Miller Robotic Interface II Owner`s manual

OM-172 324D
September1998
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Automatic Welding
Description
Automatic Welding Interface
Robotic Interface II
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller.
Now you can get the job done and get it done right. We
know you don’t have time to do it any other way.
That’s why when Niels Miller first started building arc
welders in 1929, he made sure his products offered
long-lasting value and superior quality. Like you, his
customers couldn’t afford anything less. Miller
products had to be more than the best they could be.
They had to be the best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
Miller is the first welding help you figure out what the problem is. The
equipment manufacturer in parts list will then help you to decide which
the U.S.A. to be registered to
the ISO 9001 Quality System exact part you may need to fix the problem.
Standard.
Warranty and service information for your
particular model are also provided.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
Miller offers 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 supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor
to receive the latest full line catalog or
individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller,
or visit us at www.MillerWelds.com on the web.
TABLE OF CONTENTS
OM-172 324D
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . .
1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
3
4
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
5
7
8
8
SECTION 2 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Rear Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Connecting Optional Emergency Stop Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
9
10
11
SECTION 3 – OPERATIONAL TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
SECTION 4 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Work Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Sequence Of Gas Metal Arc (GMAW), Gas Metal Arc - Pulse (GMAW-P),
And Flux Cored Arc Welding (FCAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Control Settings On Deltaweld 452/652 Ampere Model Welding Power Source . . . . . . . . .
4-7. Control Settings On Dimension 452 Or 652 Ampere Model Welding Power Source . . . . .
4-8. Control Settings On XMT 304 Inverter Model Welding Power Source . . . . . . . . . . . . . . . . .
4-9. Control Settings On Invision 456P Inverter Model Welding Power Source . . . . . . . . . . . . .
4-10. Setting Switches On Maxtron 450 Ampere Inverter Model Welding Power Source . . . . . .
13
13
13
14
15
15
15
16
17
18
19
SECTION 5 – INTRODUCTION TO PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Interface Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Pulse MIG Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Standard Pulse Welding Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Pulse Panel Mode Select Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Pulse Panel Parameter Select Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Pulse Panel Parameter Increase And Decrease Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
19
20
20
29
30
31
SECTION 6 – GETTING STARTED FOR PULSE WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Weld Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Setting Preflow Sequence Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Setting Weld Sequence Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Setting Crater Sequence Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Setting Postflow Sequence Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
32
33
33
34
34
SECTION 7 – TEACHING A PULSE WELDING PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Pulse Waveforms And Explanation Of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Typical Teach Point Settings And Resulting Synergic Setting . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Selecting Teach Point Wire Feed Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Setting Teach Point Parameters On The Pulse Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Changing To Adaptive Pulse Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
35
36
37
38
40
(Continued)
TABLE OF CONTENTS
SECTION 8 – TEACHING A MIG WELDING PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Weld Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Changing To MIG In The Process Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Setting Sequence MIG Welding Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
41
42
43
SECTION 9 – USING THE OPTIONAL DATA CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Installing Data Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Data Card Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Naming Programs And Writing To Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-4. Reading From Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-5. Reading (Or Deleting) From An Empty Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-6. Deleting Programs From Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
47
47
48
49
49
50
SECTION 10 – SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Setup Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Using Setup Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3. Selecting Welding Power Source Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-4. Selecting Security Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-5. Selecting Or Changing Access Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-6. Selecting Voltage Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-7. Selecting Inductance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-8. Selecting Purge Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-9. Selecting Voltage Sensing Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-10. Selecting Arc Start Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-11. Resetting Arc Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-12. Selecting Units For Wire Feed Speed And Motor Type . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-13. Selecting Wire Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-14. Selecting Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-15. Resetting Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-16. Selecting Arc Start/Volt Sense Error Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-17. Selecting Program Name Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-18. Remote Program Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-19. Stick Check Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-20. Jog Wire Feed Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-21. Robot Type Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-22. Arc Voltage Error Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-23. Software Version Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
51
52
53
54
55
56
56
56
57
57
58
58
59
59
60
60
61
61
61
62
62
63
63
SECTION 11 – CONTROL MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1. Using Menu Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-2. Setting Rise Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
64
64
65
SECTION 12 – MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-2. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-3. Front Panel Error Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-4. Error Displays (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-5. Interface Board PC5 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-6. Diagnostic LED’s On Interface Board PC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-7. Customer Interface Board PC4 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-8. Diagnostic LED’s On Interface Board PC4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
66
66
66
67
68
69
69
70
71
SECTION 13 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
SECTION 14 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
88
OPTIONS AND ACCESSORIES
WARRANTY
ROBOTIC INTERFACE II SET-UP INFORMATION
Please fill out the following information when setting up your equipment. It can be used for your records and also
be valuable if you ever need to call for service.
