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Processes Pulsed MIG Miller MIG (GMAW-P) (GMAW) Flux Cored (FCAW) (Gas- and Self-Shielded) The Power ofBlue. Description Wire Feeder (Use r-~ with CC/CV Power TM I ~ ~i)i)- Jj]fl OM-1 586K February 1997 Effective with Serial Number KH339697 OWNERS Sources) MANUAL ~ to YOu From . Thank you and you can congratulations on choosing Miller. Now get the job done and get it done right. We know you dont Thats have time to do it any other way. when Neils 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. why people that build and sell Miller products continue the tradition. Theyre just as conimitted to providing equipment and service that meets the high standards of quality and value established in 1929. Today, the This Owners Miller help Manual is products. you protect designed to help you get the most out of your Please take time to read the yourself against potential Safety precautions. They hazards made installation and With Miller you 11111111W can on the worksite. Weve operation quick count will on and easy. . years of reliable service with proper maintenance. And if for REGISTERED QUALITY SYSTEM some reason the unit needs ______________ repair, theres a section that will help you Troubleshooting The what the is. out figure problem parts list will then help you to decide which exact part you may need to fix the problem. Warranty and service information for your particular model are also provided. Miller is the first welding equipmeNt manufacturer IN the U.S.A. to be registered to the ISO 9001 Quality System Standard. ~~JII~ft1ll1? ~ Working as hard as you do every power source from Miller Is backed by the most hassle-free warranty in the business. Miller Electric manufactures of welders and welding For information on a full line related other equipment. quality Miller contact your local Miller distributor receive the latest full line catalog or products, to individual catalog . sheets. To locate your nearest distributor call 1-800-4-A-Miller. _ f//A Miller The Power ~fBlue. TM Front Panel Features Description 2-line Put the benefits of technology to work on the production line. The SS-64M represents a major advancement in wire feed technology, and delivers the ultimate in versatility, simplicity, programmability and performance. The SS-64M feeder includes special features for pulsed MIG (GMAW-P) welding that requires the use of inverter-type power sources. However the SS-64M retains the versatility that makes it perfectly suited to conventional MIG processes using a variety of Miller CV or CC/CV machines. welding, the SS-64M features built-in memory with eight, factory-set synergic pulse programs. Each program is specific for a wire type, wire size and gas mixture. Any of these programs can be modified for the specific requirements of your welding application. For MIG pulsed by 16-character backlit LCD Single push-button parameter select Single knob parameter adjustment control making extended holding gun trigger Wire jog control feeds wire without energizing Trigger hold control for welds without the contactor Gas purge control purges line without energizing feeder Side Panel Features by 20-character backlit LCD parameter and mode displays 4-line for programming controls for process, sequence, dual schedule, and data card modes Push-button Parameter select push button Parameter increase/decrease push buttons Processes Pulsed MIG MIG Table of Contents 1 Precautions 1. Safety 1. Consignes Soudage a de SØcuritØ pour le Larc gives you Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. 4 7 4. Operation 5. Setting Sequence 6. Setting 7. Using 8. System Setup Parameters Dual Schedule Parameters the Data Card Optional 16 supply you 18 GMAW, and GMAW-P. 19 20 Support Need fast answers to the tough welding questions? Contact your distributor. expertise of the distributor and Miller is The there to help you, every step of the way. a Technical Manual which provides more detailed service and parts information for your unit. To obtain a Technical Manual, contact your local distributor. Your distributor can also Miller offers 2. Introduction 3. Installation Your distributor (GMAW) Flux Cored (FCAW) (Gas- and Self-Shielded) Page Section Call 1 -800-4-A-MillER for your local Miller dislrlliutor. (GMAW-P) 9. Standard Pulse 22 Welding Programs 25 10. Teach Points 11. Maintenance and 12. Electrical Troubleshooting Diagram 13. Parts List Options and Accessories Warranty 23 29 32 34 with Welding Process Manuals such as SMAW, GTAW, . 1. Read Before Using Safety Precautions 1.1 Symbol Usage OM-1586K -2/97, 11/96 Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. 4A A safety_som Marks a special safety This group ELECTRIC message. of symbols Wamingl Watch means SHOCK, MOVING PARTS, Out! possible and HOT PARTS hazards. Consult symbols and related instructions below for necessary l~ Means ~Note; not 1 ~2 A Arc The actions to avoid the hazards. safety related. Welding Hazards. symbols Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. are used throughout this manual identify possible hazards. When you shown below to call attention to and symbol, watch out, and follow the related instructions safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1.3. Read and follow all Safety Standards. seethe to avoid the hazard. The 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 A Only qualified persons should install, operate, maintain, and repair this unit. before touching any parts. A During operation, keep everybody, especially children, away. ARC RAYS ELECTRIC SHOCK can Ln,_i~ ~ kill.: processes grinding, burn eyes and skin. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Noise from some ~L. i Touching live electrical parts can cause fatal shocks or severe bums. 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. can and welds cooling damage hearing. Chipping, pieces of metal or slag. can throw off a propershade of filterto protect welding or watching (see ANSI Z49.1 Standards). Weara welding helmet fitted with your face and eyes when and Z87.1 listed in Safety Wear approved safety glasses with side shields. screens or barriers to Use protective glare; warn others Do not touch live electrical parts. dry, hole-free insulating gloves Wear big enough ground. or covers work or and body protection. to input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 191 0.147 (see Safety Standards). Properly FUMES.AND GASES can be hazardous. ~ ~ L....... Welding produces fumes these fumes and gases health. install and ground this equipment according to its Manual and national, state, and local codes. Always verify the supply ground check and be sure that input power cord gTound wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet. When protective clothing made from durable, flame-resistant (wool and leather) and foot protection. material ground using dry insulating mats prevent any physical contact with the Disconnect Owners Wear yourself from work and Insulate making input connections, conductor first attach proper grounding double-check connections. Keep your If ventilation is poor, Read Material the manufacturers a Turn off all wearing an Do not use worn, Do not drape cables If earth grounding with a use. damaged, undersized, over of the separate cable your or pcorly spliced cables. body. workpiece is do not work use required, ground damp or it directly work cable. Do not touch electrode if you are in contact with the work, another electrode from a different machine. ground, or Useonlywell-maintainedequipment. Repairor replace damaged once. Maintain unit according to manual. Wear OM-1586 a safety harness if working above floor level. exhaust at the arc to approved air-supplied respirator. Safety Data Sheets (MSDSs) instructions for metals, consumables, and the coatings, only if it is well ventilated, or while 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. confined space Do not weld in locations operations. form highly near degreasing, cleaning, The heat and rays of the arc toxic and irritating gases. Do not weld cadmium parts at use an use deaners, and degreasers. Work in not in and gases. Breathing be hazardous to your can head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or remove welding fumes and gases. Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill. equipment when protectothers from flash and not to watch the arc. on can react or spraying with vapors to coated metals, such as galvanized, lead, or unless the coating is removed from the plated steel, weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give oft toxic fumes if welded. 1 CYLINDERS can if explode damaged H F RADIATION can cause interference High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. 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. Shielding only qualified persons familiar with equipment perform this installation. Have electronic Protect compressed gas cylinders from excessive mechanical shocks, slag, open flames, sparks, and arcs. heat, The user promptly install 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 Never drape Never allow Never weld a a torch welding or will result. only correct shielding gas cylinders, regulators, hoses, fithngs designed for the specific application; maintain them associated parts in good condition. Use Turn face away from valve outlet when connected for regularly interference, stop using the checked and maintained. FIRE opening cylinder valve. in OR EXPLOSION hazird. Do not install place or unit on, over, or near combustible surfaces. compressed gas cylinders, publication P-i listed in Safety on and CGA equipment, about and use. Read and follow instructions associated if notified by the FCC equipment at once. and Keep protective cap in place overvalve except when cylinder is use or installation. