Out
a
n
1Er
1Error
1Er
1Error
1Er
1Er
1Er
ror
x
g
e
It
Flow
\
Unlocked
Program
7
Arc
Error
Stop
Parameter
panel
error.
Display
This appears when pulse welding
and the motor does not stop at the
end of the weld. If there is high
used in the area,
frequency being
A motor brake circuit
turn it off.
problem
can
also
front
Select to clear
Press
8
cause
this
error.
Parameter
panel
error.
Minimum Gas Flow Error
This appears when gas flow falls
below the minimum CFH set (xx in
example). Adjust gas
flow to
bring
it above set value.
Perform
ror
4
a
system
reset.
Error
Memory Range
Display
Go
through pulse parameters to
sure they do not exceed
settings of the Range display or
perform a system reset.
make
No Tach Sensed Error
Maximum Gas Flow Error
9
it below set value.
Press
front
Select to clear
10
Gas Out Of
connections.
panel
Select to clear
Parameter
This appears only when coolant
flow switch option is installed.
Display
started.
Check
Unlocked
Program
Error
Display
This appears when pulse welding
and current is detected but the arc
be
recirculating
error.
Arc Start Error
cannot
coolant
system.
12
6
below 100 CFH.
Coolant Flow Error
Check
front
Error
Range
appears when gas flow is
greater than 100 CFH. To protect
the internal sensor, the unit shuts
down until the gas flow can be
11
The motor tach feedback is not
reaching the control. Check
Parameter
panel
error.
This
adjusted
Display
Press
Parameter
panel
error.
appears when gas flow is
above the maximum CFH set (xx in
example). Adjust gas flow to bring
The data in the program indicated
is out of usable range.
5
Press
front
Select to clear
This
saved.
ror
7
front
Select to clear
select Hot Start.
6
Arc
Press
and
correct program
and
voltage
pulse parameters
settings. Check
voltage sensing
connections.
This appears when attempting to
run an unlocked program while
other programs are locked. Either
lock the unlocked program or
select
a
different program that is
locked.
ror
ror
Ref. ST-i 55 222
OM-1588
Page
35
12-3.
Troubleshooting
~t~j1~
A
Disconnect power before
troubleshooting
.
Trouble
Wire
Remedy
feeds, shielding gas flows,
electrode wire is not
but
energized.
Sections 3-5 and
Wire feeder is on, meter(s) do not light
up, motor does not run, gas valve and
welding
pull in.
power
source
Checkinterconnectingcordconnections.
Check and reset CB1
or
feeds
(see Section 4-4).
Check gun
trigger
connection. See gun Owners
Check gun
trigger.
See gun Owners
Change
Clean
or
to correct size drive roll
replace dirty
Incorrect size
Replace
or worn
contact
tip
or
Remove weld spatter
Have
pulled,
but continues to feed after trigger is
leased, and trigger hold is not on.
re-
Check for
wire
(see
Table
(see Section 3-13).
13-1).
drive roll.
guides.
liner. See gun Owners
or
foreign
Manual.
matter from around nozzle
Authorized Service
Check for correct
slowly.
Wire does notfeed until trigger is
Factory
or worn
Manual.
Manual.
hub tension and drive roll pressure
Readjust
runs
checkcordforcontinuityandrepairorreplace(see
contactor do not
Electrode wire feeding stops
erratically during welding.
Motor
If secure,
3-7).
Agency
opening.
check drive motor
or
motor control board PCi.
input voltage.
a
short between
welding gun trigger
leads and weld cable.
Repair
short
or
replace welding
a
short between
welding gun trigger
leads and weld cable.
Repair
short
or
replace welding
gun.
Gas valve in feeder is rattling loudly
along with possible erratic or slow wire
feed speed.
Check for
Unit does not switch out of Run-In
Install, reconnect,
gun.
or
replace voltage sensing
lead.
Speed.
Wire feeder power is on, displays
up, but unit is inoperative.
OM-1 588
Page
36
light
Check
welding
gun
trigger
leads for
continuity,
and
repair
leads
or
replace gun.
Notes
OM-1 588
Page
37
SECTION 13- ELECTRICAL DIAGRAM
S
r
~
~1
~
I
I
I
~~
~
H
~1-3>~
I
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4~I
FtOWU~
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FRONT
I
DISPLAY
DSP~
SIDE DISPLAY
: i
~
DSPL1
4~
r
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I
I
II
(DATA~RD
I
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II
.
