Download Miller Electric DS-64M Swingarc Specifications

IIM-1588E
September
1997
Eff. w/Serial Number KH41 9805
Miller
~
MIG
(GMAW) Welding
Pulsed MIG
Flux Cored
(GMAW-P)
(FCAW) Welding
The Power ofBlue.
D~n
Wire Feeder
(Use
DS-64M
with CC/CV Power
Sources)
Swingarc
12 and 16 Foot
.0.
Visit
our
website at
wwwJMNerW~
OWNERS
MANUAL
From Miller to You
Thank you and congratulations on choosing Miller. Now
you can get the job done and get it done right. We know
you dont
Thats
have time to do it any other way.
why
when Niels Miller first started
building arc
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
Today,
he made
sure
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.
This Owners
Miller
help
Manual is
products.
designed
to
help
you
Please take time to read the
yourself against potential
you protect
get the
Safety precautions. They
hazards
made installation and
11111111W
most out of your
on
will
the worksite. Weve
and easy.
years of reliable
operation quick
With Miller you can count on
service with proper maintenance. And if for
REGISTERED
QUALITY SYSTEM
some reason
the unit needs
______________
repair,
theres
a
section that will
Troubleshooting
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 is the first welding
equipment manufacturer io
the U.S.A. to be registered
to the ISO 9001 Quality
System Standard.
L~~5
WorkINg as hard as you do
every power source from
Miller is backed by the most
hassle-free warranty in the
business.
Miller Electric manufactures
of welders and
welding
For information
products,
to
on
contact
full line
related
other
equipment.
quality Miller
your local Miller distributor
receive the latest full line
individual
a
catalog
catalog
or
.
sheets. To locate your nearest
distributor call 1 -800-4-A-Miller.
_
TI/A Miller
The PowerofBlue.
~fl
1 -800-4-A-MOJ.HI
for ywr local
Miller lOsiriliotor.
TABLE OF CONTENTS
SECTION 1
READ BEFORE USING
1-5.
EMF Information
1-3.
gives
-
1-4.
1-2.
Your distributor
SAFETY PRECAUTIONS
-
Symbol Usage
Arc Welding Hazards
Additional Symbols for Installation, Operation,
Principal Safety Standards
1-1.
1
1
1
and Maintenance
3
3
4
you
SECTION 1
Service
You
1-1.
always get
the fast,
1-2.
CONSIGNES DE SECURITE
-
Signification des symboles
Dangers relatifs au soudage a larc
Dangers supplØmentaires en relation
reliable response you
need. Most replacement
1-3.
be in your
hands in 24 hours.
1-4.
Principales
normes
1-5.
Information
sur
parts
-
LIRE AVANT UTILISATION
5
avec
Need fast
answers
to the
tough welding questions?
Contact your distributor.
The expertise of the
les
de sØcuritØ
9
Specifications
9
2-1.
9
SECTION 3- INSTALLATION
3-7.
Control Box Connections
provides
3-8.
14-Pin
3-9.
Motor Start Control
parts information for your
3-10.
Removing Safety
unit. To obtain
3-11. Gun Recommendation Table
help you, every
step of the way.
3-1.
3-2.
3-3.
3-4.
3-5.
Miller offers
a
Manual which
detailed seivice and
a
Technical
contact your local
distributor. Your distributor
Manual,
also
Welding
supply you with
Process Manuals
as SMAW, GTAW,
GMAW, and GMAW-P.
such
For
practical information on
welding, process applica
tions, and Miller products,
our
website at
n~Om~veIdLcum
8
SECTION 2- INTRODUCTION
3-6.
there to
8
champs electromagnetiques
Technical
distributor and Miller is
visit
le fonctionnement
7
et Ia maintenance
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
can
Iinstallation,
can
Support
more
5
5
10
11
12
13
14
14
Plug Information
15
Collar And
15
Adjusting Boom
Type, Size, And Feed Speed Capability
Installing And Threading Welding Wire
3-12. Wire
3-13.
9
10
16
Table
16
17
18
SECTION 4- OPERATION
18
4-2.
Operational Terms
Pulse Welding Terms
4-3.
Front Panel Controls
19
4-4.
Side And Rear Panel Controls
20
4-1.
18
SECTION 5- SETTiNG SEQUENCE PARAMETERS
5-1.
Parameters In A
Sequence
Program
SECTION 6- SElliNG DUAL SCHEDULE PARAMETERS
Dual Schedule Pair
6-1.
Selecting
6-2.
Dual Schedule Switch
Diagrams
SECTION 7- USING THE OPTIONAL DATA CARE
7-1.
7-2.
7-3.
System Setup Display
9-2.
9-3.
9-4.
9-5.
9-6.
9-7.
9-8.
Program
Program
Program
Program
Program
Program
Program
Program
1
2
3
4
5
6
-
-
-
-
-
-
8
-
23
24
26
Parameters
26
27
Steel
27
Steel
27
Steel
27
Steel
27
Stainless
28
Stainless
28
Nickel
7
22
25
SECTION 9- STANDARD PULSE WELDING PROGRAMS
9-1.
22
24
Card
Card
SECTION 8- SYSTEM SETUP
8-1.
21
24
Data Card Terms
Installing Data
Displays
21
Alloy
Silicon Bronze
SECTION 10-TEACH POINTS
28
28
29
10-1. Teach
29
10-2. Teach
30
10-3.
Using 15 Points
Using 4 Points
Redefining Teach Points
SECTION 11
-
MAINTENANCE AND TROUBLESHOOTING
31
33
11-1. Routine Maintenance
33
11-2. Error
34
11-3.
35
Displays
Troubleshooting
SECTION 12- ELECTRICAL DIAGRAM
36
SECTION 13- PARTS LIST
38
OPTIONS AND ACCESSORIES
WARRANTY
U
SECTION 1
SAFETY PRECAUTIONS
-
READ BEFORE USING
-
nd5/97
som
Symbol Usage
Means
a
A
Marks
not
possible
hazards
are
of symbols means Warning! Watch Out! possible
SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary
This group
ELECTRIC
actions to avoid the hazards.
Hazards
Welding
symbols
the
are
safety related.
are used throughout this manual
identify possible hazards. When you
shown below
to call attention to and
see
There
special safety message.
a
Arc
1-2.
The
Out!
procedure! The possible
adjoining symbols.
shown in the
l~ Means ~Note~
A
Watch
Warning!
hazards with this
symbol,
watch out, and follow the related instructions
safety information given below is
to avoid the hazard. The
A
grounding
workpiece
is
do not
work
use
required, ground it directly
clamp or work cable.
Do not touch electrode if you are in contact with the work,
another electrode from a different machine.
ground,
or
Use
follow all
parts
a
Safety
Standards.
Only qualified persons
repair this unit.
should
install, operate, maintain,
and
During operation, keep everybody, especially children, away.
only well-maintained equipment. Repair or replace damaged
at once. Maintain unit according to manual.
Wear
a
Keep
all
Clamp
safety
harness if
and
panels
as near
Insulate work
Touching
single
Do not connect
Do not touch live electrical
hole-free
dry,
weld
AC output in damp areas,
danger of falling.
and
Use AC
output ONLY if required for
If AC output is
unit.
Disconnect
servicing
Properly
use
remote
the
confined,
or
if
control if
present
on
this
ground
equipment according
to
its
Manual and national, state, and local codes.
making input connections,
conductor first
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
Do not
use
worn,
Do not
drape
when not in
FUMES AND GASES
over
I
or
these fumes and gases
health.
work cable to any
If ventilation is poor,
the
Material
manufacturers
your
body.
and gases. Breathing
be hazardous to your
can
use an
Safety
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 near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
Do not weld
on
poorly spliced
cables.
coated metals, such as galvanized, lead, or
unless the coating is removed from the
plated steel,
weld area, the
or
be hazardous.
out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or
remove welding fumes and gases.
Read
can
Welding produces fumes
=5 ~
cadmium
use.
damaged, undersized,
cables
electrode
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.
When
one
inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
Keep your head
welding process.
output
input power or stop engine before installing or
equipment. Lockout/tagout input power according
CFR 191 0.147 (see Safety Standards).
install and
than
workpiece to prevent
to
Turn Off
I
this
to OSHA 29
Owners
required,
more
workpiece
practical.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
body protection.
if movement is
use
a
as
parts.
insulating gloves
yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the
work or ground.
Do not
place.
output terminal.
Insulate
there is
in
metal-to-metal contact to
clamp when not connected
object.
contact with any metal
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
also
circuits are
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.
good
above floor level.
securely
the weld
ELECTRIC SHOCK can kill
live
working
covers
work cable with
worktable
or
Wear
of the
separate cable
a
summary of the more complete safety information
found in the Safety Standards listed in Section 1-4. Read and
only
A
If earth
with
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
BUILDUP OF:GAS
bum eyes and skin
can
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.
Wear
ventilate
confined
when not in
use.
or
use
spaces
HOT PARTS cncase
severe
burns.
with side shields under your
approved safety glasses
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
protective clothing made from durable,
(leather and wool) and foot protection.
Wear
kill
or
approved air-supplied respirator.
your face and eyes when
and Z87.1 listed in Safety
Wear
injure
shielding gas supply
Always
welding helmet fitted with a proper shade of filterto protect
welding or watching (see ANSI Z49.1
Standards).
a
can
before
cooling period
working
on
gun
or
torch.
flame-resistant
material
MAGNETIC FIELDS
WELDING
can cause
Welding
on
drums,
pipes,
fire
orexplosibn.
Pacemaker
Protect
yourself
and others from
Do not weld where
flying sparks
flying sparks
can
Remove all flammables within 35 ft
this is not
possible, tightly
cover
(10.7 m)
NOISE
fire,
and
Be
that
welding
aware
can cause
fire
Do not weld
on
are
they
a
fire
on a
of the welding arc.
approved covers.
closed containers such
Connect work cable to the work
unknown
Do not
Noise from
tip
processes
as
welder to thaw frozen
when not in
Wear
as
approved
CYLINDERS
partition
or
tanks, drums,
or
ear
protection
if noise level is
can
explode
If
damaged.
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.
welding
area as
Protect
or
Install
cut off
welding
cylinders in an upright position by securing to
or cylinder rack to prevent falling or tipping.
as
a
leather
wire at
Never
gloves, heavy
cap.
or
matches,
Never weld
S
can
injure
drape
Never allow
lighter
a
a
welding
over a
or
gas
eyes.
approved safety glasses with
shields even under your welding helmet.
side
other electrical circuits.
cylinder.
electrode to touch any
welding
on a
torch
pressurized cylinder
parts in good
cylinder.
explosion
will result.
Keep protective cap
use or
in
connected for
Standards.
and
opening cylinder
valve.
place over valve except when cylinder is
in
use.
Read and follow instructions
associated
and
condition.
Turn face away from valve outlet when
Wear
stationary
Use only correct shielding gas cylinders, regulators, hoses,
fittings designed for the specific application; maintain them
associated
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
a
support
Keep cylinders away from any welding
such
FLYING METAL
compressed gas cylinders from excessive heat,
slag, open flames, sparks, and arcs.
mechanical shocks,
pipes.
Remove any combustibles, such as a butane
from your person before doing any welding.
2
can
Shielding
pipes,
(see
to AWS F4.1
close to the
protective garments
shirt, cuffless trousers, high shoes, and
Page
equipment
high.
use.
Wear oil-free
OM-1588
or
If
prevent welding current from traveling long, possibly
paths and causing electric shock and fire hazards.
Remove stick electrode from holder
contact
some
damage hearing.
to
use
damage hearing.
extinguisher nearby.
ceiling, floor, bulkhead,
properly prepared according
Safety Standards).
practical
spot
the hidden side.
on
unless
keep
can
or
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
keep away.
going near arc welding, gouging,
welding operations.
strike flammable material.
them with
wearers
affect pacemakers.