Model: ROBOTIC INTERFACE II, Serial Number:
Software Version
SET-UP INFORMATION (found in set-up menu)
Range:
min V
max V
min A
max A
Shutdown: off
Program Remote Select: on
off on
Security:
off
on
Stick Check: Access:
off
on
Jog IPM:
Mig Type:
dvc on
Robot:
off
off
power source,
wire gas, and analog
Arc on and analog
Arc on and no analog
total control
Inductance:
Monitor Arc Voltage Error:
Purge:
Voltage: Arc Start:
standard
Wire Feed:
ipm
mpm
Display:
actual command
amps
hot
on
17 pin
off
Range
Seconds
Vsense
Arc Time:
Wire Type:
hardwire
softwire
OTHER IMPORTANT INFORMATION
Wire Size:
Type:
Program#:
Mig or Pulse:
Wire Speed:
factory
Gas:
custom
Voltage/Trim:
Weld Cable Size:
Approx. Length:
Material Type:
Thickness:
Travel Speed:
Type of Joint:
on
Declaration of Incorporation for
European Community (CE) Products
Miller Electric Mfg. Co.
Manufacturer’s Name:
1635 W. Spencer Street
Appleton, WI 54914 USA
Manufacturer’s Address:
Declares that the product:
Robotic Interface II
conforms to the following Directives and Standards:
Directives
Electromagnetic Compatibility Directives: 89/336/EEC, 92/31/EEC
Low Voltage Directive: 73/23/EEC
Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC
Standards
Safety Requirements for Arc Welding Equipment Part 1: EN 60974-1: 1990
Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1
(April 1995 – Draft revision)
Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989
Insulation coordination for equipment within low-voltage systems:
Part 1: Principles, requirements and tests: IEC 664-1: 1992
Electromagnetic compatibility (EMC) Product standard for arc welding equipment:
EN50199: August 1995
European Contact:
Telephone:
Fax:
dec_con1 10/95
Danilo Fedolfi, Managing Director
MILLER Europe S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
39(02)98290-1
39(02)98290-203
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_5/97
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-4. Read and follow all
Safety Standards.
If earth grounding of the workpiece is required, ground it directly
with a separate cable – do not use work clamp or work cable.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Y During operation, keep everybody, especially children, away.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on
unit.
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
Keep your head out of the fumes. Do not breathe the fumes.
Always verify the supply ground – check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding conductor first – double-check connections.
Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do not drape cables over your body.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
If ventilation is poor, use an approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the 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 off toxic fumes if welded.
OM-172 324 Page 1
ARC RAYS can 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. Sparks fly off from the
weld.
Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
Protect yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side
shields even under your welding helmet.
OM-172 324 Page 2
BUILDUP OF GAS can injure or kill.
Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
Do not touch hot parts bare handed.
Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
Pacemaker wearers keep away.
Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder – explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
Do not install or place unit on, over, or near
combustible surfaces.
Do not install unit near flammables.
Do not overload building wiring – be sure power supply system is
properly sized, rated, and protected to handle this unit.
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
OVERUSE can cause OVERHEATING
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
Do not block or filter airflow to unit.
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
WELDING WIRE can cause injury.
Do not press gun trigger until instructed to do
so.
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent 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.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-172 324 Page 3
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-172 324 Page 4
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT
UTILISATION
som _nd_fre 5/97
1-1. Signification des symboles
Signifie Mise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés
par des symboles adjacents aux directives.
Identifie un message de sécurité particulier.
Signifie NOTA ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des
risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN
MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles
et aux directives ci-dessous afin de connaître les mesures à prendre pour
éviter tout danger.
1-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques
de danger. Lorsque vous voyez un symbole, soyez vigilant et
suivez les directives mentionnées afin d’éviter tout danger. Les
consignes de sécurité présentées ci-après ne font que résumer
l’information contenue dans les normes de sécurité énumérées
à la section 1-4. Veuillez lire et respecter toutes ces normes de
sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.
Au cours de l’utilisation, tenir toute personne à l’écart et plus particulièrement les enfants.
Ne pas toucher l’électrode quand on est en contact avec la pièce, la
terre ou une électrode provenant d’une autre machine.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément
à ce manuel.
Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
Fixer le câble de retour de façon à obtenir un bon contact métal-métal
avec la pièce à souder ou la table de travail, le plus près possible de la
soudure.
UN CHOC ÉLECTRIQUE peut tuer.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est sur ON. Le circuit d’entrée et les
circuits internes de l’appareil sont également sous
tension à ce moment-là. En soudage semi-automatique ou automatique,
le fil, le dévidoir, le logement des galets d’entraînement et les pièces
métalliques en contact avec le fil de soudage sont sous tension. Des
matériels mal installés ou mal mis à la terre présentent un danger.
Il y a DU COURANT CONTINU IMPORTANT dans les
convertisseurs après la suppression de l’alimentation électrique.