~4J
~,
0
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PB3t
a
0
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0
PJ~
CA&E
___
___
0
0
0
F~I
-~
c4az
0
0
p~4
0
P~
PLGI~
j1__/A_AA/s
~
!
i~O
~
~
~
~
~
34
~
PC12
PCS
~J
~IO/R.GIO
,mci
rEDz/P_o,2
~,
~
0
p~3
~
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L
~
~PtG~3~
___________
_____
I
PC15/PL6I5
0
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~>>
PCI7IPLSI7
4
I
H~ZD
~D
LSD
LED
):i~:
I
2~~2>
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LED
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1~ ~IT
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74
3
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if
_________
ax
Figure
OM-1 588
Page
38
2>~
RClOo~3>>~~
II
I~
~41/~G41
~
II
~
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U~E
(OP11ON)
-
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PC6O
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RPS8
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vv
PC3O
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11
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(~T~UL)
L
r~i
13-1. Circuit
Diagram
~
p
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r
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OAt
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FIElD
~S10JCTfll)
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RC1002>
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________________________
901003>
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g
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0? ITOO.F OR IN P1/CC
CC ~s-~ FLIER 00000.
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OM-1 588
Page
39
SECTION 14- PARTS LIST
rrr Hardware is
common
and
not available unless listed.
(0
(0
IL)
C)
ii-
(0
r
(0
0)
.
0)
cJ
a,
U-
r
CIJ
=
C)
UC,)
C)
LL
Figure
OM-1588
Page
40
13-1. Main
Assembly
ST-800 272-B
Quantity
Item
No.
Model
Part
No.
Dia.
Mkgs.
Description
Figure
1
149251
1
149252
PLG21 ,23
..
079 878
079531
605156
PLG28,29
..
080 328
SeeNote
2
3
164475
3
164474
PLG27,28,37,38 047 636
079 739
163519
4
159297
5
139600
5
139599
6
600324
7
602243
8
602213
9
601872
10
.10
080947
151626
11
132053
12
Fig
13-2
13
149838
13
149839
13
078264
13
079216
14
075078
079217
14
15
Figl3-8
16
605227
17....
RC27,37... 047637
048144
PLG11,17
19... PLG33,34
135409
20
139813
18...
GS1,2
..21
115092
125785
...22
139816
...23
159647
...24
156243
...25
159360
...26
159646
...27
145639
28
134834
...29
...29
167774
167776
157295
31
604612
...32
082050
164969
167780
167782
NOTE: When
ordering Control Box
13-1. Main
12
Assembly
CABLE, trigger (consisting of)
CABLE, trigger (consisting of)
2
2
CONNECTOR&PINS
CONNECTOR, circ clamp str rif sz 11
CABLE, port No. 184/c (order by ft)
1
Amp
2
206358-2
17ft
CONNECTORw/SOCKETS
CONTROL BOX, (Fig 13-4)
CABLE, interconnecting (consisting of)
CABLE, interconnecting (consisting of)
1
1
....
1
2
21ft
..
....
....
1
1
2
2
Amp
206322-2
HOSE, gas
HOSE, gas
CABLE, weld cop strd No. 4/0 (order by ft)
WASHER, flat stl std .375
WASHER, lock stl split .375
NUT, stl hex full .375-16
BRACKET, spring retaining
BRACKET, spring retaining
SCREW, cap stl hexhd .375-16 x 1.500 lg
SUPPORT, hub & reel
PIPE POS1 4ft w/base or
PIPE POST, 6ftw/base
PIPE POST, 4ftw/base or
PIPE POST, 6ft w/base
PIPE POS1 4ftw/o base
PIPE POST, 6ft w/o base
BOOM ASSEMBLY
NU1 nyl hex jam .75ONPST
CONNECTOR &SOCKETS
CONNECTOR, circ pin plug
CONNECTOR &SOCKETS
CONNECTOR&PINS
....
2
CONNECTOR&PINS
CONNECTOR, circ clamp str rlf sz 17-20
CABLE, port No. 18/14 8/c (order by ft)
HOSE ASSEMBLY, gas
..
2
17ft
1
....
2
....
2
..
21ft
....
1
2
2
26ft
..