Wearers should consult their doctor before
closed containers, such as tanks,
can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks,
hot workpiece, and hot equipment can cause fires
and burns. Accidental contact of electrode to metal objects can
cause sparks, explosion, overheating, or fire. Check and be sure the
area is safe before doing any welding.
or
can
equipment,
compressed gas cylinders,
publication P-i listed in Safety
on
and CGA
Additional
1.3
For
Symbols
Installation, Operation, And Maintenance
MOVING PARTS
FIRE OR EXPLOSION hazard~
Do not install
unit on, over,
place
or
Keep away from moving parts
or near
combustible surfaces.
Do not install unit
is
building wiring
properly sized, rated, and protected
FALUNG UNIT
all
Keep
near
be
Do not overload
power
doors, panels,
closed and
flammables.
sure
causeinjury.
can
securely
in
such
as
covers, and
fans.
guards
place.
supply system
to handle this unit.
can cause
injury.
HF. RADIATION
lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
can cause
Interference.
Use
Use
equipment
support unit.
of
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
to lift and
adequate capacity
only qualified persons familiar with
equipment perform this installation.
Have
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
electronic
The
unit.
is
user
promptly
for
responsible
having a qualified electrician
problem resulting from the
correct any interference
installation.
OVERUSE
Allow
can cause
cooling period;
Reduce current
starting
to weld
Do not block
STATIC
Put
or
OVERHEATING
follow rated
reduce
or
boards
or
wrist
at once.
the
FCC about interference, stop
regularly
using
the
checked and maintained.
Keep high-frequency source doors and panels tightly shut,
keep spark gaps at correct setting, and use grounding and
shielding to minimize the possibility of interference.
again.
grounded
on
by
Have the installation
before
filter airflow to unit.
(ESD) can damage
handling
duty cycle.
duty cycle
If notified
equipment
PC boards.
BEFORE
strap
parts.
ARC WELDING
static-proof bags and
store, move, or ship PC boards.
Use proper
can cause
lnterterence.
boxes to
Electromagnetic energy can interfere with
electronic equipment such as
computers and computer-driven equipment
sensitive
MOVING PARTS
can cause
such
injury.
Keep away from moving parts.
Keep away from pinch points
robots.
as
all equipment in the welding
electromagnetically compatible.
Be
such
as
drive
To reduce
rolls.
possible,
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
Do not
point gun toward any part of the body,
people, or any metal when threading
welding
is
installed
and
Safety and Health Standards,
using
line
filters,
or
shielding
the work
grounded
area.
H
Safety in Welding and Cutting, ANSI Standard Z49.i, from
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
American
OSHA 29 CFR 1910, from
dent of Documents, U.S. Govemment
D.C. 20402.
Recommended Safe Practices for the
That Have
Superinten
Printing Office, Washington,
Preparation
for
Held Hazardous
Welding
and
Substances,
Safe
E
Handling
of
Compressed
Gases in
Cylinders,
CGA
Pamphlet
P-i, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
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.
Safe Practices For
Occupation
And Educational
Eye
And Face
American
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.
Welding Society Standard AWS F4.1, from
Welding Society, 550 N.W. LeJeune Rd. Miami, FL 33126
American
National Electrical
Protection
machine
wire.
Principal Safety Standards
of Containers
welding
to this manual.
such
other
Cutting
this
100 meters from any sensitive elec
If interference still occurs, the user must take extra measures
as moving the welding machine, using shielded cables,
so.
1-4.
is
close
Locate
tronic
area
OM-1588
Page
3
EMF Information
1-5
Considerations About Welding And The Effects Of Low
Electric And Magnetic Fields
Frequency
Welding current, as it flows through welding cables, will cause electro
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: The body of evidence, in the
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
or
magnetic fields
Keep
2.
Arrange
3.
Do not coil
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
4.
and cables
them.
operator.
body.
as
.
far away from opera
tor as
5.
clamp
workpiece
as
close to the weld
as
possible.
in the
workplace,
use
the
following
Pacemaker
then
procedures:
cables close
About Pacemakers:
cutting.
reduce
1.
wearers
following
consult your doctor first. If cleared by your doctor,
procedures is recommended.
the above
.
OM-1588
Page
4
SECTION 1
CONSIGNES DE SECURITE
UTI LISATION
-
LIRE AVANT
-
som
1-1
Signification
symboles
garde! Soyez vigilant! Cette procedure
Signifie
prØsente des risques de danger! Ceux-ci sont identifies
par des symboles adjacents aux directives.
Mise
4A
A
des
Identifie
en
message de sØcuritØ
un
Ce groupe de symbo!es signifie Mise en garde ! Soyez vigilant~ II y a des
risques de danger relies aux CHOCS ELECTRIQUES, aux PIECES EN
particulier.
MOUVEMENTetaux PIECES CHAUDES.
et
j~
Signifie
Lea
symboles prØsentØs ci-aprCs
present
risques
vigilant
danger.
sont utilisØs tout au
long
Lea
de sØcuritØ
consignes
L.installation,
prØsentCes ci-aprŁs
ne
Au
cours
de
quA
reparations
qualifiØes.
et les
lentretien
lutilisation,
vent Œtre conflØs
A
danger.
dea personnes
ne
les
champ
a
ce
manuel.
Porter
font
Maintenir solidement
doi
avec
Ia
piŁce a souder ou
ELECTRIQUE peut tuer.
contact avec des
piŁces Ølectriques peut
circuits internes de lappareil sont Łgalement sous
tension a ce moment-l. En soudage semi-automatique ou automatique,
le fil, le dŁvidoir, le logement des galets dentrainement et les piŁces
mŁtal!iques en contact avec le fil de soudage sont sous tension. Des
matŁriels mal installŁs ou mal mis a Ia terre prŁsentent un danger.
jamais
Porter des
toucher les
gants
travaille
hauteur.
en
tous les panneaux et
faon
a obtenir
un
bop
Ia table de travail, le
capots.
contact mŁtal-mŁtal
plus prŁs possible de
Ia
Isoler Ia
pince de masse quand pas
objet mŁtallique.
mis a Ia
piŁce
pour Łviter le contact
tout
I
provoquer une electrocution ou des b!essures graves.
LŁlectrode et le circuit de soudage sont sous tension
des que lappareil est sur ON. Le circuit dentrŁe et les
Ne
on
soudure.
avec
simple
quand
place
en
Fixer Ie cable de retour de
lutilisation, tenirtoute personne a lØcartet plus par
Un
harnais de sŁcuritŁ
un
ticuliŁrement lea enfants.
UN CHOC
quun materiel en bon Łtat. RŁparer ou remplacer sur-le
piŁces endommagŁes. Entretenir Iapparei! conformŁment
Nutiliser
du
manuel pour attirer votre attention et identifier les
de danger. Lorsque vous voyez un symbole, aoyez
dØviter tout
et suivez les directivea mentionnØes atm
que rØsumer linformation contenue dans les normes de sØcuritØ
CnumØrØes a Ia section 1-4 Veuillez lire et reapecter toutes cea
normea de sØcuritØ.
A
Reportez-vous aux symboles
mesures a prendre pour
directives ci-dessous afin de connaitre les
Łviter tout
nest pas relatif a Ia sØcuritØ.
NOTA
aux
Dangers relatlfs.au soudage a Parc
1-2.
A
_nd_tre 5/97
Ily
DU COURANT CONTINU IMPORTANT dans ies
a
convertisseurs
aprŁs
Ia
suppression
de Ialimenta
Ølectrique.
tion
ArrŒter les convertisseurs, dŁbrancher le courant
charger
les
indiquŁes
condensateurs
dans Ia
partie
dalimentation
selon
Łlectrique,
les
entretien avant de toucher les
et
dŁ
instructions
piŁces.
piŁces Łlectriques sous tension.
protection secs ne comportant
et des vŒtements de
pas de trous.
Sisoler de Ia piŁce et de a terre au moyen de tapis ou dautres
moyens isolants suffisamment grands pour empŁcher le contact phy
sique Łventuel avec Ia piŁce ou Ia terre.
LES FUMEES ET LES GAZ peuvent
Œtre dangereux
.
Ne pas
se
servir de
source
Łlectrique
humides, dana les endroits continŁs
Se servir dune
procŁdŁ
de
Si Iutilisation
saire,
se
source
soudage
dune
Łlectrique
courant Łlectrique dans es
l o on risque de tomber.
zones
Le soudage gŁnŁre des fumŁes et des gaz. Leur
inhalation pout Łtre dangereux pour votre sante.
ou
courant
Łlectrique
UNIOUEMENT si le
le demande.
source
servir de Ia tonction
votre tŒte des fumŁes. Ne pas
les fumees.
Eloigner
Łlectrique savŁre nŁces
de tŁlŁcommande si lappareil en est ŁquipŁ.
Łlectrique
courant
Couper lalimentation ou arrŁter le moteur avant de procŁder a linstal
lation, a Ia reparation ou a Ientretien de lapparei!. DŁverrouiller
lalimentation selon Ia norme OSI-IA 29 CFR 191 0.147 (voir normes
de sŁcuritŁ).
Installer et mettre a Ia terre correctement cet appareil conformŁment a
et aux codes nationaux, provinciaux et
son manuel dutilisation
municipaux.
Verifier et sassu
Toujours verifier Ia terre du cordon dalimentation
que le fil de terre du cordon dalimentation est bien raccordŁ a Ia
borne de terre du sectionneur ou que Ia fiche du cordon est raccordŁe
a une prise correctement mise a Ia terre.
rer
En effectuant les raccordements dentrŁe fixer dabord le conducteur
de mise a Ia terre appropriŁ et contre-vŁrifier les connexions.
Verifier
frŁquemment le cordon dalimentation pour voir siI nest pas
endommagŁ ou dŁnudŁ remplacer le cordon immŁdiatement slIest
endommagŁ un cable dŁnudŁ peut provoquer une electrocution.
Mettre Iappareil hors tension quand on ne Iutilise pas.
Ne pas utiliser des cables uses, endommagŁs, de grosseur insutfi
sante ou mat ŁpissŁs.
Ne pas enrouler les cables autour du corps.
Si Ia piŁce soudŁe doit Łtre mise a laterre, le faire directement avec un
cable distinct
ne pas utiliser le connecteur de piŁce ou le cable de
A
lintŁrieur, ventiler
veau
Ia
zone
de larc pour Ievacuation
respirer
et/ou utiliser un echappement au ni
des fumŁes et des gaz de soudage.
Si Ia ventilation est insuffisante, uti!iser
un
respirateur
a a!imenta
homologuŁ.
Ure les specifications de sŁcuritŁ des matŁriaux (MSDS5)
tion dair
et les ins
tructions du fabricant concernant les mŁtaux, les consommables,
les revŁtements, les nettoyants et les dŁgraisseurs.
espace fermŁ seulement siI eat bien ventilŁ ou
alimentation dair. Demander toujours a
un surveillant dument formŁ de se tenir a proximitŁ. Des fumees et
des gaz de soudage peuvent dŁplacer lair et abaisser le niveau
doxygŁne provoquant des blessures ou des accidents mortels.
Sassurer que lair de respiration ne prŁsente aucun danger.
Travailler dans
en
portant
un
un
respirateur a
Ne pas souder dans des endroits sttuŁs a proximitŁ dopŁrations de
de nettoyage ou de pu!vŁrisation. La chaleur et lea
rayons de Iarc peuvent rŁagir en presence de vapeurs et former
dŁgraissage,
des gaz hautement toxiques et irritants.