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference. cylinder. explosion pressurized cylinder responsible for having a qualified electrician problem resulting from the Have the installation gas cylinder. over a electrode to touch any welding on a other electrical circuits. is correct any interference Do not unit locate on, near or over, combustible surfaces. Standards. Do not install unit flammables. near building wiring be sure power supply system properly sized, rated, and protected to handle this unit. Do not overload is WELDING can causefire orexplosion. closed containers, such as tanks, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. Welding on OVERUSE can cause OVERHEATING drums, or pipes, Protect yourself and others from Do not weld where flying sparks flying sparks can Remove all flammables within 35 ft possible, tightly this is not cover Allow cooling period, Reduce current starting to weld Do not block Be that aware can cause fire Do not weld on welding on fire on a (10.7 m) of the welding arc. approved covers. if extinguisher nearby. ceiling, floor, bulkhead, closed containers such as Connect work cable to the work Do not as MAGNETIC FIELDS can affect pacemakers~ prevent welding current from paths and causing electric shock tip welder to thaw frozen when not in Wear oil-free keep away. going near arc welding, gouging, welding operations. or spot or pipes, (see HOT PARTS can cause Do not touch hot parts bare handed. Allow cooling period before working gun or and fire hazards. pipes. or such shirt, cuffless trousers, high shoes, and cut off as a welding wire at leather gloves, heavy cap. Remove any combustibles, such as a butane from your person before doing any welding. MOVING PARTS lighter or matches, can injure eyes can causeifljury~ F Keep away from moving parts such as fans. Keep all doors, panels, covers, and guards closed and securely in place. WELDING WIRE FLYING METAL on torch. use. protective garments severe burns. to AWS F4.1 welding area as traveling long, possibly Remove stick electrode from holder contact wearers Wearers should consult their doctor before partition close to the to use or tanks, drums, they are properly prepared according Safety Standards). unknown filter airflow to unit. the hidden side. unless practical again. them with Pacemaker a duty cycle. duty cycle before and hot metal. welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. fIre, and keep follow rated reduce strike flammable material. Be alert that Watch for or or Do not press gun can cause trigger injury until instructed to do so. Chipping and grinding cool, they can cause throw off metal. As welds metal or slag. flying pieces of point gun toward any part of the body, people, or any metal when threading welding wire. Do not other Wear 2 a face shield to protect eyes and skin. OM-1 586 NOISE can Noise from FLYING METAL or DIRT can damage hearing some processes or equipment Wear can with side shields or face shield. damage hearing. Wear safety glasses injure eyes. approved ear protection if noise level is high. FALLING UNIT STATIC (ESD) Put grounded on handling can boards Use proper store, move, Use damage PC boards wrist strap injury lifting eye to lift unit only, NOT running cylinders, or any other accessories. equipment of adequate capacity to lift gear; gas Use BEFORE unit. parts. or can cause If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of and boxes to static-proof bags or ship PC boards. unit. MOVING. PARTS can cause Keep away from moving parts. Keep away from pinch points such as drive rolls. 1.3 Safety and Health Standards, OSHA 29 CFR 1910, from Superinten dent of Documents, U.S. Government Printing Office, Washington, 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 Protection Association, Batterymarch Park, Quincy, MA 02269. Li gas supply when or kill not in use. Safe Handllng of Compressed Gases in Cylinders, CGA Pamphlet P-i, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Ariington, VA 22202. Code for Safety in Welding and Cutting, CSA Standard Wi 17.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1 R3. Safe Practices For Occupation And Educational Eye And Face 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 Association, Batterymarch Park, Quincy, MA 02269. Fire Protection Frequency following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields Background Paper; OTA-BP-E-53 (Washington, DC: U.S. Government Printing To very large volume of scientific at the cellular level and from studies with animals and people which clearty establish that low frequency magnetic fields can interact with, and produce changes in, biological systems. While most of this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to in terpret .the evidence in a single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science-based advice on there is Office, May 1989):. findings based on experiments . to minimize . or avoid reduce magnetic fields in the workplace, use the following procedures: 1. Keep 2. Arrange 3. Do not coil The OM-i586 shielding injure EMFinformation Considerations About Welding And The Effects Of Low Electric And Magnetic Fields strategies Shut off can Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 1.4 BUILDUP OF GAS injury. cables close cables to or together by twisting one drape or taping them. side and away from the operator. cables around the body. now a potential risks. 4. Keep welding power practical. source Connect work to and cables as far away from opera tor as 5. clamp workpiece as close to the weld as possible. About Pacemakers: The above procedures are also recommended for Consult your doctor for complete information. pacemaker wearers. 3 1. Consignes de SØcuritØ pour le Soudage a Iarc 1 1 Signification OM-1 586K/cfr a ~ des symboles Attention! Ce mode opØratoire peut en garde! Signifie presenter des dangers! Les dangers possibles sont indiques par Mise les divers symboles. message de sØcuritØ A Indique ~ Signifie NOTA; pas un special. ilØ a Ia sØcuritØ Ce groupe de symboles signifie Mise en garde! Attention!, risque de CHOCS ELECTRIQUES, dangers prØsentØs par les PI¨CES MOBILES et les PI¨CES CHAUDES. Voir les symboles et les consignes associØes ci-aprŁs pour prendre les mesures nØcessaires afin de se prØmunir contre les dangers. 12 . satety_som_cfr 2/97 2191 - Dangers du soudage a I I Jarc MISE EN GARDE A~ symboles donnØs ci-aprŁs sont utilisØs dans tout le manuel pour attirer lattention sur es dangers possibles et pour indiquer le type de danger dont ii sagit. Quand on voit le symbole, prendre garde et suivre les directives correspondantes pour Øviter le danger. Les consignes de sØcuritØ donnØes ci-aprŁs Les ne font que rØsumer Iinformation contenue dans les toutes ces normes de sØcuritØ. normes de sØcuritØ ØnumØrØes a Ia section 1-4. Lire et respecter Linstallation, Iutilisation, Ientretien reparations et les doivent Œtre confiØs ne des personnes qu qualifiØes. Aucune personne, et UN CHOC Un particuliŁrement les ELECTRIQUE peut enfants, ne 1. Ne Porter des jamais toucher gants les piŁces electriques sous tension. protection secs ne compor et des vŁtements de 4. et de Ia terre 6. dautres Sisoler de Ia piŁce au tapis ou moyens isolants suffisamment grands pour empecher le contact physique Øventuel avec Ia piŁce ou Ia terre. lalimentation ou arrŒter le moteur avant de procØder a linstallation, a Ia reparation ou a lentretien de lappareil. DØver Couper rouiller lalimentation selon Ia (voir normes de secuntØ). 5. moyen de norrne OSHA 29 CFR 191 0.147 du poste de soudage. En effectuant les raccordements dentrØe fixer dabord le conduc teurde mise a laterre appropnØ etcontre-vØnfier les connexions. 8. verifier frequemment le cordon dalimentation pour voir sil nest endommage ou dØnudØ remplacer Ie cordon immediate ment siI est endommage un cable dØnudØ peut provoquer une pas electrocution. 9. lappareil hors tension quand on ne lutilise pas. uses, endommagØs, de grosseur insuf Mettre 10. Ne pas utiliser des cables fisante ou ma! ØpissØs. 11. Ne pas enrouler les cables autour du corps. Œtre mise a Ia terre, le faire directement pas utiliser le connecteurde piŁce ou le piŁce soudØe doit cable distinct cable de retour. ne avec un 13. Ne pas toucher lØlectrode quand on est en contact avec Ia Ia terre ou une electrode provenant dune autre machine. piŁce, 14.Nutiliserquun materiel en bon Øtat. RØparerou remplacersur-le champ les piŁces endommagØes. Entretenir lappareil conformØ ment a manuel. ce hamais de sØcuntØ travaille hauteur. 15.Porter ciaux et 17.Fixer Ie cable de retour de facon a obtenir un bon contact metal metal avec Ia piŁce a souder ou Ia table de travail, le plus prŁs municipaux. Toujours vØnfier Ia terre du cordon dalimentation VØrifieretsas que le fil de terre du cordon dalimentation est bien raccordØ LE RAYONNEMENT DE LARC peut brUler les yeux et Ia peau. Le BRUIT peut endommager IouIe; les PROJECTIONS .DE LAITIER OU LES ETINCELLES peuvent blesser les yeux. Larc de soudage produit des rayons visibles et invi sibles intenses (ultraviolets et infrarouges) qui peuv ent brUler les yeux et Ia peau. Le bruit produit par cer tains procedes peut endommager Iouie. Des projec tions de metal ou de laitier sont produites par le piquage, le meulage ou le refroidissement des sou dures. Utiliser des bouche-oreilles ou des serre-tŁte si le niveau de bruit est ØlevØ. approuvØs antibruit un 16.Maintenir solidement possible en quand place on en tous les panneaux et capots. de Ia soudure. RAVONNEMENT DE LARC 2. Porter un masque a serre-tŒte muni dun verre filtrant de nuance pour protØger le visage et les yeux quand on soude ou observe Ia travail de soudage (voir les normes ANSI Z49. 1 et Z87.1 donnØes sous Ia rubnque Principales normes de sØcu appropnØe rite). 3. Porter des lunettes de sØcuritØ approuvØes avec Øcrans late raux. 4. Utiliser des paravents ou des bamŁres de protection pour les personnes a proximitØ centre les coups darc et avertir les autres personnes de ne pas IØblouissement; regarder larc. proteger BRUIT 4 proximitØ Installer et mettre a Ia terre correctement cet appareil conformØ ment a son manuel duti!isation et au codes nationaux, provin surer 1. trouver a 7. 12.Si Ia tant pas de trous. 3. se a Ia bome de terre du sectionneur ou que Ia fiche du cordon est raccordØe a une pnse correctement mise a Ia terre. tuer. simple contact avec des piŁces Ølectriques peut pro voquer une electrocution ou des blessures graves. Le lectrode et le circuit de soudage sont sous tension des que lappareil est sur ON. Le circuit dentrØe et les cir cuits intemes de lappareil sont Øgalement sous tension a ce moment-l. En soudage semi-automalique ou automatique, le fil, le dØvidoir, le logement des galets dentrainement et es piŁces metalliques en contact avec le fil de soudage sont sous tension. Des matØriels mal installØs ou mal mis a Ia terre prØsentent un danger. 2. doit 5. Porter des vŒtements de protection en tissu et cuir) et des chaussures de sØcuritØ. ignifuge durable (lame OM-1 586 . LES VAPEURS ET LES FUMEES peuvent Œtre dangereuses pour Ia sante. Le soudage produit des vapeurs dangereux de respirer. 1. 2. et des fumØes Garder Ia tŒte a lextØrieur des vapeurs et des fumØes et les respirer. quil ne Ne travaillerdans un espace confine que sil est bien ventilØ, ou en portant un appareil respiratoire a adduction dair pur. Demandera un observateur ayant recu Ia bonne formation de toujours se tenir 5. est a proximitØ. Les vapeurs et fumØes de soudage peuvent dØplacer lair et abaisser le niveau doxygŁne et causer des blessures que lair est propre a Ia graves voire mortelles. Sassurer respiration. pas Ne pas souder a 6. 4. un a appareil respiratoire ~j exploser Les bouteilles contenant des gaz de protection sont a haute pre~sion. Une bouteille endommagØe peut exploser. Etant donnØ que les bouteilles de gaz font normalement partie du materiel de soudage, les traiter avec le plus grand soin. 4. Ne 5. Ne Proteger les bouteilles de gaz comprimØ centre Ia chaleur intense, laitier, les flammes nues, les Øtincelles et larc. les chocs, le 2. Placer es bouteilles ala verticale en les fixant a a un chariot pour Øviter quelles ne tombent ou du poste de 3. Tenir les bouteilles a lØcart circuits un support fixe ne basculent. soudage ou ou dautres ~ues LE SOUDAGE une peut causer un incendie ou Se proteger et proteger les personnes a proximitØ 3. 