30ft
8
8
4
4
4
4
1
1
4
4
1
1
1
1
1
1
keying Amp
200821-1
COVER, protector motor
VALVE, 24VAC 2 way custom port 1/8 on
PANEL, end cover
INSULATOR, motor clamp
CLAMP, motor top
INSULATOR, screw machine
CLAMP, motor base
STRIP buna N compressed sheet .062 x 4.000sq
HOSE,SAE.187IDx.4100D(orderbyft)
DRIVE ASSEMBLY, wire RH (Fig 13-5)
DRIVE ASSEMBLY, wire RH (high speed) (Fig 13-5)
GUIDE, monocoil
SCREW, set stl sch 8-32 x .125 cup point
LINER, monocoil inlet wire
BUS BAR, connecting weld current
DRIVE ASSEMBLY, wire LH (Fig 13-5)
DRIVE ASSEMBLY, wire LH (high speed) (Fig 13-5)
contact
16
Factory Service Department
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
1
1
2
2
1
1
2
2
2
2
8
8
2
2
2
2
3ft 3ft
1
1
1
1
2
4
4
2
1
1
1
1
1
1
for proper number.
OPTIONAL
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1588
Page
41
1
Item
No.
Part
No.
Description
Figure
13-2.
Support,
Hub & Reel
(Fig
Quantity
13-1 Item
12)
1~
....
010191
058628
8
....
058428
RING, retaining spool
NUT, sti slflkg hex reg .625-11 w/nyl insert
WASHER, flat stl .640 ID x 1.000 OD x l4ga thk
SPRING, cprsn .970 OD x .120 wire x 1.250
WASHER, flat stl keyed 1.SOOdia x .l2Sthk
WASHER, fbr .656 ID x 1.500 OD x .l2Sthk
WASHER, brake stl
HUB, spool
9
....
080393
SUPPORT, reel
1
REEL, wire 60 lb (consisting of)
SUPPORT, reel spool
RETAINER, spool support (consisting of)
LABEL, caution falling wire reel can cause damage
NUT, spanner retaining
2
1
2
3
4
5
6
7
....
058427
....
136684
....
605941
....
010233
....
057971
....
10... t108008
11....
12...
124900
+168104
166594
13....
168103
2
2
2
4
4
2
1
1
1
IEY~ Hardware is
common
and
not available unless listed.
.3
4
.5
6
S
.8
7
10
ST-081 760-C
Figure
13-2.
Support,
Hub & Reel
OPTIONAL
+When
ordering
a
component originally displaying
a
precautionary label,
the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1588
Page
42
S
Dia.
Item
No.
Part
No.
Mkgs.
Description
Figure
1
167 697
..
3
147 139
..
.4
164 842
..
.6
.7
144 844
..
PC2O,30
171 814
..
PLG25
165 484
..
PLG24
159 264
..
167 633
..
10
089 032
..
11
153 169
..
12
010 291
13
167 700
117 Hardware is
common
..
..
13-3.
Quantity
Panel, Front w/Components (Fig
13-4 Item
28)
NAMEPLATE, (order by model and serial number)
PANEL, front
TAPE, adh acrylic double sided .010 x .500 x 3.000
METER LENS, w/gasket
STAND-OFF, 6-32 x .875 Ig
CIRCUIT CARD, schd front
CONNECTOR & SOCKETS (RC5)
See Figure 13.4 Item 35 (RC24)
RING, ext .625 shaft grv x .O45thk E
WASHER, shldr .612 ID
1
2
1
9
1
1
1
style
LENS, LED 4341 red panel mtg
ACTUATOR, switch
WASHER, flat .625 ID nylafil
KNOB, pointer
and
not available unless listed.
2
9
13
12
11
ST-800 1 12-C
10
Figure
13-3.
Panel, Front w/Components
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1588
Page
43
U~ Hardware is
common
and
S
not available unless listed.
c~)
cJ
0)
N
cJ
S
0)
cJ
C)
C,)
C)
LL
N
C,,
0
C,)
C,)
cJ
C)
C)
ST-800 273-B
Figure
OM-1588
Page
44
13-4. Control Box
Dia.
Item
No.
Mkgs.
Part
No.
Figure
162253
2
....
RC3O,40
047637
048144
134201
PCi
198037
PLG1
115092
PLG2
115093
PLG4
115091
PLG6
136810
Quantity
Description
13-4. Control Box
(Fig
13-1 Item
2)
1
PANEL, side lower
CONNECTOR & SOCKETS
2
CONNECTOR, circ pin plug keying in sockets Amp
STAND-OFF SUPPORT, PC card .312/.375
CIRCUIT CARD, motor control
200821-1
1
1
CONNECTOR&SOCKETS(RC1)
CONNECTOR & SOCKETS (RC2)
CONNECTOR & SOCKETS (RC4)
CONNECTOR & SOCKETS (RC6)
1
1
1
CASE SECTION, bottom/rear
CIRCUIT BREAKER, man reset 1P 10A250V
083432
111997.. SWITCH, rocker SPST 1OA 25OVAC
CIRCUIT CARD, HF filter dual
182403
1
184824
CB1.
