Download Miller Electric SWINGARC SINGLE 12 Specifications
Transcript
UM-1508 161 June 1998 Miller The Power ofBlue. Processes ~ MIG (GMAW) Welding Pulsed MIG Flux Cored (GMAW-P) (FCAW) Welding Description Wire Feeder (Use DS-64M with CC/CV Power Sources) Swingarc 12 and 16 Foot Visit our websiie at www.MillcrWglds.com OWNERS MANUAL From Miller to You . - ~ ; Thank you and you can congratulations on choosing Miller. Now~ get the job done and get it done right. We know have time to do it any other way. you dont Thats why when Niels Miller first started building arc welders in 1929, he made sure his 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. the people that build and sell Miller products continue the tradition. Theyre just as committed to providing equipment and service that meets the high standards of quality and value established in 1929. Today, ~~1~JII~JTU? L~i Worldn auha~d asyosdu ~uery This Owners Miller help Manual is products. you protect - designed help you get the most out of your Please take time to read the Safety precautions. They will to yourself against potential hazards made installation and ~i IJIJI 1~h With Miller you i~ I I can on - iQilPie from Miller Is- backed by the must hassle-tree warranty in the business. the worksite. Weve operation quick count and easy. years of reliable on the unit needs repair, theres a Troubleshooting section that will help you QUALITY SYSTEM some reason V Mllleristhefirstweldingequipment figure manufacturer in the U.S.A. to be ISO 9001 quality will then out what the problem is. The parts list decide which exact part help you you may need to fix the problem. Warranty and service information for your particular model are also to provided. - - Miller offers-a Technical Manual which provides more detailed seMce arid prtsinformation for your unit. To obtain a Technical Manual, contact your local distributor. Your disMbutor can also supply yo~ with WeldM9 Process Manuals - sucha SM.4W, ClAW, GMAW.andCMAW-R.. Miller Electric manufactures welding For information products, on catalog full line - equipment. quality Miller local Miller distributor to receive the latest full line individual a related other contact your - - service with proper maintenance. And if for REGISTERED of welders and - - catalog or sheets. To locate your nearest distributor call 1-800-4-A-Miller. I -: - - -: - TABLE OF CONTENTS SECTION 1 - SAFETY PRECAUTIONS - 1-4. 1-5. EMF Information 1-2. 1-3. SECTION 1 1-1. 1-2. 1-3. - 1 READ BEFORE USING Symbol Usage Arc Welding Hazards Additional Symbols for Installation, Operation, Principal Safety Standards 1-1. 1 1 3 and Maintenance 3 4 CONSIGNES DE SECURITE - symboles Dangers relatifs au soudage a larc Dangers supplØmentaires en relation 5 LIRE AVANT UTILISATION 5 des Signification 5 avec Iinstallation, le fonctionnement 7 et Ia maintenance 1-4. Principales normes 1-5. Information sur SECTION 2 2-1. les 8 de sØcuritØ 8 champs ØlectromagnØtiques 9 INTRODUCTION - 9 Specifications 9 SECTION 3- INSTALLATION 3-6. Installing Swivel Into Pipe Post Installing Control Box And Adjusting Tilt Installing Boom And Reel Support Installing Wire Guide Extension Equipment Connection Diagram Connecting Weld Cables And Gas Hoses 3-7. Control Box Connections 3-8. 14-Pin 3-9. Motor Start Control 3-1. 3-2. 3-3. 3-4. 3-5. 3-10. 9 10 10 11 12 13 14 14 Information Plug Removing Safety 15 Collar And Adjusting 15 Boom 16 3-11. Gun Recommendation Table Type, Size, And Feed Speed Capability Installing And Threading Welding Wire 3-12. Wire 3-13. SECTION 4 16 Table 17 18 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. SECTION 5 5-1. 18 21 SETTING SEQUENCE PARAMETERS - Sequence Parameters In A 21 Program 22 SECTION 6- SElliNG DUAL SCHEDULE PARAMETERS 6-1. Selecting Dual Schedule Pair 6-2. Dual Schedule Switch SECTION 7 7-1. 7-2. 7-3. 23 Diagrams 24 USING THE OPTIONAL DATA CARD - Data Card Terms 24 Installing Data Displays 24 Card 25 Card SECTION 8 8-1. 22 26 SYSTEM SETUP - System Setup Display 26 Parameters 27 SECTION 9- STANDARD PULSE WELDING PROGRAMS 9-1. 9-2. 9-3. 9-4. 9-5. 9-6. 9-7. 9-8. Program Program Program Program Program Program Program Program SECTION 10 - 10-1. Teach 1 2 3 4 5 6 7 8 - - - - - - - - Steel 27 Steel 27 Steel 27 Steel 27 Stainless 28 Stainless 28 Nickel 28 Alloy 28 Silicon Bronze 29 TEACH POINTS 29 15 Points Using Using 4 Points Redefining Teach Points 30 10-2. Teach 10-3. SECTION 11 - 31 33 MAINTENANCE AND TROUBLESHOOTING 33 11-1. Routine Maintenance Displays Troubleshooting 11-2. Error 11-3. 34 35 SECTION 12- ELECTRICAL DIAGRAM 36 SECTION 13- PARTS LIST 38 OPTIONS AND ACCESSORIES WARRANTY OM-1 588G . . . SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING - sorn 1-1 Symbol Usage Means a A shown in the Marks 1 .2~. A Watch Warning! hazards with this Out! There possible are procedure! The possible hazards are adjoining symbols. Arc not safety Welding actions to avoid the hazards. related. Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch Out, and followthe related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 -4. Read and follow all Safety Standards. If earth with grounding of the separate table a - workpiece is required, ground it directly clamp or work cable. do not use work Do not touch electrode if you are in contact with the work, another electrode from a different machine. ground, or Use only well-maintained equipment. Repairor replace damaged at once. Maintain unit according to manual. parts A Only qualified persons should install, operate, maintain, repair this unit. A r1~ This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary special safety message. a lET Means Note~ -~ _nd_5/97 and During operation, keep everybody, especially children, away. safety Wear a Keep all worktable Insulate work can kill and working covers Clamp work cable with good or ELECTRIC SHOCK harness if panels as near above floor level. securely in place. metal-to-metal contact to the weld as workpiece practical. clamp when not connected to workpiece to prevent object. contact with any metal Do not connect Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard. single weld more than one electrode work cable to any or output terminal. SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters. Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts. Do not touch live electrical parts. Wear dry, hole-free insulating gloves and body protection. yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. FUMES AND GASES Insulate Do not there is a Use AC If AC AC output in damp areas, if movement is confined, danger of falling. use or if is required, use remote output control if present on unit. Disconnect servicing to OSHA 29 Properly Owners input power or stop engine before installing or equipment. Lockout/tagout input power according CFR 191 0.147 (see Safety Standards). this install and Manual and Always verify ground this equipment according to its national, state, and local codes. the - 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. Do not . Do not equipment head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or remove welding fumes and gases. If ventilation is poor, use an Read Safety the Material manufacturers worn, drape cables over your body. to Data Sheets (MSDS5) and the coatings, highly poorly spliced cables. near degreasing, cleaning, or spraying The heat and rays of the arc can react with vapors to toxic and irritating gases. Do not weld cadmium or arc approved air-supplied respirator. instructions for metals, consumables, Do not weld in locations form - when not in use. damaged, undersized, exhaust at the 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. on coated metals, such as galvanized, lead, or unless the coating is removed from the plated steel, weld area, the use use cleaners, and degreasers. operations. - Turn off all fumes and gases. Breathing these fumes and gases can be hazardous to your health. Work in 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 be hazardOus. Welding produces ~ Keep your output ONLY if required for the welding process. output 11 can 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 can burneyesand skin. BUILDUP OF GAS 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. can injure shielding gas supply when or kill not in use. Always ventilate confined spaces approved air-supplied respirator. or use Wear a welding helmet fitted with a proper shade offilterto protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). Wear approved safety glasses HOT helmet. can cause severe Do not touch hot Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. Wear PARTS burns~ with side shields under your Allow parts cooling period bare handed. before working on gun or torch. protective clothing made from durable, flame-resistant (leather and wool) and foot protection. material MAGNETIC FIELDS can affect pacemakers. WELDING Welding can cause fire or explosion. Pacemaker Protect yourself and others from Do not weld where flying sparks flying sparks can NOISE fire, and that welding aware can cause fire Do not weld on on keep a fire closed containers such as Wear Connect work cable to the work unknown Do not prevent welding paths use or equipment and as approved ear protection if noise level is CYLINDERS can explode it damaged. causing or welding area as traveling long, possibly electric shock and fire hazards. welder to thaw frozen Shielding 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. pipes, (see to AWS F4.1 close to the current from or cut Protect off welding wire at compressed gas cylinders from excessive heat, slag, open flames, sparks, and arcs. mechanical shocks, Install pipes. Remove stick electrode from holder contact tip when not in use. cylinders in an upright position by securing to a stationary or cylinder rack to prevent falling or tipping. support Keep cylinders away from any welding Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. Remove any combustibles, such as a butane from your person before doing any welding. lighter or matches, Never drape Never allow Never weld Use a a welding welding on a torch over a or gas other electrical circuits. cylinder. electrode to touch any pressurized cylinder - cylinder. explosion will result. only shielding gas cylinders, regulators, hoses, fittings designed for the specific application; maintain them FLYING METAL can injure correct associated eyes. wire brushing, and grinding cause sparks and flying metal. As welds cool, they. can throw off slag. Wear approved safety glasses with side shields even under your welding helmet. Page 2 Keep protective cap in place use or connected for use. over Read and follow instructions associated Standards. and and parts in good condition. Turn face away from valve outlet when Welding, chipping, OM-i 588 can high. partition or tanks, drums, they are properly prepared according Safety Standards). to processes the hidden side. unless practical some damage hearing. extinguisher nearby. ceiling, floor, bulkhead, on a damage hearing. can Noise from strike flammable material. welding sparks and hot materials from welding can go through small cracks and openings to adjacent areas. Be spot or and hot metal. Be alert that easily keep away. going near arc welding, gouging, welding operations. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. Watch for wearers Wearers should consult their doctor before closed containers, such as tanks, drums, or pipes, 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. on equipment, valve except when valve. cylinder is in compressed gas cylinders, publication P-i listed in Safety on and CGA opening cylinder . 1-3 Additional Symbols For Installation, Operation, And Maintenance MOVING PARTS FIRE OR EXPLOSION hazard Do not install place or unit on, over, Keep away or near combustible surfaces. Do not install unit moving parts such Keep all doors, panels, covers, closed and securely in place. flammables. injury as and fans. guards building wiring be sure power supply system properly sized, rated, and protected to handle this unit. Do not overload is near from can cause - FALLING UNIT can cause injury H~F~ RADIATION running only, lifting cylinders, or any other accessories. Use equipment of adequate capacity to lift and Use can cause intØr~tereflce. NOT eye to lift unit High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. gear, gas support unit. electronic The unit. only qualified persons familiar with equipment perform this installation. Have using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of If having a qualified electrician problem resulting from the for responsible is user correct any interference installation. promptly OVERUSE Allow can cause OVERHEATING cooling period; Reduce current starting to weld Do not block STATIC Put or (ESD) on handling duty cycle. follow rated reduce or duty cycle before again. filter airflow to unit. grounded or by at interference, stop using the the FCC about once. Have the installation regularly checked and maintained. panels tightly shut, Keep high-frequency keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference. source doors and damage PC boards can boards If notified equipment wrist strap BEFORE ARC WELDING parts. Use proper static-proof bags and boxes to store, move, or ship PC boards. can cause interference. 