4. Ne pas souder dans un endroit o des matØnaux inflammables. garde que les Øtincelles et les projections ne pØnØtrent dans des petites zones adjacentes en sinfiltrant dans des Autres , dangers relatifs a Eloigner le visage de 8. a ctØ 2. 9. EN Replacer chapeau garde proximite. Se 6. 7. ou causer 8. 9. 2. appareils 3. soudage OM-1 586 et dØpasse de rautre ctØ de apres utilisation. toujours avoir plafond, sur un extincteur a Un un plancher, une des recipients fermØs tuyaux a moms quils ne comme soient des reservoirs, prepares de faon de IAWS (voir Ia degeler des tuyaux. porte-electrode ou couper le fil du bec contact quand de Iutilise pas. on ne protection non huileux comme des gants Øpaisse, des pantalons sans revers, des 11. Porter des vŒtements de en cuir, une chemise chaussures montantes et un casque. 12.Ne pas porter des matiŁres combustibles ,.II. ~ ,.~, ,.., sur soi comme un ~,., et Ientretlen LES PI¨CES CHAUDES peuvent provo quer des brlures graves. Ne pas toucher les piŁces chaudes les mains 1. 7 flues. 2. , Laisser LES pØnode de refroidissement pistolet ou Ia torche. une PI¨CES MOBILES peuvent avant de causer des blessures. 1. Se tenir a IØcart des me piŁces en mouvement corn les ventilateurs. Sassurer que tous les capots, panneaux, portes protecteurs sent bien fermØs et femiement et maintenus. - ~.,. ~ puissance suffisante. LES ECLATS DE METAL ou LES SALETES peuvent provoquer des lesions aux veux Si ron utilise un ØtØvateur a fourche pour dØplacer I appai~iI, s assurer que Ia fourche est suffisamment longue incendies et si Ion soude sur au ras Ianneau de Ia bouteille Ne pas utiliser le chalumeau soudeur pour rappareil; q~ on Raccorder le cable de retour ala piŁce, le plus pres possible de Ia de soudage, pour empŒcher que le courant de soudage ne suive une trajectoire longue et Øventuellement inconnue etquil ne provoque des risques dØlectrocution et dincendie. blessures de levage que pour soulever NE PAS Iutiliser pour soulever les chariots, les bouteilles de gaz ou autres accessoires. Pour soulever Ia source de courarit, utiliser des quand zone 2. Nutiliser sur appropriØe conformØment a Ia norme F4.i rubrique Pnncipales normes de securitØ). ~A des piŁces autre, le feu peut prendre de Iautre ctØ. Ne pas souder des fOts ou des lappareil a cotØ dun objet ou dun ou aux rappeler que cloison graves 1. le Prendre 5. TOMBANT, LE MATERIEL peut sen- dommager Ia sortie du robinet de Ia bouteille toucher le produrt inflammable. matØriels et leurs 10.Lire et suivre les consignes relatives aux bouteilles de gaz compnmØ, au materiel connexe ainsi que Ia publication P-i de Ia CGA donnØe sous Ia rubrique Principales normes de sØcuritØ. dune surface combustible. Ne pas installer conserver ces louvre. I,nstallation, Iutilasation UN INCENDIE OU UNE EXPLOSION peut Œtre cause par un appareil place au contact, au-dessus ou a ctØ de surfaces combustibles. 1. Ne pas placer lappareil au contact, au-dessus, ou toucher bon Øtat. k..,., .~+ 1 3 bouteille de gaz. sur une electrode de 10. Enlever lØlectrode enrobØe du Enlevertoutes les matiŁres inflammables dans un rayon de moms de 10 m de larc. Si cela nest pas possible, bien les recouvrir en utilisant des bches approuvØes. Prendre chalumeau soudeur une lapplication particuliŁre; des Øtincelles les Øtincelles peuvent atteindre un laisser des et du metal chaud. 2. jamais poser Nutiliser que des bouteilles de gaz de protection, des dØtendeurs, tuyaux souples et des raccords appropriØs conus pour 7. explosion. Ne pas souder sur des recipients fermØs comme des reservoirs, des fOts ou des tuyaux ils peuvent exploser. Larc de soudage peut produire des Øtincelles. Des Øtincelles, une piŁce chaude et un materiel chaud peuvent provoquer des incendies et des blessures. Le des objets contact accidentel de IØlectrode sur mØtalliques peut produire des Øtincelles, lexplosion, Ia surchauffe ou un incendie. Sassurer que le lieu ne presente pas de danger avant deffectuer le soudage. 1. de une bouteille. jamais soudage Nejamais soudersur une bouteille sous pression : elle exploserait. 6. en 1. degraissage, au Consulter les fiches signalØtiques et les consignes du fabncant relatives au mØtaux, produits dapport, revŒtements, nettoyants et iraissants. LES BOUTEILLES peuvent elles sont endommagØes. de Ne pas souder sur des mØtaux revŒtus comme lacier galvanise, p10mb ou cadmiØ a moms que Ia piŁce nait ØtØ entiŁrement dØcapØe, que le poste de travail soit bien ventilØ. Sil y a lieu, porter un appareil respiratoire a adduction dair pur. Les revŒtements et les mØtaux gui contiennent de tels ØlØments Deuvent dØaaaer des vaoeurs toxiques lors du soudacie. 7. 3. Si Ia ventilation est mauvaise, utiliser adduction dair pur approuvØ. proximitØ dopØrations nettoyage ou de pulvØrisation. La chaleur et les rayons de larc peuvent reagir avec les vapeurs pour former des gaz hautement toxiques et irritants. A IintØneur, ventiler le poste de travail ou utiliser un dispositif place au niveau de larc pour Øvacuer les vapeurs et fumØes de soudage. 1. Porter des lunettes de sØcuritØ raux o U Øcran facial avec Øcrans late- lappareil. 5 LELECTRICITE STATIQUE peutendom mager les piŁces des circuits imprimØs. 1. Mettre un bracelet antistatique AVANT de mani puler les cartes de circuits imprimØs ou les piŁces. 2. Utiliser des sacs et boltes antistatiques adequats pour ranger, dØplacer ou expedier les cartes de circuits imprimØs. LES CHAMPS MAGNETIQUES PRO DUITS PAR LES COU RANTS ELEVES peuvent nuire au fonctionnement du sti mulateur cardiaque 1. Les personnes qui portent un slimulateurcardiaque doivent se tenir Øloignees du paste de soudage. Les 2. personnes qui portent un stimulateur cardiaque devraient consulter leur mØdecin avant de sapprocher dun poste de soudage ou de gougeage a larc ou de soudage par points. peut crØer des interferences dans les systŁmes de ra dionavigation, les services de sØcuritØ, les ordinateurs et le materiel de tØlØ communications. 1. Ne confier cette installation qu un personnel qualifiØ et connaissant bien lequipement Ølectro nique. Lutilisateur a Ia responsabilitØ de faire cornger 2. rapidement par un Ølectncien qualifie les problŁmes dintrtØrences resultant de linstalla LA HAUTE FREQUENCE LES PI¨CES MOBILES peuvent provo quer des blessures. Se tenir a lØcart des piŁces mobiles. 1. Se tenir a lØcart des points de pincement, ex. 2. galets dentrainement. LE FIL DE SOUDAGE peut percer Ia peau. Attendre les instructions avant dappuyer sur Ia 1. gachette. Ne pas pointer le pistolet sur une partie du corps, sur dautres personnes, ou sur une piŁce metal lique lorsquon enfile le fil de soudage. tion. UNE UTILISATION EXCESSIVE peut se traduire par une SURCHAUFFE DU MA TERIEL. Laisser RØduire le courant ou le facteur de marche avant de recommencer a souder. 3. Utiliser le facteur de marche nominal. une penode Dans le 4. donnØ par le Conseil fØdØral des communications, arrŒter dutiliser immØdiatement lequipement. Faire verifier et entretenir rØguliŁrement linstalla cas tion. 5. Tenir les portes et panneaux de Ia source de haute frequence bien fermØs, maintenir les Øclateurs au bon rØglage et utiliser une mise a Ia terre et un Øcran de protection afin de rØduire au minimum Ia possibilitØ dinterfØrences. de ref roidissement. 1. 2. dun avertissement dinterfØrence 3. UNE TENSION C.C. IMPORTANTE est LJ~ 1 4 DE GAZ DE PRO LACCUMULATION TECTION peut Łtre nuisible a Ia sante voire model. 1. Quand on nutilise pas le gaz de protection, fermer prØsente sur les onduleurs aprŁs Ion ait coupØ Ialimentation. 1. Avant de toucher les pieces, que mettre londuleur hors tension, couper lalimentation et decharger les condensateurs dentrØe conformØment aux le robinet de Ia bouteille. directives de Ia section Entretien. PrlncIpa~es normes de sØcurltØ Safely in Welding and Cutting, norme ANSI Z49.1, de lAmencan Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Govemment Pnnting Office, Washington, D.C. 20402. Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, normeAWSF4.1,delAmencanWeldingSociety,550N.W.Lejeune Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet a Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Regles de secunte en soudage, coupage et procØdes connexes, P-i, de CSA Wi 17.2, de IAssociation canadienne de norrnalisation, norrnes, 178 Rexdale Boulevard, Rexdale (Ontano) Canada M9W 1 R3. nomie vente de Safe Practices For Occupation And Educational Eye And Face Rd, Miami FL 33126 Protection, norme ANSI Z87.i, de lAmerican National Standards Institute, 1430 Broadway, New York, NY 10018. National Electrical Code, NFPA Standard 70, de Ia National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. Cutting and Welding Processes, norme NFPA 51 B, de Ia National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. 1 5 Informations sur les champs ØlectromagnØtiques soudage et sur les effets des champs ØlectnfrØquence. Voici une citation tirØe des conclusions generates du document Biological Effects of Power Frequency Electric & Magnetic Fields Background Paper (Effets biologiques des charnpsØlectnques et magnØtiDocument de base), OTA-BP ques aux frequences dubllsat]on -E-53 (Washington, DC: U.S Govemment Printing Office, mai 1989) publiØ par IOffice of Technology Assessment (Congres des EtatsUnis): ... des experiences au niveau cellulaire et des etudes sur Ihomme et lanimal rious ont apportØ une foule de renseignements : il est maintenant dair que les champs magnetiques basse frØquence peuvent influer sur les systŁmes biologiques et les modifier. Ces tra vaux sont generalement dexcellente qualitØ, mais les rØsultats obtenus sont complexes. Dans IØtat actuel de nos connaissances dans le domaine scienhitique, nous ne sommes pas en mesure dinterpreter nos observations a Ia IumiŁre dune thØone gØnerale. Et, ce qui est encore plus regrettable, nous ne pouvons nen affirmer de dØfinitif au sujet des nsques Øventuels, ni proposer des mØthodes scientifiques prØcises pour rØduire ces nsques ou pour les Øviter.~ NOTA DonnØes ques et sur le magnetiques Pour rØduire IintensitØ des champs magnetiques au paste de travail: basse i. Grouper solidement les cables en les entrelaartt ou en les serrant avec un ruban adhesif. - 2. Disposer les cables sur un seul ctØ et a lØcart de lopera - 6 teur 3. 