Si..
PC8O
PLG81
PLG82
PLG89
PLG9O
115093
158720
131054..
153501
073756
151187..
11
+162 364
010290
1
1
1
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
(RC81)
(RC82)
CONNECTOR & SOCKETS (RC89)
CONNECTOR & SOCKETS (RC9O)
STAND-OFF, 6-32 x .625 Ig
LATCH, slide flush mtg hole 1.000 wide
1
1
1
1
4
x
1.500
1
Ig
WRAPPER
1
BUSHING, strain relief 1.030 ID
1
1
LABEL, warning general precautionary
163520
CABLE, port No. 18/14 11/c (order byft)
141162.. CONNECTOR & PINS, (consisting of)
079739
CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2
601222.. CLAMP, Univ 50A
176089
TUBING, plstc PVC .250 ID x .375 OD x 9.000
600399
WIRE, strd l4ga blk 600V 105c (order by ft)
138044
BUSHING, strain relief .120/150 ID x .SOOmtg hole
107983
BLANK, snap-in nyl .500mtg hole
CONNECTOR w/SOCKETS
048282
000527
BLANK, snap-in nyl .875mtg hole
072817
RELAY, end 24VAC DPDT
035704
RECTIFIER, integ 40A 800V
030170
BUSHING, snap-in nyl .750 ID x 1.000mtg hole
145948
BRACKET, mtg control box
13-3
PANEL, front w/components
Fig
155629
CABLE, ribbon 1 4posn (RC1 2) (RC5O)
154938
STRIP~ mtg PC card
097132
STAND-OFF, 6-32 x .375 Ig
CIRCUIT CARD, interface
189124
134464
PLG9
RC7O
...22
...23
CR101
SRi.
24
...25
...26
29...
PLG12,50
PC5O
PLG51
...32
158720
CONNECTOR & SOCKETS
PLG52
158719
PLG53
PLG54
131 204
148439
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
115092
CONNECTOR & SOCKETS
PLG55
PC1O
PLG11
PLG15
PLG17
PLG18
PLG1O,24
36... PLG16,41
35...
STAND-OFF, 6-32
191 996
115092
CIRCUIT CARD, processor w/proms
CONNECTOR & SOCKETS (RC11)
153501
CONNECTOR & SOCKETS
162382
170980
155023
Fig
13-7
010 146
+When
ordering
a
x
1.500
17ft
1
1
1
1
35ft
1
1
1
1
4
1
(RC51)
(RC52)
(RC53)
(RC54)
(RC55)
126689
115093
4
10
Ig
1
(16 MEG)
1
1
(RC15)
CONNECTOR & SOCKETS (RC17)
CONNECTOR & SOCKETS (RC18)
CABLE, ribbon 34posn (RC1O) (RC24)
CABLE, ribbon 24posn (RC16) (RC41)
PANEL, side w/components
CLAMP nyl .625dia
component originally displaying
a
precautionary label, the
1
1
1
1
1
1
label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1 588
Page
45
Hardware is
common
and
not available unless listed.
.
See Table 13-1 For
Drive Roll & Wire Guide Kits
18
20
21
16
6
8
9
10
26
27
~94
38
36~~
29
30
33
~~f
32
ST-8O1 456-A
Figure
OM-1588
Page
46
13-5. Drive
Assembly,
Wire
Rem
No.
Dia.
Mkgs.
Part
No.
Figure
1
010668..
172075..
149962.:
.4
149486..
.5
163282..
.6
.7
165798..
165799..
.8
132750..
.9
150520..
10
133493
11
133350
12
156354
M1,2
M1,2.... 156353
12
153491
153492
*153 493
13
155098
153550
155099
155100..
154031
133493
184136..
.14
182414..
15
182415
.16
137248..
17
129351
.18
602200..
.19
604772..
.20
182156..
182155..
132746..
181522..
132747..
133739..
.21
...22
...23
...24
.25
...26
27
PC51
PLG57
PLG58....
183330..
153631
131 204
604311
131 203
132611
28
149959..
179265..
...29
..31
108940
...32
604538..
.33
151437..