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 as robots. all equipment in the welding electromagnetically compatible. Be such as To reduce drive possible, rolls. sure WELDING WIRE can cause Be injury possible interference, keep weld cables as short as together, and down low, such as on the floor. welding operation equipment. sure according Do not press gun trigger until instructed to do is close Locate tronic area this welding 100 meters from any sensitive elec and machine is installed grounded to this manual. If interference still occurs, the user must take extra measures as moving the welding machine, using shielded cables, using line filters, or shielding the work area. so. such point gun toward any part of the body, people, or any metal when threading welding wire. Do not other 14. Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49. 1, from Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 Safety and Health Standards, American Superinten Printing Office, Washington, OSHA 29 CFR 1910, from dent of Documents, U.S. Government D.C. 20402. Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 National Electrical Code, NFPA Standard 70, from National Fire Batterymarch Park, Quincy, MA 02269. Protection Association, Safe 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 1R3. Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.i,from American National Standards Institute, 1430 Broadway, New York, NY 10018. Cutting And Welding Processes, NFPA Standard 51 B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. OM-1588 Page 3 EMF Information 1-5. 1: Considerations About Welding And The Effects Of Low Electric And Magnetic Fields Welding current, as it flows through welding cables, fields. There has been and still is magnetic fields. However, Frequency 1. Keep will cause electro 2. Arrange 3. Do not coil some concern after examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when To or reduce magnetic fields or taping side and away from the one them. operator. 4. or drape cables around your Keep welding power practical. source Connect work to and cables body. as . far away from opera tor as 5. clamp workpiece as close to the weld as possible. About Pacemakers: cutting. procedures: cables to together by twisting about such 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 welding cables close in the workplace, use the following Pacemaker wearers consult your doctor first. If cleared by your doctor, following the above procedures is recommended. then . OM-1588 Page 4 SECTION 1 - CONSIGNES DE SECURITE UTI LISATION LIRE AVANT - som Signification i-t symboles Signifie Mise en garde! Soyez vigilant! Cette procedure prØsente des risques de danger! Ceux-ci sont identifies par des symboles adjacents aux directives. 4A A des Identifie message de sØcuritØ un ru~N~d Ce groupe de symboles signifie Mise en garde ! Soyez vigilant Ily a des risques de danger relies aux CHOCS ELECTRIQUES, aux PIECES EN particulier. MOUVEMENTetauxPIECESCHAUDES. Reportez-vousauxsymboles et auxdirectives ci-dessous af in de connaItre lea mesures a ~ Dangers relatifs 1-2. A au soudage a larc Ne pas toucher IØlectrode quand on est en contact avec Ia ou une electrode provenant dune autre machine. Les symboles presentØs ci-aprŁs sont utilisØs tout au long du present manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant et suivez les directives mentionnØes atm dØviter tout danger. Les consignes de sØcuritØ prØsentØes ci-aprŁs ne font ace manuel. A vent Œtre confiØs A Porter Au coursde un harnais de sØcuritŁ Maintenir solidement lentretien lutilisation, qu des personnes reparations qualifiees. et les lutilisation,tenirtoute personne a lØcart ne Ia Nutiliser quun materiel en bon Øtat. RØparer ou remplacer sur-le champ les piŁces endommagØes. Entretenir lappareil conformØment de sØcuritØ. Linstallation, piŁce, terre que rØsumer linformation contenuedans les normes de sØcuritØ ØnumØrØes a Ia section 1-4 Veuillez lire et respecter toutes ces normes prendre pour Øviter tout danger. nest pas relatif a Ia sØcuritØ. NOTA Signifie ndtre 5/97 en quand place on travaille en tous lea panneaux et hauteur. capots. Fixer le cable de retour de facon a obtenir un bon contact mØtal-mØtal avec Ia piŁce a souder ou latable detravail, le plus prŁs possible de Ia doi soudure. et plus par ticuliŁrement les enfants. Isoler Ia pince de masse quand pas mis a obiet metallique. Ia piŁce pour Øviter le contact avec tout UN CHOC ELECTRIQUE peutluer simple contact avec des piŁces Ølectriques peut provoquer une electrocution ou des blessures graves. LØlectrode et le circuit de soudage sont sous tension des que Iappareil eat sur ON. Le circuit dentrØe et les circuits internes de lappareil sont egalement sous tension ace moment-l. En soudage semi-automatique ou automatique, le fil, le dØvidoir, le logement des galets dentraInement et les piŁces mØtalliques en contact avec le fil de soudage sont sous tension. Des matØriels mal installØs ou ma! mis a Ia terre prØsentent un danger. Un Ne toucher lea jamais piŁces Łlectriques Porter des gants et des vŒtements de pas de trous. sous Ily a DU COURANT CONTINU IMPORTANT dans Ies aprŁs Ia suppression de Ialimenta convertisseurs tion Ølectrique. ArrŒter lea convertisseurs, dØbrancher le courant electrique, et dØ charger lea condensateurs dalimentation selon lea instructions indiquŁes dans Ia partie entretien avant de toucher lea piŁces. tension. protection secs ne comportant LES FLJMEES ET LES Œtredangereux. de Ia piŁce et de Ia terre au moyen de tapis ou dautres moyens isolants suffisamment grands pour empŒcher le contact phy sique Øventuel avec Ia piŁce ou Ia terre. Sisoler Ne pas se servir de source Ølectrique humides, dans lea endroits confines Se servir dune procØdØ de soudage Si lutilisation saire, se source Eloigner UNIQUEMENT si le arrØterle moteuravantde procŁder linstal a lentretien de Iappareil. DØverrouiller selon Ia norme OSHA 29 CFR 191 0.147 (voir normes ou ou sØcuritØ). Installeret mettre a laterre correctement cetappareil conformŁment a et aux codes nationaux, provinciaux et son manuel dutiliaation municipaux. Toujours verifier laterre du Verifier et sassu rer que le fil de terre du cordon dalimentation est bien raccordØ ala borne de terre du sectionneur ou que lafiche du cordon est raccordØe a une prise correctement mise a Ia terre. cordon dalimentation - En effectuant les raccordements dentrØe fixer dabord le conducteur de mise a Ia terre appropriŁ et contre-vØrifler lea connexions. frequemment le cordon dalimentation pour voir si! nest pas endommagØ ou dŁnudŁ remplacer le cordon immØdiatement sil est endommagØ un cable dŁnudŁ peut provoquer une electrocution. Mettre Iappareil hors tension quand on ne lutilise pas. Ne pas utiliser des cables uses, endommages, de grosseur insuffi sante ou mal epissŁs. Verifier - - Ne pas enrouler lea cables autour du corps. Si Ia piŁce soudØe doitŒtre mise a laterre, lefairedirectementavec un cable distinct ne pas utiliser le connecteur de piŁce ou le cable de votre tŒte des fumØes. Ne pas respirer lea fumØes. et/ou utiliser un Øchappement au ni des fumØes et des gaz de soudage. Si Ia ventilation est insuffisante, utiliser un respirateur a alimenta A source lation, a Ia reparation de l o le demande. Couper lalimentation lalimentation ou electrique courant electrique peUveflt Le soudage genŁre des fumØes et des gaz. Leur inhalation peut Œtre dangereux pour votre sante. zones Ølectrique courant Ølectrique savŁre nØces Ia fonction de tØlØcommande si lappareil en est ØquipØ. dune servir de Ølectrique dana lea on risque de tomber. courant GAZ IintØrieur, ventiler Ia veau zone de larc pour evacuation tion dair homologuØ. Lire lea specifications de sØcuritØ des matØriaux (MSDS5) et tes ins tructions du fabricant concernant lea mØtaux, les consommables, les revŒtements, lea nettoyants et lea dØgraisseurs. Travailler dana en un espace fermØ seulement siI eat bien veritilØ ou portant un reapirateur a alimentation dair. Demandertoujours a un surveillant dQment formØ de se tenir a proximitØ. Des fumØes et des gaz de soudage peuvent deplacer lair et abaisser le niveau doxygŁne provoquant des blessures ou des accidents mortels. que lair de respiration ne prØsente aucun danger. Ne pas souder dana des endroits situØs a proximitØ dopØrations de dŁgraissage, de nettoyage ou de pulvŁrisation. La chaleur et lea rayons de larc peuvent reagir en presence de vapeurs et former Sassurer des gaz hautement toxiques et irritants. Ne pas souder des mØtaux munis dun revŒtement, tels que lacier galvanisØ, plaque en p10mb ou au cadmium a moinsque le revŒte ment nait ØtØ enlevØ dans Ia zone de soudure, que Iendroit soft bien ventilØ, et si nØceasaire, en portant un respirateur a ailments tion dair. Lea revŒtements et toua lea mØtaux renferniant ces ØlØ ments peuvent dØgager des fumØes toxiques en cas de soudage. - retour. OM-1588 Page 5 LES RAVONS DE LARC LES ACCUMULATIONS DE GAZ ris voquer des brlures sur Ia peau. quent de provoquer desbiessures peuvent pro dans les yeux et mŒme lamort. Le rayonnement de arc du procØdØ de soudage gØnŁre des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brOlures dans les yeux et pendant le sur Ia peau. Des Øtincelles sont projetees soudage. Fermer lalimentation non Veiller Porter un casque de soudage muni dun Øcran defiltre approprie pour protØger votre visage et vos yeux pendant le soudage ou pour regar der (voirANSi Z49. 1 et Z87. 1 ØnumØrØ dans les normes de sØcuritØ). Porter des protections approuves ou des barriŁres pour protØger des tiers de dair ~I souda~e effectuØ Se protØger et dautres metal chaud. PrØvoir une dutiliser le projection dØtincelles ou servir dun respi chaudes a mains de refroidissement avant Ia torche. MAGNETIQUES peuvent affecter les stimulateurs Porteurs de stimulateur Les dabord cardiaque, restez a distance. consulter leur mØdecin avant de des de cardiaques. porteurs dun stimulateur cardiaque doivent operations de soudage a arc, soudage par points. sapprocher de gougeage ou et de LE BRUIT Ne pas souder dans un endroit l o des substances inflammables. parties pØriode pistolet LES CHAMPS sur personnes de Ia ou se homologuØ. Ne pas toucher des des conteneurs termØs tels que des reservoirs, tambours ou des conduites peut provo9uerleurØclatement. Des Øtincelles peuventŒtre projetees de larc de soudure. La projection dØtincel les, des piŁces chaudes et des Øquipements chauds peut provoquer des incendies et des brQlures. Le contact accidentel de lØlectrode avec des objets mØtalliques peut 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. ~ de flues LE SOUDAGE peut provoquer incendie ou une explosion. Le en cas lØclair lØblouissement; demander aux autres personnes de ne pas re garder larc. Porter des vŒtements de protection constituØ dans une matiØre dura ble, resistant au feu (cuir ou lame) et une protection des pieds. et de m protecteur DES PI¨CES CHAU DES peuvent pro voquer des brOlures graves. pour les oreilles si le niveau sondre est trop ØlevØ. Utiliser des Łcrans du gaz utilisation. toujours a bien aØrer les espaces confines rateur dadduction ou I des Øtincelles peuvent tomber peut affecter IouIe. sur Le bruit des processus et des DØplacertoutes es substances inflammables a une distance del 0,7 de arc de soudage. En cas dimpossibilitØ es recouvrirsoigneuse ment avec des protections homologuŁs. Des Øtincelles et des matØriaux chauds du soudage peuvent facile Øquipements peut affecter roule. m ment passer dans dautres zones en traversant de petites fissures Porter des protections approuves pour lea oreilles si le niveau sondre est trop ØlevØ. et des ouvertures. SurvelllertoutdØclenchemeritdincendie ettenirunextincteurproxi mite. Le soudage effectuØ peut dØclencher sur un plafond, plancher, paroi incendie de lautre un ou Si des BOUTEILLES sont endomma gØes, elles pourront exploser. separation ctØ. Ne pas effectuer le soudage sur des conteneurs fermØs tels que des reservoirs, tambours, ou conduites, a moms quils naient ØtØ prepa rØs correctement conformØment a AWS F4.1 (you les normes de ~1 _____________ Brancher te 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 Øventuels en provoquant des risques dØlec trocution et dincendie. Ne pas utiliser le poste de soudage pour dØgeler des conduites ge lees. En de utilisation, enlever (a baguette dØlectrode du portecouper le fit a Ia pointe de contact. Porter des vŁtements 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. cas electrode non ou Avant de souder, retirer toute substance combustible de telles quun allumeur au butane ou des allumettes. vos poches DES PARTICULES