Arrêter les convertisseurs, débrancher le courant électrique, et décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie entretien avant de toucher les pièces.
Ne jamais toucher les pièces électriques sous tension.
Porter des gants et des vêtements de protection secs ne comportant
pas de trous.
S’isoler de la pièce et de la terre au moyen de tapis ou d’autres
moyens isolants suffisamment grands pour empêcher le contact physique éventuel avec la pièce ou la terre.
Ne pas se servir de source électrique àcourant électrique dans les zones
humides, dans les endroits confinés ou là où on risque de tomber.
Se servir d’une source électrique àcourant électrique UNIQUEMENT si le
procédé de soudage le demande.
Si l’utilisation d’une source électrique àcourant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de
sécurité).
Installer et mettre à la terre correctement cet appareil conformément à
son manuel d’utilisation et aux codes nationaux, provinciaux et
municipaux.
Toujours vérifier la terre du cordon d’alimentation – Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la
borne de terre du sectionneur ou que la fiche du cordon est raccordée
à une prise correctement mise à la terre.
En effectuant les raccordements d’entrée fixer d’abord le conducteur
de mise à la terre approprié et contre-vérifier les connexions.
Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas
endommagé ou dénudé – remplacer le cordon immédiatement s’il est
endommagé – un câble dénudé peut provoquer une électrocution.
Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct – ne pas utiliser le connecteur de pièce ou le câble de
retour.
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
Eloigner votre tête des fumées. Ne pas respirer
les fumées.
A l’intérieur, ventiler la zone et/ou utiliser un échappement au niveau
de l’arc pour l’évacuation des fumées et des gaz de soudage.
Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air homologué.
Lire les spécifications de sécurité des matériaux (MSDSs) et les
instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.
Travailler dans un espace fermé seulement s’il est bien ventilé ou en
portant un respirateur à alimentation d’air. Demander toujours à un
surveillant dûment formé de se tenir à proximité. Des fumées et des
gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations de
dégraissage, de nettoyage ou de pulvérisation. La chaleur et les
rayons de l’arc peuvent réagir en présence de vapeurs et former des
gaz hautement toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien
ventilé, et si nécessaire, en portant un respirateur à alimentation
d’air. Les revêtements et tous les métaux renfermant ces éléments
peuvent dégager des fumées toxiques en cas de soudage.
OM-172 324 Page 5
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et
sur la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer
des brûlures dans les yeux et sur la peau. Des étincelles sont projetées
pendant le soudage.
Porter un casque de soudage muni d’un écran de filtre approprié pour
protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
Porter des protections approuvés pour les oreilles si le niveau sondre est
trop élevé.
Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair
et de l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.
Porter des vêtements de protection constitué dans une matière durable, résistant au feu (cuir ou laine) et une protection des pieds.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent être
projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec des
objets métalliques peut provoquer des étincelles, une explosion, un
surchauffement ou un incendie. Avant de commencer le soudage, vérifier
et s’assurer que l’endroit ne présente pas de danger.
Se protéger et d’autres personnes de la projection d’étincelles et de
métal chaud.
Ne pas souder dans un endroit là où des étincelles peuvent tomber sur
des substances inflammables.
Déplacer toutes les substances inflammables à une distance de 10,7
m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués.
Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et
des ouvertures.
Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
Ne pas effectuer le soudage sur des conteneurs fermés tels que des
réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les normes de
sécurité).
Brancher le câble sur la pièce le plus près possible de la zone de soudage pour éviter le transport du courant sur une longue distance par
des chemins inconnus éventuels en provoquant des risques d’électrocution et d’incendie.
Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef.
Avant de souder, retirer toute substance combustible de vos poches
telles qu’un allumeur au butane ou des allumettes.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
Le soudage, l’écaillement, le passage de la pièce
à la brosse en fil de fer, et le meulage génèrent
des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.
Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
OM-172 324 Page 6
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.
Ne pas toucher des parties chaudes à mains nues
Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
Porteurs de stimulateur cardiaque, restez à distance.
Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher
des opérations de soudage à l’arc, de gougeage ou
de soudage par points.
LE BRUIT peut affecter l’ouïe.
Le bruit des processus et des équipements peut affecter
l’ouïe.
Porter des protections approuvés pour les oreilles si
le niveau sondre est trop élevé.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz
font normalement partie du procédé de soudage, les
manipuler avec précaution.
Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des arcs.
Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de
se renverser.
Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
Une électrode de soudage ne doit jamais entrer en contact avec une
bouteille.
Ne jamais souder une bouteille pressurisée – risque d’explosion.
Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la
bouteille.
Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille.
Lire et suivre les instructions concernant les bouteilles de gaz comprimé, les équipements associés et les publications P-1 CGA énumérées dans les normes de sécurité.