.34
128237..
.35
+179263
178937..
...36
601872..
602213..
.37
602243..
601966..
...38
.39
167387..
168825
41
...42
Part
133308..
of 132 129
Quantity
Description
13-5. Drive
Assembly, Wire (Fig
13-1 Items 29 &
33)
SCREW, cap sti sch .250-20 x 1.500
CARRIER, drive roll w/components 24 pitch
SPACER, carrier drive roll
PIN, rotation arm rocker
NUT, .250-28 stl
SPRING, pressure arm retaining
WASHER, flat .257 ID sti
ARM, pressure
SPACER, rotation pin
RING, retaining ext .250 shaft x .O2Sthk
PIN, hinge
MOTOR, gear 1/8hp 24VDC 272RPM (consisting of)
MOTOR, gear 1/8hp 24VDC 500RPM (consisting of)
KIT, brush replacement (consisting of)
CAP, brush
BRUSH, carbon
KIT, cover motor gearbox (consisting of)
COVER, motor gearbox (consisting of)
4
4
4
2
2
2
2
2
2
2
1
1
1
1
2
2
1
1
GASKET, cover
SCREW, cover
SPACER, locating
RING, rtngext.2soshaftgrvx.O25thk
1
5
2
1
KIT, brush holder
WASHER, flat
PIN, cotter hair
SPRING, indicator
SCREW, hexwhd-slt stl slffmg 8-32 x .500
WASHER, lock stl split No. 8
WASHER, flatstl SAE No.8
SPRING, cprsn
SPRING, cprsn
BUSHING, spring
SHAFT, spring
CARRIER, shaft
WASHER, flat .375 ID x .625 OD x .062
KNOB, extension
1
1
1
1
1
1
1
2
1
2
1
1
1
1
CIRCUIT CARD, digital tach (consisting of)
CONNECTOR & SOCKETS
GROMMET, rbr .250 ID x .375mtg hole
CONNECTOR&PINS
OPTICAL ENCODER DISC
FITTING, brs barbed M 3/l6tbg x .312-24
ADAPTER, gun/feeder LH
SCREW, cap stl hexwhd .250-20 x .750
WASHER, flat stl SAE .312
KNOB, plstcT 1.1251gx .312-18x 1.500 bar
SCREW, hexwhd-slt stl slffmg 10-32 x .500
COVER, drive roll (consisting of)
LABEL, warning electric shock and pinch
NUT, stl hex full .375-16
WASHER, lock stl split .375
WASHER, flat stl .375
SCREW, cap stl hexhd .375-16 x 1.250
1
1
1
1
1
1
1
4
1
1
2
1
1
1
1
1
1
SPACER, locating
DRIVE, pinion 40T 24P .376 bore
RING, retaining ext .375 shaft x .O2Sthk
2
1
1
Motor
Optional High Speed
Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
*Recommended
OM-1588
Page
47
Table 13-1. Drive Roll and Wire Guide Kits
a,
.~
Wire Size
E~5
-(~
~
V-GROOVE
U-GROOVE
UC-GROOVE
VK-GROOVE
E~
~c,
~
4 RoIl
Drive
4 RoIl
Drive
4 RoIl
Drive
4 Roll
Drive
Kit
Roll
Kit
Roll
Kit
Roll
Kit
Roll
151 036
072000
151 052
132958
Fraction
Metric
.023-025 in
0.6mm
150 993
149 518
151 024
087 130
.030 in.
0.8
mm
150 993
149 518
151 025
053 695
.035 in.
0.9
mm
150993
149518
151 026
053700
.040 in.
1.0
mm
150993
149518
161 189
053696
.045 in.
1.1/1.2mn
150994
149519
151 027
053697
151 037
053701
151 053
132957
151 070
083489
.052 in.
1.3/1.4mn
150994
149519
151 028
053698
151 038
053702
151 054
132956
151 071
083490
mm
150995
149520
151 029
053699
151 039
053706
151 055
132955
151 072
053708
1.8mm
150995
149520
151056
132959
(.079 in.)
2.0
mm
150995
149520
151 040
053704
151 057
132960
151 073
053710
(.094 in.)
2.4mm
150 996
149 521
151 041
053 703
151 058
132 961
151 074
053 709
2.8
mm
150 996
149 521
151 042
053 705
151 059
132 962
151 075
053 711
3.2mm
150 997
149 522
151 043
053 707
151 060
132 963
151 076
053 712
1.6
.068-.072in
5/64 in.
fl)
(isi)
Each Kit Contains An Inlet
Guide, Intermediate Guide, And 045 233 Antiwear Guide With 604612 Setscrew 8-32
x
.125, Along
With 4 Drive Rolls.
