Download Miller Electric DS-64M Swingarc Specifications
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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~ ~D ~) FCI3 I~a V .~ J .1 ~t1-2>> ~ 11 V VV Pc~r~ ~ R~7/R.~1 ~ ~I (~-<I3 ~ E~-<I ~ ~ - ~I ~ ~V(3~_<~3 (I~ ~~>~L<11 <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 ~ ~ ~ ~CTU2 F~ ~2CTE FflD PSTtfl) ~ I FUER am I I I ! ~.BII1I~ I I I I I I a-a I OCBA ,~_~~A__.Er_A~__\r__&_\ I WEO~II1U Ii I I 2 3 4 0 5 I ~9æ92~W9æ ar000000000ll 6 I 2 ____________________________ 1:0w ~W1 > ___________________________ I (<fl-I FLIER ~3ISV am/Row a I C<wlV-2 _______________________ I____ Lv I I v_v_v__v_v_v_vv_v LLSJ~1 I fl-a> I I _____ rr~w~ J~T~1T~It~T a fl-a> ~L0 I _______ p~ ~7 >>(I C<~-2 H I ___________________ S S I~5c aav>> ~4~g N1~A~ ~ ~4-a>> aVFua as~~> ~2m042 ~~>> FC4MZSI ~ > 20/Cl (I a~ar I0m2a ~ __ <CW-4 ( (a-tv) ltt4IC Il~ &w-a ~ 0~4T 20~ S 0J6U2T t~ 20~ 0 ~ ~ r~-i <<w-c ~-<(~-7 ~-<<w-a r~. rj~~ia 5ie.r ~ ~<<W3 ~c~-a flatv ~ 202041 >4SIU.IIftftj.~j.IL2,aH~ I I w-a>>a~!a~!~~j p~t~ I (<fl-Il (<W-2 I C L~Ci~~~!PeL. ~J ~I~o lw/ta 5 H >)~~a__<l1 W>> ~ > C mitE (.2.3-tv) p ta asp sp laSI-l)p-) ~I-l > >:~>> fl-i> r-~i I I ad ToFoaaI --U 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