4. Eviter denrouler les cables Eloigner le plus possible soudage. Ia ou de tes poser source sur IØpaule. de courant et les cables de 5. Raccorder le connecteur de pres possible Stimulateurs piŁce a Ia piŁce a souder, le cardiaques: Les recommandations ci-avant sadressent aussi, normalement, qui utilisent un stimulateur cardiaque. amples renseignements, consultez votre mØdecin. aux plus de Ia soudure. personnes Pour de plus OM-1586 2. Introduction 21 Specifications Type of Input Power 24 Volts AC Single-Phase 10 Amperes 50/60 Hertz Welding Power Source Type Wire Feed Range Range Constant Voltage (CV) DC For GMAW Or Constant Voltage (CV) / Constant Current (CC) DC For GMAW-P All Need 14-Pin And Contactor Control Standard: 50 To 780 ipm (1.3 To 19.8 mpm) To 3.2 Optional High Speed: 92 To 1435 ipm (2.3 To 36.5 mpm) 12 ft Height Maximum With 4 ft (1.2 in) Post (3.7 m) .023 To 1/8 in Max 60 lb 16 Vertical Lift Of Boom Horizontal to 60 280 lb 100 12 ft 160 lb 16ft(4.9m): (95 kg) 210 lb (6.4 m) Net: 210 lb (127 kg) (95 kg); Ship: Horizontal to 60 Above Honzontal (3.7 m): (73 kg) ft(4.9 m) Boom 21 ft (73 kg); Ship: Weight 750 Spool Weight: (27 kg) 17ft(5.2m) Net: 160 lb Circuit Volts, Amperes, 100% Duty Cycle (0.6 mm) Boom Weight Welding Rating Wire Diameter Speed 350 lb (159 kg) Above Horizontal 3. Installation Installing Swivel iiitoPipe:Post 31 .!~ Swingpak Base Pipe ST-i 52 268 5 or CBC Cart Post With Base 4 3 Steel Bolt Secure as shown using as a mini mum 1/2 in diameter SAE grade 5 steel bolts. 4 Swivel Insert Assembly into pipe post. Lubricate swivel. 5 Safety Collar A Do not remove until instructed to. Tools Needed: ~ 3/4in OM-1 586 7 32 Installing Boom and Reel Support ST-142 596-C ______ 3 1 Swivel Plates 2 Yoke 7 Remove hardware plates and yoke. 3 swivel Boom Set boom into swivel 4 from as shown. Yoke Pin 5 pin through yoke. Install pin and spread ends. Install ter 5 4 cot 2 6 Bolt *0 Install bolt, tighten hardware, and back bolt off one half tum. 6 Locking Install Knob locking knob but do not tighten. 7 Reel Support Install reel support. Tools Needed: ~ 3/8, 3/4 in 3.3 Installing 1 Wire Guide 2 Bolt Wire Guide Extension ST-152 323 Fitting 3 Monocoil Liner 4 Wire Guide Extension 4 Tighten bolt to secure liner in wire guide fitting. Do not overtighten bolt and crush liner. Tools Needed: c:::::::J=~n 3/8 in . 8 OM-1 586 34 Adjusting Control 1 Tht Bracket 2 Rear Pivot Screw 3 Front Screw Tilt Bracket ST-801 279 Loosen rear pivot screw. Remove front screw. Pivot control down ward to desired viewing angle. Re place and tighten front screw. Tighten pivot screw. 1 2 3 OM-1 586 9 / ST-801 805/ Ref. ST-175 086 / Ref. ST-180 311-B 1 . 300/400 Ampere Model CC/CV Inverter Welding Power Source Use settings shown for both pulse MIG welding and MIG welding. 2 Ampere Model DC Welding Power 450 Inverter Source 3 14-Pin Cord 4 Positive 5 Negative () Be sure (+) weld Weld Cable Weld Cable for are peak properly pulse welding (see welding source Owners Manual). Workpiece 7 Voltage Sensing (Optional Use) MIG MIG cc ~ power 60 PANEL see STICK Lead I Wire Feeder For connections 9 TIG F 6 8 PULSED sized amperage if cables SCRATCH .nG Section 3.7. (C) *~RE~OTE V/A CONTROL INDUCTANCE/DIG Gun v-SENSE STAAT Be sure gun is rated for peak am perage if pulse welding. Install ac cording to its Owners Manual. 10 Gas Hose From Boom 11 Shielding Gas Supply 6 9 10 OM-1586 3.6 CoflnectingWeId Cabtes And Gas Hoses Ref. ST-801 805/ Ref. ST-152 800-A The weld cable and shielding gas hose extend 10 ft (3 m) from the boom. Route weld through reed cable from boom if applicable. relay, If the welding power source or gas supply are further from the boom, extend cable or 1 Weld Cable 2 Insulated Bolt hose as follows: Sleeving cables from together welding power weld Use electrical tape and insulated sleeving 3 source and boom. to cover connection. Shielding Gas Hose Connect hose to gas supply or ex tension hose. The hose from the boom has 5/8-18 right-hand threads. Tools Needed: ~ 518 in OM-1 586 11 Control Box Connections 37 ~ ~ Optional 1 Reed ST-i 57433-B / Ref. ST-i 57434 Relay Connection 2 Wire Feed Motor And Gas Valve Control Receptacle 3 Wire Feed Motor And Gas Valve Control Plug From Boom 4 14-Pin Cord 5 Volt Sense Lead (Optional Use) 6 Gun Trigger Plug From Boom 4 3.8 14-Pin Plug Information pin. Pin Information A 24 volts B Contact closure to A G Circuit C +10 volts dc D Remote control circuit common. E 0 to +10 volts dc command Fl Voltage feedback; F Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes. M CC/CV Select N Inductance REMOTE 14 The remaining pins are ac with respect to socket G. completes 24 volts ac contactor control circuit. for 24 volts AC circuit. common output to remote control with input 0 to +10 volts (+24 V = respect signal from dc, to socket D. remote control with respect to socket D. 1 volt per 10 arc volts. CV) (0-10 V) not used. . 12 OM-1586 Motor Start Control: 3,9 ST-157 480-A I Ref. SB-146 862-D change wire feed starting speed proceed as follows: To Turn Off unit and welding power source. Remove wrapper. 1 Front Panel Remove screw ner, and open from upper left cor front panel. hinged 2 Motor Board PCi 3 Motor Start Control Potentiometer R70 Rotate potentiometer clockwise to increase time it takes the motor to ramp up to speed. Remove protec rubber white tive cap before making adjustment. Adjust poten tiometer R70 using a small nonconductive screwdriver. Close and secure front reinstall wrapper. panel, and Tools Needed: Non-Conductive __- 1E~~J~1J 3.10 Removing Safety Coflarand Adjusting 1/4 in Boom Ref. ST-152 380-A 1 Locking Knob knob Tighten to prevent boom movement. Loosen knob to allow boom Change knob upward movement. movement. position to limit Pull boom down slightly and re safety collar. Boom should balance in any position from hori move 2 zontal to 60 degrees above hori zontal. If necessary, adjust boom as follows: 2 Threaded Rod 3 Jam Nut Loosen jam 1 nut and tum threaded I Rod rod until boom balances. Tighten nut. Be sure several full jan, threads are through vent boom falling. 4 yoke to pre Yoke safety collar for use in disas sembling or moving boom. Retain Increasing Spring Pressure For A Heavy Gun Tools Needed: L~ 1-i/8in OM-1586 13 Gun Recommendation Table 311 Gun Process GMAW-P GMAW Hard Hard or or Self-Shielding 312 Wire Speed M25, M40, Or GA-50C Cored Wires FCAW Motor GW-500 Or GW-600 Cored Wires GA-4OGL Or GA-5OGL Wires Type, Size, Wire Type and Feed Speed Capability Wire Size Feed mm) Standard All .023 To 5/64 in (0.6 To 2 Standard All 3/32 To 7/64 in (2.4 To 2.8 Standard All 1/8 in Optional High Speed All .023 To 5/64 in 14 Table mm) (3.2 mm) (0.6 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 1pm (1.3 To 7.6 92 To 1440 1pm (2.3 To mpm) 35.6 mpm) OM-1 586 Installing and Threading Welding Wire 3.13 ST-152 648-A / Ref. ST-i 57432 / Ref. ST-i 37391-A / ST-i42 597-A/ Ref. S-0627-A I Ref. ST-i 50 922 For soft wire that outlet cable has proper size welding wire size. When installing gun, position linerextending fro moutlet wire guide as close as possible to drive rolls without touching. Be sure Install gun. Lay gun cable out straight. Cutoff end of wire. Push wire through guides up to drive rolls; continue to hold wire. Press Jog button to feed wire out gun. Install or (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 feeder (see 2 in small diameter stainless steel wire, use 2 dnve rolls and set drive roll pressure from 0 to a maximum of 4 on the pressure indicator scale (so that only llner for the the inner spring is ting will mance compressed). This set generally give the best perfor for these pressure types of wires. Cut wire oft. Close To adjust drive roll pressure, hold nozzle about wire Adjust tension adjustment above). Repeat cover. for other side. spool. nut so wire is taut when wire feed stops. Install wire guide. 4- Install drive rolls. NONCONDUCTIVE SURFACE No Wire Slip iONCONDUCTIVE I SURFACE Wire Slips Tools Needed: 1 OM-1 586 3/16,5/64 in ~ ~ 15/16,3/8 in 15 4. Operation 41 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 Pulse Adaptive The wire feeder Welding less of Cold Wire change automatically regulates pulse frequency welding wire stickout. to maintain a constant length, regard arc 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 increases, Trim Arc Synergic The arc on time increases, and the weld in length adjustment pulse welding. Increasing placed by volts in MIG programs. the puddle becomes tnm increases the actual arc operator programs pulse parameters for a specific wire feed speed. pulse parameters between these wire feed speed increments. more fluid. length. Trim is re The wire feeder determines Side Panel Terms Is used to select the Process Mode Sequence pair of programs Is used to select a Card Mode Is used to select use Only Mode functions with rameter 4.2 1 Apk Pulse Peak = Increasing Apk to be used, including Pulse, Adaptive Pulse, or Mig. Is used to select and program the weld sequences which include weld, crater, bumback, preflow, and run-in. Mode Dual Schedule Mode Security type of process Welding a of the optional that can be used data card data card. Allows using postflow, together. storage and retrieval the lock feature for capabilities. restricting range of program pa changing. Terms Amperage increases penetra tion. Vpk Peak = Voltage Arc voltage during peak current phase of the pulse waveform. This determines arc length during adaptive pulse welding. 2 Abk 3 PPS arc = Increasing speed. 4 Background Amperage = Maintains 3 between pulses. Pulses Per Second Amps PPS increases travel _________________ _________________ Pulse Width In PWms Milliseconds Increasing width. = PWms increases bead Time / . 16 OM-1586 FrOnt. Pane! Controls 4.3 Ref. ST-155 222 crease/decrease 1 Display 2 Parameter Select Button Press button to move > on display. Display Control 3 Turn control to to by>. Turning control one click causes Trim (arc length) to increase/decrease by one or Volt to increase/decrease by 0.1. click causes selected, turning control one wire feed speed (1PM) to in crease/decrease by one. When MPM is selected, clicks causes wire feed crease by 0.1. ule Mode valve. When click Prg # is causes (see Section 6). setting. To change type of process (Pulse, Adaptive Pulse, or MIG) use side panel controls (see Section 4.4). 4 a default Trigger Hold Button And Indicator Trigger Hold be set Indicator light three to in selected, turning control program number (Pm #) one to in- momentarily feed welding wire with energizing welding circuit or shielding gas Push to Jog speed is varied using the Display Control while Jog button is pressed. Default setting is 200 1PM. 6 can Button Light per program ba on for programs Purge Button on a comes momentarily energize gas valve energizing the welding circuit. Push to where this feature is active. out holding gun triggerthroughout cycle, press and release button to turn feature on (indicator light turns on). ~ Jog and Purge only work side of the feeder. with To weld without weld turning control speed (MPM) Jog out sis. When 1PM is 5 one. The program number cannot be changed while welding, with exception of Dual Sched Pulse is change value pointed by To start weld cycle, press and release gun trig ger within three seconds after an arc has been struck. To end weld cycle, press and release gun trigger. on the active Jog and Purge buttons at the displays pulse parameters on the side panel display and voltage on front panel display. Holding same the time ____L2 6~ 5 0 4.4 Side and Rear Panel Controls 1 Mode 2 Mode Select Button Ref. ST-157433-B/ Ref. ST-155 223 Display Press button to move> in display. 