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
DES ORGANES MOBILES peuvent
provoquer des blessures.
Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces infllammables.
Rester à l’écart des organes mobiles comme le
ventilateur.
Maintenir fermés et fixement en place les portes,
panneaux, recouvrements et dispositifs de
protection.
Ne pas installer l’appareil à proximité de produits inflammables
Ne pas surcharger l’installation électrique – s”assurer que l’alimentation est correctement dimensionné et protégé avant de mettre
l’appareil en service.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
LA CHUTE DE L’APPAREIL peut
blesser.
Utiliser l’anneau de levage uniquement pour soulever l’appareil, NON PAS les chariot, les bouteilles de gaz ou tout autre accessoire.
Utiliser un engin d’une capacité appropriée pour
soulever l’appareil.
En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du côté
opposé de l’appareil.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
Prévoir une période de refroidissement, respecter le cycle opératoire nominal.
Réduire le courant ou le cycle opératoire avant de
recommancer le soudage.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
Ne pas obstruer les passages d’air du poste.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimes.
DES ORGANES MOBILES peuvent
provoquer des blessures.
Ne pas s’approcher des organes mobiles.
Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent provoquer des blessures.
Ne pas appuyer sur la gachette avant d’en avoir
reçu l’instruction.
Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil
de soudage.
Le rayonnement haute frequence peut provoquer
des interférences avec les équipements de radio–navigation et de communication, les services
de sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance
correcte et utiliser une terre et et un blindage pour réduire les interférences éventuelles.
L’énergie électromagnétique risque de provoquer
des interférences pour l’équipement électronique
sensible tel que les ordinateurs et l’équipement
commandé par ordinateur tel que les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il
incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de
travail.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
Porteurs de stimulateur cardiaque, restez à distance.
Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.
OM-172 324 Page 7
1-4. Principales normes de sécurité
Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS
F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL
33126
National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Règles de sécurité en soudage, coupage et procédés connexes, norme
CSA W117.2, de l’Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et sur les effets, pour l’organisme,
des champs magnétiques basse fréquence
Afin de réduire les champs électromagnétiques dans l’environnement
de travail, respecter les consignes suivantes :
1
Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore
un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs
magnétiques et champs électriques à haute fréquence représente un
risque à la santé humaine”. Toutefois, des études sont toujours en cours
et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait
souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage.
OM-172 324 Page 8
2
3
4
5
Garder les câbles ensembles en les torsadant ou en les
attachant avec du ruban adhésif.
Mettre tous les câbles du côté opposé de l’opérateur.
Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
Garder le poste de soudage et les câbles le plus loin possible de
vous.
Relier la pince de masse le plus près possible de la zone de
soudure.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est
alors recommandé de respecter les consignes ci–dessus.
SECTION 2 – INSTALLATION
2-1. Specifications
Specification
Description
Type Of Input Power From Welding
Power Source
Single-Phase 115 Volts AC, 5 Amperes, 50/60 Hertz
Welding Power Source Type
Constant Voltage (CV) DC, With Contactor And 14-Pin Remote Control For GMAW Welding
Constant Voltage (CV)/Constant Current (CC) DC Inverter, With Contactor And 14-Pin Remote
Control For GMAW-P Welding
Wire Feed Speed Range*
Standard: 50 To 780 ipm (1.3 To 19.8 mpm)
Wire Diameter Range
.030 To .062 in (0.8 To 1.6 mm)
Welding Processes
Gas Metal Arc (GMAW), Gas Metal Arc - Pulse (GMAW-P), Flux Cored Arc (FCAW), And
Submerged Arc Welding (SAW)
Overall Dimensions
Length: 21-3/4 in (552 mm); Width: 15-1/4 in (387 mm); Height: 10 in (254 mm)
Weight
Ship: 75 lb (34 kg)
*These are the wire feed speed ranges while GMAW welding. While Pulse welding, the wire feed speed ranges may be more limited (see
Section 6).
2-2. Connection Diagram
The proper interface kit must be installed in the interface unit to
1
Robot (Will Vary According To
Application)
2
Motor/Drive Assembly
3
Positive (+) Voltage Sensing
Lead
4
Gas Cylinder
5
Gas Hose
6
Robot Control
7
Robot Input/Output Cable
8
Remote Program Select
Cable (Optional)
9
Gas And Motor Control Cable
allow it to be connected to the robot.
6
2
3
4
5
1
10 Interface Unit
7
11 Welding Power Source
8
12 17-Socket Plug And Interconnecting Cord
17
9
13 14-Socket Plug And Interconnecting Cord
14 Negative (–) Weld Cable
15 Workpiece
16 Negative (–) Voltage Sensing
Lead
15
10
16
17 Positive (+) Weld Cable
11
12
13
14
Adapter cord 043551 must be ordered when using an inverter power source equipped with
only a 14-socket receptacle.