VOLANTES S Le soudage, lØcaillement, a Ia brosse en le passage de fil de fer, et le a piŁce meulage gØnŁrent desØtincellesetdesparticules mŁtalliquesvolan tes. Pendant Ia de projeter pØriode de refroidissement des soudures, elles risquent du laitier. Porter des lunettes de sØcuritØ avec Øcrans latØraux ou un manipuler avec precaution. Proteger les bouteitles de gaz comprime dune chaleur excessive, des chocs mØcaniques, du laitier, des flammes ouvertes, des Øtin celles et des arcs. Placer lea bouteilles debout en les fixant dans un support station naire ou dans un porte-bouteilles pour es empŒcher de tomber ou de se renverser. Tenir les bouteilles cuits electriques. Ne jamais placer eloignees des circuits de soudage ou autres cir une torche de Une electrode de une bouteille. soudage Ne jamais souder une ne soudage sur une bouteille a gaz. jamais entrer en contact avec doit bouteille pressurisee - risque dexplosion. Utiliser seulement des bouteilles de gaz protecteur, rØgulateurs, tuyaux et raccords convenables pour cette application specifique; les maintenir ainsi que les ØlŁments associØs en bon Øtat. Ne pas tenir Ia tŒte en face de Ia sortie en ouvrant Ia soupape de Ia bouteille. peuvent blesser les yeux. ~ Des bouteilles de gaz protecteur contiennent du gaz haute pression. Si une bouteille eat endomma gee, elle peutexptoser. Dufaitque es bouteilles degaz font normalement partie du procŁdØ de soudage, es sous sØcuritØ). dage . Maintenir le dutilisation chapeau ou de protection sur a soupape, sauf en cas de branchement de Ia bouteille. Lire et suivre les instructions concernant les bouteilles de gaz cornlea equipements associØs et les publications P-i CGA Ønu mØrØes dans es normes de sØcuritØ. prime, Øcran facial. . OM-1588 Page 6 - 1-3. Dangers supplØrnentaires en relation avec le fonctionhement Iinstllation, et Ia maintenance I RisqueDINCENDIEOU bES. Ne pas placer Iappareil proximitØ sur, Maintenir fermØs et fixement lappareil a proximitØ de produits inflammables Ne pas surcharger installation electrique sassurer que lalimen tation est correctement dimensionnØ et protØgØ avant de mettre panneaux, - en MOBILES peuvent Rester a IØcart des organes mobiles ventilateur. au-dessus ou a de surfaces infilammables. Ne pas installer lappareil ORGANES provoquer des blessures. DEXPLOSION~ et le place es portes, dispositifs de protection. service. LA CHUTE DE LAPPAREIL en recouvrements comme LE RAVONNEMENT HAUTE FRE. QUENCE (H.F) risque de provoquer desinterfØrences. peut blesser. Le rayonnement hautefrequence peut provoquer des interferences avec les Øquipements de ra dio-navigationetdecommunication, lesservices de sØcuritØ et les ordinateurs. Utiliser lanneau de levage uniquement pour sou lever lappareil, NON PAS les chariot, les bouteil les de gaz ou tout autre accessoire. engin dune capacitØ appropriØe pour Iappareil. En utilisant des fourches de levage pour dØplacer lunitØ, sassurer que lesfourches sont suftisamment longues pour dØpasser du ctØ oppose de lappareil. Utiliser un soulever L~EMPLOI EXCESStF peut SURCHAUFFER LEQUIPEMENT. PrØvoir ter le une pØriode de ref roidissement, cycle opØratoire nominal. RØduirelecourantou recommancer Ne pas obstruer les passages dair le respec Demander seulement a des personnes qualifiees familiarisØes des Øquipements electroniques defaire fonctionner linstalla tion. avec Lutilisateur est tenu de faire corriger rapidement par les interferences resultant de linstallation. LES CHARGES signale des interferences, arrØter immØdiatement lappa Effectuer rØguliØrement LE SOUDAGE A LARC risque de provoquerdes interferences. poste. ELECTRSTATIQUES Ia connexion avec Ia barrette de terre pieces. Utiliser des pochettes et des boltes antistatiques pour stocker, dØplacer ou expØdierdes caries de circuits manipuler de linstallation. et lentretien lecycleopØratoireavantde LØnergie des caries ou des imprimes. electromagnØtique risque Veiller ace que tout lŁquipement patible electromagnØtiquement. Pour rØduire Ia zone de soudage soit com maintenir les cables de les grouper, et es poser aussi possibilitØ dinterfØrence, aussi courts que possible, que possible (ex. par terre). soudage bas de Ia Veiller a souder a une distance de 100 metres de tout Ølectronique sensible. ORGANES MOBILES provoquer desib!essures. DES Ne pas sapprocher sapprocher peuveæt Veiller a ce que ce poste de soudage soit conformØment a ce mode demploi. Ne pas des points de coincement tels que des rouleaux de commande. LES FILS DE SOUDAGE peuventpro voquerdes.bIessures.~ Ne pas sonnes le fil de le avant den avoir pistolet vers soi, dautres per ou toute piŁce mØcanique en engageant soudage. diriger et mis a Ia terre aprØs avoir pris les mesures prØcØdentes, il de prendre des mesures supplØmentaires le deplacement du poste, lutilisation de cables blindØs, de filtres de ligne ou Ia pose de protecteurs dans Ia zone telles que lutilisation de travail. :;LES CHAMPSMAGNETIQUESpeuveflt atfecterIes stimulateurs cardiaques. Porteurs de stimulateur gachette pose equipement En cas dinterfØrences incombe a lutilisateur des organes mobiles. Ne pas appuyer sur Ia recu instruction. de provoquer des interferences pour Iequipement electronique sensible tel que les ordinateurs et Iequipement commandØ par ordinateur tel que les robots. primes. Etablir le contrle Maintenir soigneusement fermØs les portes et les panneaux des sources de haute frØquence, maintenirles Øclateurs a une distance correcte et utiliser une terre et et un blindage pour rØduire les inter fØrences Øventuelles. peuvent endommager les circuits im avant de Ølectricien Si le FCC reil. soudage. du un qualifiØ 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-1 588 Page 7 1-4. Principales normesde sØcuritØ Safety in Welding and Cutting, norme ANSI Z49. 1, de American ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 Wel Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. 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 Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet a Compressed Gas Association, 1235 Jefferson Davis High Suite 501, Arlington, VA 22202. P-i, de way, RŁgles de sØcuritØ en soudage, coupage et procØdØs connexes, norCSA Wi 17.2, de lAssociation canadienne de normalisation, vente de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1 R3. me Safe Practices ForOccupation And Educational EyeAnd Face Protec tion, norme ANSI Z87.1, de lAmerican National Standards Institute, 1430 Broadway, New York, NY 10018. National Electrical Cutting and Welding Processes, tection Protection Association, Code, NFPA Standard 70, de Ia National Fire Pro Association, Batterymarch Park, Quincy, MA 02269. Information I -5~ DonnØes des le sur leS et sur les pour lorganisme, Atm de 1 Le courant de soudage, pendant son passage dans les cables de sou dage, causera des champs ØlectromagnØtiques. II y a eu et ii 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 National Research Council aconclu: Laccumulation de preuves, sui vant le jugement du comitØ, na pas dØmontrØ que lexposition aux champs magnØtiques et champs Ølectriques a haute frØquence reprØ risque a Ia sante humaine. Toutefois, des etudes sont en cours et les preuves continuent a Œtre examinØes. En at sente un toujours tendant que les conclusions finales de a recherche soient Øtablies, ii vous serait souhaitable de rØduire votre exposition aux champs Ølec tromagnØtiques pendant le soudage ou NFPA SiB, de Ia National Fire MA 02269. champs ØlectromagnØtiques soudage Ølectrique effets, champs magnØtiques basse frequence sur norme Batterymarch Park, Quincy, le coupage. de rØduire les champs ØlectromagnØtiques dans lenvironnement travail, respecter les consignes suivantes Garder les cables ensembles en les torsadant attachant avec du ruban adhØsif. 2 Mettre tous les cables du ctØ 3 Ne pas courber pas et votre corps. 4 Garder le poste de de 5 ne oppose de les lopØrateur. pas entourer pas soudage ou en et les cables le es cables autour de plus loin possible vous. 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 ci-dessus. . OM-1588 Page 8 SECTION 2- INTRODUCTION Specifications 2-1. Type of 24 Volts AC Constant Amperes 50/60 Hertz Height With 4 ft (1.2 m .023 To 1/8 in (0.6 To 3.2 mm) pm Max Optional High Speed: ipm (2.3 To 36.5 mpm) 92 To 1435 ) Post Vertical Lift Of Boom Range Standard: 50 To 780 (1.3 To 19.8 mpm) Voltage (CV) 12 ft Maximum Wire Diameter Speed Range DC For GMAW Or Constant Voltage (CV) / Constant Current (CC) DC For GMAW-P All Need 14-Pin And Contactor Control Single-Phase 10 Wire Feed Welding Power Source Type Input Power Welding Circuit Rating 100 Horizontal to 60 12 ft Volts, 16 ft Spool Weight: (27 kg) (4.9 m): (127 kg) 280 lb 60 lb 16 ft (4.9 m) Boom 21 ft (5.2 m) Above Horizontal (3.7 m): (94 kg) 207 lb Amperes, 100% Duty Cycle 750 (3.7 m) Boom 17 ft Weight (6.4 m) Horizontal to 60 Above Horizontal SECTION 3-INSTALLATION 3-1. Installing Swivel Into Pipe Post 5 . 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 Insert Assembly into pipe post. Lubricate swivel. 2 5 Safety A Do Collar not remove until instructed to. 3 Tools Needed: ~=::~ 3/4 in ST-152 382 OM-1588 Page 9 3-2. Installing Control Box And Adjusting Tilt 1 Weld Control 2 Bracket 3 Screw Bracket and installed screws are onto bottom of control at factory. Swivel 4 Loosen Place control screws. on Tighten swivel and slide forward. screws. 2 5 Tilt Bracket 6 Rear Pivot Screw 7 Front Screw Loosen front rear pivot screw. Remove Pivot control down screw. ward to desired viewing angle. Re place and tighten front screw. Tighten pivot screw. 3~ Tools Needed: ST-800 174! ST-801 278 3-3. Installing Boom And Reel Support 1 Swivel Plates 2 Yoke Remove plates 3 hardware and Set boom into swivel pin 5 7 as pin through yoke. Install and spread ends. cot Bolt Install bolt, washers, Tighten hardware, and 4 shown. Yoke Pin Install ter swivel Boom 4 3 from yoke. one half turn. 6 Locking Install and nut. back bolt off Knob locking knob but do not tighten. 7 Reel Support Install reel support. 2 Tools Needed: ~ 3/8, 3/4 in ST-15S 170 OM-1 588 Page 10 3-4. Instafling 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: tEII~~J4J 3/8 in ST-152 383 OM-1588 Page 11 3-5. Equipment Connection Diagram 1 300/400 Ampere Model CC/CV Inverter Welding Power Source Use settings shown for both pulse MIG welding and MIG welding. 2 450 S Ampere Model CV Welding Power Inverter Source 3 14-Pin Cord 4 Positive 5 Negative (-) Be sure Weld Cable (+) weld Weld Cable cables are sized properly for peak amperage if pulse welding (see welding power source Owners Manual). PULSED 6 Workpiece 7 Voltage Sensing (Optional Use) .~- W~PANEL Be V-SENSE START ~*~RE~OTE INDUCTANCE/DIG Gun gun is rated for peak am perage if pulse welding. Install ac cording to its Owners Manual. STICK SCRATCH 8 Lead V/A CONTROL 9 sure Wire Feeder For connections see Gas Section 3-7. 10 Shielding 11 Supplied 12 Gas Hose From Boom Y Supply Adapter S ST-801 806/ Ref. ST-175 086 / Ref. sT-i 80311 -B OM-1 588 Page 12 3-6. Connecting Weld Cables And Gas Hoses The weld cables and hoses extend lOft shielding gas (3 m) from the boom. Route weld through If the reed cables from if relays, boom applicable. welding power source or gas further from the boom, extend cables or hoses as follows: supply are 1 Weld Cable 2 Insulated Bolt Sleeving together welding power weld Use electrical tape sleeving 3 cables from source and boom. and insulated to cover connection. Shielding Gas Hose Connect hose to gas supply or ex tension hose. The hose from the boom has threads. 5/8-18 right-hand Tools Needed: ~-_ 5/8 in R&. ST-801 806 / Ret. ST-152 800-A OM-1 588 Page 13 Control Box Connections 3-7. Optional Reed Relay Connection 2 Wire Feed Motor And Gas Valve Control 3 Receptacle Wire Feed Motor And Gas Valve Control Plug From Boom 4 14-Pin Cord 5 Volt Sense Lead (Optional Use) oIJ~ 6 Gun Trigger Plug From Boom 0 10 2 ST-800 177-A/ Ref. ST-800 175 3-8. 14-Pin Plug Information REMOTE 14 *The remaining pins OM-1588 Page 14 are Pifl* Pin Information A 24 volts B Contact closure to A G Circuit C +10 volts dc output to remote control with D Remote control circuit common. E 0 to +10 volts dc command H Voltage feedback; 0 to +10 volts dc, 1 volt per 10 F Current 0 to +10 volts dc, 1 volt per 100 amperes. M CC/CV Select (+24 N Inductance not used. ac with common respect to socket G. completes 24 volts ac contactor control circuit. for 24 volts AC circuit. input feedback; (0-10 V) V = CV) respect signal from to socket D. remote control with arc volts. respect to socket D. 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 clockwisetoin time it takes the motor to crease speed. ramp up to Remove protec tive white rubber cap before mak ing adjustment. Adjust potentiome using a small nonconduc ter R70 tive screwdriver. Reinstall wrapper. Tools Needed: Non-Conductive - c::I:I::::z:J=:==11 1/4 in ST.162 132 / Ref. SA-183 121-B 3-10. Removing Safety Collar And Adjusting Boom 1 Knob Locking knob Tighten to prevent boom movement. Loosen knob to allow movement. Change knob position to limit upward movement. boom Pull boom down move safety slightly and re collar. Boom should position from hori degrees above hori necessary, adjust boom balance in any zontal to 60 zontal. If as follows: 2 Threaded Rod 3 Jam Nut Loosen jam nut and turn threaded rod until boom balances. jam nut. Be sure threads are through vent boom falling. 