3 Parameter 4 Parameter Select Button Press button to Display move > in display. 5 Parameter Increase Button 6 Parameter Decrease Button 7 Power Switch 8 Circuit Breaker CB1 5 .6 CB1 protects the wire feeder from overload. OM-1586 17 5. Setting Sequence Parameters Setting Sequence 5 1 Parameters in a Program ~ See Menu Guide for detailed programming steps. length. If set to zero, is short. If set to 99, Thm is arc length length is arc arc long. If time is set to zero in Weld se quence, welding continues until gun trigger is released. If time is set to zero in any timed se the Weld, except quence sequence is skipped. Pulse Weld 1. Trim Volts Inductance 1PM 0-99 10.0-38.0 0-99% 50-780 X MIG Pulse Crater 2. X 0-25.0 X X X X MIG 3. X X 0-2.50 X Pulse Burnback Seconds 0-0.25 X MIG 0-9.9 4. & 5. Post- flow/Preflow 6. Pulse Run-In MIG X = Setting X X 0-2.50 X X available. A Weld Time V a, C) 0. 025sec. U) (I) C) U V U) c Crater Time U C, ~ Preflow Time ~ H Run-In Time Bumback Time / / a, C, 0 / Time Time Bumback Preflow 18 Run-In Arc Strike Weld Crater Posthow Sequence End Trigger Trigger Pressed Released OM-1 586 G. Setting Dual Schedule Parameters Selecting 6.1 Dual Schedule Pair : rti~ . Dual Schedule is used with two consecutive weld programs 1 & 2, 3 & 4, 5 & 6, or 7 & 8. Any program type (MIG, Pulse) can Adaptive Pulse, or be combined in dual schedule. 1 Display Side Panel Use side panel to turn feature on. See Menu Guide for detailed pro gramming steps. 2 Front Panel Press front Display panel parameter select button to select program number. Display Control 3 Front Panel 4 Dual Schedule Switch Section ~ Switch type is set in Setup. See Section 8. 5 (See 6.2) System Welding Gun Trigger Selecting dual schedule program A or B is done by using Display Con trol, dual schedule switch, or gun trigger (depending on system set up). When program B is active, turn Display Control one click clock wise to select another pair of 4 Display dual Control schedule programs. g7 Programs can be rearranged in desired order using the data card. See Section 7. Display Control OM-1 586 19 Dual Schedule Switch 62 1 / Momen2P (Momentary-Contact Switch Or DSS-1O) 2 Diagrams Maint 2P 2-Pole 1 (Maintained-Contact DSS-9M) 3 Maint 1 P (Maintained-Contact 1-Pole Switch, Or DSS-8) 4 Trigger lishing a ~ If trigger is used schedule switch, is disabled. for > > A 3 4 B 4 3 0 2 > > A scheduling afterestab welding arc. > 2 2 > Allows dual > > 2 2-Pole Switch Or 1 1 1 > 2 1 dual 0- Trigger Hold \~B p p 4 3 Adapter 1 > ___________ 3 7. Using the 7.1 I > > > 3 2 TR 3 > A\~~> I 2 2 TR 1 > 4 > Optional Data Card Data Card Terms SA-158 435 CARD SCREEN TERMS WRITE READ Programs Programs To Card From Card PULSE MIG TERMS PPS Amperage (Pulses Per Second) PWms ~ (Pulse Width In Milliseconds) -r Abk Time (Background Amperage) 20 OM-1 586 7.2 Installing Data Card ST-156 266-B Label 1 to data card. Write pro gram information on label. Apply label 2 Data Card 3 Card Slot 3 For Blank Data Card: Insert card into slot. To format card, turn On power. Select Card from menu. Data card formats when unit enters Card mode. 1 For Power Source Data Card: Insert card into slot. Tum On pow Push Parameter Select button er. within 3 seconds and the 8 pro grams and setup information are read into the wire feeder memory. ready Unit is to use when Please message disappears from Wait front panel display. Card Displays 7.3 ~ See Menu Guide for detailed programming steps. Security mode only functions with a data card. 1 Card 2 Moving Display ________________ Moving be 3 Line line is under value that Sequence can Dual Schd changed. >Ca Write r d Security Press Be I ow 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. 4 Read 3 Transfers program data from card to unit. 5 Delete 4 Deletes program data from card. 6 Done Exits card display. 5 6 OM-1 586 21 a. System Setup 8 1 Display Settings Note ~ DISPLAY SETTING >System >Range * See Menu Guide for detailed programming steps. NOTES Select the process the welding power source is able to do. Welding power source minimum and maximum voltage values are always needed. Amperage for pulse welding. Set values to match welding power source ranges. * of setup >Access When on, restricts >Mig Type Default is Off. Set to On >Voltage Default is use only values are required screens. for older CV 14-pin receptacle. Use welding V. Sense when power source than 50 ft more without voltage feedback (15m) of weld cable is at 14-socket used (including receptacle. gun cable length). >Arc Start** Use Hot Start only with 450 Inverter Model Ampere welding source power and large diameter wires. The arc starts in CV and switches to CC. >Dual Schedule See Section 6.2. >Tngger When on, trigger can be used to switch between programs that have at least 0.2 seconds of preflow time pro grammed. DSS-1 0 be used to When on, is. >Arc lime Displays >Wire Feed Choose to >Model** Pulse programs differ between bench and boom models. >Memory Program Reset: unit defaults to original factory setting for the last active program. Setup information change. If setup card is in card slot, program will be loaded from card. System a can accumulated display >Teach Default is 15 >Gas Flow,, Setting >Software Know this when Automatically ** , Can be used or meters points, immediately but can must be Meter Off if talking Prg depending on panel display> type, but installed for all programs and motor must match selection. . does not setup excluding System, Arc Time, and will be loaded from card. shuts down if be set to 4 option or per minute and motor 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 22 Trim, 1PM, original factory settings setup card is in card slot, program When on, the system age is sensed. or cycles. inches per minute >Shutdown , time and Reset: unit defaults to Model. If * arc change Volts where the front >Remote error. OM-1586 0. Standard Pulse Welding Programs Note ~ Apk = PPS = Peak Amperage, Vpk factory set programs. interpolations from the 9.1 Wire Program SizelType: 1 = Peak Pulses Per Second, PWms = Voltage, If selection is set for 4 Abk Background Amperage, (milliseconds). Four teach points were used for fifteen teach points, the remaining points are = Pulse Width taught points. Steel .035 Gas: Ar - CO2 or Ar- Oxy /40 CFH (19 Urn) 1PM / MPM Apk Vpk Abk PPS PWrns 700/17.8 440 367 160 180 2.9 400 /10.2 385 324 108 126 2.3 200 /5.1 335 287 61 81 2.0 100/2.5 328 274 37 47 1.7 9.2 Wire Program 2 Steel CO2 CFH (19 Urn) Gas: Ar 1PM / MPM Apk Vpk Abk PPS PWms 700/17.8 518 376 195 205 3.6 400/10.2 476 361 157 168 3.0 200/5.1 412 303 93 106 2.4 100/2.5 375 277 50 66 2.2 93 Wire Program Size/Type: 3 - or Ar Oxy / 40 .045 Size/Type: - Gas: Ar .052 - CO2 or Ar - Oxy /40 CFH (19 Urn) Apk Vpk Abk PPS PWms 625 / 15.9 560 393 200 229 3.6 400/10.2 525 362 148 189 3.5 200/5.1 475 317 102 131 2.7 100/2.5 445 296 50 80 2.4 Wire Program Size/Type: 4 COMMENTS Steel Gas: Ar- .062 CO2 or Ar-Oxy/40 CFH (19 Urn) 1PM! MPM Apk Vpk Abk PPS PWms 400/10.2 580 366 200 200 4.3 300/7.6 539 348 160 200 4.2 200/5.1 499 315 121 170 3.6 100/2.5 460 283 69 118 2.6 OM-1 586 COMMENTS Steel IPM/MPM 9.4 COMMENTS COMMENTS 23 Program 95 Wire Size/Type: Stainless 5 Gas: Ar .035 - He - C02140 CFH (19 1/rn) 1PM! MPM Apk Vpk Abk PPS PWms 700/17.8 403 339 132 191 2.8 400 /10.2 318 316 87 146 2.4 200/5.1 295 285 53 94 1.9 100/2.5 280 260 32 45 1.8 9,6 Wire Program S Gas: Ar - He - C02/40 CFH (19 Urn) 1PM! MPM Apk Vpk Abk PPS PWms 700/17.8 480 390 200 227 3.2 400/10.2 425 324 155 185 2.5 200/5.1 360 280 100 115 2.0 100/2.5 350 262 40 70 2.0 Program Wire Size/Type: .035 7 Nickel Nickel Alloy Gas: Ar - He! 40 CFH (19 Urn) Apk Vpk Abk PPS PWrns 700/17.8 350 345 130 144 3.7 400/10.2 310 300 80 105 3.3 200/5.1 280 275 48 55 2.9 100/2.5 260 251 28 36 2.5 Wire Program 8 SilicOn Bronze., Size/Type: .035 Gas: SiBr COMMENTS . : Argon/40 CFH (19 Urn) IPM/MPM Apk Vpk Abk PPS PWms 510/13.0 340 307 100 125 3.7 400/10.2 310 298 83 97 3.4 200/5.1 277 266 48 55 3.0 120/3.1 242 252 31 31 3.0 24 COMMENTS Alloy 1PM! MPM 1:9,8 . Stainless Size/Type: .045 :97 COMMENTS COMMENTS OM-1586 10. Teach Points / TeachUsingl5Points 101 The teach mode allows the user to create cus tom pulse programs. The teach mode selec tion for 15 teach points gives a more defined curve the for a specific range. At each teach point, adjust five parameters to shape user can pulse waveform of the weld output. The six parameters are: 1PM (MPM), Apk, Vpk, Abk, PPS, and PWms. the Under some conditions, the wire feeder limits wire feed speed to maintain all pulse parame ters within the capability of the system. Apk, Vpk, Abk, PPS, and PWms acting togetherprovide the energy necessaryto bum off welding wire at a set wire feed speed. The graph below shows that as wire feed speed in creases, energy increases (Apk, Vpk, Abk, PPS, and PWms acting synergically). A 0 Apk = Peak Amperage Vpk = Peak Voltage Abk = Background Amperage PPS = Pulses Per Second IPM/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 All Teach Points Set At 50 1PM 350/8.9 (1.3 MPM) Increments 300/7.6 250/6.4 200/5.1 150/3.8 100/2.5 50/1.3 Apk 100 180 210 240 270 300 330 360 370 420 450 480 510 540 565 Apk Abk 10 20 30 40 50 60 70 80 90 100 110 120 130 140 200 Abk PPS 20 55 80 105 130 160 185 210 235 260 290 315 340 365 400 PPS PWms OM-1586 1 2 3 4 5 PWms 25 10.2 Teach Using 4 Points The teach mode allows the userto create custorn pulse programs. The teach mode selec- points gives the whole welding quickly. At each teach point, the user adjust five parameters to shape the pulse tion for 4 teach range can waveform of the weld output. The six parame(MPM), Apk, Vpk, Abk, PPS, and Apk, Vpk, Abk, PPS, and PWms acting together provide the energy necessary to bum oft 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). Under some conditions, the wire feeder limits speed to maintain all pulse parame within the capability of the system. wire feed ters ters are: 1PM PWms. L~ Apk = Peak Amperage A Vpk = Peak Voltage El Abk = Background Amperage o PPS IPM/MPM 780/19.8 = PWms Pulses Per Second = Pulse Width (Milliseconds) 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 (2.5), 200 (10.2), And 700 (17.8 MPM) Intervals Of 100 350 /8.9 (5.1), 400 1PM Increments 300/7.6 250/6.4 200/5.1 150/3.8 100/25 50/1.3 100 180 210 240 270 300 330 360 370 420 450 480 510 540 565 100 180 210 240 270 300 330 360 370 420 450 480 510 540 565 Apk Vpk Abk 10 20 30 40 50 60 70 80 90 100 110 120 130 140 200 Abk PPS 20 55 80 105 130 160 185 210 235 260 290 315 340 365 400 PPS Apk Vpk PWms 1 2 3 4 5 PWms . 