2 Kits
OM-1588
Required
Page
48
For Dual Models.
S0549-D
S
.
Dia.
Item
No.
Part
No.
Mkg s.
Figure
1
147 139
.
.
..
2
155 024
.
.
..
3
154 933
.
.
..
4
PC6O
156 623
.
.
153 501
.
.
..
5
PLG6O
PLG41
..
6
PC4O
..
..
..
158 160
.
.
7
144 844
.
.
8
154 109
.
.
153 169
Quantity
Description
.
.
13-6.
Panel, Side w/Components (Fig
TAPE, adh acrylic double sided .010
LENS, clear anti-glare
PANEL, inner control
CIRCUIT CARD, data card
x
.
500
x
13-4 Item
37)
2
3.000
1
1
1
CONNECTOR & SOCKETS (RC6O)
See Fig 13-3, Item 40 (RC41)
1
CIRCUIT CARD, side display
STAND-OFF, 6-32 x .875 Ig
4
PLATE, ident inner control
ACTUATOR, switch
4
1
1
5
Hardware is
common
and
not available unless listed.
6
2
-S
7
8
ST-800 113-B
Figure
To maintain the
Replacement
13-6.
Panel, Side wlComponents
factory original pertormance of your equipment, use only Manufacturers Suggested
required when ordering parts from your local distributor.
Parts. Model and serial number
OM-1 588
Page
49
U~ Hardware is
common
and
not available unless listed.
V
\
\
\__~
\
\
\
\
\
~
.
CD
L)
CD
C.)
CJ
0)
CJ
ST-142 306-C
Figure
OM-1 588
Page
50
13-7. Boom
Assembly
Quantity
Item
No.
Model
Part
No.
Description
Figure
.1.010313..
2
010910..
3
079622..
4
079621..
5
079667..
5
080812..
6
079632..
7
079665..
7
080811..
8
079664..
9
139633..
10
159999..
10
160513..
11
073742
12
073741
13
079029..
14
075462..
15
602250..
16
079020..
17
155335
18
149858..
18
151625..
19
150258
20
024605
21
075101..
079030..
22
23
174754
080157..
24
174688..
142804
134327
When
25
073666..
26
047224..
27
602246..
28
010493..
29
139818..
ordering
a
13-7. Boom
Assembly (Fig
12
13-1 Item
I
16
15)
PIN, coffer hair .072 x 1.437
WASHER, flat stl SAE .375
WASHER, shld .381 ID x .750 OD
PULLEY, V sgl grv 7.7SOdia x 8.000P x .625 bore
PIPE, plstc .500 x 133.750
PIPE, plstc .500x 181 .750
BOLT, U stl .250-20 x .875 wide x 1.375 deep.
GUIDE, wire
GUIDE, wire
GUIDE, wire inlet
LINER, monocoil 3/32-1/8 wire x 15.687
4....
4
6....
6
2....
2
2....
2
2
2
2
2
2
BOOM, dual
BOOM, dual
1
PIN, clevis .750 OD x 2.156 Ig
CLEVIS, .812 yoke 6.062 Ig .750-l6thd
NUT, stl hex full fnsh .750-16
SHAFT, boom counterbalance
WASHER, flat stl SAE .750
NUT, stl hex elastic stop .750-16
PIPE, blk 3.000 x .875
SPRING, cprsn 3.750 OD x .625 wire x 36.000
SPRING, cprsn 3.750 OD x .640 wire x 36.000
RETAINER, spring
BEARING, ball thr sgl row .750 x 1.625 x .625
NUT, stl hex special .750-16 x 1.250
WASHER, lock stl ext tooth .750
BASE, swivel boom (consisting of)
FITTING, grease 1/8NPT
BRACKET, mtg control tilt
LABEL, Swingarc caution heavy spring
LABEL, warning general precautionary
BOLT, mach stl hexhd .750-16 x 2.750
KNOB, T-bar .500-l3thd
WASHER, flat stl std .500
BUSHING, snap-in nyl .625 ID x .875mtg hole
GUARD, motor protector
component originally displaying
a
precautionary label, the
1....
1
1....
1
2....
2
1....
1
2....
2
1....
1
1
1
1
1
1....
1
1....
1
1....
1
1....
1
1....