ST-801 078-A
OM-172 324 Page 9
2-3. Rear Panel Connections
1
2
B
C
A
M
L
K
J
P NT
R S
D
E
FG
1
Receptacle
2
Keyway
3
14-Pin Receptacle (Connection To Welding Power
Source)
4
17-Pin Receptacle (Connection To Welding Power Source
With 17-Pin Receptacle)
5
19-Socket Receptacle (Motor/
Shielding Gas Control
Connection To Motor Drive
Assembly)
6
10-Socket Receptacle (Optional Remote Program Select
Connection To Robot Control)
H
Example Receptacle
To connect matching interconnecting cord to one of the above receptacles, align keyway, insert plug,
and tighten threaded collar. Connect remaining end of cord to
matching receptacle on applicable
equipment (see Section 2-2).
8
7
7
4-Pin Receptacle (Optional
External Voltage Sensing
Connection)
To connect interconnecting cord to
receptacle, align keyway, insert
plug, and tighten threaded collar.
3
6
Cord for voltage sensing connection divides in two. Secure ring terminal on one cord to clamp and attach clamp to work. Secure ring terminal on remaining cord to motor/
drive assembly where weld cable is
connected.
8
5
4
If optional external voltage sensing connections are used, remove
Interface Panel (Robot Control Connection)
Receptacle will vary according to
the robot control being used with
the system. Follow connection
directions included with interface
panel kit.
jumper link from across terminals D and E on internal terminal strip
2T and install jumper link across terminals C and D. See Section 2-4
for the location of 2T.
Ref. S-0003-A / ST-800 962-A
OM-172 324 Page 10
2-4. Connecting Optional Emergency Stop Push Button
Terminal strip 2T provides connection points for an optional normally
closed Emergency Stop (E-stop)
push button. To make connections,
proceed as follows.
Remove top cover.
2
1
Terminal Strip 2T
2
Strain Relief
Loosen strain relief and insert leads
from normally closed E-stop push
button. Route leads to 2T.
1
Remove jumper link across terminals A and B on 2T. Keep for future
use.
Connect one lead from E-stop
switch to terminal A and the remaining lead to terminal B.
Tools Needed:
1/4 in
Tighten strain relief and reinstall top
cover.
ST-801 146
SECTION 3 – OPERATIONAL TERMS
The following is a list of terms and their definitions as they apply to this interface unit:
General Terms:
Adaptive Pulse Welding
When the “adaptive pulse” welding process is selected, the unit will automatically regulate pulse frequency in order to maintain a constant arc length, regardless of change in welding wire stickout.
Abk (Background
Amperage)
Abk is the low weld current. Background current preheats welding wire and
maintains the arc. When background current is too low, the arc is unstable and
hard to maintain.
Apk (Peak Amperage)
Apk is the high pulse of welding current. Peak current melts the welding wire
and forms a droplet. The droplet is forced into the weld puddle.
In short circuit GMAW welding, an increase in inductance will decrease the
number of short circuit metal transfers per second (provided no other changes
are made) and increase the arc-on time. The increased arc-on time makes the
pool more fluid.
Inductance
PPS (Pulses Per Second)
PWms (Pulse Width in
Milliseconds)
PPS, pulse rate, and frequency (Hz) are used interchangeably. A PPS or pulse
rate of 60 Hz means 60 pulses of current are produced each second.
PWms is the time spent at peak current (1.2 ms is .0012 seconds). This time
must be long enough to form a droplet of welding wire. The stiffness or fluidity
of the molten weld puddle is controlled by PWms.
Synergic
Synergic refers to the unit’s ability to use preprogrammed pulse parameters to
determine the actual pulse settings of Peak Amperage, Background Amperage,
Pulse Frequency and Pulse Width at any specific wire feed speed setting.
Trim
Term used to represent arc length adjustments in pulse programs. Increasing
trim increases the actual arc length. Likewise, decreasing trim shortens arc
length. Trim is replaced by volts in MIG programs.
Pulse Panel Terms:
Card Mode
Is used to select use of the optional data card storage and retrieval capabilities.
Process Mode
Is used to select the type of process to be used, including Pulse, Adaptive
Pulse, or Mig.
Sequence Mode
Is used to select and program the weld sequences which include preflow, runin, weld, crater, burnback, and postflow.
OM-172 324 Page 11
Setup Screen Terms:
Access Code
NOTE: The optional Data Card is required to activate this feature. With code
off, access to the setup displays is not restricted. With code on, the operator
must know and enter the access code to access or change any of the setup
displays.
To use code, press Parameter Select button to enter access code. When the
correct letter is entered, the indicator automatically moves to the next character. When the final access code letter is entered, the display automatically
changes to the initial setup display.