Ne pas souder des mŁtaux munis dun revŒtement, tels que lacier
galvanisŁ, plaque en plomb ou au cadmium a moms que le revŁte
ment nail ŁtŁ enlevŁ dans Ia zone de
soudure, que lendroit soft
bien ventilŁ, et si nŁcessaire, en portant un respirateur a a!imenta
tion dair. Lea revŒtements et tous lea mŁtaux renfermant ces ŁlŁ
ments peuvent dŁgager des fumŁes toxiques en cas de soudage.
retour.
Ne pas toucher lŁlectrode
terre
ou une
quand
on est en
contact avec Ia
piŁce,
Ia
electrode provenant dune autre machine.
OM-1588
Page
5
LES RAVONS DES L~ARC peuvent pro
voquer des brlures dans les yeux et.~
sur Ia peau
larc du procØdØ de soudage
gØnŁre des rayons visibles et invisibles intenses
et
infrarouges) susceptibles de provoquer
(ultraviolets
des brOlures dans les yeux et sur Ia peau. Des Øtincelles sont projetØes
pendant le soudage.
Le
Porter
un
muni dun Øcran de filtre
soudage
na
mŒmØ la mort.
I
de
rayonnement
casque de
LES ACCUMULATIONS DE GAZ
quent de provoquer des blessures ou
appropriØ
Fermer lalimentation du gaz protecteur
non utilisation.
Veiller
toujours a
rateur dadduction
bien aØrer les espaces confines
dair homologue.
ou se
en cas
servir dun
de
respi
pour
et vos yeux pendant le soudage ou pour regar
ANSI Z49. 1 et Z87.1 ØnumØrØ dans es normes de sØcuritØ).
protØger votre visage
der
(voir
Porter des
protections approuves
pour
es
DES
trop ØlevØ.
Utiliser des Øcrans
des barriŁres pour
ou
protØger des tiers de Øclair
Ne pas toucher des
IØblouissement; demander aux autres personnes de ne pas re
garder larc.
Porter des vŒtements de protection constituØ dans une matiŁre dura
ble, resistant au feu (cuir ou lame) et une protection des pieds.
et de
m.
~
~I
les, des
parties
chaudes a mains
nues
PrØvoir une pŁriode de refroidissement avant
dutiliser le pistolet ou Ia torche.
LE SOUDAGE peut provoquer
J
incendie
expIosion~
ou une
affecter les stimulateurs
Porteurs de stimulateur
a
projection
dØtincelles
et de
LE BRUIT
des Øtincelles
Ne pas souder dans un endroit l o
sur des substances inflammables.
restez a distance.
cardiaque,
porteurs dun stimulateur cardiaque doivent
dabord consulter leur mØdecin avant de sapprocher
des operations de soudage a larc, de gougeage ou
de soudage par points.
incendies et des brOlures. Le contact accidentel de lØlectrode avec des
provoquer des Øtincelles, une explosion, un
surchauffement ou un incendie. Avant de commencer le soudage,
verifier et sassurer que lendroit ne prØsente pas de danger.
personnes de
cardiaques.
Les
objets mØtalliques peut
Se protØger et dautres
metal chaud.
MAGNETIQUES peuvent
LES CHAMPS
soudage effectuØ sur des conteneurs fermØs tels
que des reservoirs, tambours ou des conduites peut
provo~uer leur Łclatement. Des Øtincelles peuvent Œtre
projetees de larc de soudure. La projection dØtincel
piŁces chaudes et des Øquipements chauds peut provoquer des
Le
~
PI¨CES
CHAUDES peuvent pro
voquer des brOlures graves.
oreilles Si le niveau sondre est
peut affecter louIe.
peuvent tomber
Le bruit des processus et des
DØplacertoutes les substances inflammables a une distance de 10,7
de larc de soudage. En cas dimpossibilitØ les recouvrir soigneuse
ment avec des protections homologuØs.
Des Øtincelles et des matØriaux chauds du soudage peuvent facile
equipements petit
affecter
louIe.
m
ment passer dans dautres
des ouvertures.
zones en
traversant de
Surveillertout dØclenchement dincendie ettenir
un
petites fissures
Porter des protections
le niveau sondre est
soudage effectuØ
peut dØclencher
un
Ne pas effectuer le
sur un
extincteur proxi
plafond, plancher, paroi
incendie de lautre
Si des BOUTEILLES sont endomma
elles pourront exploser.
separation
ou
gØes,
ctØ.
Des bouteilles de gaz protecteur contiennent du gaz
haute pression. Si une bouteille est endomma
gee, elle peutexploser. Dufaitquelesbouteillesdegaz
font normalement partie du procØdØ de soudage, es
des conteneurs fermØs tels que des
reservoirs, tambours, ou conduites, a moms quils naient ØtØ prepa
rØs correctement conformØment a AWS F4.1 (voir les normes de
soudage
sur
sØcuritØ).
Brancher le cable
sur Ia piŁce le plus prŁs possible de Ia zone de sou
pour Øviter le transport du courant sur une longue distance par
des chemins inconnus Łventuels en provoquant des risques dØlec
trocution et dincendie.
dage
Ne pas utiliser le
poste de soudage pour dØgeler des conduites ge
lees.
En cas de non utilisation, enlever Ia baguette dØlectrode
electrode ou couper le fil a Ia pointe de contact.
du porte
Porter des vŒtements 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.
Avant de souder, retirer toute substance combustible de
telles quun allumeur au butane ou des allumettes.
vos
poches
DES PARTICULES VOLANTES
peuvent blesser les jeiix.
soudage, lØcaillement,
le passage de Ia piŁce
fil de fer, et le meulage gØnŁrent
des Øtincelles et des particules mØtalliques volan
tes. Pendant Ia pØriode de refroidissement des soudures, elles risquent
Le
a
a
brosse
en
de pro jeter du laitier.
Porter des lunettes de sØcuritØ
OM-1588
Page
6
avec
Øcrans latØraux
pour les oreilles si
et
mite.
Le
approuvØs
trop ØlevØ.
ou un
Øcran facial.
sous
manipuler
avec
precaution.
ProtŁger les bouteilles de gaz comprimØ dune chaleur excessive,
des chocs mØcaniques, du laitier, des flammes ouvertes, des Øtin
celles et des arcs.
Placer les bouteilles debout en es fixant dans un support station
naire ou dans un porte-bouteilles pour les empŒcher de tomber ou
de
se renverser.
eloignØes des
Tenir les bouteilles
cuits electriques.
Ne
jamais placer
Une electrode de
une bouteille.
Ne
jamais
souder
une
torche de
soudage
une
ne
bouteille
circuits de
soudage
soudage sur une
jamais entrer
doit
pressurisØe
ou
autres cir
bouteille a gaz.
en
contact avec
risque dexplosion.
Utiliser seulement des bouteilles de gaz protecteur, rŁgulateurs,
tuyaux et raccords convenabtes pour cette application spØcifique;
les maintenir ainsi que les ØlØments associŁs en bon Øtat.
Ne pas tenir Ia tŒte
bouteille.
en
face de Ia sortie
en
ouvrant Ia soupape de Ia
Maintenir le chapeau de protection sur Ia soupape, sauf
dutilisation ou de branchement de Ia bouteille.
en cas
Lire et suivre les instructions concernant les bouteilles de gaz corn
les Łquipements associØs et les publications P-i CGA Łnu
mØrØes dans les normes de sØcuritØ.
prime,
1-3.
Dangers supplØmentaires
etla maintenance
en
-
:
:
:PES ORGANES MOBILES peuvent
provoquer des blessures.
00
DINCENDIE
DEXPLOSION.
Risque
sur, au-dessus
de surfaces infllammables.
placer lappareil
Ne pas
proximitØ
le foæctioflnement.
relation avecIinstallation,
ou
Rester a lØcart
ventilateur.
a
Maintenir fermØs et fixement
Ne pas installer lappareil a proximitØ de produits inflammables
sassurer que lalimen
Ne pas surcharger linstallation Ølectrique
tation est correctement dimensionnØ et protØgØ avant de mettre
lappareil en service.
LA CHUTE DE LAPPAREIL
des organes mobiles
panneaux,
en
recouvrements
et
comme
le
place les portes,
dispositifs de
protection.
I.E RAVONNEMENT HAUTE FRE
QUENCE (HF.) risque de provoquer
des interferences.
peut
blesser.
Le
de levage uniquement pour sou
lever lappareil, NON PAS les chariot, les bouteil
les de gaz ou tout autre accessoire.
Utiliser
un
dune
engin
capacitØ appropriØe
pour
soulever
lappareil.
En utilisant des fourches de levage pour dØplacer lunitØ, sassurer
que es fourches sont suffisamment longues pour dØpasser du ctØ
oppose de Iappareil.
rayonnement haute frequence peut provoquer
des interferences avec les Øquipements de ra
dionavigation et de communication, les services
de sØcuritØ et les ordinateurs.
Utiliser lanneau
Demander seulement a des personnes qualifiØes familiarisØes
des Øquipements Ølectroniques de faire fonctionner linstalla
tion.
avec
Iutilisateur est tenu de faire corriger rapidement par
les interferences resultant de installation.
un
Ølectricien
qualifiØ
Si le FCC
signale
des
interferences, arrØter immØdiatement lappa
reil.
LEMPLOI
EXCESSIF peut
SURCHAUFFER LEQIJIPEMENt
Effectuer
rØguliØrement
correcte et utiliser
PrØvoir
pØriode de refroidissement, respec
ter le cycle opØratoire nominal.
RØduire le courant ou le cycle opØratoire avant de
une
recommancer
le
Ia barrette de terre
manipuler des cartes ou des pieces.
Utiliser des pochettes et des boites antistatiques
pour stocker, dØplacer ou expØdier des cartes de
circuits imprimes.
avant de
DES ORGANES MOBILES peuvent
provoquer des blessures.
sapprocher
terre et et un
blindage
des organes mobiles.
Ne pas sapprocher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE
voque! 4es blessures.
peuvent ~ra
1...:..
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 equipement
Ølectronique sensible.
Veiller a ce que ce poste de soudage soit pose et mis a Ia terre
conformØment a ce mode demploi.
En cas dinterfØrences aprØs avoir pris les mesures prØcØdentes, il
incombe a lutilisateur de prendre des mesures supplØmentaires
telles que le deplacement du poste, lutilisation de thbles blindes,
lutilisation de filtres de ligne ou Ia pose de protecteurs dans Ia zone
Veiller ace que tout
de travail.
LES CHAMPS MAGNETIQIJES peuvent
affecter lea stimulateurs cardiaques.
Porteurs de stimulateur
Ne pas appuyer
reu linstruction.
Ne pas
Ia
gachette
avant den avoir
pistolet vers soi, dautres per
piece mØcanique en engageant
soudage.
diriger
sonnes ou
le fil de
sur
le
toute
pour rØduire les inter
de
LØnergie
ØlectromagnØtique
risque
provoquer des interferences pour lØquipement
Ølectronique sensible tel que les ordinateurs et
lØquipement commandØ par ordinateur tel que
les robots.
primØs.~
Ne pas
une
LE SOUDAGE
LES CHARGES ELEcTROSTATIQUES
peuvent endommager lea circuits Im
avec
de installation.
A LARC risque de
des
interferences.
provoquer
soudage.
Ia connexion
et lentretien
fØrences Øventuelles.
Ne pas obstruer les passages dair du poste.
Etablir
le contrle
Maintenir soigneusement fermØs les portes et les panneaux des
sources de haute frØquence, maintenir les Øclateurs a une distance
cardiaque,
restez a dis
tance.
Les porteurs dun stimulateur cardiaque doivent
dabord consulter leur mØdecin avant de sappro
cher des operations de soudage a larc, de gou
geage ou de soudage par points.
