Miller GA-5OGL Specifications

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
~
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IdlE>>
an
V
~
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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
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Id11-7>>
I
9
?
9
~
Fe1-3
~
(
SRi
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>
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~
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pp
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PS. ~4
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14491
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15-3>
pci
4.01(54 CIA(S)
PS. ajir,cins
~ I
si-s 7>
Fe-I>>
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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
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Mtg.
Co.
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