4 E Tighten several yoke Yoke safety collar for use in assembling or moving boom. Retain 0 full to pre dis Rod Tools Needed: .~ 1-1/8 in Increasing Spring Decreasing Spring Pressure For A Pressure For A Heavy Gun Ughter Gun 5T-142 599-B OM-1 588 Page 15 3-11. Gun Recommendation Table Process GMAW-P GMAW FCAW - Hard Hard or or Cored Wires Speed GW-500 Or GW-600 Cored Wires M25, M40, Or GA-50C Self-Shielding Wires Wire GA-4OGL Or GA-5OGL And Feed Type, Size, 3-12. Wire Motor - - Gun Type Speed Capability Table Wire Size Feed Standard All Standard All 3/32 To 7/64 in (2.4 To 2.8 mm) Standard All 1/8 in (3.2 mm) Optional High All .023 To 5/64 in .023 To 5/64 in (0.6 (0.6 To 2 To 2 mm) Speed Capability 50 To 780 ipm (1.3 To 19.8 mpm) 50 To 700 ipm (1.3 To 17.8 mpm) 50 To 300 pm mm) 92 To 1440 (1.3 ipm (2.3 To 7.6 mpm) To 35.6 mpm) . . OM-1588 Page 16 3-13. Installing And Threading Welding Wire Tools Needed: 3/16,5/64 in ~ 15/16,3/8in 0 wire Install El Adjust tension wire is wire feed taut spool. nut so when stops. 4, 4- NONCONDUCTIVE SURFACE No Wire lET Be NONCONDUCTIVE SURFACE Slip that outlet cable has proper size liner for the welding wire size. sure 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 offend of wire. Push wire through guides up Wire Slips ii:r Forsoft wire or small diameter stainless steel wire, use2drive rolls and set drive roll pressure from 0 to a maximum of 4 on the pressure indicator scale (so that the inner spring is compressed). setting will generally give the best performance for these types of wires. only This To adjust drive roll pressure, hold nozzle (51 mm) from nonconductive surface and press gun trigger to feed wire against surface. Tighten knob so wire does not slip. Do not overtighten. If contact tip is completely blocked, wire should slip at the about 2 in feeder (see pressure adjustment above). Cut wire off. Close Repeat cover. for other side. to drive Jog rolls; continue to hold wire. Press button to feed wire out gun. ST-i 52 564-B / Ref. ST-156 92g / Ref. SC-i 50922 / Ref. ST-i 56 930/ 5-0621-A OM-1 588 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 change automatically regulates pulse frequency welding wire stickout. to maintain a constant arc length, regard in When weld amperage is not present, wire feeds for about three seconds at set wire feed speed. Then the welding power source contactor deenergizes and wire continues to feed at the wire jog Jog speed. Inductance As inductance Trim Arc Synergic The operator programs pulse parameters for a specific wire teed speed. The wire feeder determines the pulse parameters between these wire feed speed increments. increases, arc on time increases, and the weld length adjustment in pulse welding. Increasing placed by volts in MIG programs. puddle becomes more trim increases the actual arc fluid. length. Trim is re Side Panel Terms: Process Mode Sequence Is used to select the Mode type of process to be used, including Pulse, Adaptive Pulse, or Mig. Is used to select and program the weld sequences which include weld, crater, burnback, and run-in. postflow, preflow, Dual Schedule Mode Is used to select a Card Mode Is used to select use Security Only Mode functions with rameter 4-2. Pulse Welding pair a of programs that can be used of the optional data card data card. Allows using together. storage and retrieval capabilities. the lock feature for restricting range of program pa changing. Terms Apk 1 Peak = Amperage Increasing Apk increases penetra tion. Vpk Peak = Voltage voltage during peak current phase of the pulse waveform. This determines arc length during adaptive pulse welding. Arc 3 / \ 2 Abk Background Amperage = Maintains 3 PPS 4 1 Increasing 2 Time 18 / pulses. increases travel PWms Pulse Width In Milliseconds width. Page between Pulses Per Second Increasing PPS speed. Amps OM-1 588 = arc = PWms increases bead Front Panel Controls 4-3. 1 Ii~.a.. I 2 3 8 ow~7 4 4 // ST-162 ~27 1 Display while welding, with ule Mode 2 Parameter Select Button Press button to 3 Display move > on change value pointed to by>. 4 Active Side Indicator 5 Trigger Trigger Hold When 1PM is selected, click causes wire feed To weld without crease/decrease by When MPM is clicks causes by 0.1. Prg # is crease When click selected, turning control three wire feed speed (MPM) to in selected, turning control one program number (Prg #) to in crease/decrease by one. The program number cannot be changed Light holding gun trigger through cycle, press and release button to feature on (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 6 trigger may be used to change trigger. Side Select Button The feeder remembers the last used pro gram for each side and returns to that pro gram when the active side is changed. Jog Button momentarily feed welding wire with energizing welding circuit or shielding Push to gas valve. Jog speed is varied using the Display Con trol while Jog button is pressed. Default set ting is 200 1PM. 8 out weld release gun causes 7 out can be set on a per program ba sis, Indicator light comes on for programs where this feature is active. turn one. Light Hold Button And Indicator Turning control one click causes Trim (arc length) to increase/decrease by one or Volt to increase/decrease by 0.1. turning control one speed (1PM) to in The gun active side of the feeder. Pulse is a default setting. To change type of process (Pulse, Adaptive Pulse, or M IG) use side panel controls (see Section 4-4). display. Control Turn control to exception of Dual Sched (see Section 6). Purge Button momentarily energize gas valve energizing the welding circuit. Push to without lt7 Jog and Purge only work on the active side of the feeder. Holding the Jog and Purge buttons at the time displays pulse parameters on the side panel display and voltage on front panel display. same OM-1 588 Page 19 4-4. Side And Rear Panel Controls 1 Mode 2 Mode Select Button Display Press button to move> 3 Parameter Display 4 Parameter Select Button in Press button to move> in display. display. 5 Parameter Increase Button 6 Parameter Decrease Button 7 Power Switch 8 Circuit Breaker CB1 CB1 protects the wire feeder from overload. 5 6 2 Ret. ST-162 128/ Ref. ST-162 133 OM-1 588 Page 20 SECTION 5- SETTING SEQUENCE PARAMETERS ience Parameters In A Program OM-1588 Page 21 SECTION 6 6-1. Selecting - SETTING DUAL SCHEDULE PARAMETERS Dual Schedule Pair H Dual Schedule is used with two consecutive weld programs 1 & 2, 3&4, 5&6, or7&8.Anyprogram type (MIG, Adaptive Pulse, or _____________________ Pulse) can be combined in dual schedule. Side Panel 1 Use side See panel Menu Display to turn feature Guide for on. detailed programming steps. 2 Front Panel Display Press front panel parameter select button to select program number. 3 Front Panel 4 Dual Schedule Switch Section 6-2) UJ Switch type Display Control is set in (See System Setup. 5 Welding Gun Trigger Selecting dual schedule program A or B is done by using Display Con trol, dual schedule switch, trigger setup). (depending on or gun system When program B is active, turn Display Control one click clock wise to select another pair of dual schedule programs. ~ Programs in be rearranged desired order using the data can . card. See Section 7. 2 ik Al __________________ 24. 250 OV 1PM I>Prg Dual 3 Or c~ Display Control 5 . OM-1 588 Page 22 6-2. Dual Schedule Switch Diagrams 1 Momen 2P (Momentary-Contact 2-Pole Switch) 2 1 1 2 2 > > (Maintained-Contact Switch) Maint 2P 2-Pole 3 Maint 1 P (Maintained-Contact 1-Pole Switch) 4 Trigger scheduling after estab welding arc. Allows dual lishing A 3 1 2 > 0 a fl~ If trigger is used for dual schedule switch, Trigger Hold is disabled. B 4 0 3 4 1 > TRI\ 2 > 3 IBO 4 0 3 Adapter 1 > 2 > TR\___ 3 >> A~ OM-1 588 Page 23 SECTION 7- USING THE OPTIONAL DATA CARD 7-1. Data Card Terms CARD SCREEN TERMS WRITE Programs To Card ~ READ Programs From Card PULSE MIG TERMS PPS Amperage (Pulses Per Second) I I~ I PWms Width In (Pulse Milliseconds) -r Apk (Peak Amperage) -r Abk Time (Background Amperage) SA-158 435 7-2. Installing Data Card 1 Label Apply label to data card. Write pro gram information on label. 2 Data Card 3 Card Slot For Blank Data Card: Insert card into slot. Toformatcard, 3 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 within 3 seconds and the 8 pro er. grams and setup information are read into the wire feeder memory. Unit is ready Wait message disappears from front to use when Please panel display. . ST-i 56 266-B OM-1 588 Page 24 7-3. Card Displays f~ See Menu Guide for detailed programming steps. Security mode only functions with a data card. Display 1 Card 2 Moving Line Moving line is be changed. Sequ ence 3 under value that can Write Dual Schd Pr >Card Secu r ty ess Be low 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 signed. Side Panel Parameter Select Once 4 Transfers program data from card to unit. 5 3 Read Delete Deletes program data from card. 6 Done 4 Exits card display. 5 6 OM-1 568 Page 25 SECTION 8- SYSTEM SETUP 8-1. System Setup Display Note ~ DISPLAY SETTING * >System >Range See Menu Guide for detailed programming steps. NOTES Select the process the * . Parameters welding power source is able to do. Welding power source minimum and maximum voltage values are always pulse welding. Set values to match welding power source ranges. needed. values Amperage are required for >Access When on, restricts of >Mig Type Default is Off. Set to On >Voltage Default is use setup only 14-pin receptacle. screens. for older CV welding power Use V. Sense when more source without than 50 ft (1 5m) voltage feedback at 14-socket of weld cable is used receptacle. (including gun cable length). >Arc Start~ Use Hot Start only with Inverter Model switches to CC. >Dual Schedule See Section 6-2. >Trigger When on, trigger can welding power source and large diameter wires. The be used to switch between programs that have at least 0.2 seconds of arc starts in CV and time pro preflow grammed. >Remote When on, a dual schedule switch panel display> can be used to change Volts or Trim, 1PM, Prg depending on where the front >Arc Time Displays >Wire Feed Choose to >Memory Program Reset: unit defaults to original factory setting for the last active program. Setup information change. If setup card is in card slot, program will be loaded from card. accumulated display arc time and cycles. inches per minute or meters per minute and motor type, Reset: unit defaults to original factory settings for all programs and card is in card slot, program will be loaded from card. System setup Total Reset: unit defaults to setup * or is. When on, the system age is sensed. >Teach Default is 15 points, but >Gas Flow Setting >Software Know this when Can be used -- for all programs and setup excluding System does not and Arc Time. If setup including System and . Arc Time. If card is in card slot, program will be loaded from card. >Shutdown Automatically original factory settings but installed motor must match selection. immediately can must be Meter Off if talking 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-1 588 Page 26 SECTION 9- STANDARD PULSE WELDING PROGRAMS Note ~ Apk Peak = PPS = Amperage, Vpk factory set programs. interpolations from the 9-1. Wire Program Sizefrype: 1 - = Peak Pulses Per Second, PWms = If selection is set 4 Abk Background Amperage, (milliseconds). Four teach points were use d for for fifteen teach points, the remaining points are Voltage, Pulse Width taught points. Steel Gas: Ar .035 - CO2 or Ar Oxy / - 40 CFH (19 Urn) Vpk Abk PPS PWms 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 1PM / MPM Apk 700/17.8 9-2. Wire Program Size/Type: 2 - Steel Gas: Ar .045 - CO2 or Ar - Oxy /40 CFH (19 U/rn) 1PM / MPM Apk Vpk Abk PPS PWms 700/ 17.8 518 35.0 195 205 3.6 400/10.2 466 31.3 147 158 2.9 200 / 5.1 412 28.5 93 106 2.4 100 / 2.5 375 26.5 50 66 2.2 9-3. Wire Program Size/Type: 3 - Gas: Ar Apk 625/15.9 - CO2 or Ar - Oxy / 40 CFH (19 Urn) Vpk Abk PPS PWrns 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 9-4. Wire Program Size/Type: 1PM / MPM 4 - .062 Gas: Ar - CO2 or Ar . Oxy / 40 CFH (19 Urn) Vpk Abk PPS PWrns 550 36.8 200 195 4.1 300/7.6 510 36.3 145 175 3.8 200/5.1 480 31.6 110 155 3.2 100/2.5 460 28.7 69 94 2.6 / 10.2 COMMENTS Steel Apk 400 COMMENTS Steel .052 1PM / MPM COMMENTS COMMENTS OM-1588 Page 27 9-5. Program Wire Size/Type: .035 5 - Stainless 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 - Stainless Gas: Ar Size/Type: .045 - He - CO2 /40 CFH (19 Urn) 1PM / MPM Apk Vpk Abk PPS PWms 700/17.8 480 39.0 200 227 3.2 400/10.2 425 32.4 155 185 2.5 200/5.1 360 28.0 100 115 2.0 100/2.5 350 26.2 40 70 2.0 9-7. Wire Program Size/Type: .035 7 - Nickel Nickel Gas: Ar Alloy - He / 40 CFH (19 U/rn) 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 Size/Type: .035 8 - COMMENTS Alloy 1PM / MPM 9-8. COMMENTS COMMENTS . Silicon Bronze SiBr Gas: Argon / 40 CFH (19 U/rn) IPM/MPM Apk Vpk Abk PPS PWms 510/13.0 340 30.7 100 125 3.7 400/10.2 310 29.8 83 97 3.4 200 / 5.1 277 26.6 48 55 3.0 120/3.1 242 25.2 31 31 3.0 COMMENTS . OM-1588 Page 28 SECTION 10- TEACH POINTS 10-1. Teach Using 15 Points L~ Apk = Peak Amperage A Vpk = Peak Voltage o Abk = Background Amperage O PPS 1PM / MPM = PWms Pulses Per Second = Pulse Width (Milliseconds) 780/ 19.8 750/19.1 700/17.8 650/16.5 600/15.2 550 / 14.0 500 / 12.7 450/11.4 Example Of A Synergic Setting For 425 1PM With 400 / 10.2 All Teach Points Set At 50 (1.3 MPM) Increments 1PM 350/8.9 300/7.6 250 / 6.4 200/ 5.1 150/3.8 100/2.5 50/1.3 Apk Vpk 100 180 210 240 270 300 330 360 370 420 24 27 30 33 36 37 42 10 20 30 40 50 60 70 80 90 100 110 120 130 PPS 20 55 80 105 130 160 185 210 235 260 290 315 340 user to create pulse programs. The teach mode selection for 15 teach points gives a more defined curve for a specific range. At each teach point, the user can adjust five param eters to shape the pulse waveform of the custom weld output. The six parameters (MPM), Apic, Vpk, Abk, PPS, and are: 1PM Abk 400 PPS 54 Abk The teach mode allows the 200 540 51 21 2 140 365 510 48 18 PWms Apk Vpk 480 45 10 3 Apk, Vpk, Abk, PPS, and PWms acting together provide the energy necessary to burn off welding wire at a set wire feed speed. The graph below shows that as wire feed speed increases, energy increases (Apk, Vpk, Abk, PPS, and PWms acting synergically). 