OM-1588
Page
7
1-4
Pruncipafes
normes
de sØcuntØ
Safetyin Welding
Cutting, norme ANSI Z49.1, de IArnerican Wel
ding Society, 550 N.W. Lejeune Rd, Miami FL 33126
and
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
Recommended Safe Practice for the Preparation for Welding and Cut
of Containers That Have Held Hazardous Substances, norme
AWS F4. 1, de lAmerican Welding Society, 550 N.W. Lejeune Rd, Mia
ting
mi FL 33126
National Electrical Code, NFPA Standard 70, de Ia National Fire Pro
tection Association, Batterymarch Park, Quincy, MA 02269.
DonnØes
des
Handling
of
Compressed Gases
in
Cylinders,
CGA
Pamphlet
P-i, de Ia Compressed Gas Association, 1235 Jefferson Davis High
way, Suite 501, Arlington, VA 22202.
Regles
de sØcuritØ en soudage, coupage et procØdØs connexes, norCSA Wi 17.2, de lAssociation canadienne de normalisation, vente
de normes, 178 Rexdale Boulevard, Rexd ale (Ontario) Canada M9W
1R3.
me
20402.
I ~5.
Safe
Information
sur
le
sur
soudage electrique
champs magnØtiques
basse
les
Safe Practices For Occupation And Educational Eye And Face Protec
tion, norme ANSI Z87.i, de lAmerican National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51 B, de Ia National
Protection Association, Batterymarch Park, Quincy, MA 02269.
effets, pour lorganisme,
Afin de rØduire
de travail,
frØquence
1
soudage, pendant son passage dans les cables de sou
dage, causera des champs Ølectromagnetiques. 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
node de recherche de 17 ans, un comitØ special ruban bleu du
a
Fire
champs ØlectromagnØtiques
et sur les
conclu: Laccumulation
champs ØlectromagnØtiques
Garder les cables ensembles en
avec du ruban adhØsif.
2
Mettre tous les cables du ctØ
3
Ne pas courber pas et
dans lenvironnement
es
torsadant
ou en
les
ne
oppose
de
lopØrateur.
pas entourer pas les cables autour de
votre corps.
4
de preuves, sui
jugement du comitØ, na pas dØmontrØ que lexposition aux
champs magnØtiques et champs Ølectriques a haute frØquence reprØ
sente un risque a Ia sante humaine.
Toutefois, des etudes sont
toujours en cours et es preuves continuent a Œtre examinØes. En at
tendant que les conclusions finales de a recherche soient Øtablies, il
vous serait souhaitable de rØduire votre exposition aux champs Ølec
tromagnØtiques pendant le soudage ou le coupage.
es
respecter les consignes suivantes
attachant
Le courant de
National Research Council
.
Garder le poste de
de
soudage
et les cables le
plus
loin
possible
vous.
vant le
5
Relier Ia
pince
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, ii
est alors recommandØ de
respecter
es
consignes
cidessus.
.
OM-i588
Page
8
SECTION 2- INTRODUCTION
Specifications
2-1.
Type
of
Welding
Input
24 Volts AC
Constant
Wire Feed
Type
50/60 Hertz
Range
Welding Circuit
Rating
.023 To 1/8 in (0.6
To 3.2 mm)
Standard: 50 To 780
To 19.8 mpm)
Voltage (CV)
DC For GMAW Or
Constant Voltage (CV) /
Constant Current (CC) DC
For GMAW-P
All Need 14-Pin And
Single-Phase
10 Amperes
Wire Diameter
Speed
Range
Power
Source
Power
ipm (1.3
Weight
12 ft
100
750
Volts,
Amperes,
100%
Duty Cycle
Max
Optional High Speed:
92 To 1435 ipm (2.3 To
36.5 mpm)
(3.7 m):
(94 kg)
207 lb
16 ft
Spool Weight:
60 lb (27 kg)
(4.9 m):
(127 kg)
280 lb
Contactor Control
12 ft
Maximum
Height
With 4 ft
(1.2 m)
(3.7 m)
17 ft
Post
Vertical Lift Of Boom
Horizontal to 60
16 ft
Boom
(4.9 m)
21 ft
(5.2 m)
Above Horizontal
Boom
(6.4 m)
Horizontal to 60
Above Horizontal
SECTION 3-INSTALLATION
Installing Swivel
3-1.
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 grade 5
steel bolts.
4
Swivel Assembly
Insert
into
pipe post.
Lubricate
swivel.
2
5
Safety
A
Do
Collar
not
remove
until
instructed to.
1
3
Tools Needed:
~
r
3/4in
ST-152 382
OM-1 588
Page
9
3-2.
OM-1 588
Installing
Page
10
Control Box And
Adjusting
Tilt
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:
cII::::::J===u
3/8 in
ST-i 52 383
OM-1588
Page
11
1
300/400 Ampere Model
CCICV Inverter Welding
Power Source
Use settings shown for both
pulse MIG welding and MIG
welding.
S
Ampere Model CV
Welding Power
450
Inverter
Source
3
14-Pin Cord
4
Positive
5
Negative ()
Be
sure
Weld Cable
(+)
Weld Cable
weld
cables
are
sized
properly for peak amperage if
pulse welding (see welding power
source Owners
Manual).
6
Workpiece
7
Voltage Sensing
(Optional Use)
Lead
50
PANEL
Be
sure gun is rated for peak am
perage if pulse welding. Install ac
0
cording
9
REMOTE
INDUCTANCE/DIG
V/A CONTROL
to its Owners
For connections
10
Manual.
Wire Feeder
Shielding
see
Gas
Section 3-7.
Supply
11
Supplied
12
Gas Hose From Boom
Y
Adapter
.
.
ST-801 806/ Ref. ST-175 086 / Ref. ST-180 311-B
OM-1 588
Page
12
3-6.
Connecting
Weld Cables And Gas Hoses
The weld cables and shielding gas
hoses extend 10 ft (3 m) from the
boom.
Route
weld
through
reed
from
cables
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
hoses
as
follows:
Sleeving
together
welding power
weld
cables
source
from
and boom.
Use electrical tape and insulated
to cover connection.
sleeving
3
Shielding
Gas Hose
Connect hose to gas supply or ex
tension hose. The hose from the
has
boom
threads.
5/8-18
right-hand
Tools Needed:
~r 5/8
in
Ret ST-801 806/ Ref. ST-i 52 800-A
OM-1588
Page
13
Control Box Connections
3-7.
14-Pin
3-8.
Plug
REMOTE 14
O~<
0
Information
pj~*
Pin Information
A
24 volts
B
Contact closure to A
G
Circuit
OB
C
+10 volts dc
C
D
Remote control circuit
common.
E
0 to +10 volts dc
command
H
Voltage feedback;
0 to +10 volts
F
Current
0 to +10 volts dc, 1 volt per 100 amperes.
M
CC/CV Select (+24 V
N
Inductance
H
ac
with
common
respect
to socket G.
completes
24 volts
ac
contactor control circuit.
for 24 volts AC circuit.
output
to remote control with
respect
to socket D.
G0 0M 0D
0
*The
remaining pins
input
feedback;
=
signal
from remote control with
dc, 1 volt per 10
arc
respect
to socket D.
volts.
CV)
(0-by)
are 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
potentiometer clockwise to 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
~=
~==~
~
1/4 in
ST~162 132 / Ref. SB-146 862-D
3-10.
Removing Safety Collar
And
Adjusting
Boom
1
Locking
Tighten
Knob
knob
to
prevent boom
movement. Loosen knob to aJlow
boom
movement.
Change
position to limit upward
knob
movement.
Pull boom down slightly and re
safety collar. Boom should
move
balance in any position from hori
zontal to 60 degrees above hori
zontal. If necessary,
as
boom
2
Threaded Rod
3
Jam Nut
Loosen jam nut and turn threaded
rod until boom balances. Tighten
jam nut. Be sure several full
threads are through yoke to pre
vent boom falling.
2
3
4
E
adjust
follows:
Yoke
Retain safety collar for use in
assembling or moving boom.
0
dis
4
1
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-1 588
Page
15
3-11. Gun Recommendation Table
Process
GMAW-P
GMAW
-
Motor
Hard
Hard
or
or
Cored Wires
M25, M40, Or GA-50C
Wires
GA-4OGL Or GA-5OGL
Type, Size,
Speed
Wire
Type
And Feed
Speed Capability
Table
Feed
Wire Size
Standard
All
Standard
All
3/32 To 7/64 in (2.4 To 2.8 mm)
Standard
All
1/8 in (3.2 mm)
Optional High
OM-1 588
Page
16
All
.
GW-500 Or GW-600
Cored Wires
Self-Shielding
FCAW
3-12. Wire
-
Gun
.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 pm
50 To 700
(1.3
To 19.8
mpm)
ipm (1.3
To 17.8
mpm)
5010300
ipm (1.3
To 7.6
9210 1440
1pm (2.3
To 35.6
mpm)
mpm)
3-13.
Installing And Threading Welding Wire
Tools Needed:
j
Install
E
wire
Adjust tension
wire
is
taut
3/16,5/64 in
~ 15/16,3/8
in
spool.
nut so
when
wire feed stops.
4-
-,
Be
sure
Forsoft wire or small diameter stainless
that outlet cable has proper
welding wire size.
size liner for the
When installing gun, position liner
extending from outlet wire guide as
close as possible to drive rolls without
touching.
Install gun. Lay gun cable out straight. Cut
oft end of wire. Push wire through guides up
to drive
Jog
rolls; continue
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
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 for
cover.
other side.
to hold wire. Press
button to feed wire out gun.
ST-152564.B/Ref. ST-156 929/Ref. SC-iSO 922/Ret. ST-156 930/5-0627-A
OM-1588 Page 17
SECTION 4- OPERATION
4-1.
Operational
Note ~
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
Welding
The wire feeder
less of
Cold Wire
Jog
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
speed.
Inductance
As inductance increases,
Trim
Arc
Synergic
The
arc on
time
increases, and the weld puddle becomes
length adjustment in pulse welding. Increasing
placed by volts in MIG programs.
the
trim increases the actual
operator programs pulse parameters for a specific wire feed speed.
pulse parameters between these wire feed speed increments.
arc
more
fluid.
length.
Trim is
re
The wire feeder determines
Side Panel Terms:
Process Mode
Sequence
Mode
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.
or
Mig.
weld, crater, burnback, postfiow,
preflow,
Dual Schedule Mode
Is used to select
a
Card Mode
Is used to select
use
Security
Only
Mode
functions with
rameter
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.
.
OM-1 588
Page
18
4-2.
Pulse
Welding
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.
2
Abk
Background Amperage
=
Maintains
_/~
Amps
3
PPS
arc
=
between
Increasing PPS
speed.
4
PWms
pulses.
Pulses Per Second
=
increases travel
Pulse Width In
Milliseconds
2
I4
Increasing
PWms increases bead
width.
t
Time
/
OM-1588
Page
19
Front Panel Controls
4-3.
3
0
8
p
7
4
o/p~~o
4
7/
\\\\
5
6
5
ST-162 127
1
Display
2
Parameter Select Button
while
welding, with exception of Dual Sched(see Section 6).
ule Mode
Pulse is
Press button to
3
move > on
display.
Display Control
Turn control to
change value pointed to by>.
control
click
Turning
length) to increase/decrease by
to increase/decrease by 0.1.
one
When 1PM is selected,
click causes wire feed
crease/decrease by
click
Prg
# is
causes
crease/decrease by
Page
20
5
Trigger
change type
(arc
Trigger
sis. Indicator
control
one
Hold
can
be set
light
Light
per program ba
on for programs
where this feature is active.
to in
To weld without
out weld
cycle,
one.
control
(Prg #)
one
holding gun trigger through
press and release button to
(indicator light
turns
on).