Arc Start
NOTE: Do not use the Hot Start setting for .035 in (9 mm) or smaller wire. Use
the Hot Start mode for pulse welding with 450 Ampere Inverter Model when
high initial weld current is necessary to start large diameter welding wires.
When in Hot Start, the 450 Ampere Inverter Model starts the arc in the CV
mode and switches to CC once the arc is started. Do not use Hot Start unless
using 450 Ampere Inverter Model.
Arc Time
Allows actual arc time up to 9,999.99 hours and weld cycles up to 999,999 to
be accumulated and displayed on the digital display, and can be reset to zero
as required.
Mig Type (Voltage
Correction)
With DVC Voltage Correction On, the unit uses closed-loop feedback from the
17-pin cord or voltage sensing leads to maintain set voltage parameters. With
DVC Voltage Correction Off, feedback from the arc is not used for closed-loop
feedback to maintain voltage parameters. Feedback from the arc is still used
for other functions.
Be sure voltage sensing leads are connected or voltage feedback is available
through the 17-pin receptacle via the welding power source.
Name Feature
When using the optional Data Card and turning the name feature on, programs
written to the card can be identified by name, number, job number, etc.
Program Reset
By selecting program reset in the memory reset mode, the unit defaults to original factory program settings for the program last active. All other program and
setup information remains the same.
Range
The interface requires that the voltage and amperage range of the welding
power source be entered. Obtain this information from the welding power
source Owner’s Manual.
Security
NOTE: The optional Data Card is required to activate this feature. Is used to
limit what the operator can control. This includes accessing the number of the
program, 1 through 8, and the range of welding parameters within the program.
Software Screen
Selection of this function will display the software version of the unit. When
talking with factory service personnel, this number may be required.
System Reset
By selecting system reset in the memory reset mode, the unit defaults to original factory settings for all programs and all set up excluding System, Arc Time,
and Model Type.
Voltage (Control Feedback)
Allows voltage to be monitored at the output terminals by two methods. This
can be selected through the 17-pin cord connection if the welding power source
has a 17-pin receptacle, or through the unit’s external voltage sense lead.
If the 17 Pin setting is used, it is recommended that the voltage sensing terminals on the welding power source be used to monitor arc voltage at the workpiece.
When using the V. Sense setting, arc voltage feedback is through the voltage
sense leads connected to the feeder. Use this setting when there is more than
50 ft (15 m) of weld cable used.
Arc Start/Volt Sense
Shutdown
When this feature is on, the system immediately shuts down if no arc voltage is
sensed. An error message is displayed. When this feature is off, wire feeds
even when there is no arc voltage sensed.
Wire Feed Mode
Allows the selection of inches per minute or meters per minute for wire feed
speed. This mode is also used to select motor type; standard speed, low
speed, or high speed. High speed motor is available as factory option.
OM-172 324 Page 12
SECTION 4 – OPERATION
4-1. Safety Equipment
1
2
3
Wear the following while welding:
1
Dry, Insulating Gloves
2
Safety Glasses With Side
Shields
3
Welding Helmet With Correct
Shade Of Filter (See ANSI
Z49.1)
sb3.1 1/94
4-2. Work Clamp
1
1
Tools Needed:
Work Clamp
Connect work clamp to a clean,
paint-free location on workpiece, as
close to weld area as possible.
Use wire brush or sandpaper to
clean metal at weld joint area. Use
chipping hammer to remove slag
after welding.
sb4.1* 2/93
OM-172 324 Page 13
4-3. Controls
Front Panel
3
2
1
1
Display
2
Reset Button
After clearing an error, press this
button to reset the display.
3
Purge Button
Push to energize gas valve. If a
purge time value is programmed,
the gas will flow for the programmed
length of time. If a value is not programmed, the gas flows until the
Purge button is released.
8
7
This button allows purging of air
from gun shielding gas line, and adjusting shielding gas regulator without energizing the welding circuit.
6
5
Front panel and pulse panel controls, and the gun trigger do not
work when the Purge button is
pressed.
4
4
Front Panel
Contactor On Light
Lights when welding power source
contactor is energized.
9
5
10
Wirefeed On Light
Lights when wirefeed motor is On.
11
6
Gas On Light
Lights when gas flow is On.
7
12
8
13
Retract Button
Push to retract welding wire without
energizing welding circuit or shielding gas valve.
Advance Button
Push to feed welding wire without
energizing welding circuit or shielding gas valve.
Pulse Panel
14
9
Display
10 Data Card Slot
Insert optional data card here. See
Section 9 for information on using
the data card.
Pulse Panel
11 Increase Button
12 Decrease Button
13 Parameter Select Button
15
14 Mode Select Button
See Section 5 for information on using pulse panel controls.
Rear Panel
15 Power Switch
User power switch to tun unit On
and Off.