1
1....
1
1....
1
1....1
1....1
label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1588
Page
51
Notes
.
OM-1 588
Page
52
Notes
OM-1 588
Page
53
Notes
.
.
__
OM-1 588
Page
54
~k ~II
miner ~
SERVICE VIDEOS
SERVICE TRAINING
FROM MILLER ELECTRIC
These Service Videos will
help you
-
learn about main
tenance, troubleshooting, and servicing specific Miller
equipment.
Also, if you
can
included test will
points
Miller Certified Service Technician,
help you recertify. Passing the
are a
these videos
earn
five
points towards the forty
needed.
You will find each of these
professionally produced
videos to be very informative and
your Service Video Library.
:
a
valuable part of
11
XMT 304 Video Kit
(#197 018)
(#197 007)
(#197 009)
LI
324-1016
$3.00
324-1031
$86.00
S-62& S-54 &
324-1014
$86.00
324-1018
$3.00
324-1032
$86.00
Additional Deltaweld Test Sheet
(#197 011)
324-1019
Additional S-MM Test Sheet
(#197 017)
Payment
Check
$3.00
324-1017
Information
or
Money
Order
Send check
or
money order
payable
to:
Neenah
Printing
Attn: Literature Distribution Center
P0. Box 506
Neenah, WI 54957-0506
Purchase Order
Visa
Mastercard
_______________
Name of Card holder
__________________________________________________
Account #__________________________________
Cardholders
Exp.
Date
__________
signature
To Order call 920-751-2120
or
60M)
$126.00
Deltaweld 452 Video Kit
(#197 010)
LI
S-MM Video Kit
(#197 015)
-
324-1009
Additional Bobcat 225 NT Test Sheet
$86.00
324-1030
Additional S-62 & S-64 Test Sheet
(#197 014)
videos
Bobcat 225 NT Video Kit
$3.00
324-1008
S-62 & 5-64 Series Video Kit
(#197 012)
Package (2
(#197 006)
L1
Additional XMT 304 Test Sheet
(#197 019)
Feeder Series
$86.00
324-1035
Fax 920-751-2121
Distributor Name
Customer
#_________________
$3.00
Miller ~
WELDING EQUIPMENT
SERVICE ENGINEERING
SELF-PACED
TRAINING COURSE
FROM MILLER ELECTRIC
-
Learn the basics of
Welding equipment troubleshooting
servicing With this three module course designed
for home study, industrial and educational use. This
course Will provide the basic knowledge to begin a
career in servicing welding equipment,
act as a
refresher, or provide a welding salesman or technician
service and troubleshooting techniques.
and
A certificate of
completion
Training Department
is awarded
upon successful
by the
completion
Miller
of the
course.
MODULE 1
MODULE 2
Visual
Inspection
High Frequency
Safety
Load Bank
U Welding Equipment
Service
registered
Check
$60.00
Symbols
Component Identification
Troubleshooting
Additional Text
(Includes
text and
registered
(#145 871)
answer
card.)
exams, and
card.)
answer
Information
Payment
J
Electronic
Operation
Operation
U
(#145 870)
Engineering Training Course
(Includes text, videotape,
MODULE 3
Volt-ohm Meter
or
Money
Order
Send check
or
money order payable to:
Neenah
Printing
Attn: Literature Distribution Center
P0. Box 506
Neenah,
II]
Purchase Order
Mastercard
LI
WI
54957-0506
Visa
______________
Name of Card holder
Account #__________
Cardholders
Exp. Date
signature
To Order call 920-751-2120
or
Fax 920-751-2121
Distributor Name
Customer #
$35.00
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(Equipment
Warranty Questions9
This limited
Call
1 -800-4-A-MILLER
for your local
Miller distributor
/
with
Effective January 1, 1999
serial number preface of KK
warranty supersedes all previous Miller warranties and is
guarantees or warranties expressed or implied.
-
Your thstrtbutor also gives
you..~
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
Service
such defects in material
workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
~ get the fast,
reliable response you
-parts
can-bØin your
ttandsin24hptirs.
.
*
LIMITED WARRANTY
Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
a
H
Need fast
answers to
the
:togh welding questions?
U.
.
0:
Contact your distributor::
The.expettise of the
distributor and Miller is
there io.help you,: every
periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
*
*
5 Years Parts
Original
*
Inverters
stepoftheway. :~
2.
C
3.
-
1.
and
2.