26 OM-1586 103 Redefining Teach Points Ref. S-0259 / Ref. ST-154 109 Redefining 1PM Teach Point 1PM determines the weld metal de position rate. Trim 50 Redefining 1PM is notnoimally required unless special wire or unusual is joint design ~ needed. /~ Use front panel parameter select button to move> to select 1PM. Use Display Control to select teach point Purge I Pu se QAL~ Li value. Press and hold Purge button while turning Display Control to redefine the 1pm teach point. For example: Trim 50 >460 teach points at 150, 200, ipm; the teach point at 200 can be adjusted to a wire feed speed of 151 to 249 ipm. there 1PM >450 1 Prg are 1PM 1 Prg Pu I se and 250 Amperage 2 Apk Peak 3 Abk Background Amperage Peak and background amperage depend on the range of the welding power Pulse Parameters Pulses Per Second Of PPS 4 Redefining source. 20-400 PWms 5 Pulse Width Of 1.0-5.0 Milliseconds Use side pulse panel controls to change See Menu parameters. Guide for detailed programming steps. After values are set, strike and maintain an arc for five seconds. Do this for each teach point. 2 End weld by releasing gun trtgger, by pulling gun out of weld. Re peat for each custom teach point. not The Trim taught arc length represents (arc length) setting of 50. a Once the teach points are set, the wire feeder adjusts parameters be tween teach points synergically. 3 400 1PM 340 Apk 340 Apk 340 Apk 70 Abk 70 Abk Abk >160 PPS 160 PPS PPS 1.4 PWms >1.9 PWms >70 160 OM-1 586 75 ___y4 27 Wire Program Number_ Date Sizefrype. Flowrate - Gas Equipment Used Power Source__ Serial Number_ Serial Number Wire Feeder Gun Model_________________ Weld Cable Wire Manufacturer_________________ 1PM! MPM CFH(Umin) Apk Abk ~If.. Positive______ Negative fl~*~ PPS PWms Vpk COMMENTS . Pref low Seconds;_________ Run-In TrimNolts:________ 1PM / MPM:___________________________________ Seconds:____________________________ Crater Volts:___________________ 1PM I MPM:___________________________ Seconds:__________________________ Postf low Seconds;________ 28 OM-1 586 11. Maintenance and Troubleshooting 11 1 Routine Maintenance , ~ it~j1~ A Disconnect power before maintaining. 3 Months Replace Repair Or Replace Unreadable Labels Cracked Weld Cable 14-Pin Replace Cracked Parts ~ Co~~ Gas Hose And Gun Cable Fittings 6 Months Blow Out Or Vacuum Inside. During Heavy Service, Clean M~ Clean Drive Rolls Monthly OM-1 586 29 11.2 Error Displays r!1~H~ Ref. 5T-155 222 EEJ R e I e a s e I 2 00 No Volt 1Er ror 3 1 Memory Prg _CRC Er ror Release Error Trigger Display This appears if the trigger is closed when the unit power is turned on, or if the 2 trigger is stuck or defective. No Volt Sensed Error Display The Memory Prg Er Range ror arc voltage sense circuit is not receiving feedback. Check voltage connections. Check sensing connections at 14-position plugs/ receptacles at the unit and welding power source. Turn unit off and back ~ on after correcting problem. Tach No I If this when Sensed Er 3 Start 7 N __________ Arc Stop Ga 9 N s C F H F I 1Error 1Er 1Er ror 8 x x o w ror _______________________ Ma x C F H GasF x Er ror 10 Gas of 11 12 1Er I 1_Unlock 1Er N 30 Ian saved. Perform 4 a system reset. Memory Range Error Display The data in the program indicated is out of usable range. Go through pulse parameters to make sure they do not exceed settings of the Range display or perform 5 a system reset. No Tach Sensed Error Display The motor tach feedback is not reaching the control. Check connections. 6 panel Parameter error. Arc Start Error cannot Er be Arc Stop Error Display This appears when pulse welding and the motor does not stop at the end of the weld. If there is high frequency being used in the area, turn it off. A motor brake circuit problem can also Press front Select to clear 8 cause panel this error. Parameter error. Minimum Gas Flow Error This appears when gas flow falls below the minimum CFH set (xx in example). Adjust gas flow to bring it above set value. and voltage voltage sensing front Press panel Select to clear error. 9 Parameter Maximum Gas Flow Error This appears when gas flow is above the maximum CFH set (xx in example). Adjust gas flow to bring it below set value. Press front Select to clear 10 panel Parameter error. Gas Out Of Range Error This appears when gas flow is greater than 100 CFH. To protect the internal sensor, the unit shuts down until the gas flow can be adjusted below 100 CFH. 11 Coolant Flow Error This appears only when coolant flow switch option is installed. coolant Check recirculating system. Display 12 Unlock Error Display pulse parameters settings. Check This appears when attempting to run an unlocked program while other programs are locked. Either lock the unlocked program or select a different program that is connections. locked. started. correct program ror ______________________________ Coo Display This appears when pulse welding and current is detected but the arc Out Range CRC Error front Press Select to clear x low Memory The data in the program indicated is not the same data that was ___________ Arc 7 Parameter ror \ n pulse select Rot Start. 61 Mi continues to occur welding, it may help to error Press front panel Select to clear error. Check and t Flow ror ___________________ ror OM-1586 . 11 3 Troubleshooting ~ A Trouble Wire feeds, shielding gas flows, but energized. Wire feeder is on, meter(s) do not light up, motor does not run, gas valve and welding power not pull in. source contactor Electrode wire feeding stops erratically dunng welding. or Check interconnecting cord connections. If secure, check cord for (see Sections 3.5 and 3.7). Check and reset CB1 feeds trigger Check gun trigger. See gun Owners Clean or Replace to correct size drive roll replace dirty tip is repair or replace or Manual. Manual. (see Section 3.13). (see Section 13.6). drive roll. guides. liner. See gun Owners foreign Factory Authorized Check for but continues to feed after trig ger is released, and trigger hold is not pulled, wire or spatter Check for correct slowly. or worn or worn contact Remove weld Have connection. See gun Owners hub tension and drive roll pressure Incorrect size trigger and (see Section 4.4). Check gun Change Wire does not feed until continuity do Readjust runs troubleshooting Remedy electrode wire is not Motor Disconnect power before Manual. matter from around nozzle 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 weld a short between welding gun trigger leads and weld cable. Repair short or replace weld- ing gun. on. Gas valve in feeder is rattling loudly along with possible erratic or slow wire feed speed. Check for Unit does not switch out of Run-In Install, reconnect, ing gun. or replace voltage sensing lead. Speed. Wire feeder power is on, displays up, but unit is inoperative. OM-1 586 light Check welding gun trigger leads for continuity, and repair leads or replace gun. 31 12. Electrical Diagram 121 Circuit Diagram I :IcT~ Fcv - - L~ ~H ~ ~ ~T~W41 H ~ 413E-~-<3~3 ~ I ~-~-<tI ~ >-~-< >-2< csi 32 I OM-1 586 uumd _~J A SD-183 495-A ~ftM Sf1 I FlIER Fe~ (EC FaD I I ~MI Iii ~ -~~m ~r iii~ I liii diii EREDI ~lR~ I mT0AWAI wro I 113451 ~ ~ I 99æ92~92~ arooo000ooolI 0 StE 14~flI_I ~sS I A ~- ~ P1W P15-2> Vs - I i F5.i54 ~ Idmffism ~ut/uzn3 ~1J~1L~c wfa~ r~ FcW~e>I P1W-I> ii ~vvv~v~.vvvvv ; ~~1~~ ~ v_v_v_v_v_v_v_v ~~flflB Fe4-7 >)~a~ 51414(1 (~QI iacrna S P1E4~,uRP1oaHecSIwC cca3_2>,4!~<lI (w7~~<$Fe2-4 (0nv) ~I ~c 34 (s/ui) FLIER 545 ~ - <<FeE-i ~ ~ IdlE>> an V ~ ~ P1544>> dWanv ~ r~~~j~i ICR r4045C CR104 I ~5L SEW 4521 ___ Po1.tp I C ~-1 ~ OBIEI4T S ii __ ~ _i I QRENT SEC ~ ~II-I>> ~ ___ C ____________ ~ > I rn/tv (.3454ev) ~ _________ ICTI-4 I S PR-S FLIER 514(11. 4PL013 ~ I S ___________ P154-I>> 1514 ERICh 1514 tIC SF 11SF. CS (4 RJER SIC DASH P15>1>> <<Fe2-7 P152-2>> <<~-~ _____ _____________________ It/tv (.2EV-tv) < Wt Id112>> nsiwa nt Os/mO ~u U IdTI-3 > S -5V P15>2>> ~ ~&4WC ~ <Fe2-6 P151-I>; ~(~-11 Fe1-1 14 P14 fl404 Id11-7>> I 9 ? 9 ~ Fe1-3 ~ ( SRi > > Fe12>) ~ I <<1(153-7 ___________ I ~ rn m W>FFSItD ______k5_ i1E~&~~ I m~ ~-i> _J I ,PWIR-JS (N SLII) I I ~I,r I I II ~NC ,-1_ nAAA a V tV~ p t~ ? pp p PS. ~4 S ~ 14491 2 15-3> pci 4.01(54 CIA(S) PS. ajir,cins ~ I si-s 7> Fe-I>> 54-2>> 4(2 5(5 OM-1 586 2 Ic Fe4~ .1 - 2455401 / CC 10 lOVER SEC 49 245552 ~p 33 13. Parts List 13 1 Main Assembly ST-i 57 507-G ~ Hardware is common and not available unless listed. or 0) U, 0) LI~ . Co Co N N C,) a LL N N C,) N 0~ C) 0) .4- N C,) a / 34 Lb N OM-1 586 I Quantity Item No. 1 1 2 3 3 Dia. Model Part No. Mkgs. Description 12 149 251 CABLE, trigger (consisting of) 149 252... CABLE, trigger (consisting of) PLG23.... 079 878 CONNECTOR & PINS 079 531 CONNECTOR, circ clamp str rlf sz 11 Amp 206358-2 605 156 CABLE, port No. 184/c (order by ft) PLG28.... 080 328 CONNECTOR w/SOCKETS, free hanging See Note... CONTROL BOX, (Fig 13.2) 164475... CABLE, interconnecting (consisting of) 164 474... CABLE, interconnecting (consisting of) CONNECTOR & PINS 047 636 PLG37,38 079 739 CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2 I 16 1 ... 1 1 2 17ft .... 1 .... 2 .. 21ft 1 .... 1 1 .... 1 1 1 2 .... 2 .... 2 .. 163 519 4 139 600... 139599... 010 603 010 606 603 106 056 112 600 324... 5 6 149 884... 6 080 947... 602 243... 7 602 213... 8 601 872... 9 080 157... 10 132 053... 11 12 Fig 13.3... 149 838... 13 .149 839... 13 .078 264... 13 .079216... 13 075078... 14 .079217... 14 15 Fig 13.5... 047637... 16... RC37 17 PLG33.... 135409... 115092... 18... PLG7 605 227... 19 125 785... 20.... GS1 4 CABLE, port No. 18/14 8/c (order by ft) HOSE, gas (consisting of) HOSE, gas (consisting of) FITTING, hose brs barbed nipple 1/4tbg FITTING, hose brs nut .625-18RH HOSE, npm brd No. 1 x .250 ID (order by ft) FITTING, hose brs ferrule .475 ID x .718 Ig CABLE, weld cop strd No. 4/0 (order by ft) BRACKET, spring retaining BRACKET, spring retaining WASHER, flat stl std .375 WASHER, lock stl split .375 NUT, stl hex full .375-16 FITTING, grease 1/8NPT SCREW, cap stl hexhd .375-16 x 1.500 Ig SUPPORT, hub & reel PIPE POST, 4ff w/base or PIPE POST, 6ftw/base PIPE POST, 4ff w/base or PIPE POST, 6ff w/base PIPE POST, 4ff w/o baseor PIPE POST, 6ff w/o base BOOM ASSEMBLY CONNECTOR & SOCKETS CONNECTOR & PINS CONNECTOR & SOCKETS NUT, nyl hex jam .75ONPST VALVE, 24VAC 2 way custom port 1/8 oil 139 265... COVER, motor & components 156243... CLAMP, motor top 159 360... INSULATOR, screw machine 145 639... STRIP, buna N compressed sheet .062 x 4.000sq 167774... DRIVE ASSEMBLY, wire (Fig 13.4) .167 776... DRIVE ASSEMBLY, wire (high speed) (Fig 13.4) 157295... GUIDE, monocoil 604612... SCREW, set stl sch 8-32 x .125 cup point 082 050... LINER, monocoil inlet wire 159 646... CLAMP, motor base 17ft .. 2 21ff 1 1 2 2 26ft 2 26ft 1 .... .... .. 2 2 30ff .. 2 30ff .... 8 .... 1 8 4 4 1 .... .... .... 4 .... 1 .... 4 4 1 4 1 1 1 1 1 1 .... 1 1 .... 1 1 .... 1 1 .... 1 .... 1 .... 1 1 .... 1 1 .... 1 1 .... 1 1 .... 1 .... .... 21 22 23 24 25 25 26 27 28 29 159647... INSULATOR, motor clamp 180 146 KIT, trigger isolation (consisting of) CIRCUIT CARD, assembly trigger 180 118 180 277 PLUG, assembly PLUG/LEADS 180276 30 4 .... 