Rear Panel
ST-800 755-B / ST-800 962-A
OM-172 324 Page 14
4-4. Shielding Gas
1
Shielding Gas Cylinder
2
2
Valve
1
Open valve on cylinder just before
welding.
Close valve on cylinder when finished welding.
sb5.1* 6/92 – S-0621-C
4-5. Sequence Of Gas Metal Arc (GMAW), Gas Metal Arc - Pulse (GMAW-P),
And Flux Cored Arc Welding (FCAW)
Install & Connect
Interface Into
Welding System
Put On
Personal Safety
Equipment
Adjust Weld
Parameters
As Needed
Turn On
Welding System
Equipment
Turn On Shielding
Gas
Set All Controls
And Verify
Program Selection
Perform Test
Weld
Begin
Welding
ssb6.1* 9/92
4-6. Control Settings On Deltaweld 452/652 Ampere Model Welding Power Source
Set controls as shown for all
welding processes when
using this interface unit.
1
2
Voltage Adjustment Control
Voltage Control Switch
Position of Voltage Adjustment control does not matter when Voltage
Control switch is in REMOTE position.
1
2
ST-800 453 / Ref. ST-162 502-B
OM-172 324 Page 15
4-7. Control Settings On Dimension 452 Or 652 Ampere Model Welding Power Source
1
Dimension 452 Model
Hot Start Switch
3
Amperage/Voltage Adjustment
Control
Setting at controls and switch position does not matter when Process
Selector switch is in GMAW position and remote Amperage/Voltage
Control switch is in REMOTE position.
Set controls as shown for all
welding processes when using this interface unit.
1
Arc Force (Dig) Control
2
2
3
26 28
2224
20
30
18
32
16
34
14
36
12
ST-800 166-B / Ref. ST-161 964-A
Dimension 652 Model
Arc Force (Dig) Control
2
Amperage/Voltage Adjustment
Control
Setting at controls does not matter
when Process Selector switch is in
GMAW position and remote Amperage/Voltage Control switch is in
REMOTE position.
Set switches as shown for all
welding processes when using this interface unit.
1
1
2
ST-800 091 / ST-162 500-A
OM-172 324 Page 16
4-8. Control Settings On XMT 304 Inverter Model Welding Power Source
Set controls as shown for all
welding processes when
using this interface unit.
1
4
2
3
ST-801 192 / Ref. ST-175 086
1
2
Voltage/Amperage Adjustment Control
Mode Switch
The Mode switch setting determines both the
process and output On/Off control. Source of
control (panel or remote) for the amount of
output is selected on the V/A Control switch.
Unit does not support remote MIG to
For remote control, make connections to
Remote 14 receptacle, and place switch in
Remote position. Remote control is a percent of V/A Adjust control setting. Value selected on V/A Adjust is maximum available
on remote.
4
Inductance/Dig Control
Voltage/Amperage Control Switch
When set towards minimum, short-circuit
amperage at low arc voltage is the same as
normal welding amperage.
For front panel control, place switch in Panel
position and use the V/A Adjust control.
When set towards maximum, short-circuit
amperage is increased at low arc voltage to
PULSED MIG selection.
3
assist with arc starts as well as reduce sticking while welding.
Select setting best suited for application.
Control adjusts inductance when a MIG
(GMAW) position is selected on the mode
switch. Inductance determines the “wetness” of the weld puddle. When set higher,
“wetness” (puddle fluidity) increases.
Inductance
is only used in MIG
(nonpulsed) welding applications.
OM-172 324 Page 17
4-9. Control Settings On Invision 456P Inverter Model Welding Power Source
Set controls as shown for all
welding processes when
using this interface unit.
1
2
3
ST-801 718 / ST-180 311-B
1 Voltage Adjustment Control
2 Inductance Control
Inductance determines the “wetness” of the
weld puddle. When set higher, “wetness”
(puddle fluidity) increases.
OM-172 324 Page 18
3
Remote On/Off Receptacle (Optional)
Sockets 1 and 2 are connected in parallel
with the Power On/Off switch. For remote
On/Off control, connect a suitable plug from
a remote switch to the receptacle and place
front panel Power On/Off switch in Off position. Unit can then be turned On and Off
through the use of the remote switch.
4-10. Setting Switches On Maxtron 450 Ampere Inverter Model Welding Power Source
Set switches as shown for all welding processes
when using this interface unit.
Ref. ST-150 171-C / Ref. SC-154 197
SECTION 5 – INTRODUCTION TO PROGRAMMING
5-1. Interface Unit
1
1
Interface Unit
The interface unit is designed for
use in pulse MIG welding (adaptive
or standard), or MIG welding.
The unit is factory-equipped with
eight programs for pulse MIG welding (see Section 5-2). The programs contain parameters that
maximize welding performance for
each combination of wire and
shielding gas.