To start weld cycle, press and release gun
trigger within three seconds after an arc has
been struck. To end weld cycle, press and
release gun
6
trigger.
Side Select Button
to in
one.
changed
7
The feeder remembers the last used pro
gram for each side and returns to that pro
gram when the active side is changed.
Button
Jog
Push to
out
on a
comes
change
of
use
Light
Hold Button And Indicator
Volt
The program number cannot be
OM-1 588
Active Side Indicator
turn feature on
selected, turning
To
setting.
4
one or
turning
speed (1PM)
program number
default
Trim
causes
When MPM is selected, turning control three
clicks causes wire feed speed (MPM) to in
crease by 0.1.
When
a
process (Pulse, Adaptive Pulse, orMIG)
side panel controls (see Section 4-4).
flT The gun trigger may be used to
active side of the feeder.
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
Purge
Button
Push to
without
UT
momentarily energize gas
energizing the welding circuit.
Jog
and
Purge only
work
on
valve
the active
side of the feeder.
Holding
same
the Jog and Purge buttons at the
time displays pulse parameters on
the side
front
panel display
panel display.
and
voltage
on
4-4.
Side And Rear Panel Controls
Display
1
Mode
2
Mode Select Button
Press button to move> in
display.
3
Parameter
4
Parameter Select Button
Display
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.
3
\~/~
I
I
I
I
I
I
I
I
I
I
I
Ref. ST-162
128/Ret ST-162
OM-1 588
133
Page
21
SECTION 5- SETtiNG SEQUENCE PARAMETERS
See Menu Guide for detailed
programming steps.
Trim is
arc
length
length
is short.
is
If time
length.
If set to zero,
If set to 99,
arc
arc
long.
is
sequence,
set
to
welding
zero
in
Weld
continues until
gun trigger is released.
If time is set to zero in any timed
the
except Weld,
sequence
sequence is skipped.
X
=
Setting
available.
0
Run-In
-
25
sec.
Arc
Strike
Trigger
Released
OM-1588
Page
22
.
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, or 7 & 8. Any program
________
(MIG, Adaptive Pulse, or
Pulse) can be combined in dual
type
schedule.
1
Side Panel
Display
Use side panel to turn feature on.
See Menu Guide for detailed
programming steps.
2
Front Panel
Press front
Display
panel parameter select
button to select program number.
Control
3
Front Panel
4
Dual Schedule Switch
Section
Display
(See
6-2)
lET 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,
trigger
(depending
on
or
gun
system
setup).
When program B is active, turn
Display Control one click clock
wise to select another pair of dual
schedule programs.
~ Programs can be rearranged
in desired order using the data
card. See Section 7.
24.
250
OV
1PM
>Prg
1
Dual
A
4
Or
i
~
Display
~~tJ
Control
Display
Control
I>Prg
Dual
31
Al
OM-1 588
Page
23
6-2.
Dual Schedule Switch
Diagrams
1
Momen2P
(Momentary-Contact
DSS-1O)
2-Pole
Switch Or
2
Maint 2P
(Maintained-Contact
DSS-9M)
2-Pole Switch Or
>
3
2
2
>
2
>
>
2
Maint 1 P
1-Pole
>
4
(Maintained-Contact
Switch, Or DSS-8)
Trigger
Allows dual
A
3
lishing
1
>
0
A
0
B
4~
B
0
3
7/0>
___________
3
BO
A~>~>
OM-1588
Page
24
Adapter
~
If
4
1
>
2
2
>
>
3
>
4
>
scheduling after estab
welding arc.
3
>
trigger
is
used
schedule switch,
is disabled.
4
TR
I
3
>
0
1
a
2
TR\___
for
Trigger
dual
Hold
.~
SECTION 7- USING THE OPTIONAL DATA CARD
7-1.
Data Card Terms
CARD SCREEN TERMS
WRITE
READ
Programs
Programs
To Card
From Card
PULSE MIG TERMS
Amperage
-r
Apk (Peak
Amperage)
1JAbk
Time
(Background
Amperage)
SA-158 435
7-2.
Installing Data Card
1
Label
Apply
label to data card. Write pro
on label.
gram information
2
Data Card
3
Card Slot
For Blank Data Card:
Insert card into slot. To format
card,
turn On power. Select Card from
menu. Data card formats when unit
enters Card mode.
For Power Source Data Card:
Insert card into slot. Turn On pow
Push Parameter Select button
er.
within 3 seconds and the 8 pro
grams and setup information are
read into the wire feeder memory.
Unit is ready to use when Please
Wait
message disappears from
front panel display.
5T-156 266-B
OM-1 588
Page
25
7-3.
Card
Displays
UT See Menu Guide for detailed
programming steps. Security
mode only functions with a
data card.
1
Card
2
Moving
Display
Une
Moving line is
changed.
under value that
can
be
Sequ
ence
3
Dual Schd
>Card
Secu
Pr
rity
Write
Transfers program data from unit
to card. The program card can hold
up to 32 programs. When writing to
the card, the next available pro
gram number is automatically as
ess
Be low
signed.
Side Panel
Parameter
Select Once
4
Read
Transfers program data from card
to unit.
5
Delete
Deletes program data from card.
6
4
Done
Exits card
5
OM-1588
Page
26
display.
SECTION 8- SYSTEM SETUP
8-1.
System Setup Display
Note ~
DISPLAY SETTING
>System
>Range
Parameters
See Menu Guide for detailed
NOTES
Select the process the
*
*
programming steps.
welding
power
source
is able to do.
Welding power source minimum and maximum voltage values are always
for pulse welding. Set values to match welding power source ranges.
of setup
>Access+
When on, restricts
>Mig Type
Default is Off. Set to On
>Voltage
Default is
use
only for
14-pin receptacle.
needed.
Amperage
values
are
required
screens.
older CV
welding power
Use V. Sense when
source
than 50 ft
more
without
(1 5m)
voltage feedback
at 14-socket
of weld cable is used
receptacle.
(including gun
cable
length).
>Arc Start*k
Use Hot Start
only with
450
Inverter Model
Ampere
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
be used to switch between programs that have at least 0.2 seconds of
can
preflow
time pro
grammed.
>Remote
When on,
is.
>Arc Time
Displays
>Wire Feed
Choose to
>Model~
Pulse programs differ between bench and boom models.
>Memory
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
DSS-10
accumulated
display
setup card is in
When on, the system
age is sensed.
>Teach
Default is 15
>Gas Flow
Setting
>Software
Know this when
Can be used
*~
arc
time and
change
points,
card
can
must be Meter Off if
talking
or
Trim, 1PM,
or
Prg depending
on
where the front
panel display>
or
meters per minute and motor
original factory settings
type,
for all programs and
but installed motor must match selection.
information does not
setup excluding System, Arc Time,
and
slot, program will be loaded from card.
immediately
but
Volts
cycles.
inches per minute
>Shutdown
Automatically
be used to
can
Reset: unit defaults to
Model. If
*
a
shuts down if
be set to 4
option
no arc
voltage
is sensed. When
off,
wire feeds even if
no arc
volt
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
error.
OM-1588
Page
27
SECTION 9- STANDARD PULSE WELDING PROGRAMS
Note ~
Apk
Peak
=
Amperage, Vpk
=
Peak
Voltage,
Abk
=
Background Amperage,
Pulses Per Second, PWms Pulse Width (milliseconds). Four teach points were use d for
factory set programs. If selection is set for fifteen teach points, the remaining points are
PPS
=
=
interpolations from
Program
9-1.
1
the 4
taught points.
Steel
I
Wire
Gas: Ar
.035
Size/Type:
-
CO2
or
Ar-
Oxy /
40 CFH
(19 L/m)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
700117.8
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.
Program
Wire
Sizefrype: .045
2
Steel
Gas: Ar
-
CO2
or
Ar
-
Oxy /
40 CFH
(19 L/m)
1PM I MPM
Apk
Vpk
Abk
PPS
PWms
700 / 17.8
518
37.6
195
205
3.6
400/10.2
476
36.1
157
168
3.0
200/5.1
412
30.3
93
106
2.4
100/2.5
375
27.7
50
66
2.2
9-3.
Wire
Program
Size/Type:
3
Gas: Ar-
CO2
or
Ar
-
Oxy /40
CFH
(19 L/m)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
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
Program
Wire
Size/Type: .062
4
Gas: Ar
-
CO2
or
Ar
-
Oxy 140 CFH (19 1/rn)
Apk
Vpk
Abk
PPS
PWms
400/10.2
580
36.6
200
200
4.3
300/7.6
539
34.8
160
200
4.2
200/5.1
499
31.5
121
170
3.6
100/2.5
460
28.3
69
118
2.6
Page
28
COMMENTS
Steel
1PM I MPM
OM-1588
COMMENTS
Steel
.052
9-4.
COMMENTS
COMMENTS
9-5.
Wire
Program
Size/Type:
5
Stainless
.035
Gas: Ar
-
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
Size/Type:
Stainless
.045
Gas: Ar
1PM / MPM
Apk
700/17.8
-
He
-
CO2 /
40 CFH
(19 Urn)
Vpk
Abk
PPS
PWms
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
Size/Type:
.035
7
Nickel
Nickel
Alloy
Gas: Ar
-
He / 40 CFH
(19 L/m)
Apk
Vpk
Abk
PPS
PWms
700/17.8
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
Wire
Program
8
COMMENTS
Alloy
1PM / MPM
9-8.
COMMENTS
COMMENTS
Silicon Bronze
Size/Type: .035 SiBr
Gas:
Argon /
40 CFH
(19 Urn)
IPM/MPM
Apk
Vpk
Abk
PPS
PWrns
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
120/3.1
242
25.2
31
31
3.0
COMMENTS
OM-1588
Page
29
SECTION 10- TEACH POINTS
10-1. Teach
Using
15 Points
Apk
=
Peak
Amperage
Voltage
A
Vpk
=
Peak
o
Abk
=
Background Amperage
o
~
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
350/8.9
(1.3 MPM)
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
PWms
1
The teach mode allows the
2
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 parameters 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
56
Apk
Vpk
140
200
Abk
365
400
PPS
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
5
PWms
Undersomeconditions,thewirefeederlim
its wire feed speed to maintain all pulse pa-
rameterswithinthecapabilityofthesystem.
10-2. Teach
Using
4 Points
Apk
=
Peak
Amperage
A
Vpk
=
Peak
Voltage
o
Abk
=
Background Amperage
o
PPS
=
Pulses Per Second
1PM / 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
Setting
400/10.2
A
Synergic
For 425 1PM With
Teach Points Set At
350/8.9
Intervals Of 100
200
400
700
(5.1),
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
480
510
540
45
48
51
54
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
PWms
2
1
The teach mode allows the
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
.
450
100
Apk
Vpk
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
Under
565
56
Apk
Vpk
140
200
Abk
365
400
PPS
5
some
its wire feed
PWms
conditions, the wire feeder lim
speed
rameters within the
to maintain all
pulse pa
capability of the system.
OM-1588
Page
31
10-3.
Redefining
Teach Points
ri~H *4
1PM
1
1PM determines the weld metal de
position
rate.
fl~~ Redefining 1PM is not normally
Redefining
.
required unless special wire or
is
unusual
design
joint
1PM Teach Point
needed.
Use front
button to
Trim
50
Prg
1/
Purge
~
>460
1PM
Prg
to
select teach
Press and hold Purge button while
turning Display Control to redefine
the ipm 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.
ArL
Trim
50
1
select
to select 1PM. Use
Display Control
point value.
Pulse
1PM
>450
panel parameter
move>
1
2
Apk
Peak
3
Abk
Background Amperage
Amperage
Peak and background amperage
depend on the range of the welding
Pulse
power
4
source.