4 565 56 450 5 PWms Under some conditions, the wire feeder lim its wire feed speed to maintain all pulse pa rameters within the capability of the system. PWms. OM-1 588 Page 29 10-2. Teach 4 Points Using L~ Apk = Peak Amperage A Vpk = Peak Voltage E 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 A Synergic Setting For 425 1PM With 400 / 10.2 Teach Points Set At Intervals Of 100 200 (5.1), 700 (2.5), (10.2), And 1PM (17.8 MPM) 350/8.9 300 / 7.6 400 Increments 250 / 6.4 200/5.1 150/3.8 100/2.5 50/1.3 Apk Vpk 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 PWms 1 2 3 450 480 510 540 45 48 51 54 4 565 56 Apk Vpk 140 200 Abk 365 400 PPS 5 PWms I The teach mode allows the custom user pulse programs. The to create teach mode Apk, Vpk, Abk, PPS, acting together provide the energy necessary to and PWms selection for 4 teach burn off welding speed. The graph below shows that as wire feed speed increases, energy increases (Apk, Vpk, Abk, PPS, and PWms acting points gives the whole 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. OM-1588 range Page 30 welding synergically). wire at a set wire feed Undersomeconditions,thewirefeederlim its wire feed speed to maintain all pulse parameters within the capability of the system. 10-3. Redefining Teach Points 1PM 1 1PM determines the weld metal de . position rate. ~ Redefining (PM is not normally Redefining required unless special wire or is unusual joint design 1PM Teach Point needed. Use front panel parameter select button to move> to select 1PM. Use Trim 50 Prg 1/ Purge ~ 1PM >460 1 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. Ar~d Trim 50 1 Pulse 1PM >450 Display Control point value. 2 Apk 3 Abk Peak - Amperage Background Amperage - Peak and background amperage depend on the range of the welding Pulse power source. 4 Pulses Per Second Of PPS 20-400 5 PWms - - Pulse Width Of 1.0-5.0 Milliseconds Use side pulse Redefining panel controls to change See Menu parameters. Guide for detailed Pulse Parameters programming steps. are set, strike and maintain an arc forfive seconds. Do this for each teach point. After values 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 a (arc length) setting of 50. points are set, the parameters be points synergically. Once the teach wire feeder adjusts tween teach 3 400 I 340 1>70 160 ___y4 340 Apk Apk 70 Abk Abk >160 PPS 1.4 1PM PPS PWms I I I 340 Apk 70 160 I>i PPS .9 Ref. S.0259 I Ref. ST-154 109 OM-1 588 Page 31 Date___________________ Program Number_______________________ Wire Size/Type Gas Equipment Used - Power Source_ Serial Number___________________________ Wire Feeder Serial Number Gun Model______________________ Weld Cable Wire CFH(L/min) Flowrate______ - Negative____________________ Positive______ Manufacturer________________ Mtg. Date_______________________________ IPM/MPM Apk Abk PPS PWms Vpk COMMENTS . Preflow Run-In Seconds:_________ Trim/Volts:________ 1PM I MPM:___________________________________ Seconds:___________________________ Crater Volts:_____________________ 1PM I MPM:_____________________________ Seconds:_____________________________ Postflow Seconds:________ . OM-1588 Page 32 SECTION 11 - MAINTENANCE AND TROUBLESHOOTING 11-1. Routine Maintenance ~:i~ A Disconnect power before maintaining. Repair replace or cracked weld cable. Replace cracked parts. a Check 14-pin cord. Check gas hose and Check gun cable. fittings. Months Blow out inside. or vacuum During heavy Or service, clean monthly. OM-1588 Page 33 11-2. Error Displays ~EIIJL1 Release 0~ Trigger 2 No 00 Volt Sensed Er ror 3 1 Memory Prg CRC 1 Error 4 Memo Prg ry Er Range ror 1 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 power after on correcting problem. No If this Tach when error continues pulse welding, to occur it may help to select Hot Start. Sensed Er ror 3 6 \ Memory CRC.Error Display The data in the program indicated is not the same data that was 1Er Arc Start Perform N a system reset. Go Er Stop ror 8 N Mi Ga 9 n s C F H F I x x o w N Ma x C F H x x GasF low Gas Out 10 of 11 Range N Coolant Flow 12 T~Un P r locked o g r am 1Er 1Er 1Er 1Er 1Er through pulse parameters to make sure they do not exceed settings of the Range display or perform a system reset. 5 No Tach Sensed Error frequency being used in the area, turn it off. A motor brake circuit problem Press cause this error. Parameter panel error. This appears when gas flow falls below the minimum CFH set (xx in example). Adjust gas flow to bring it above set value. Press front Select to clear Parameter panel error. Maximum Gas Flow Error 9 flow to bring it below set value. Press front Select to clear 10 Parameter panel 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 below 100 CFH. Coolant Flow Error The motor tach feedback is not reaching the control. Check connections. This appears only when coolant flow switch option is installed. Check Press front panel Select to clear Parameter 6 coolant recirculating system. error. 12 Arc Start Error Display Unlocked Program Error Display This appears when pulse welding and current is detected but the arc This appears when attempting to unlocked correct program and voltage pulse parameters settings. Check program while other programs are locked. Either lock the unlocked program or select a different program that is voltage sensing connections. locked. cannot ror also Minimum Gas Flow Error 8 11 ror can front adjusted Display ror Display example). Adjust gas Memory Range Error Display The data in the program indicated is out of usable range. Arc Error Stop appears when gas flow is above the maximum CFH set (xx in ror 4 Arc This saved. 7 7 Parameter panel error. This appears when pulse welding and the motor does not stop at the end of the weld. If there is high Select to clear source. Turn unit off and back 5 Display voltage sense circuit is not receiving feedback. Check voltage connections. Check sensing connections at 14-position plugs/ receptacles at the unit and welding Press front Select to clear be started. Check and run an ror . ror Ref. ST-155 222 OM-1588 Page 34 11-3. Troubleshooting ~~ii1~ Disconnect power before A Trouble Wire Remedy feeds, shielding gas flows, but electrode wire is not source Check interconnecting cord 3-7). Check and reset CB1 or feeds Check gun trigger Check gun trigger. Change Clean or Replace Have trigger is pulled, trigger is re- but continues to feed after leased, and trigger hold is Gas valve in feeder is contact Factory tip switch Check for or spatter or worn wire Manual. (see Table (see Section 3-13). 13-1). drive roll. guides. liner. See gun Owners or Manual. foreign Manual. matter from around nozzle Authorized Service 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 See gun Owners or worn Check for correct slowly. Unit does not 4-4). connection. See gun Owners replace dirty Remove weld along with possible feed speed. Section to correct size drive roll Incorrect size Wire does not feed until (see hub tension and drive roll pressure Readjust runs continuity and repair or replace (see contactor do not Electrode wire feeding stops erratically during welding. Motor connections. If secure, check cord for Sections 3-5 and energized. Wire feeder is on, meter(s) do not light up, motor does not run, gas valve and welding power pull in. troubleshooting slow wire or out 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. light Check welding gun trigger leads for continuity, and repair leads or replace gun. OM-1 588 Page 35 SECTION 12- ELECTRICAL DIAGRAM __]__ F~S-8 (cprc,~) L~ I AAAAA E~C PC PCT14 > PC118>> ~. ~-4 ~ ~ ~tl-8 > .~ ~-, ~ 79 PCTl-3 > ~ P~ ~ raown ~ Rmlm2sl 2 ___ ~2 ~I -~~ 7 ~3~2 I~ ~ ~ LifT ~1. 13~L<~ ~ ~ _____ ( J~< ~ ~3*~< ~ ~3~3 I !<~~ ~ I p-~+,_s-4, ~x _L17 ~L<4~ . Figure OM-1 588 Page 36 12-1. Circuit Diagram . IIII!d it Liii- (1) 9 -J (0 S SECTION 13- PARTS LIST R~ Hardware is common and riot available unless listed. (0 . 0) c~) C.) CJ cJ U, L (0 c,J N CJ r a U) C) ~-..-,--~C) U, U- C,) C) ST-BOO 272-B Figure OM-1 588 Page 38 13-1. Main Assembly Quantity Model Part No. Dia. Item No. Mkgs. Figure 149 251 149252 1 PLG21,23 .. 079878 079531 605156 PLG28,29 .. 2 080 328 SeeNote 164475 3 164474 3 PLG27,28,37,38 047 636 079 739 163519 4 159297 5 139600 5 139599 6 600324 7 602243 8 602213 601872 9 10 080947 151626 11 132053 Fig 12 13-2 13 149838 13 149839 13 078264 13 079216 14 075078 14 079217 18... 19... PLG11,17 PLG33,34 20 ..21 GS1,2 .. .. 1 2 2 CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2 CABLE, port No. 18/14 8/c (order by ft) HOSE ASSEMBLY, gas HOSE, gas HOSE, gas CABLE, weld cop strd No. 4/0 (order by ft) WASHER, flat stl std .375 WASHER, lock stl split .375 NUT, stl hex full .375-16 BRACKET, spring retaining BRACKET, spring retaining SCREW, cap stl hexhd .375-16 x 1.500 Ig SUPPORT, hub & reel PIPE POST, 4ftw/baseor PIPE POST, 6ftw/base PIPE POST, 4ft w/base or PIPE POST, 6ftw/base PIPE POST, 4ft w/o base PIPE POST, 6ft w/o base 2 2 2 17ft 1 .. .... 21ft 1 2 2 26ft 3Oft 8 8 4 4 4 4 1 1 4 4 1 1 1 1 1 1 1 1 1 1 2 2 2 115092 135409 CONNECTOR&SOCKETS 2 2 CONNECTOR & PINS 2 2 COVER, protector motor VALVE, 24VAC 2 way custom port 1/8 orE PANEL, end cover INSULATOR, motorclamp CLAMP, motor top INSULATOR, screw machine CLAMP, motor base STRIP, buna N compressed sheet .062 x 4.000sq 1 1 2 2 139813 125785 159360 159646 145639 134834 167774 167776 157295 604612 082050 164969 167780 33 1 1 2 CONNECTOR&PINS 21ft 2 26 32 .. 1 CONNECTOR, circ pin plug keying Amp 200821-1 ...25 30 .... 17ft 1 2 CONNECTOR&SOCKETS 156243 29 2 047 637 048144 24 ...29 206358-2 1 139816 159647 ...27 str rlf sz 11 Amp CONNECTOR, clamp CABLE, port No. 184/c (order by ft) CONNECTORw/SOCKETS CONTROL BOX, (Fig 13-4) CABLE, interconnecting (consisting of) CABLE, interconnecting (consisting of) circ .... 2 23 22 2 1 CONNECTOR&PINS 2 605227 ... 2 CABLE, trigger (consisting of) CABLE, trigger (consisting of) BOOM ASSEMBLY NUT, nyl hex jam .75ONPST Figl3-8 16 RC27,37 Assembly 1 15 17.... 13-1. Main 16 12 Description 167782 HOSE,SAE.187IDx.4100D(orderbyft) DRIVE ASSEMBLY, wire RH (Fig 13-5) DRIVE ASSEMBLY, wire RH (high speed) (Fig 13-5) GUIDE, monocoil SCREW, set stl sch 8-32 x .125 cup point LINER, monocoil inlet wire BUS BAR, connecting weld current DRIVE ASSEMBLY, wire LH DRIVE ASSEMBLY, wire LH (Fig 13-5) (high speed) (Fig 13-5) 1 1 2 2 2 2 8 8 2 2 2 2 3ft 3ft 1 1 1 1 2 4 4 2 1 1 1 1 1 1 NOTE: When ordering Control Box contact 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 39 1 Item No. Part No. Description Figure 1 2 3 .... 058427 .... 136684 .... 605941 .... 010233 .... 057971 6.... 010191 7 4 5 .... 058628 8 .... 058428 9 .... 080393 .... 124900 12... +168104 166594 13.... 