Download Miller Electric DS-64M Swingarc Specifications
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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 ~ 4~I FtOWU~ ~ FRONT I DISPLAY DSP~ SIDE DISPLAY : i ~ DSPL1 4~ r l~l~+iT1T!~ ~~vvvv~ ~1 H~00 ~ I I II (DATA~RD I ~ II . ~4J ~, 0 ~ 0 PB3t a 0 C4&E 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 ~ ~ L ~ ~PtG~3~ ___________ _____ I PC15/PL6I5 0 ~16/R.OII ~>> PCI7IPLSI7 4 I H~ZD ~D LSD LED ):i~: I 2~~2> 2 I ~ L~1I LED LED )~ )~ FT 1~ ~IT II I~ ~I3>~I ~I I 4>4 3>3 -- ~III~2> L~ 2 PC2O ~> I E~r,1Is.,G~ ~ -l D~ ~T~II~IT ~I~I ~jjj~ ~ ~ 24-~~-<~ ____ K~ 2 ~ ~s~ 3<~< 3 h ~ ~-~< 24~2 >~<~ 2~-~ *-~< 4~-< 3.E~43 ~ 3E-~ LOT <~ (__L<II~E_!~*1t,__L<~ ~ ELI I~I I l0~II ~L< ~ I4~_L<44_~.4>_L<1 ax 2 ~ Pt~7/Pt~7~ ~ 2E-L.(~ (-TX2)~R~< 14-~-<I I ~ff ~ 44- 54- ~ 2 4~-< 2~E~52 7 4~-< 7E~*7 ~ 4E~-< 34~3 *154 34-~~< >~~A~.(j >~.( 24 74 3 I if _________ ax Figure OM-1 588 Page 38 2>~ RClOo~3>>~~ II I~ ~41/~G41 ~ II ~ ~ ~43 U~E (OP11ON) - ~ PC6O ~ ~LECT RPS8 ~ ~ ~~Ii L~~JI ~ VVVVVVVVVV~vvv~V vv PC3O ~ I ~I 11 L: I I csa (~T~UL) L r~i 13-1. Circuit Diagram ~ p ~ r I RW~M OAt ~XCT FIElD ~S10JCTfll) i FLTfl~4W 0094 f~H I ~ ! POlIO I 000-0 0001000000 I 00110/POOl I I I ~o ~ I I 10i~L~0 _________________________ 9600 ocor000000000 RCIOO-I> PC100 RC1002> ~-4 I/O ELIOt ________________________ 901003> ~ 00100 g - - 001000> J%Y ~ %T~T~ - ~ AL 1)00 flI 10000100 0? ITOO.F OR IN P1/CC CC ~s-~ FLIER 00000. UPLER I +4709 J 14 000010100 IF-11 17flN009900 cx/cv ______ aswr t~ se INIYXWICC 5? PC5O (if/OAR LL~a~ U PcBO FLIER 90*00 (qi2~2~ ~ rorri ____________ ~ ~ 5, INTERr~CE BOARD OJ~4T ~ a 00040)> RcoimaI I~!MSRi (11/AR ~ NERO-I>) I ~ _________________ 0000 #2 ~ 0003-2>> ~lWN0~< ~_. ROll-I>> ~flI2 ~ ~ R00o_o>>.a~*RI~~t!] I~$~–~?!~t!J>_ nal-w(Lrn) -- ____________ 14 POt ~Nat #9 ~ ~ ROlO_l>)AL*R1>~~N1 I)oE~e>-*eI>--- ~1g!~g~11 __________ RcwR~3 ~ Ii~0ErsC00ooT OPlfltI I o~omao __________________ C I p 0060 0.9W ( ~&rcgo~4 fl ________________ I 77?7~tT~ CCR000-0 0001-4> (lIAR ~ ROll-I>> (19/1091 90100 OR 0909 ROll-I> -v_M-v---v-v-v-. 00013>> R00l-2>>-~--~, B ~ -<cw 0001_2>>a_ I I - LJ__~~ L fl~a ~c I 1R09 a&H0 I ooJcrNa 0909p4 I I WSTSC1OR ,~ I 0C44 Pt i fi1 I!t I , ~~~24WCF6T _______________ 002>> mioi - a pci U010R BOARD AC 10 P0000 I ~RS1 noox~ 004 mioi ma 29,10 00.0 ~e ~ L_J SD-184 792-B 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 :~ed.Mo~r~aoe~em V / / :~t ~ / 7 40 / / o~ 7 ......:c4;, // .7.,- V: :0 / / . / .0~ / / / (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.~ .~ ~
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