Pulses Per Second Of
PPS
20-400
5
Pulse Width Of
PWms
1 .0-5.0 Milliseconds
panel controls to change
parameters. See Menu
Use side
pulse
Redefining
Guide for detailed
Pulse Parameters
programming
steps.
After values
maintain
are
an arc
set, strike and
for five seconds.
Do this for each teach
point.
by releasing gun trigger,
by pulling gun out of weld. Re
peat for each custom teach point.
End weld
not
The
Trim
2
taught arc length represents
(arc length) setting of 50.
a
points are set, the
adjusts parameters be
teach points synergically.
Once the teach
wire feeder
tween
___r3
I
I
75
400
1PM
340
Apk
340
Apk
340
Apk
70
Abk
70
Abk
Abk
>160
PPS
1.4
1>70
160
PPS
160
PPS
PWms
>1.9
PWms
Ret. S-0259/Ref. ST-154 109
OM-1588
Page
32
S
Date___________________ Program Number
Wire
Size/Type
CFH(L/min)
Flowrate
Used
Power Source
Serial Number
Serial Number
Wire Feeder
Wire Manufacturer________________
Mfg.
Positive
Negative
-
Gun Model_____________________ Weld Cable
~
Equipment
Date
_______________
1PM / MPM
Apk
Abk
PPS
PWms
Vpk
COMMENTS
Preflow Seconds:_________
Run-In Trim/Volts:________ 1PM / MPM:____________________________________ Seconds:___________________________
Crater Volts:____________________ 1PM / MPM:____________________________ Seconds:____________________________
Postflow Seconds:________
OM-1588
Page
33
SECTION 11
-
MAINTENANCE AND TROUBLESHOOTING
11-1. Routine Maintenance
A
OM-1588
Page
34
Disconnect power before
maintaining.
11-2. Error
Displays
I
Release
Trigger
2
00
No
1Error
Volt
Sensed
1
~
M
e m o
r
Prg
y
CRC
Er
ror
4
Memory
Prg
Range
Er
ror
Release
Trigger
Error
Display
This appears if the trigger is closed
when the unit power is turned on, or
if the trigger is stuck or defective.
2
No Volt Sensed Error
The
arc
Display
voltage sense circuit is not
receiving feedback. Check voltage
connections.
Check
sensing
connections at 14-position plugs!
receptacles at the unit and welding
source.
power
Turn
unit off and
back
after
on
correcting problem.
\
No
1Error
Tach
Sensed
If this
when
Arc
Error
Start
3
to
it may
occur
help
to
Memory
CRC Error
Display
Er
Stop
ror
N
Mi
n
C F H
GasFI
9
x
x7
J
o w
Perform
a
system
reset.
Memory Range
Error
N
x
C F H
x
Gas
Out
No Tach Sensed Error
the
reaching
Coo
F
I
12
It
ow
\~
Un
P
r
I
0
oc
g
r
ked
am
8
6
control.
it above set value.
ror
Parameter
front
Press
panel
Select to clear error.
Maximum Gas Flow Error
flow to
bring
it below set value.
front
Press
Select to clear
10
panel
Parameter
error.
Gas Out Of
Range
Error
This appears when gas flow is
greater than 100 CFH. To protect
the internal sensor, the unit shuts
down until the gas flow can be
Check
below 100 CFH.
Coolant Flow Error
panel
Parameter
This appears only when coolant
flow switch option is installed.
coolant
Check
recirculating
system.
error.
Arc Start Error
cannot
Er
Minimum Gas Flow Error
adjusted
Display
be
started.
Check
Unlocked
Program
Error
Display
This appears when pulse welding
and current is detected but the arc
1
Parameter
panel
error.
This appears when gas flow falls
below the minimum CFH set (xx in
example). Adjust gas flow to bring
12
Error
front
Select to clear
The motor tach feedback is not
Press
front
Select to clear
I ofRange~]
11
Press
11
x
_GasFlow
10
through pulse parameters to
sure they do not exceed
settings of the Range display or
perform a system reset.
make
connections.
Ma
Display
example). Adjust gas
Display
Display
ror
Error
saved.
5
Er
Stop
9
Go
8
Arc
This appears when pulse welding
and the motor does not stop at the
end of the weld. If there is high
frequency being used in the area,
turn it off. A motor brake circuit
problem can also cause this error.
This appears when gas flow is
above the maximum CFH set (xx in
The data in the program indicated
is out of usable range.
Arc
7
Parameter
panel
error.
The data in the program indicated
is not the same data that was
4
7
continues
select Hot Start.
6
N
error
pulse welding,
front
Select to clear
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.
1Error
1Error
Ref. ST-i 55222
OM-1 588
Page
35
11-3.
Troubleshooting
r!~
~
E~1~II~
A
Disconnect power before
Trouble
Wire
Remedy
feeds, shielding gas flows,
electrode wire is not
but
energized.
Wire feeder is on, meter(s) do not light
up, motor does not run, gas valve and
welding power
pull in.
source
Check interconnecting cord connections. If secure, check cord for
Sections 3-5 and 3-7).
Check and reset CB1
or
feeds
Check gun
trigger
Check gun
trigger.
Change
Clean
or
Replace
Wire does not feed until trigger is pulled,
but continues to feed after trigger is re-
leased, and trigger hold is
Gas valve in feeder is
along with possible
feed speed.
switch
See gun Owners
replace dirty
or worn
contact
tip
or
or worn
wire
Manual.
(see
guides.
spatter
Have
Authorized Service
Check for
13-1).
drive roll.
Remove weld
Factory
Table
(see Section 3-13).
liner. See gun Owners
or
Manual.
foreign
Manual.
matter from around nozzle
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.
not on.
rattling loudly
erratic
connection. See gun Owners
to correct size drive roll
Check for correct
slowly.
not
4-4).
hub tension and drive roll pressure
Incorrect size
Unit does
Section
b
Readjust
runs
(see
continuity and repair or replace (see
contactor do not
Electrode wire feeding stops
erratically during welding.
Motor
troubleshooting
or
out
slow wire
of
Run-In
Check for
gun.
Install, reconnect,
or
replace voltage sensing
lead.
Speed.
Wire feeder power is on, displays
up, but unit is inoperative.
OM-1588 Page 36
light
Check
welding gun trigger
leads for
continuity,
and
repair
leads
or
replace gun.
Notes
014-1588
Pegs 37
SECTION 12- ELECTRICAL DIAGRAM
.
Ft~ ~CTE
C~
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R~7/R.~1
~
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~
-
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(I~
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<I1 ~
ax
E~+~*~
~<I
~
~
~
<2+.~<~2 *~~-<2(-2>_~-.(j
(i~~ ~-< E-~-<7~1 ~:
__
i
~
<
ax
I~
Figure
OM-1588
Page
38
3
3
>~<
<~ E~-<IE-a~-,.>~-<I
~
12-1. Circuit
E~*3
Diagram
~
~
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w-a>>a~!a~!~~j
p~t~
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30-184 792-A
OM-1588
Page
39
SECTION 13- PARTS LIST
U7 Hardware is
common
and
.
not available unless listed.
Co
Co
Ll~
LI~
Co
N-
Co
.
0)
0)
U-
/~
cJ
Co
CD
-
CJ
N
Cj
CC)
C)
0)
L
C)
0)
U-
Figure
OM-1 588
Page
40
13-1. Main
Assembly
ST-BOO 272-B
Quantity
Item
No.
Model
Part
No.
Dia.
Mkgs.
Figure
1
149251
1
149252
PLG21,23
.
.
.079878
079531
605156
PLG28,29
.
.
.
080 328
SeeNote
164475
164474
2
3
3
PLG27,28,37,38
139600
139599
600324
602 243
602213
..
601 872
10.
080 947
10.
151 626
11
132053
Fig
13-2
13.
149
838
13.
149
...13.
078
839
264
...
13.
079
216
...
14.
075
078
14.
079
217
15.
16.
17.
...18...
19...
CONNECTOR&PINS
CONNECTOR, circ clamp str rif sz 11
CABLE, port No. 184/c (order by if)
CONNECTOR w/SOCKETS
CONTROL BOX, (Fig 13-4)
1
....
159297
12.
2
13-8
Amp
206358-2
...
...
HOSE ASSEMBLY, gas
HOSE, gas
HOSE, gas
CABLE, weld cop strd No. 4/0
WASHER, flatstl std .375
WASHER, lock stl split .375
NUT, stl hex full .375-16
2
l7ft
1
1
Amp 206322-2
2
17ff
1
...22
139816...
...23
159647...
...24
156243...
...25
159360...
...26
159646...
...27
145639...
...28
134834
...29
167774...
...29
167776
30
157295
...604612...
...082 050...
...164969...
...167780...
167
NOTE: When
ordering Control
782...
BRACKET, spring retaining
BRACKET, spring retaining
SCREW, cap stl hexhd .375-16
SUPPORT, hub & reel
PIPE POST, 4ft w/base or
PIPE POST, Bft w/base
PIPE POST, 4ff w/base or
PIPE POST, 6ft w/base
PIPE POST, 4ff w/o base
PIPE POST, 6ff w/o base
....
1
1
....
....
2
2
2lft
..
....
1
26ff
..
30ff
8
....
8
4
4
....
....
4
4
1
1
x
1.500
Ig
4
1
....
4
1
1
1
1
1
1
1
2
2
keying Amp
....
1
200821 -1
COVER, protector motor
VALVE, 24VAC 2 way custom port 1/8 orf
PANEL, end cover
INSULATOR, motorclamp
CLAMP, motor top
INSULATOR, screw machine
CLAMP, motor base
STRIP, buna N compressed sheet .062 x 4.000sq
HOSE, SAE .187 ID x .410 OD (order by ft)
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)
Box contact
21ff
..
....
2
(order by if)
...
125 785
1
2
2
...
GS1,2
....
2
2
...
139813
....
2
CONNECTOR & PINS
CONNECTOR, circ clamp str rlf sz 17-20
CABLE, port No. 18/14 8/c (order by if)
BOOM ASSEMBLY
605 227
NUT, nyl hex jam .75ONPST
CONNECTOR & SOCKETS
047 637
RC27,37
048144.. CONNECTOR, circ pin plug
PLG11, 17... 115092... CONNECTOR & SOCKETS
135409... CONNECTOR & PINS
PLG33,34
Fig
2
CABLE, interconnecting (consisting of)
CABLE, interconnecting (consisting of)
163519
.6.
Assembly
CABLE, trigger (consisting of)
CABLE, trigger (consisting of)
047 636
079 739
13-1. Main
16
12
Description
2
2
2
1
2
1
2
2
8
2
2
....
....
....
....
....
1
1
1
2
2
....
2
....
2
....
....
....
....
....
....
....
....
....
2
1
2
1
2
2
8
2
2
3ff.... 3ff
1
1
....
....
1
1
2
4
4
...
2
1
1
1
....
....
....
1
1
1
Factory Service Department 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-1 588
Page
41
Part
No.
Item
No.
Figure
1
2
3
....
058427
....
136684
....
605941
....
010233
....
057971
6....
010191
7
4
5
....
058628
8
....
058428
9
....
080393
11
124900
....
+168104
166594
13....
13-2.
Support,
Hub & Reel
(Fig
13-1 Item
12)
RING, retaining spool
NUT, stl slflkg hex reg .625-11 w/nyl insert
WASHER, flat stl .640 lDx 1.0000D x l4gathk
SPRING, cprsn .970 OD x .120 wire x 1.250
WASHER, flat stl keyed 1.Soodiax .l2Sthk
WASHER, fbr .656 ID x 1.500 OD x .l2Sthk
WASHER, brake stl
HUB, spool
SUPPORt reel
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
10... 108008
12...