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 ID x 1.000 OD x l4gathk SPRING, cprsn .970 OD x .120 wire x 1.250 WASHER, flat stl keyed 1 .500dia x .l2Sthk WASHER, fbr .656 ID x 1.500 OD x .l25thk 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 11 13-2. Quantity 168103 2 2 2 2 2 4 4 2 1 2 1 1 UT 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 component originally displaying a precautionary label, the label should also be ordered. To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-1588 Page 40 S Dia. Item No. Part No. Mkgs. Figure 167697 147 139 164 842 144 844 6 7 .... PC2O,30 171 814 PLG25 PLG24 165 484 167 633 089 032 11 153 169 .12 010 291 .13 167 700 Hardware is common 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 CONNECTOR & SOCKETS (RC5) See 159 264 Quantity Description Figure 13.4 Item 35 1 2 1 9 1 1 (RC24) 1 RING, ext .625 shaft grv x .O45thk E style WASHER, shldr .612 ID LENS, LED 4341 red panel mtg ACTUATOR, switch WASHER, flat .625 ID nylafil KNOB, pointer and 1 4 6 1 1 4 not available unless listed. 9 ST-800 112-C 11 Figure 13-3. Panel, Front w/Components To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-1588 Page 41 Hardware is common and not available unless listed. 0) CM 0) S CM / / \ CM \ C.) C,, C) U- 0) CM I.-. C) U- 0 C) 0) C.. 0) 0) ST-BOO 273-B Figure OM-1 588 Page 42 13.4. Control Box Part No. Dia. Item No. Mkg s. Figure 2 .... RC3O,40 13-4. Control Box (Fig 13-1 Item 2) 1 162253.. PANEL, side lower CONNECTOR & SOCKETS 2 047637 .... 048144 4 CONNECTOR, circ pin plug keying in sockets Amp 200821-1 10 134201.. STAND-OFF SUPPORT, PC card .312/.375 183120.. CIRCUIT CARD, motor control PCi .4 Quantity Description PLG1 115092 PLG2 115093 PLG4 115091 PLG6 136810 1 CONNECTOR & SOCKETS CONNECTOR & SOCKETS 1 CONNECTOR & CONNECTOR & 1 (RC1) (RC2) SOCKETS (RC4) SOCKETS (RC6) 1 1 1 CASE SECTION, bottom/rear 083432.. CIRCUIT BREAKER, man reset 1P 10A250V 111997 SWITCH, rocker SPST 1OA 25OVAC 184824.. CB1 ...6 7 51 8 PC8O PLG81 PLG82 PLG89 PLG9O 182403 115093 158720 131 054 +162364 1 CONNECTOR & SOCKETS (RC82) CONNECTOR & SOCKETS (RC89) CONNECTOR & SOCKETS (RC9O) 1 x .625 1 1 1 4 Ig mtg hole 1.000 wide x 1.500 1 Ig 1 WRAPPER 1 BUSHING, strain relief 1.030 ID 134464 LABEL, warning general precautionary 163520 CABLE, port No. 18/14 11/c (order by if) CONNECTOR & PINS, (consisting of) 141 162 079739 CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2 601222 CLAMP, univ 50A 176089 TUBING, plstc PVC .250 ID x .375 OD x 9.000 600399 WIRE, strd l4ga blk 600V 105c (order by if) 138044 BUSHING, strain relief .120/.150 ID x .500mtg hole 107983 BLANK, snap-in nyl .500mtg hole CONNECTOR w/SOCKETS 048 282 000527 BLANK, snap-in nyl .B75mtg hole 072817 RELAY, end 24VAC DPDT 035704 RECTIFIER, integ 40A 800V 030170 BUSHING, snap-in nyl .750 ID x 1 .000mtg hole 145948 BRACKET, mtg control box PANEL, front w/components Fig 13-3 155629 CABLE, ribbon l4posn (RC12) (RC5O) 154938 STRIP, mtg PC card 097132.. STAND-OFF, 6-32 x .375 Ig CIRCUIT CARD, interface 184775 010290 12 13 14 PLG9 15 16 17 18 19 20 21 RC7O 22 ...23 CR101 SRi 24 ...25 26 ...27 ...28 29... PLG12,50 ... PC5O ...32 .35... 36... 1 17ft 1 1 1 1 35ft 1 1 1 1 1 1 3 1 1 1 1 4 1 PLG51 158720 CONNECTOR & SOCKETS 1 PLG52 158719 1 PLG53 PLG54 PLG55 131204 CONNECTOR & SOCKETS CONNECTOR & SOCKETS CONNECTOR & SOCKETS 148439 115092 126689 34 PC1O PLG11 191 504 PLG15 PLG17 153501 PLG18 162382 PLG1O,24 PLG16,41 ... 170980 ... 155023 115092 115093 Figl3-7 .37 010146 +When 1 CIRCUIT CARD, HF filter dual CONNECTOR & SOCKETS (RC81) 153501 073756.. STAND-OFF, 6-32 151187.. LATCH, slide flush 11 1 ordering a (RC51) (RC52) (RC53) (RC54) CONNECTOR & SOCKETS (RC55) STAND-OFF, 6-32 x 1.500 Ig CIRCUIT CARD, processor w/proms CONNECTOR & SOCKETS (RC11) CONNECTOR & SOCKETS (RC15) CONNECTOR & SOCKETS (RC17) CONNECTOR & SOCKETS (RC18) CABLE, ribbon 34posn (RC1O) (RC24) CABLE, ribbon 24posn (RC16) (RC41) PANEL, side w/components CLAMP, nyl .625dia component originally displaying a precautionary 1 1 1 4 1 1 1 1 1 1 1 1 1 label, the label should also be ordered. 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-1 588 Page 43 OJ~ Hardware is common and not available unless listed. S See Table 13-1 For Drive Roll & Wire Guide Kits 19 20 17 23 24 16 9 12 2 26 28 36 29 30 33 32 31 ST-801 456-A Figure OM-1588 Page 44 13-5. Drive Assembly, Wire Item No. Dia. Mkgs. Part No. Figure 010 668 .. 172 075 .. 149 962 149 486 .. .. 163282 .. 165 798 .. 165799 ... 132 750 .. 150 520 .. 10 133 493 .. 11 133350 .. 12 12 156 354 M1,2 M1,2.... 156 353 153 491 153 492 *153 493 155 098 153 550 155 099 155 100 154 031 133 493 184 136 .14 182 414 182 415 137 248 129 351 602 200 19 ...22 ...23 ...24 ...25 ...26 ...27 PC51 PLG57. PLG58. 604 182 182 132 181 132 133 183 153 131 604 131 772 156 155 746 522 747 739 330 631 204 311 203 ...28 132 611 ...29 149959 .30 179265 .31 108940 ...32 604 538 151 437 .34 128237 +179263 178937 ...36 601 872 602213 602 243 ...38 601 966 167387 168825 133308 ...42 Part Quantity Description .. .. ... 13-5. Drive Assembly, Wire (Fig 13-1 Items 29 & 33) SCREW, cap sti sch .250-20 x 1.500 CARRIER, drive roll w/components 24 pitch SPACER, carrier drive roll PIN, rotation arm rocker NUT, .250-28st1 SPRING, pressure arm retaining WASHER, flat .257 ID stl ARM, pressure SPACER, rotation pin RING, retaining ext .250 shaft x .O25thk 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 RING, rtng ext .250 shaft grv x .O25thk KIT, brush holder WASHER, flat PIN, cotter hair SPRING, indicator SCREW, hexwhd-slt stl slftmg 8-32 x .500 WASHER, lock stl split No. 8 WASHER, flat stl SAE No. 8 SPRING, cprsn SPRING, cprsn BUSHING, spring SHAFT, spring CARRIER, shaft WASHER, flat .375 ID x .625 OD x .062 KNOB, extension CIRCUIT CARD, digital tach (consisting of) 4 4 4 2 2 2 2 2 2 2 1 1 1 1 . 2 2 1 1 1 5 2 1 1 1 1 1 1 1 1 2 1 2 1 1 1 1 1 CONNECTOR & SOCKETS GROMMET, rbr .250 ID x .375mtg 1 1 hole CONNECTOR&PINS 1 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 KNOB, plstcT 1.125 lgx .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 hexfull .375-16 WASHER, lock stl split .375 1 1 1 4 1 2 1 1 1 1 WASHER,flatstl.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 1 2 1 1 of 132 129 Optional High Speed Motor *Recommended 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. OM-1 588 Page 45 Table 13-1. Drive Roll and Wire Guide Kits G) .~ Wire Size E~ (~ ~j(~ ~ Metric Fraction .023-025 in 0.6 ~ E5 V-GROOVE VK-GROOVE UC-GROOVE 4 Roll Drive 4 Roll Drive 4 Roll Drive 4 Roll Drive Kit Roll Kit Roll Kit Roll Kit Roll 151 036 072 000 151 052 132 958 mm 150993 149518 151 024 087130 .030in. 0.8mm 150993 149518 151025 053695 .035 in. 0.9mm 150 993 149 518 151 026 053 700 .040 in. 1.0 150993 149518 161 189 053696 mm U-GROOVE .045 in. 1.1/1.2mr 150994 149519 151 027 053697 151 037 053701 151 053 132957 151 070 083489 .052 in. 1.3/1.4mr 150994 149519 151 028 053698 151 038 053702 151 054 132956 151 071 083490 mm 150995 149520 151 029 053699 151 039 053706 151 055 132955 151 072 053708 1.8mm 150995 149520 151056 132959 2.0mm 150 995 149 520 151 040 053 704 151 057 132 960 151 073 053 710 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 (i~85~) 3.2 mm 150997 149522 151 043 053707 151 060 132963 151 076 053712 1.6 .068-.072in 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-1 588 Required Page 46 For Dual Models. S-0549-D . Item No. Dia. Part No. Mkg s. Figure 155 024 154 933 .6 156 623 PLG6O. PLG41 153 501 PC4O. 158 160 13-6. Panel, Side w/Components (Fig TAPE, adh acrylic double sided .010 LENS, clear anti-glare PANEL, inner control CIRCUIT CARD, data card 147 139 PC6O. Quantity Description 144 844 154 109 153 169 x .500 x 13-4 Item 37) 2 3.000 1 1 1 CONNECTOR & SOCKETS (RC6O) See Fig 13-3, Item 40 (RC41) CIRCUIT CARD, side display 1 STAND-OFF, 6-32 x .875 Ig PLATE, ident inner control ACTUATOR, switch 4 1 1 4 5 IIT Hardware is common and not available unless listed. 4 6 3 2 7 9 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 use only parts Manufacturers Suggested from your local distributor. OM-1588 Page 47 ffT Hardware is common and not available unless listed. 0 C) ~ LI) \ \ \ ~ (0 LI) a, CLI C) CLI 0) c~J ST-142 306-C Figure OM-1588 Page 48 13-7. Boom Assembly 1 Quantity Item No. Model Part No. I Description Figure 1 010313 2 010910 3 079622 4 079621 5 079667 5 080812 6 079632 7 079665 7 080811 8 079664 9 139633 10 159999 10 160513 11 073742 12 073741 13 079029 14 075462 15 602250 16 079020 17 155335 18 149858 18 151625 19 150258 20 024605 21 075101 22 079030 23 +174754 080157 174688 24 142804 134327 25 073666 26 047224 27 602246 28 010493 29 139818 +When ordering a 13-7. Boom Assembly (Fig 13-1 Item a precautionary label, 16 15) PIN, cotter hair .072 x 1.437 WASHER, flat sti SAE .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 .750 OD x 2.156 Ig CLEVIS, .812 yoke 6.062 Ig .750-l6thd NUT, stl hex full fnsh .750-16 SHAFT, boom counterbalance WASHER, flat stl SAE .750 NUT, stl hex elastic stop .750-16 PIPE, blk 3.000 x .875 SPRING, cprsn 3.750 OD x .625 wire x 36.000 SPRING, cprsn 3.750 OD x .640 wire x 36.000 RETAINER, spring BEARING, ball thr sgl row .750 x 1.625 x .625 NUT, stl hex special .750-16 x 1.250 WASHER, lock stl ext tooth .750 BASE, swivel boom (consisting of) FITTING, grease 1/8NPT BRACKET, mtg control tilt LABEL, Swingarc caution heavy spring LABEL, warning general precautionary BOLT, mach stl hexhd .750-16 x 2.750 KNOB, T-bar .500-l3thd WASHER, flat stl std .500 BUSHING, snap-in nyl .625 ID x .875mtg hole GUARD, motor protector component originally displaying I 12 4.. .4 6.. .6 2.. .2 2.. .2 2 .2 8....10 2 2.. 2.. 1 1.. 1.... 2....2 1.... 1 2....2 1 ....1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 the label should also be ordered. To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-1588 Page 49 Notes . Index No. M/2.4 GOM Series Issued October 1997 Single and Dual, Bench and Boom Mounted, Programmable, Constant Speed Wire Feeders The 6DM Series of semiautomatic wire The dual 6DM models feeders offers the ultimate in versatility, V simplicity, programmability and performance. Designed primarily for the pulsed MIG welding process, all 6DM models are equipped with eight synergic pulse programs for use with the Phoenix456, Invision~ 456, as well as the same process both sides, or one can be used for welding. Only one gun can be operated at a time. The Swingarc~* boom models are ideal when welding on lai~e weidments requiring long reach and maneuver abifity. Swingarc models are available in single and dual models with 12 ft (3.6 m) and 16 ft (4.9 m) boom lengths. other inverter st~4e and conventional-type CV and CCICV welding To meet your specific welding requirements, the factory set programs can be easily modified using the teach mode. In addition to pulsed MTG capabilities, on on conventional MIG and the other used for pulsed MIG power sources. the 60M offers features not found are ideal when a standby gun is required, or for applications that require two different wire sizes and/or types. The dual models can perform A 60M wire feeder coupled with a Miller CV or CC/CV a complete, precise system for optimum welding performance. power source offers conventional MIG welding systems. D-60M, Dual Wire Feeder ~n~-f~nJ1n~. Features Benefits Microprocessor based with digital motor speed control and Offers precise control and regulation of the welding conventional systems. motor tachometer feedback Available in bench Processes . not found in arc single or dual, Accommodates a wide variety of applications to fill virtually any semiautomatic wire feed requirement, increasing productivity while decreasing overhead. boom models or Operator-friendly front panel One control for Two, back-lit liquid crystal Easy-to-set and view all welding parameters setting weld parameters. and selectable features. displays Pulsed MIG (GMAW-P) ~ Welding MIG (GMAW) Teach mode for pulse programs Full-feature, adjustable weld Flux Cored and Quick and easy selection of the right pulse program based on your wire and gas. programs ~ Welding (Gas Eight, built-in synergic pulse (FCAW) Welding Self-shielded) Description to meet your specific application. sequence control Programmable, security system Consistent results are possible by programming limits to the range of parameter adjustments. Eliminates inadvertent changes of preset parameters that could affect weld quality. Dual schedule Allows two capabilities Use with CC/CV and CV Power Sources Electronic Mfg. Co. pulse programs You can select and adjust any parameter within the weld weld time, crater, burnback and postflow, as required. Arc time totalizer and counter Miller Electric Allows field modification of welding conditions, such as sequencepreflow, run-in, hot and cold, to be programmed for one wire. Handy feature for conducting job studies and maintenance schedules. cycle trigger hold control Allows the operator to make Gas purge and wire jog control Purge Quick-change quick connect No tools drive rolls and for Miller guns long extended welds without holding gun trigger. gas line and feed wire without energizing system. required. Easy attachment. Rotatable wire drive assembly Eliminates sharp bends in the gun cable, thus improving wire feed performance and extending the service life of the gun liner. (Bench models only.) Covered drive roll assembly Protects drive roll and gears from dust, dirt and other atmospheric contaminants. Smooth, positive and Phone: 920-734-9821 Sealed ball bearing, driven system USA and Canada FAX: 920-735-4134 International FAX: 920-735-4125 Easy loading and threading welding wire European HeadquartersUnited Kingdom Phone: 44(0)1625-525556 FAX: 4.4 (0)1625-537553 Ordering Web Sitewww.MillerWelds.com Bench Models An Illinois Tool Works 1635 West Appleton, Company Spencer Street WI 54914 USA International HeadquailersUSA S-60M of Wire threads accurate wire feed offers long, uninterrupted service life. through drive system without having to release the drive roll pressure arm. Information Single Wire D-60M Dual Wire Miller all-gear Swingare Boom Models #131 794 SS-60M Single Wire #131 796w 12 ft Notes: Drive Rolls must be ordered (3.7 m) boom #131797* 16 ft (4.9 m) boom #131798* Refer to separately. Mounting Equipment section When pulsing using Miller inverter power international-style connectors for sou,ves, DS-60M Dual Wire 4/0 weld cable must be ordered The Power ofBIue. to order boom mounts. 