1 .... 1 .... 1 1 2 1 Note: When ordering Control Box contact factory department .... .... .... 1 .... 1 .... 1 ... service .... 1 .... .... 1 .... 1 .... 1 1 4 1 1 1 1 2 1 1 1 1 1 1 1 for proper number. OPTIONAL factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. To maintain the OM-1 586 35 132 Control Box (Fig 131 Item 2) ST-157 508-0 ~ Hardware is common and not available unless listed. cJ N cJ Co Cj U, C.) CJ . 0) Co Co U, 0 cj 01 0 U, 36 OM-1 586 Item No. Part No. Dia. Mkgs. 1 147139 2 155024 144844 PC4O 5....PLG16,41 ..6 158160 ... 155023 PC6O 156623 PLG6O 153 501 RC7O 048282 079 532 079 535 079531 154938 8 PC5O 163917 PLG51 .... 158720 PLG52 .... 158719 PLG53 .... 131 204 PLG54 .... 148439 PLG55 10 12 .. ... 115092 PC1O 184775 PLG11 115092 PLG15 11 .... .... .... 153501 PLG17 .... 115093 PLG18 .... 162382 ... 170980 ... 155629 PLG1O,24 PLG12,50 13 126689 14 097132 15 138044 16 600399 17 176089 .18 601222 19 Quantity Description TAPE, adh acrylic double sided .010 x .500 x 3.000 LENS, clear anti glare STAND-OFF, No. 6-32 x .875 Ig CIRCUIT CARD, schd side CABLE, ribbon 24posn 6.000 in (RC16) (RC14) CIRCUIT CARD, cybercard CONNECTOR & SOCKETS CONNECTOR w/SOCKETS (RC6O) 1 14 1 1 1 1 1 CONNECTOR, circ 4 pin Amp 211882-1 CONNECTOR, circ pin push-in 18-l4ga Amp 66359-6 CONNECTOR, circ clamp str rlf Amp 206358-2 STRIP, mtg PC card CIRCUIT CARD, interface (RC51) SOCKETS (RC52) SOCKETS (RC53) SOCKETS (RC54) SOCKETS (RC55) processor w/proms CONNECTOR&SOCKETS(RC11) CONNECTOR&SOCKETS(RC15) CONNECTOR & SOCKETS (RC17) CONNECTOR&SOCKETS(RC18) CABLE, ribbon 34posn 12.000 in (RC1O) (RC24) CABLE, ribbon l4posn 3.000 in (RC12) (RC5O) STAND-OFF, 6-32 x 1.500 Ig STAND-OFF, 6-32 x .375 Ig BUSHING, strain relief .120/.150 ID x .500mtg hole WIRE, strd l4ga blk 600V 105C (order by ft) TUBING, plstc PVC .250 ID x .370 OD x 9.000 CONNECTOR & CONNECTOR & CONNECTOR & CONNECTOR & CONNECTOR & CIRCUIT CARD, 4 SOCKETS 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 1 35ft 1 1 089899 CLAMP, Univ 50A LATCH, slide flush 20 134464 LABEL, warning general precautionary 1 21 +154 927 WRAPPER 1 22 155261 PANEL, side lower RECTIFIER, integ 40A 800V CIRCUIT BREAKER, man reset 1 P 1 OA 250V SWITCH, rocker SPST 1OA 25OVAC BLANK, snap-in nyl .875mtg hole STAND-OFF, 6-32 x .625 Ig CIRCUIT CARD, HF filter 1 23 SRi 035704 24 CB1 083432 Si 111997 .25 26 000527 27 073756 PC8O 28 PLG81 PLG82 182299 .... 115093 .... 158720 PLG83 ... PLG89 ... 115092 131 054 29 010290 30 163520 31 ... PLG9 32 33 ... RC4O 35 36 OM-1 586 1 1 1 1 2 1 1 (RC82) 1 CONNECTOR & SOCKETS (RC83) CONNECTOR & SOCKETS (RC89) BUSHING, strain relief 1.030 ID 1 1 1 l7ft 079739 CABLE, port No. 18/14 11/c (order byft) CONNECTOR & PINS, (consisting of) CONNECTOR, circ clamp str rlf sz 17 & 20 047637 CONNECTOR& SOCKETS 1 048144 CONNECTOR, circ pin plug keying in sockets STAND-OFF SUPPORT, PC card .3121.375 CIRCUIT CARD, motor control 2 1 141 162 134201 34 CONNECTOR & SOCKETS CONNECTOR & SOCKETS 1 1 1 8 1 PCi 183120 PLG1 115092 PLG2 115093 PLG3 115094 PLG4 115091 CONNECTOR&SOCKETS(RC1) CONNECTOR & SOCKETS (RC2) CONNECTOR & SOCKETS (RC3) CONNECTOR & SOCKETS (RC4) PLG6 136810 CONNECTOR & SOCKETS (RC6) 1 181499 CASE SECTION, bottom/rear 1 1 1 1 37 13.2 Item No (Continued) Dia. Part No. Mkgs. 37 38 :1 145948 PC2O,30. PLG25 169502 164899 Quantity Description BRACKET, mtg control box CIRCUIT CARD, display front CONNECTOR & SOCKETS (RC25) ext .625 shaft grv 1 1 1 .O45thk E 39 159264 RING, retaining 40 167633 41 167698 42 010291 WASHER, shldr .612 ID PANEL, front WASHER, flat .625 ID nylafil KNOB, pointer ACTUATOR, switch LENS, LED 4345 green NAMEPLATE, (order by model and serial number) 43 167700 44 153169 45 179201 46 x style 1 1 1 1 1 8 1 1 47 164842 48 030170 49 154933 50 154109 LENS, w/gasket BUSHING, snap-in nyl .750 ID PANEL, inner control PLATE, ident inner control PLG39 115092 CONNECTOR & SOCKETS 1 RC7 135409 CONNECTOR&SOCKETS 1 When ordering a component originally displaying a x 1 .000mtg precautionary label, the hole 1 1 1 label should also be ordered. of your equipment, use only Manufacturers Suggested Parts. Model and serial number required when ordering parts from your local distributor. To maintain the Replacement 1 METER factory original performance I 38 OM-1 586 133 Hub & Reel Support, (Fig 131 Item 12) ST-146 339-B IJ~ Hardware is common and not available unless fisted. 3 5 4 3 2 11 12 13 14 includes Item 8 8 Item No. Part No. 1 142399.. 2 010191 3 058628.. 4 058428 5 108 008 6 124900 7 +168 104 8 166594.. 9 168103.. 10 057971 11 010233 12 605941 13 136684.. 14 058427.. Description SUPPORT, reel WASHER, fbr .656 ID x 1.500 OD x .l25thk WASHER, brake sti HUB, spool 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 WASHER, flat stl keyed 1 .500dia x .l25thk SPRING, cprsn .970 OD x .120 wire x 1.250 WASHER, flat stl .640 ID x 1.000 OD x l4ga thk NUT, stl slflkg hex reg .625-11 w/nylon insert RING, retaining spool Quantity 1 2 2 1 1 1 1 1 1 1 1 1 1 1 OPTIONAL a precautionary label, the label should also be ordered. factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. +When ordering a component originally displaying To maintain the OM-1 586 39 134 Drive Assembly, Wire (Fig 13 1 Item 25) ST-801 456-A IrT Hardware is common and not available unless listed. See Section 13.6 For Drive Roll & Wire Guide Kits 19 21 17 25 6 26 2 27 28 37 36 29 30 32 40 31 OM-1586 Item No. Part No. Dia. Mkgs. Description Quantity 4 10 SCREW, cap stl sch .250-20 x 1.500 CARRIER, drive roll w/components 24 pitch 149 962 SPACER, carrier drive roll 149 486 PIN, rotation arm rocker 163 282 NUT, .250-28 stl 165 798 SPRING, pressure arm retaining 165 799 WASHER, flat .257 ID stl 132750...ARM, pressure 150 520 SPACER, rotation pin 133493... RING, retaining ext .250 shaft x .O25thk 11 133350... 1 1 010 668 ... 2 172 075 ... 3 2 ... 5 2 ... 6 2 ... 7 2 ... 8 9 12 4 ... 4 12 4 2 2 ... PIN,hinge MOTOR, gear 1/8hp 24VDC 272RPM (consisting of) 156 353 MOTOR, gear 1/8hp 24VDC 500RPM (consisting of) 153 491 KIT, brush replacement (consisting of) 153492 CAP, brush *153 493 BRUSH, carbon 155 098.... Kfl~ cover motor gearbox (consisting of) 153 550 COVER, motor gearbox (consisting of) M1,2 M1,2 156 354 2 1 ... 1 ... 1 .... 13 GASKET 155 099 cover 2 2 1 1 1 155100 SCREW,cover 154 031 SPACER, locating 133493.... RING, rtng ext .250 shaft grvx .O25thk 184 136 KIT, brush holder 5 182414...WASHER,flat 182415... PIN,cotterhair 137 248 SPRING, indicator 129 351 SCREW, hexwhd-slt stl slffmg 8-32 x .500 602 200 WASHER, lock stl split No. 8 604772 WASHER, flatstl SAE No.8 182 156 SPRING, cprsn 182 155 SPRING, cprsn 132 746... BUSHING, spring 181 522 SHAFT, spring 132 747 CARRIER, shaft 133 739 WASHER, flat .375 ID x .625 OD x .062 183330... KNOB, extension CIRCUIT CARD, digital tach (consisting of) 153 631 1 2 1 1 ... 14 15 16 17 1 1 ... 18 1 ... 19 1 ... 20 2 ... 21 1 ... 22 23 2 1 ... 24 25 26 27 1 ... 1 ... 1 ... PC51 PLG57 .. 1 1 ... CONNECTOR & SOCKETS 604 311 GROMMET, rbr .250 ID x .375mtg hole 131 203 CONNECTOR & PINS OPTICAL ENCODER DISC .132 611 149959... FITTING, brs barbed M 3/l6tbg x .312-24 179 265 ADAPTER, gun/feeder LH 108 940 SCREW, cap sti hexwhd .250-20 x .750 604 538 WASHER, flat stl SAE .312 151 437 KNOB, plstc T 1.125 Ig x .312-18 x 1.500 bar 128 237 SCREW, hexwhd-slt stl slffmg 10-32 x .500 +179 263 COVER, drive roll (consisting of) 178 937 LABEL, warning electric shock and pinch 601 872 NUT~ stl hex full .375-16 602 213 WASHER, lock stl split .375 602 243 WASHER, flat stl .375 601 966 SCREW, cap stl hexhd .375-16 x 1.250 .... 131 204.... 1 1 .... PLG58 28 .... 1 ... 1 ... 29 30 1 1 ... 31 4 ... 32 1 ... 33 34 35 1 ... 2 ... 1 ... 1 .... 36 37 38 39 1 ... 1 ... 1 ... 1 ... SPACER, locating 168 825... DRIVE, pinion 40T 24P .376 bore 133308... RING, retaining ext .375 shaft x .O25thk 167 387 40 41 42 2 ... 1 1 Part of 132 129 Optional High Speed Motor *Recommended Spare Parts. Part of Option 148 098 Two Meter w/Tach. a precautionary label, the label should also be ordered. factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. +When ordering a component originally displaying To maintain the OM-1 586 41 135 Boom Assembly (Fig 131 Item 15) ST-142 601-E \ \ 0) \ \~_ Co Co 0)~ ~ \ \ \ \ \ to cJ Co C%J N cJ IE? Hardware is common and not available unless listed. 42 OM-1 586 Quantity 1 010493 2 159991 2 159989 3 079665 3 080811 4 079664 5 139633 6 073742 7 073741 8 079029 9 075462 10 602250 11 079020 12 149858 12 080723 13 150258 14 024605 15 075101 16 079030 17 +174754 18 174688 080157 142804 134327 073666 19 047224 602246 22 079667 22 080812 23 079632 24 010910 ...25 079622 ...26 010313 27 079621 ...28 139336 149322 +When Model Part No. Item No. ordering a Description 12 BUSHING, snap-in nyl .625 ID x .875mtg hole BOOM, single BOOM, single GUIDE, wire GUIDE, wire GUIDE, wire inlet LINER, monocoil 3/32-1/8 wire x 15.687 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 SPRING, cprsn 3.750 OD x .625 wire x 36.000 SPRING, cprsn 3.750 OD x .687 wire x 33.750 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) BRACKET, mtg control tilt FITTING, grease 1/8NPT LABEL, Swingarc caution heavy spring LABEL, warning general precautionary SCREW, mach stl hexhd .750-16 x 2.750 KNOB, T-bar .500-l3thd WASHER, flat stl std .500 PIPE, plstc .500 x 133.750 PIPE, plstc .500 x 181.750 BOLT, U stl .250-20 x .875 wide x 1.375 deep WASHER, flat stl std .406 ID x .812 OD x .O65thk WASHER, shld .318 ID x .750 OD x .254thk PIN, cotter hair .072 x 1.437 PULLEY, V sgl grv 8.875dia x 8.000P x .375 bore GUARD, motor protector CLAMP, hose .405 .486c1p component originally displaying a precautionary label, the I 1 16 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 5 2 2 2 2 2 2 1 1 1 1 2 2 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-1 586 43 13,~6; Drive.RoII& Wire Guide Kits S-0549-C 0 a 0 WureSuze V-GROOVE U-GROOVE VK-GROOVE UC-GROOVE ~ w ~w 4 RoIl Drive 4 Roll Drive 4 Roll Drive 4 RoIl Drive Kit Roll Kit Roll Kit Roll Kit Roll 149518 151024 087130 150993 149518 151025 053695 0.9mm 150993 149518 151026 053700 151036 072000 151052 132958 .045in. 1.1 mm 150994 149519 151 027 053697 151 037 053701 151 053 132957 151 070 083489 .052in. 1.3mm 150994 149519 151028 053698 151038 053702 151054 132956 151071 083490 1.6mm 150995 149520 151029 053699 151039 053706 151055 132955 151072 053708 1.8 mm 150995 149520 151 056 132959 (.079in.) 2.0mm 150995 149520 151040 053704 151057 132960 151073 053710 (.094in.) 2.4mm 150996 149521 151041 053703 151058 132961 151074 053709 2.8mm 150996 149521 151 042 053705 151 059 132962 151 075 053711 3.2mm 150997 149522 151043 053707 151060 132963 151076 053712 C Fraction Metric .023-.025in 0.6mm 150993 .030in. 0.8mm .035in. (.062 in.) .068-072 in 5/64 in. 1/8 in. (.125 in.) S-0549-C Each Kit Contains An Inlet Guide, Intermediate Guide, And 045 233 Antiwear Guide With 604612 Setscrew 8-32 With 4 Drive Rolls. 