Quantity
Description
168103
2
2
2
2
2
4
4
2
1
2
1
1
1
1
Hardware is
common
and
not available unless listed.
8
7
6
9
10
ST-081 760-C
Figure
13-2.
Support,
Hub & Reel
OPTIONAL
+When
ordering
a
To maintain the
Replacement
OM-1 588
Page
42
component originally displaying
a
precautionary label,
the label should also be ordered.
factory original performance of your equipment, use only Manufacturers Suggested
Parts. Model and serial number required when ordering parts from your local distributor.
Item
No.
Part
No.
Dia.
Mkgs.
Figure
1
2
167697
3
147139
4
164842
5
144844
6
PC2O,30.
171 814
PLG25
165484
PLG24
159264
167633
10
089032
11
153169
12
010291
13
167700
Hardware is
common
Quantity
Description
13-3.
Panel, Front w/Components (Fig
13-4 Item
28)
1
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
1
2
1
9
1
1
CONNECTOR & SOCKETS (RC5)
See Figure 13.4 Item 35 (RC24)
RING, ext .625 shaft grv x .O45thk E style
1
1
WASHER, shldr .612 ID
LENS, LED 4341 red panel mtg
ACTUATOR, switch
WASHER, fIat .625 ID nylafil
KNOB, pointer
and
4
6
1
1
4
not available unless listed.
9
13
12
11
ST-800 112-C
10
Figure
13-3. Panel, Front
w/Components
To maintain the factory original performance of your equipment,
Replacement Parts. Model and serial number required when ordering
use
only
Manufacturers
Suggested
parts from your local distributor.
OM-1588
Page
43
lET Hardware is
common
and
not available unless listed.
0)
.
/
/
(
\
\
C)
U-
F
C)
C)
U-
C)
C)
c)
c~,
Figure
OM-1588
Page
44
13-4. Control Box
cJ
c
C)
273~BS
Item
No.
Dia.
Mkgs.
Part
No.
Figure
2
....
RC3O,40.
1
2
048144
CONNECTOR, circ pin plug keying in sockets Amp 200821-1
STAND-OFF SUPPORT, PC card .312/.375
CIRCUIT CARD, motor control
PCi
183 120
PLG1
115092
PLG2
115093
PLG4
115091
PLG6
136810
1
182403
115093
CONNECTOR & SOCKETS
158720
131 054
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
153501
CONNECTOR & SOCKETS
073 756
STAND-OFF,
Ig
LATCH, slide flush mtg hole 1.000 wide
13
134464
14
163520
1
(RC81)
(RC82)
(RC89)
(RC9O)
1
1
1
4
.625
x
1.500
1
Ig
107983
048 282
CONNECTOR w/SOCKETS
1
000 527
BLANK, snap-in nyl .875mtg hole
RELAY, end 24VAC DPDT
RECTIFIER, integ 40A 800V
BUSHING, snap-in nyl .750 ID x 1 .000mtg hole
BRACKET, mtg control box
PANEL, front w/components
CABLE, ribbon l4posn (RC12) (RC5O)
STRIP, mtg PC card
STAND-OFF, 6-32 x .375 Ig
CIRCUIT CARD, interlace
1
141 162
18....
176089
19....
600399
138044
072817
035 704
030170
145948
Fig
PLG12,50
1
1
601 222
...28
1
1
17....
CR101
SRi.
x
1
BUSHING, strain relief 1.030 ID
LABEL, warning general precautionary
CABLE, port No. 18/14 11/c (order by ft)
CONNECTOR & PINS, (consisting of)
CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2
CLAMP, univ 50A
TUBING, plstc PVC .250 ID x .375 OD x 9.000
WIRE, strd l4ga blk 600V 105c (order by tt)
BUSHING, strain relief .120/.150 ID x .SOOmtg hole
BLANK, snap-in nyl .500mtg hole
079 739
RC7O
6-32
1
WRAPPER
16....
13-3
155629
154938
097132
PC5O
184775
PLG51
158720
PLG52
PLG53
158719
PLG54
148439
PLG55
115092
131 204
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
1
171t
1
1
1
1
35ft
1
1
1
1
3
1
1
1
1
4
1
1
(RC51)
(RC52)
(RC53)
(RC54)
(RC55)
1
1
1
1
PC1O
PLG11
161 781
STAND-OFF, 6-32 x 1.500 Ig
CIRCUIT CARD, processor w/proms
115092
CONNECTOR & SOCKETS
1
PLG15
PLG17
PLG18
153501
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
1
PLG1O,24
PLG16,41
170980
CABLE,
CABLE,
PANEL,
CLAMP,
1
126689
36...
1
PC8O
PLG81
PLG82
PLG89
PLG9O
SWITCH, rocker SPST 1OA 25OVAC
CIRCUIT CARD, HF filter dual
010290
35...
1
111 997
12
...32
CASE SECTION, bottom/rear
CIRCUIT BREAKER, man reset 1P 10A250V
Si
+162 364
1
1
083 432
11
4
10
CONNECTOR &SOCKETS(RC1)
CONNECTOR & SOCKETS (RC2)
CONNECTOR & SOCKETS (RC4)
CONNECTOR & SOCKETS (RC6)
CB1
PLG9
2)
PANEL, side lower
151 187
29...
13-1 Item
CONNECTOR&SOCKETS
10
24
(Fig
162253
184824
...8
13-4. Control Box
047 637
134201
...6
Quantity
Description
115093
162382
155023
Fig
13-7
010146
4
1
(RC11)
(RC15)
(RC17)
(RC18)
ribbon 34posn (RC1O) (RC24)
ribbon 24posn (RC16) (RC41)
side w/components
nyl .625dia
1
1
1
1
1
a precautionary label, the label should also be ordered.
factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
+When
ordering
a
component originally displaying
To maintain the
OM-1588
Page
45
fly Hardware is
common
and
not available unless listed.
See Table 13-1 For
Drive Roll & Wire Guide Kits
18
21
17
6
9
26
2
27
36
30
33
32
31
ST-8O1 456-A
Figure
OM-1588
Page
46
13-5. Drive
Assembly,
Wire
1
Item
No.
Part
No.
Dia.
Mkgs.
Figure
1
010668..
2
3
172075..
149962..
4
149486..
5
163282..
6
165798..
7
165799..
8
132750..
10
133493..
11
133350..
M1,2
M1,2
12
156354..
...
156353..
153491
153 492
*153 493
155 098
155 099
155 100
154 031
133493....
14
15
16
17
18
PC51
PLG57
PLG58
...29.
149959
...30.
179265
...31.
108940
...32.
604 538
...33.
151 437
...34.
128237
...35.
+179263
178937
...36.
601 872
...37.
602213
...38.
602 243
...39.
601 966
167387
40
168825
133308
42
Assembly,
Wire
(Fig
13-1 Items 29 &
33)
4
4
4
2
2
2
2
2
2
2
1
1
1
1
2
2
1
....
153 550
184 136
182 414
182 415
137 248
129 351
602 200
604 772
182156
182155
132746
181 522
132747
133739
.183330
.153631
131 204
.604311
131 203
132611
13-5. Drive
SCREW, cap stl 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 stl
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)
GASKET, cover
SCREW, cover
SPACER, locating
150520..
12
Quantity
Description
...
...
...
...
...
..
.
1
1
5
2
RING,rtngext.2soshaftgrvx.O2Sthk
1
KIT, brush holder
WASHER, flat
PIN, coffer 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, fIat .375 ID x .625 OD x .062
KNOB, extension
CIRCUIT CARD, digital tach (consisting of)
1
1
1
1
1
1
1
2
1
2
1
1
1
1
1
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, flatstl SAE .312
1
1
1
1
1
4
1
KNOB, plstcT 1.125 Igx .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
SPACER, locating
DRIVE, pinion 40T 24P .376 bore
RING, retaining ext .375 shaft x .O25thk
1
2
1
1
1
1
1
1
2
1
1
Optional High Speed Motor
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.
Part
of 132 129
*Recommended
OM-1 588
Page
47
Table 13-1. Drive Roll and Wire Guide Kits
w
~
Wire Size
V-GROOVE
U-GROOVE
UC-GROOVE
VK-GROOVE
~
~
Metric
Fraction
4 Roll
Drive
4 RoIl
Drive
4 RoIl
Drive
4 RoIl
Drive
Kit
Roll
Kit
Roll
Kit
Roll
Kit
Roll
151 036
072000
151 052
132958
.023-025 in
0.6
mm
150993
149518
151 024
087130
.030 in.
0.8
mm
150993
149518
151 025
053695
.035 in.
0.9
mm
150993
149518
151 026
053700
.040 in.
1.0
mm
150993
149518
161 189
053696
.045in.
1.1/1.2mn
150994
149519
151027
053697
151037
053701
151053
132957
151070
083489
.052 in.
1.3/1.4mn
150994
149519
151 028
053698
151 038
053702
151 054
132956
151 071
083490
1.6mm
150995
149520
151 029
053699
151 039
053706
151 055
132955
151 072
053708
1.8
mm
150995
149520
151 056
132959
2.0
mm
150995
149520
151 040
053704
151 057
132960
151 073
053710
2.4
mm
150996
149521
151 041
053703
151 058
132961
151 074
053709
2.8
mm
150996
149521
151 042
053705
151 059
132962
151 075
053711
3.2mm
150997
149522
151043
053707
151060
132963
151076
053712
.068-072 in
5/64 in.
(.079 in.)
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.
S-0549-D
Item
No.
Dia.
Mkgs.
Part
No.
Figure
147 139
155024
154933
...6
PC6O
PLG6O
PLG41
PC4O
156623
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
1
153501
CONNECTOR & SOCKETS (RC6O)
See Fig 13-3, Item 40 (RC41)
158160
4
154109
CIRCUIT CARD, side display
STAND-OFF, 6-32 x .875 Ig
PLATE, ident inner control
153169
ACTUATOR, switch
4
144844
1
1
UT Hardware is common and
not available unless listed.
4
6
7
8
9
ST-800 113-B
Figure
13-6.
Panel, Side w/Components
To maintain the factory original performance of your equipment,
Replacement Parts. Model and serial number required when ordering
only Manufacturers Suggested
parts from your local distributor.
use
OM-1588
Page
49
Hardware is
common
and
not available unless listed.
7
0)
(0
U,
(0
cJ
C,,
cJ
ST- i42 306-G
Figure
OM-1 588
Page
50
13-7. Boom
Assembly
Quantity
Model
Part
No.
Item
No.
Description
Figure
010313
.
.
010910
.
.
3
079 622
4
079 621
.
.
5
079 667
.
.
5
080 812
.
.
6
079 632
.
.
7
079665
.
.
7
080811
.
.
8
079 664
.
.
9
139 633
.
.
159999.
.
10
160513.
.
11
073742
12
073 741
.
.
13
079 029
.
.
14
075 462
.
.
15
602 250
.
.
16
079 020
.
.
17
155 335
.
.
18
149 858
.
.
18
151 625
.
.
19
150 258
.
.
20
024 605
.
.
21
075 101
.
.
22
079 030
.
.
23
+174 754
.
.
080 157
.
...
174 688
.
...
10
24
.
.
.
.
142 804
.
.
134 327
.
.
073 666
.
.
25
.
26
.
047 224
.
.
.
602 246
.
.
010 493
.
.
139 818
.
.
27
28
29
.
.
Assembly (Fig
13-1 Item
16
15)
PIN, cotterhair.072x1.437
WASHER,flatstlSAE.375
WASHER, shld .381 ID x .750 OD
PULLEY, V sgl grv 7.75Odia x 8.000P x .625 bore
PIPE, plstc .500 x 133.750
PIPE, plstc .500 x 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
BOOM, dual
BOOM, dual
PIN, clevis.7500Dx2.1561g
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, sti hex special .750-16x 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
1
2
.