12 ft (3.7 m) boom #131799 16 ft (4.9 m) boom #131800 Certified by Canadian Standards Association to both Canadian and U.S. Standards. (#138 181, two required). Pulse MUG Welding Process When Pulse MIG welding, the power source rapidly switches the output from high peak I current to low background current in precisely peak current pinches off a spray-transfer droplet while the low background current cools the puddle and regulated intervals. maintains the arc The with little or no w metal w transfer. With proper adjustment of the pulse parameters, the Pulse MIG welding process can produce high-quality welds when using a broad range of material types, thicknesses, and joint configurations. Advantages of Pulse MIG Process over conventional MIG Welding a Equal or faster travel speeds a Can use larger, more economical wire L BACKGROUND TIME AMPERAGE (CURRENT) PULSE MIG WAVE FORM diameters a Reduces eliminates spatter or Lower heat input; therefore, reduced distortion a Better out-of-position puddle control a Potential reduction in fume particulate Optimum bead shape and penetration emission 60M a Design Features Available in Swingarc Programming Features single or dual wire, bench or style. a boom Swingarc models provide: 360 degree turning radius power source: Counterbalanced boom shielding gas In-boom cable routing (1) (2) (3) (4) 12 or 16 ft (3.6 or 4.9 m) boom length gas hose a variety of Mifier Power Source Data Card see For conventional MIG welding (12 mm) .052 in (1.3 mm) Gun Arc time counter accumulates and maintenance, (8) .035 in (0.9mm) and Accessones. Accommodates .023-1/8 in (0.6-32 mm) a see Options On-Board Programming and Diagnostics: diameter welding wire All factory-set synergic Microprocessor-based control be modified to meet pulse programs can specific welding 3 yearsparts and labor required. etc. Feeder can be Security Capabilities: Feeder can be programmed to limit the range of parameter control, the number of programs available, and the selectable parameters that are available to the operator three-digit code can be programmed A to applications Millers True Bluefi Warranty~ as shielding gas speed range Four-drive-roll Pasifeed’ wire drive system provides easy threading of welding wire time Ideal for job time studies, shift output, Note: For XMT 304 Power Source Data Card, motor displays (up to 9,999.99 hours) and weld cycles (up to 999,999 cycles). arc Counter can be reset toO (zero) Sificon bronze wire with Argon Series power source. 24VDC high-torque, permanent magnet trigger can be used to make program selection .035 in 50780 1PM (1.319.8 rn/mm.) wire feed Low voltageoperates length (in Adaptive Pulse mode) can be regulated at the power source output studs or at the welding gun Arc voltage (7) .035 in (0.9mm) only, the . Operating Features: arc .062in (1.6mm) shielding gas page 5) off 24 VAC Selectable Feeder will compensate for variations in tip-to-work distance and provide a constant Nickel alloy wire with ArgonlHelium also be used with the Deltaweldfi Dimension .045 in sensed after 3 seconds actual Phoenix 456, or the XMT~304 CC/CV inverter power source (with an optional or (0.9mm) (0.9mm) (6) .045 in (12mm) (5) the 60M with the Invision456, can a .035 in shielding gas For pulse MIG/conventional MIG welding 60M not 309 stainless steel wire with Argon/CO2 power sources: use is present when the gun trigger is pressed Drops out contactor and gas valve if arc is Mild steel wire with Argon/Oxygen loft (3m) 4/0 weld power cable and Can be used with Automatic shutdown if no wire feed speed Eight Synergic Pulse MIG Programs factoryset for use with the Invision456 welding manually programmed for restrict unauthorized set-up access to the screen the voltage and/or amperage range of the power source being used Automatic shutdown if arc voltage is not detected when gun trigger is depressed . Control Panels Sequence I ~ Chart Speed Voltage or Arc Length sec. not active not active sec. adjustable adjustable adjustable adjustable sec. adjustable adjustable Burnback 0a2ssec. notactive adjustable (voltage only) Postf low 09.9 not active not active Wire Feed -4 Sequence Time -5 Preflow 09.9 Run-in 02.5 Weld 025 Crater D2.5 1 1 -6 sec. 2- 6DM Series Side Panel 1. Mode sec. adjustable in the Mat process mode Miller CV inverter power source. Note: Inductance is only Displays. when using a 2. Mode Select Button. Provides choice of tour modes: Process Mode. Pulse, adaptive pulse, MIG. Also or used to teach customized pulse programs. Sequence Mode. Allows variety ot sequences program. (Refer to Sequence Chart.) in weld Dual Schedule Mode. Links two weld programs welding conditions are required 3- when two different 4- for one wire. Card Mode. Writes programs to optional Data Card or reads programs from the Data Card. 3. Parameter Select Button. Selects parameter to be changed. 60M Series Front Panel 1. Parameter Select Selects 4. Parameter voltage or arc length, wire teed speed, and program number. 2. Purge Button. Purges gas line and gun without energizing feeder. 3. Gun Display 5. Parameter Increase Button 6. Parameter Decrease Button Trigger Receptacle. Prewired for single- and dual-schedule operation. Receptacle will accommodate a variety of dual schedule switches. 4. Trigger Hold Button and Light System remains energized triggerideal when making when operator releases gun extended welds. 5. Digital Display 6. Jog Button. Feeds wire without energizing the power source contactor and gas valve. 7. Display Control. Single-knob control for setting all adjustable, displayed parameters. Typical Installations All 60M feeders are supplied with aloft (3m), 14-pin control cord. Pulse MIG Invision 456, Note To connect the 60M feeder to 450 power source use an existing Maxtron adapter cord #043661. or Conventional MIG Welding Phoenix~1 14-Pin Control Cord and XMT 304 power 60M _______________________ source (MIG Invision 456, or Pulse) Feeder loft (3m) Gas Hose lOft (3m) 4/0 Weld Cable Phoenix~~ aod XMT 304 power source (MIG or (supplied wth Swingarc) (supplied wth Swingarc) 60M (3m) 14-Pin Control Cord (supplied with Swingarc) 10 ft Pulse) Conventional MIG Welding Miller electronically~\ CC/CV controlled CV or power source with 14-pin receptacle (MIGonly) Miller lOft (3 m) lOft (3m) 4/0 Weld Cable (supplied with Swingarc) elewonicafly controlled CV or 14-pin receptacle (MIG only) (supplied with Swingarc) N,.~ CC/CV power source with Gas Hose 1 lOft (3m) 14-Pin Control Cord tsuoolied with t 6DM Specifications Industrial (Sub(ect to change without notice.) Input Power Electrode Wire Diameter Capacity Wire S-60M Bench 24VAC .0231/8in 507801PM 50/60 Hz (0.63.2 mm) (1.319.8 rn/mm.) 12 ft Speed (Usewith CCICV Power Sources.) Range* Background Current Range Pulses per Second Width Dimensions Net 100600A 0200A 20400 1.05.0 H: 581b(26kg) 621b(28kg) PPS Milliseconds Peak Current Single Wire Models ~ Pulse l4in(356mm) W: 14 in (356 mm) D: 26-1/2 in (673 mm) Weight Ship Weight SS-60M, Swingarc~ 12 ft (3.6 m) Boom 160 lb (73 kg) 280 lb (127 kg) Swingarc~ 16 ft (4.9 m) Boom 210 lb (95 kg) 350 lb (159 kg) 16 ft SS-60M, Dual Wire Models D-60M, Bench 12 ft 24 VAC .0231/8 50/60 Hz (0.63.2 mm) in 1PM 50780 100600 A 0200 20400 PPS A (1 .319.8 rn/mm) H: 14-3/4 in (375 mm) 1.05.0 Milliseconds W: 18 in (457 mm) D: 32 in (813 mm) DS-60M, Swingarc~ 16 ft DS-60M, Swingarc~ 82 lb (37 kg) 90 lb (41 kg) 12 ft (3.6 m) Boom 207 lb (94 kg) 318 lb (144 kg) 16 ft (4.9 m) Boom 280 lb (127 kg) 411 lb (186 kg) Applies only when 6CM feeders are used with the lnvision~456 and Phoenix~456 power sources. Drive Roll Kits Select drive roll kits from chart below according to type and wire size being used. Drive roll kits include necessarj guides and feature ti~J in~. V groove for hard wire Wire size .023/.025 in (0.6 mm) (0.8 mm) #151 025 .035 in (0.9 mm) #151 026 .040 in (1.0mm) #161 190 .045 in (1.1/1.2 mm) (1.3/1.4 mm) 1/l6in(1.6mm) .068/.072 in (f : ~. V knurled for hard-shelled cored wires anti-wear sleeve for the inlet guide. ;~?~: wire or softshelled cored wires (i.e., hard lacing types) #151 024 .030 in .052 in U groove for soft wire or soft-shelled cored wires an #151 036 #151 052 #151 027 #151 037 #151 053 #151 070 #151 028 #151 038 #151 054 #151 071 #151029 #151039 #151055 #151072 #151 065 (1.8 mm) 5/64 in (2.0 mm) #151 040 #151 057 #151 073 3/32 in (2.4 mm) #151 041 #151 058 #151 074 (2.8 mm) #151 042 #151 059 #151 075 #151 043 #151 060 #151 076 7/64 in 1/8 in (3.2 mm) Nylon Wire Guides for Feeding Aluminum Wire Wire Size Inlet Guide Intermediate Guide .047 in #151 203 #151 204 #151 205 #151 206 #151 207 #151 208 (1 .2 mm) 1/l6mn (1.6 mm) 3132 in (2.4 mm) . Note: U are groove drive rolls recommended when feeding aluminum wire. . ~lle~ Options and Accessories Skill Level Index I The box following A the stock number of field-installed options contains a letter and number. The letter indicates required to install the option. The number indicates the approximate time required for installation (see the skill level legend). Easy. No previous experience needed. Average. Requires removal of service panels. Mechanical ability is helpful. C Difficult. May require the use of an ohmmeter and/or splicing of electrical wires. Repair or replacement of component parts is WeldCurrentSensor #160963 D1echnical. May require the use of an ohmmeter and the ability to read a circuit diagram. Repair or replacement of component parts is complex. B more difficult Example: I B: 301 Skill Level: B, Time: 30 minutes IA:051 This option is required when using M feeders with older style Mifier CV power sources: Deltaweldfi prior to serial no. KG14 1349 and Dimension~ prior to serial no. KC 253517. Power Source Data Card for XMT 304 CCICV #043 390 J Simply insert the Data Card in the 60M control and with the push of a button the Remote Program Selectoi~ eight synergic pulse programs for the XMT are loaded in memory and ready to use. RPS-8 304 The eight XMT programs are for~ .030 in steel wire with Argon/CO2 #160 977 Field Wire Straightener For .035.045 in (0.91.1mm) (B: 201 #141580 Fight-position rotary switch used to remotely select weld programs. Includes For 1/161/8 in (1.63.2mm) 33 ft (10 #141581 m) cord to connect feeder. wire A:051 Reduces cast in wire. .035 in steel wire with Argon/CO2 .045 in steel wire with wire A:05] Improves wire feeding performance and increases life of gun liner and contact tip. Argon/CO2 .030 in SS wire with Pulse tn-mix .035 in SS wire with Pulse in-mix I .045 in SS wire with Pulse In-mix .035 in SiB wire with Argon .035 in Nickel wire with Ar/He High-Speed Motor For single and right side of dual models. #132 129 Factory only For left side of dual wire models. Control Detachment Kit For S-60M Model #13493610ft.