2 Kits Required For Dual Models. 44 x .125, Along OM-1 586 Options and Accessories SS-60M A Skill Level Index The box to the right of the options contains a stock number of field-installed letter and number. The letter indicates the skill level required to install the option. The number indicates the approximate time required for installation (see legend). C Easy. No previous experience needed. Average. Requires removal of service panels. Mechanical ability is helpful. Difficult. May require the #160963 IAI :051 when using the 60M feeder with Miller conventional MIG power not have 1 7-pin receptacle. sources that do Power Source Data Card for XMT 304 CCCV #043 390 Simply insert the Data Card in the 60M control push of a button the eight pulse synergic programs for the XMT 304 are loaded in memory and ready to use. software use of electrical wires. splicing component parts is Weld CurrentSensor Required B more of ohmmeter and/or an Repair May require the use of an ohmmeter and ability to read a circuit diagram. Repair or replacement of component parts is complex. Technical. D the Example: replacement of or I difficult. upgrade that enables the 60M control to better communicate with other peripheral equipment and improves performance in an automatic welding B I :30 I Skill Level: B, Time: 30 minutes welding gun. Use in place of the trigger for dual scheduling. standard cell. Features: two programmable outputs, remote start/stop, remote program select, arc voltage monitor, arc error monitor and wire stuck check. and with the #041793 IAI:051 DSS-9M Two-position slide switch that attaches to the welding gun. Selects welding condition when utilizing the dual schedule feature. Gun trigger operates as standard trigger. eight XMl programs are for: Argon/CO2 .035 in steel wirewith Argon/CO2 .045 in steel wire with Argon/CO2 The .030 in steel wire with .030 in SS wire with Pulse hi-mix .035 in SS wire with Pulse hi-mix .045 in SS wire with Pulse hi-mix Wire .035 in SiB wire with For . in Argon Straightener ( mm) .035 in Nickel wire with Ar/He wire Al :051 #141580 DSS-10 Remote Increase/Decrease Switch For 1/161/8 in wire (1.63.2mm IAI:051 #141581 Reduces cast in wire. performance and tip. Improves wire feeding increases I~e of gun liner #042749 IAI:051 Two-position, momentary contact switch that attaches to the welding gun. Use with the Remote Parameter Increase/Decrease feature parameters at the welding gun welding. Gun trigger operates as standard trigger. to fine tune and contact while High-Speed Motor For single and right side of dual #132129 Factory only 60MDataCard #155910 For left side of dual wire models. Blank Card. Stores up to 32 complete weld programs. Ideal for saving custom programs and models. transferring programs to other 60M feeders. #132130 Factory only speed range of 901400 1PM (2.335.6 m/min). Not recommended for wire sizes larger than 5/64 in (2.0 mm). Provides wire Same speed motor must be used on each side of the dual wire models. Factory-written synergic Pulse MIG programs will not operate with high-speed motor. Adjustable Spool Carrier #096 075 I A 1:20 I For use only with Swingarc models with 6 ft (1.8 m) pipe post mounted on Swingpak base. Replaces standard spool assembly. Positions welding wire lower for easier loading and unloading. Extension Cords For optimum performance, do not extend 60M more than 60 ft (18 m) from power feeder source. 14-Pin Extension Cord Dual Schedule Switches For use with Dual Schedule Control ki 60M feeder. #043690 #043691 25ft(7.6m) 50ft(15m) Water Coolant Selectors Remote Program RPS-8 #160977 Field Systems Systems literature, Refer to Water Coolant ____ RPS-8 Mini Eight-position IBI:201 #173047 Field I B 1:20 rotary switch used to remotely select weld programs. 33 ft (10 m) cord. Automation Upgrade Module This module consists of OM-1 586 an Index No. AY/7.2. I Includes DSS-8 #172 886 I/O board and #079693 Al :051 Requires adapter cord #157364. Two-position trigger switch that easily attaches to the and Accessories Continued Options One of the is following required for mounting Swingarc~ booms: the SS-60M and DS-60M Swingpak Base pipe post with base plate CBC Cart (for use with 12 ft 3.7 ml model only) the 6 ft (1.8 m) pipe post without base plate (ordered separately) Pipe The Post Bases Swingpak~ Swingpak-1 2 base to mount a 12 ft Swingpak-16 base is for use witha l6ft(4.9m)boom. Order a (3.7 m) boom. The 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 with a a three-compartment The entire unit storage locker. can be moved forklift truck CBC Carts For use Specifications and Ordering Information with 12 ft (3.7 m) boom only. The Weight Ship Weight Model Slock No. Length Width Nd CBC Cartaccommodatesa power source, 12ft (3.7 m) Swingarc feeder, and two gas cylinders. Swingpak-12 #085 276 65 in (1.7 m) 50‰ in (1.3 m) 412 lb (187 kg) 418 lb #085 934 79 in (2.0 m) 66‰ in (1.7 m) 504 lb (229 kg) 510 lb Designed to provide mobility and a neat, orderly arrangement of welding equipment Swingpak-16 (231 kg) CBC Carl #152 638 68 in (1.7 m) 34 in (864 mm) 295 lb (134 kg) 434 lb (197 kg) CBC-HD Cart #152 637 70 in (1.8 m) 34 in (864 mm) 328 lb (149 kg) 510 lb (231 kg) The CBC is the standard model with lOin 2 in wide (51 mm) heavy-duty model is designed for use on rough or uneven surfaces and features 12 in (305 mm) diameter by 3 in (76 mm) wide wheels. (254 mm) diameter by wheels. The CBC-HD Note: The 4 ft (1.2 rn) pipe post is recommended for (4.9 m) Swingarc use not with the CBC Cart. The 16 ft base 4ft(1.2m) no 4 ft with base (1.2 m) 6ft(1.8m)nobase 6 ft (1.8 m) with base For 12 ft Boom (3.7 m) (18 in (457 mm) Base Plate) (24 (4.9 m) Boom (610 mm) Base Plate) For 16 ft in #075018 #075078 #149 838 #078 264 #019217 #079217 #149 839 #079 216 feeder cannot be used. CBC Cart Features 2000 lb Pipe Post Model (190 kg) CBC Cart with 12 ft (907 kg) load capacity Swingarc SS-60M, cylinder. Maxtron 450 power source and gas Multi-position boom Swing-out outriggers Wide front-wheel stance and automotive- type steering Mounting power facilities for most Miller CV sources Compartment in base of cartto add ballast weight when using lightweight power sources. Minimum ballast weight of 300 lb (136 kg) required Fold-up gas bottle loading Order 6 ft (1.8 m) Pipe only Post #079 217 a ramp I OM-1 586 fi (Equipment with This limited warranty Effective January 1, 1997 serial number preface of KH supersedes previous alt guarantees or Subject to the terms and conditions Mtg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN Miller newer) Miller warranties and is exclusive with warranties LIMITED WARRANTY below, or a expressed or no other implied. Millers True Bluefi Limited Warranty shall not apply to: Electric 1. Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturers warranty, if any. OR OF 2. Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear. 3. LIEU OF OTHER WARRANTIES, EXPRESS INCLUDING WARRANTIES THE MERCHANTABILITY AND FITNESS. ALL IMPLIED, notified in within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the claim procedures to be followed. warranty writing Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that 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 Equipment that has been modified 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. than Miller, or the an 1. 2. International distributor. 5 Years Parts 3 * Original * Inverters 3 Years Warranty Questions? Call (input and output 3. rectifiers In the event of Parts and Labor Transformer/Rectifier Power Sources * Semi-Automatic and Automatic Wire Feeders * Inverter Power * Intellitig * Robots Cutting Supplies allowed. Motor Driven Guns Process Controllers * IHPS Power Sources * Water Coolant * HF Units * Grids * Spot * Systems ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR Welders Load Banks REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY SDX Transformers OTHER * Cyclomatic Equipment Running Gear/Trailers Plasma Cutting Torches (except APT, ZIPCUT & PLAZCUT Models) Deutz Engines (outside North America) Field Options (NOTE: Field options are covered under True Bluefi for the remaining warranty period of the product they * * Miller installed in, or for whichever is greater.) are 4. 6 Months 5. 90 * Days a minimum of one year Batteries Parts and Labor MIG Guns/TIG Torches APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches Remote Controls 77w Power ofBlue. TO THE EXTENT PERMuTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY. * * Miller the the Parts and Labor * warranty claim covered by this warranty, appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customers risk and expense. Millers option of repair or replacement will be FOB., Factory 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 Power Sources (1 year labor) Engine Driven Welding Generators (NOTE: Engines are warranted separately by engine manufacturer.) 1 Year a exclusive remedies shall be, at Millers option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in only) * * 1-800-4-A-MILLER for your local Miller distributor. Years Labor main power rectifiers Plasma Arc MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT. * Accessory Kits Replacement Parts (No labor) LEGAL THEORY WHICH, BUT FOR THIS MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER. PROVISION, Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state. In Canada, legislation additional warranties herein, and in some or provinces provides remedies other than to the extent thaI they may not be for certain as stated waived, the limitations and exclusions set out above may not appty. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province. miller warr 1/97 Owners Record S Please complete and retain with your personal records. Serial/Style Number Model Name Purchase Date (Date when equipment wae delivered to original cuetomer.) Distributor Address City State lip Resources Available Always provide Model Name and Serial/S tyle Number. Contact your Distributor for: Welding Supplies Options To locate the distributor nearest you, call and Consumables and Accessories Personal Safety Equipment 1-800-4-A-Miller. Service and Miller Electiic Repair Mfg. An Illinois Tool Wodcs Replacement Parts 1635 west Appleton, Training (Schools, Videos, Books) Owners Co. company Spencer Street WI 54914 USA International Headquarters-liSA Phone: 414-734-9821 USA & Canada FAX:414-735-4134 Manuals Technical Manuals (Servicing Information and International FAX: 414-735-4125 European Headquarters KIngdom Phone: 44 (0) 1625-525556 FAX: 44 (0)1625-537553 Parts) United Circuit Diagrams Welding Process Contact the Delivering Carrier to: For assistance in File a Handbooks claim for loss or damage during shipment. settling claims, equipment manufacturers Transportation Department. tiling or contact your distributor andfor p U/A Miller w PAINTED IN USA ' lgg7 Miller Etecthc Mtg. Co. The Power ofB&