13-7. Boom
I
12
4
6
2
2
4
....
6
....
2
....
2
....
2
2
8
10
....
2
2
2
2
2
....
2
....
1
1
1
1
2
1
2
1
....
....
....
....
....
....
1
1
2
1
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
.
.
1
1
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.
+When
ordering
a
component originally displaying
a
OM-1585
Page
51
Notes
I
OPTIONS AND ACCESSORIES
WELD CURRENT SENSOR
AUTOMATION UPGRADE
WATER FLOW SHUTDOWN
(#160 963)
option is required when using
M feeders with older style Miller
MODULE
SWITCH
This module consists of
CV power sources: Deltaweldfi
prior to serial no. KG141 349 and
enables the 60M control to better
overheating by shutting
communicate with other
system if
This
Dimension
prior
to serial
(#172 886)
For
board and software
no.
an
equipment and improves
POWER SOURCE DATA CARD
performance
welding cell.
outputs,
(#043 390)
Simply
insert the Data Card in the
of
60M control and with the
button the
push
eight synergic pulse
a
start/stop, remote
voltage
arc
monitor and wire
arc error
XMT programs are for:
.030 in steel wire with Argon/CO2
eight
Argon/CO2
Argon/CO2
in
For .035045
(0.91.1
mm)
(#141 580)
For 1/161/Bin
(1.63.2 mm)
wire
(#141 581)
Reduces cast in wire.
.035 in SS wire with Pulse tn-mix
wire
Improves
feeding performance and
.045 in SS wire with Pulse tn-mix
increases life of gun liner and
.035 in SiB wire with
contact
Argon
.035 in Nickel wire with Ar/He
For
Blank Card
can use
factory
programs in the 60M, but will
factory
set
voltage
and
CONTROL DETACHMENT KIT
only.
For S-60M Model
10 ft.
25 ft
(3m) Field
(7.6 m) Field
For D-60M Model
(#134 935)
Separates
25 ft
(7.6 m)
For
use
with Dual Schedule
Control in 60M feeder.
Field
the feeder control
(#079 693)
Requires adapter cord #157 364.
Two-position trigger switch that
easily attaches to the welding gun.
Use in place of the standard trigger
for dual scheduling.
right
side of dual
(#041 793)
Two-position slide switch that
attaches to the welding gun.
Selects welding condition when
utilizing the dual schedule feature.
Gun trigger operates as standard
trigger.
RPS-8 REMOTE PROGRAM
SELECTOR
(#132 130) Factory only
speed range of 90
1400 1PM (2.3 35.6 rn/mm). Not
recommended for wire sizes larger
than 5/64 in (2.0 mm).
(#160 977) Field
Eight-position rotary switch used
remotely select weld programs.
Includes 33 ft (10 rn) cord to
Provides wire
Same
speed
motor must be used
each side of the dual wire
models.
For 60M bench models
DUAL SCHEDULE SWITCHES
For left side of dual wire models
on
current range to be reset.
(#134936)
(#134 937)
and
(#132 129) Factory only
programs and transferring
programs to other 60M feeders.
the
single
models
Stores up to 32 complete weld
programs. Ideal for saving custom
require
tip.
HIGH-SPEED MOTOR
60M DATA CARD
450
dual
DSS-9M
.030 in SS wire with Pulse tn-mix
The Maxtron
a
DSS-8
wire
(#155 910)
both sides of
stick check.
use.
.045 in steel wire with
on
two water flow shutdown
programmable
remote
WIRE STRAIGHTENER
.035 in steel wire with
water does not flow.
required
model,
programs for the XMT 304 are
loaded in memory and ready to
The
Protects water-cooled gun from
down
If
automatic
an
program select,
monitor,
peripheral
with the water hose kits
use
(#180 390)
switches must be ordered.
Features: two
FOR XMT 304 CC/CV
that
upgrade
KC25351 7.
in
I/O
Factorywritten synergic
connect feeder.
DSS-10 REMOTE
INCREASE/DECREASE SWITCH
Pulse MIG programs will not
operate with highspeed motor.
(#042 749)
Two-position, momentary
WATER HOSE KIT
switch that attaches to the
For
gun. Use with the Remote
Parameter Increase/Decrease
bench-style
(#096 746)10
feeders
ft
(3 m)
Use with Miller coolant
systems
and water-cooled
welding
Can be used with
or
optional
water flow
guns.
without
safety
switch.
Gun trigger operates
trigger.
If water kit is to be used
assembly and base. Ideal when
using Automation Upgrade
sides of
dual wire feeder, a kit
must be ordered for each side of
Accommodates 60 lb
Module.
the feeder.
of wire.
on
both
contact
welding
feature to fine tune parameters at
the welding gun while welding.
module from the wire drive
a
to
as
standard
WIRE REEL ASSEMBLY
(#108 008)
(27 kg)
coil
6/97
OPTIONS AND ACCESSORIES
REEL COVERS
CARRYING CART
Accommodates 60 lb
(27 kg)
coil
of wire.
ADJUSTABLE SPOOL CARRIER
(#056 301)
Carries wire feeder and
(#058 256)
For S-60M single
miscellaneous
wire model and
left side of D-60M dual wire model.
welding sup plies.
Height: 34 in (863 mm). Lower tray
height: 9 in (228 mm). Shipped
disassembled.
(#091 668)
right side
For
of D-60M dual wire
FEEDER CART
(#142 382)
Low-profile, creeper
model. Protects wire from
contaminants.
cart.
Shipped
disassembled.
SPOOL COVERS
Fits
a
12 in
(304 mm) spool of
wire.
(#057 607)
For S-60M
single
left side of D-60M dual wire model.
(#090 389)
For right side of D-60M dual
model.
Swingpak
base.
Replaces standard spool
assembly. Positions welding
lower for easier loading and
unloading.
optimum performance,
extend 60M feeder
(#058 435)
Electrically isolated. Suspends
(18 m) from
over
work
(#146 236)
work
strain and
power
more
do not
than 60 ft
source.
14-Pin Extension Cord
area.
TURNTABLE ASSEMBLY
changes
wire
EXTENSION CORDS
For
Allows feeder to rotate
wire
on
HANGING BAIL
feeder
wire model and
(#096 075)
use only with Swingarc models
with 6 ft (1.8 m) pipe post mounted
For
as
operator
position. Reduces
bending of gun cable.
(#043 690) 25 ft (7.6 m)
(#043691) 50ft (15 m)
WATER COOLANT SYSTEMS
Refer to Water Coolant
Systems
literature, Index No. AY/7.2.
6/97
Effective January 1, 1997
(Equipment witb a serial number preface of KH
This limited warranty
Miller
*
Subject to the terms and conditions
Mtg. Co., Appleton, Wisconsin,
original retail purchaser that new Miller
Electric
its
warrants to
newer)
supersedes all previous Miller warranties and is exclusive
guarantees or warranties expressed or implied.
LIMITED WARRANTY
below,
or
with
no
other
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
date ot this limited warranty
is free of detects in material and workmanship at the time it is
shipped by Miller. THIS WARRANTY IS EXPRESSLY IN
*
Remote Controls
*
Accessory
*
Replacement Parts (No labor)
equipment sold after the effective
LIEU
OF
OTHER WARRANTIES, EXPRESS OR
WARRANTIES
OF
THE
MERCHANTABILITY AND FITNESS.
ALL
Spoolmate
INCLUDING
IMPLIED,
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such detect or
failure, at which time Miller will provide instructions
warranty claim procedures to be followed.
1.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
periods. All warranty time periods start on the date that
3.
time
the
*
Original
*
Inverters
shall not
apply
to:
as
by Miller, but manutactured by others,
engines or trade accessories. These items are
the
manufacturers warranty, it any.
by
Consumable components; such as contact tips, cutting
nozzles, contactom, brushes, slip rings, relays or parts
that tail due to normal wear.
Equipment 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
specifications for the equipment.
than
delivered to the original retail purchaser,
equipment
or one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to
an International distributor.
was
5 Years Parts 3
Warranty
Items furnished
such
covered
2.
on
185
MilIer~s True Bluefi Umited
the
1.
Kits
Years Labor
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
main power rectifiers
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
2.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
3.
3 Years
and output rectifiers
(input
only)
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EOUIPMEN1I
Parts and Labor
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Millers option: (1) repair; or
(2) replacement; or, where authorized in writing by Miller in
*
Transtormer/Rectifier Power Sources
*
Plasma Arc
*
Semi-Automatic and Automatic Wire Feeders
*
Inverter Power
*
Intellitig
*
Robots
*
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
engine manufacturer.)
1 Year
Power Sources
Cutting
Supplies
allowed.
Parts and Labor
*
Motor Driven Guns
*
Process Controllers
*
Positioners and Controllers
*
Automatic Motion Devices
*
Orbital Weld Heads
*
the
(w/exception
of
Spoolmate 185)
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY,
GUARANTY OR
Systems
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
MIGHT
BY
ARISE
PROVISION,
IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EOUIPMENT FURNISHED BY MILLER IS EXCLUDED
AND DISCLAIMED BY MILLER.
HF Units
*
Grids
Spot
Welders
Load Banks
SDX Transformers
Miller
Cyclomatic Equipment
Running
Gear/Trailers
Torches
PLAZCUT Models)
Plasma
*
Deutz
*
Field
.p
Cutting
Engines (outside
installed in,
whichever is
V//A Miller
(except APT,
ZIPCUT &
North
4.
6 Months
s.
go
or
for
a
greater.)
Batteries
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
available, but may vary from state to state.
an
America)
Options
(NOTE: Field options are covered under True Bluefi
for the remaining warranty period ot the product they
are
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE
FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEOUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
IHPS Power Sources
Water Coolant
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit tor the purchase price (less reasonable
depreciation based upon actual use) upon return of the
goods at customers risk and expense. Millers option ot
repair or replacement will be FOB., Factory at Appleton,
Wisconsin, or FOB. at a Miller authorized service tacility as
determined by Miller. Therefore no compensation or
reimbursement tor transportation costs of any kind will be
minimum of
one
year
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
*
Days
Parts and Labor
MIG Guns/TIG Torches
Warranty provides specific legal rights, and other
rights may be available, but may vary from province to
province.
ThePowerofB&
miIIer_wsrr 5197
OwNers Record
Please complete and retain with your personal records.
Serial/Style Number
Model Name
Purchase Date
(Date which equipment
was
delivered to
original customer.)
Distributor
Address
City
Zip
State
Resources Available
Always provide Model Name and Serial, Style Number.
Contact your Distributor for:
To locate distributor nearest you call
1-800-4-A-Miller.
Welding Supplies
Options
and Consumables
and Accessories
Personal
Safety Equipment
Miller Elecbic
Service and Repair
Mfg.
An Illinois Tool Works
Replacement
Parts
1635 West
Appleton,
Training (Schools, Videos, Books)
Owners
and
USA & Canada FAX: 920-735-4134
(Servicing
International FAX: 920-735-4125
Information
European Headquarters
United Kingdom
Phone: 44 (0)1625-525556
FAX: 44 (0)1625-537553
Circuit Diagrams
Contact the Delivering Carrier for:
File
a
Headquarters-USA
Phone: 920-734-9821
Parts)
Welding
Stmet
WI 54914 USA
International
Manuals
Technical Manuals
Spencer
Co.
Company
Process Handbooks
claim for loss
or
damage during
shipment.
For assistance in
filing
or
sewing claims,
equipment
Department.
contact your distributor and/or
manufacturer~s Transportation
~//i Miller
PRINTED IN USA
'
77ThwerqfBk~
1997 MIter Electric
Mtg.
Co.
8/97