(3m) #134937 25ft(7.6m) IB:551 25ft(7.6m) Blank C.ard. Stores up to 32 complete weld programs. Ideal for saving custom programs and only. Field-installed only. Separates the feeder control module from the wire drive assembly and base. Ideal when using Automation Upgrade Module. transferring programs to other 60M Automation Upgrade Module #172886 factory programs in the 60M, but will require the factory set voltage and current range to be reset can use wire sizes This module consists of an I/O board and software 1PM larger than 5/64 in (2.0mm). speed motor must be used on each side Factory-written synergic Pulse MIG programs will not operate with high-speed motor. of the dual wire models. Water Hose Kit #09674610ft(3m) feeders. The Maxtron~ 450 speed range of 901400 (2.3 35.6 rn/mm). Not recommended for Same (B:551 For 60M bench models 60MDataCard #155910 Factory only Provides wire (B:551 For D-60M Model #134935 #132 130 upgrade that enables the 60M control to better communicate with other peripheral equipment and impmves performance in an automatic welding cell. Features: two IA:101 For bench-stylefeeders. Use with Mifier coolant systems and water-cooled welding guns. Can be used with or without optional flow safety switch. water If water kit is to be used dual wire feeder, a on both sides of a kit must be ordered for each side of the feeder. programmable outputs, remote start/stop, remote program select, arc voltage monitor, arc error monitor and Water flow Shutdown Switch wire stick check. #180390 1k151 For use with the water hose kits. Protects water-cooled gun from overheating by shutting down system if water does not flow. I If required on both sides of a dual model, two water flow shutdown OMiller. switches must be ordered. Options and Accessories Dual Schedule Switches For use with Dual Schedule Control in 60M feeder. DSS-8 #079 693 LA: 051 Requires adapter cord #157364. Two-position trigger switch that easily attaches to the welding gun. Use in place of the standard trigger for dual scheduling. Wire ReelAssembly #108008 Accommodates 60 lb (27 kg) coil of wire. FeederCart #142382 IA:201 Low-profile, creeper cart Shipped disassembled. Reel Covers Accommodates 60 lb (27 kg) coil of wire. #058 256 For S-60M single wire model and left side of D-60M dual wire modeL #091668 For right side of D-60M dual wire model. Protects wire from contaminants. DSS-9M #041 793 LA: 051 Two-position slide switch that attaches to the welding gun. Selects welding condition when utilizing the dual schedule feature. Gun trigger HangingBail #058435 (A:151 Electrically isolated. Suspends feeder over operates as standard trigger. work area Spool Covers Fits a 12 in (304 mm) spool of wire. #057607 A:05J DSS-10 Remote IncreaselDecrease Switch For S-60M single wire model and left side of #042749 D-60M dual wire model. IA:051 Two-position, momentary contact switch that #090389 attaches to the welding gun. Use with the Remote Parameter Increase/Decrease feature For right side of D-60M dual wire modeL TurntableAssembly LA:051 Allows feeder to rotate #146236 as (B: 201 operator changes work position. Reduces strain and bending of to fine tune parameters at the welding gun while welding. Gun trigger operates as gun cable. standard trigger. Adjustable Spool Carrier #096 075 A: 201 For use only with Swingarc models with 6 ft (1.8 m) pipe post mounted on Swingpak base. Replaces standard spooi assembly. Positions welding wire lower for easier loading and unloading. Extension Cords For optimum performance, do not extend 60M feeder more than 60 ft (18m) from power source. 14-Pin Extension Cord Carryingcart #056301 #043690 25 ft (7.6 m) IA:301 Carries wire feeder and miscellaneous welding supplies. Height 34 in (863mm). Lower tray height 9 in (228mm). Shipped disassembled. #043691 50ft(15m) Water Coolant Systems Refer to Water Coolant Systems literature, Index No. AY172. 6 ~Het Mounting Equipment for Swingarc~M Booms One of the following is required for mounting the SS-60M and DS-60M booms: Swingarc~ Swingpak~ Basepipe post with base plate CBC Cart (for use with 12 ft (3.7 mj model only)the 6 ft (1.8 m) pipe post without base plate (ordered separately) Pipe Post The Bases Swingpak Order a Swingpak-12 base to mount a 12 ft (3.7 m) boom. The Swingpak-16 base is for use a 16 ft (4.9 m) boom. with Each base accommodates a power source, Swingarc feeder system, water coolant system, and gas cylinder. The base plate is solid to help better organize components and cables. Base includes a three-compartment storage locker. The entire unit can be moved with a forklift truck Order pipe post with base for Swingpak base. and Specifications CBC Cart For use with 12ft (3. 7m) boom only. Cart accommodates a The CBC power source, 12 ft (3.7 m) Swingarc feeder, and two gas cylinders. Designed to provide mobifity and a neat, orderly arrangement of welding equipment. Order 6 ft (1.8 m) pipe post with no base for CBC cart Ordering Information Model Stock No. Length Width Swingpak-12 #085 276 65 in (1.7 m) 50-7/Bin Swingpak-16 #085 934 79 in (2.0 m) 66-7/B in CBC Cart #152 637 70 in (1.8 m) 34 in Net (1.3 m) (1.7 m) (864 mm) Weight Ship Weight 412 lb (187 kg) 418 lb 504 lb (229 kg) 510 lb (231 kg) 328 lb (149 kg) 510 lb (231 kg) ______________ Pipe 4 ft Post Model For 12 ft Boom (3.7 m) in 1457 mmj Base Plate) For 16 ft (4.9 m) Boom (24 in 1610 mm] Base Plate) #075 078 #075 078 4ft(1.2m)withbase #149838 #078264 6 ft #079 217 #079217 #149839 #079216 (1.2 m) no base (18 ____________ Note: The 4 ft with the (1.2 m) pipe post is not recommended for use CBC Cart. The 16 ft (4.9 m) Swingarc feeder cannot (1.8 m) base no __________________ 6ft(1.8m)wittibase be used. CBC Cart Features (907 kg) load capacity Multi-position boom Swing-out outriggers I 2000 lb CBC Cart with 12 ft Swingarc SS-60M, power source and gas cylinder. For use with 12ft. (3.7m) boom only. Wide front-wheel stance and automotive- type steering 12 in (305mm) diameter by 3 in (76mm) wide wheels Mounting facilities for most Mifier CV power sources Compartment in base of cart to add ballast weight when using lightweight power sources. Minimum ballast weight of 300 lb (136 kg) required no.nI Order 6 ft (1.8 m) Pipe Post #079217 Only Fold-up gas bottle loading ramp 1~ OMiller. , (190 kg) Checklist and Quotation Sheet System Equipment and Options 60M Bench Models 6DM Swingarc Models Stock No. Description #131 794 #131 796 S-60M, single D-60M, dual #131 797 #131 798 Single, 12 ft Boom Single, 16 ft Boom #131 799 Dual, 12 ft Boom Dual, l6ft Boom #131 800 Power SourceMIG or Oty. Pulse MIG lnvisionfi456 See Lit. Index. No. DCI2O XMTfi304 CC/CV See Lit. Index No. DC/i 8.8 Phoenix~ 456 See Lit. Index. No. DC/21 ~T!~!_~ .-~-_______- Deltaweldfi See Lit. Index No. DC/i 6.2 Oimension See Lit. Index No. DC/i 9.2 Options for any 6CM Model Weld Current Sensor #160 963 For Data Card for XMP5304 #043390 8 programs for XMTfi304 Blank Data Card #155 910 Store up to 32 programs High-Speed Motors #132 129 #132 130 For left side of dual #134 936 #134 937 For S-60M, lOft For S-60M, 25 ft #134 935 For D-60M, 25 ft #172 886 Ideal for automatic For older-style Miller power sources (pg. 5) single, or right side of dual Options for Bench Models Control Detachment Kit Automation Upgrade Module Water Hose Kit #096 746 Water Flow Shutdown Switch #180 390 Use with #096 745 #141 580 #141 581 .035045 Wire Straighteners Wire Reel Assembly Reel Covers Spool covers in wire 1/161/Bin wire #108 008 #058 256 #091 668 For #057 607 #090 389 For Carrying Cart #056 301 Feeder Cart #142 382 Hanging Bail #058 435 Assembly #145236 Options for Swingarc Models Adjustable Spool Carrier Mounting Equipment #096 075 Turntable applications_________ For For single, or left side of right side of dual dual single, or left side of dual right side of dual See Options & Accessories Miscellaneous Drive Roll Kit See Drive Roll Kit table Extension Cords See Options & Accessories Remote Program Controls See Options & Accessories Dual Schedule Switches See Options & Accessories Water Coolant See Lit Index No. AY/7.2 Systems Welding Gun Primary Power Cable See Ut Index No. M/10.O Secondary Weld Cable Supplied 4/0 International-Style Connector Clamp Gas Supply Regulatorlflowmeter Gas Hose(s) with Fittings Welding Wire Spare Consumables #138 181 with Swingarc~ models only recommended_for_Pulsed_MIG For 410 weld cable (see page 4) Ground Cable with Work Supplied with Swingam models only Helmet Welding Gloves Total Quoted Price: Date: Distributed Miller The Power ofBlue. Lithoin USA by: -___ Effective January 1, 1998 (Equipment with a serial numher preface of IJ WArranty Questions? Call This limited or newer) warranty supersedes all previous Miller warranties and is exclusive with guarantees or warranties expressed or implied. no other 1 Miller distrlhutur~ Your.distributor also gives you Miller warrants its to equipment - sold after the effective date of this limited You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is help Remote Controls * Accessory Kits workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR OF WARRANTIES INCLUDING THE IMPLIED, * Replacement Parts (No labor) is free of detects in material and * Millers 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 defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be tollowed. 1. Spoolmate Items furnished as covered 2. 185 True Bluefi Limited such 3. periods. All warranty time periods staff on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an 1. you, every Consumable components; such * Original * Inverters step of the way. apply to: by others, as contact are tips, cutting or parts wear. by any party other 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. Equipment that has been modified than Miller, International distributor. 5 Years Parts shall not but manufactured engines or trade accessories. These items by the manufacturers warranty, if any. that tail due to normal Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty Warranty by Miller, nozzles, contactors, brushes, slip rings, relays time answers * warranty MERCHANTABILITY AND FITNESS. APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches Electric Within the Service thereto below, * Subject to the terms and conditions Mtg. Co., Appleton, Wisconsin, original retail purchaser that new Miller LIMITED WARRANTY 1-8004-A-MILLER tOr your local or 3 Years Labor - MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE main power rectifiers (input output rectifiers only) and AND MAINTENANCE OF WELDING EOUIPMENT. 2. 3. 3 Years 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 * Transformer/Rectifier Power Sources * Plasma Arc * Semi-Automatic and Automatic Wire Feeders * Inverter Power * Intellitig * Engine Driven Welding Generators (NOTE: Engines are warranted separately by engine manufacturer.) 1 Year Cutting Power Sources Supplies Parts and Labor allowed. * Motor Driven Guns * Process Controllers * Positioners and Controllers * Automatic Motion Devices * Robots * the appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment ot or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customers risk and expense. Millers option of repair or replacement will be FOB., Factory at Appleton, Wisconsin, or FOB. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be (w/exception ot Spoolmste 185) TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE 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. REMEDIES. IHPS Power Sources EXPRESS WARRANTY NOT PROVIDED HEREIN ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS ANY Water Coolant Systems AND HF Units * Grids * Spot Welders * Load Banks * SDX Transformers * Miller * Running Gear/Trailers * Plasma PROVISION, Engines (outside North in, or for whichever is greater.) a minimum ot one Some states in the U.S.A. do not allow limitations of how long implied warranty lasts, or the exclusion of incidental, consequential damages, so the above apply to you. This warranty provides specific legal rights, and other rights may be year limitation or 6 Months 5. 90 Batteries or exclusion may not available, but may vary from In Canada, legislation additional warranties herein, and 4. IMPLICATION, an indirect, special America) Options (NOTE: Field options are covered under True Bluefi for the remaining warranty period otthe product they installed BY ALL ANY AND TO RESPECT WITH EOUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER. Field are ARISE PURPOSE, Cyclomatic Equipment Cutting Torches (except APT, ZIPCUT & PLAZCUT Models) Deutz MIGHT OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR in state to state. some or provinces provides for certain remedies to the extent that other than they may not be as stated waived, the apply. This Warranty provides specific legal rights, and other rights may be available, but may vary from province to province. limitations and exclusions set out above may not Limited * rofBh,e. II Days Parts end Labor MIG Guns/TIG Torches miller wsrr 1198 Owners Record Please complete and retaiN with your personal records. Model Name Serial/Style Number Purcbase Date (Date which equipment was delivered to original customer.) Distributor Address City Slate li~ Resources Available Always provide Model Name and Serial/Style Number. Contact your Distributor top: To locate distributor nearest you call 1-800-4-A-Miller. Welding Supplies Options and Consumables and Accessories Personal Safety Equipment Service and Repair Replacement Miller Electric Parts (Servicing Information Headquarters-USA Phone 920 735-4505 USA & Canada FAX 920 735-4134 International FAX 920~735-4125 Diagrams Welding European Headquarters United Kingdom Phone: 44 (0) 1204-593493 - Process Handbooks FAX:44(0)1204-598066 ~ww.MillerWeIdscx,m CuntacttbeoetiveriniCarrierf,p: File a claim for loss or damage during shipment. For assistance in filing contact your distributor manufacturers settling claims, and/or equipment or Transportation Department. p//A Miller PRINTED IN USA . ~Spencer Sfreet. Appleton WI 54914 USA International Circuit Co 1635 Training (Schools, Videos, Books) Technical Manuals and Parts) Mfg An Jflkipis Tool ~iis Company ' 1998 Miller Eleuric Mfg. Co. 5/98