Parts
(No labor)
lBS
True Bluefi Limited
Warranty
*
Semi-Automatic and Automatic Wire Feeders
*
Inverter Power
Cutting
Power Sources
Intellitig
*
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
Parts and Labor
Motor Driven Guns
(w/exception
of
Spoolmate
185)
Process Controllers
*
Positioners and Controllers
*
Automatic Motion Devices
*
Robots
*
as
by Miller, but manutactured by others,
engines or trade accessories. These items are
by the manutacturers warranty, if any.
Consumable components; such
as contact tips, cuHing
nozzles, contactors, brushes, slip rings, relays or parts
3.
wear.
that has been modified by any party other
Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specitications for the equipment.
Equipment
than
by this warranty, the
option: (1) repair; or(2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost ot repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods
at customers risk and expense. Millers option of repair or
replacement will be FOB., Factory atAppleton, Wisconsin, or
FOB. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
In the event of
a
warranty
RFCS Foot Controls
claim covered
be,
at Millers
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
OR
INCIDENTAL
INDIRECT,
SPECIAL,
DIRECT,
CONSEQUENTIAL
PROFIT),
DAMAGES
IHPS Power Sources
ANY OTHER LEGAL THEORY.
*
Water Coolant
ANY
*
HF Units
*
Grids
*
Maxstar 140
*
Spot
Systems
Load Banks
*
SDX Transformers
*
Miller
Field
6 Months
5.
90
*
Days
Batteries
Parts
MIG Guns/TIG Torches
ANY
MIGHT
ARISE
BY
IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
WITH
RESPECT
TO
AND
ALL
ANY
PURPOSE,
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
(except APT,
DISCLAIMED BY MILLER.
ZIPCUT &
Options
(NOTE: Field options are covered under True
Bluefi for the remaining warranty period of the
product they are installed in, or for a minimum of
whichever is greater.)
one year
4.
EXPRESS
PROVISION,
Cyclomatic Equipment
Running Gear/Trailers
Plasma Cutting Torches
PLAZCUT Models)
OF
OR
WARRANTY NOT PROVIDED HEREIN
OR
IMPLIED
GUARANTY
WARRANTY,
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER
LEGAL THEORY WHICH,
BUT FOR THIS
AND
Welders
*
(INCLUDING LOSS
CONTRACT, TORT
WHETHER BASED ON
*
*
to:
Items furnished
exclusive remedies shall
Supplies
*
*
apply
BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
Plasma Arc
*
shall not
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
*
*
Spoolmate
AND USE
Transformer/Rectifier Power Sources
1 Year
*
that fail due to normal
output rectifiers only)
*
*
Kits
Replacement
covered
3 Years Labor
Parts and Labor
3 Years
other
Remote Controls
Accessory
such
main power rectifiers
(input
no
APT, ZIPCUT & PLAZCUT Model Plasma Culling
*
Millers
International distributor.
*
exclusive with
or
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
1.
newer)
Torches
time
Support.
or
a
Some states in the U.S.A. do not allow limitations of how
long
implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
an
available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that
they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.
miller_warr 9/ag
..
,,,,.~.
.
I.
~
Owners
Record
...~.
Please
complete
and retain with your
Model Name
(Date
which equipment
was
.
Number
Serial/Style
Purchase Date
records.
personal
delivered to
original customer.)
.~..
..
.
.
.
Distributor
Address
.
City
,...
..
State
Zip
~
Resources Available
H
Always provide
Model Name and
Serial/Style
Number.
.
.
.
..
.
...
(
Contact your Distributor for:
Welding Supplies and Consumables
To locate
Options
a distributor or service agency
you, call 1-800-4-A-Miller or visit our
website at www.MillerWelds.com
and Accessories
/
near
Personal
/
Safety Equipment
Service and Repair
Replacement
H
Co
Parts
Training (Schools, Videos, Books)
Technical Manuals
and Parts)
(Servicing
Information
k~temahon
.
Circuit
Diagrams
Welding
H
K3ngdom;~
Phone: 44 (0) f~(}4593493
FAX 44(0) 1204~598D66
Process Handbooks
www
Contact the
Delivering
Carrier for:
File
a
claim for loss
or
-
UnIted
.,.:
~.
.~
.
~HerWeJdscom
damage during
shipment.
For assistance in
filing
contact your distributor
manufacturers
settling claims,
and/or equipment
or
Transportation Department.
p//A
PRINTED IN USA
'
1999 Miller Etethic
Mfg.
co.
9/99
illet.~
.~ ~