The unit also provides memory for
the creation of up to eight MIG programs (see Section 8).
The weld programs require the user
to enter information specific to the
welding application. This information is entered as a part of program
development (see Section 6 for
pulsed MIG information), and during setup (see Section 10).
ST-801 077-A
OM-172 324 Page 19
5-2. Pulse MIG Programs
Program
Hardwire Selected*
Softwire Selected*
1
.035” Steel, Argon – Oxy
.045” 4043, Argon
2
.045” Steel, Argon – Oxy
.045” 5356, Argon
3
.035” Steel, Argon – CO2
.035” 4043, Argon
4
.045” Steel, Argon – CO2
.035” 5356, Argon
5
.035” 309, Argon – CO2
1/16” 4043, Argon
6
.045” Steel, 309, Argon – CO2
1/16” 5356, Argon
7
3/64” 5356, Argon
.045” Steel, Argon – CO2
8
.035” SIB, Argon
.045” Steel, Argon – Oxy
The eight pulse programs are
shown in the table. Each program
can be used in standard pulse MIG
or adaptive pulse MIG.
In an adaptive pulse MIG program,
the unit manipulates certain weld
variables to hold arc voltage
constant. This feature is described
in Section 7-5.
The factory-set parameters for
each program can be changed to
customize them for an application
(see Section 7).
Selecting
hardwire or softwire is
done during setup (see Section 10).
5-3. Standard Pulse Welding Programs
The following sixteen (16) pulse welding programs are in the control memory. Use this information if it is necessary to
change a standard program, or as a basis to build your own custom program. If at any time while changing a standard
program, or while building your own custom program, you want to go back to the standard program in the control
memory, see Section 10-15 for System memory Reset instructions. See Section 7 for explanation of Pulse welding
settings.
Apk = Peak Amperage, Abk = Background Amperage, PPS = Pulses Per Second, PWms = Pulse Width (milliseconds).
OM-172 324 Page 20
Program 1 – .035 Steel, Argon-Oxy
Wire Size/Type: .035” Steel
Gas: Ar - Oxy / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
750 / 19.1
460
90
210
2.4
700 / 17.8
450
90
200
2.4
650 / 16.5
440
85
190
2.3
600 / 15.2
430
85
180
2.3
550 / 14.0
420
80
170
2.3
500 / 12.7
410
80
160
2.2
450 / 11.4
400
75
150
2.2
400 / 10.2
380
70
140
2.2
350 / 8.9
360
65
130
2.1
300 / 7.6
340
60
120
2.1
250 / 6.4
320
55
110
2.0
200 / 5.1
300
50
100
2.0
150 / 3.8
280
45
80
1.9
100 / 2.5
260
40
60
1.6
50 / 1.3
230
35
40
1.5
COMMENTS
Program 2 – .045” Steel, Argon-Oxy
Wire Size/Type: .045” Steel
Gas: Ar - Oxy / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
750 / 19.1
540
150
250
3.0
700 / 17.8
530
150
240
3.0
650 / 16.5
520
145
230
2.9
600 / 15.2
510
135
220
2.9
550 / 14.0
500
125
210
2.8
500 / 12.7
490
115
200
2.8
450 / 11.4
480
110
190
2.7
400 / 10.2
470
105
175
2.7
350 / 8.9
460
98
165
2.6
300 / 7.6
450
95
150
2.6
250 / 6.4
430
85
130
2.6
200 / 5.1
410
75
110
2.5
150 / 3.8
370
55
90
2.5
100 / 2.5
330
40
70
2.4
50 / 1.3
300
30
55
2.3
COMMENTS
OM-172 324 Page 21
Program 3 – .035 Steel, Argon-CO2
Wire Size/Type: .035” Steel
Gas: Ar - CO2 / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
750 / 19.1
470
90
210
2.3
700 / 17.8
470
90
210
2.3
650 / 16.5
460
85
200
2.3
600 / 15.2
450
85
190
2.2
550 / 14.0
440
80
180
2.2
500 / 12.7
430
80
170
2.2
450 / 11.4
410
80
160
2.2
400 / 10.2
390
75
150
2.1
350 / 8.9
370
70
140
2.0
300 / 7.6
350
70
120
2.0
250 / 6.4
330
65
100
2.0
200 / 5.1
310
55
80
2.0
150 / 3.8
290
50
65
1.9
100 / 2.5
270
40
50
1.7
50 / 1.3
250
30
40
1.6
COMMENTS
Program 4 – .045” Steel, Argon - CO2
Wire Size/Type: .045” Steel
Gas: Ar - CO2 / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
750 / 19.1
560
135
240
3.0
700 / 17.8
560
130
235
3.0
650 / 16.5
550
130
230
2.9
600 / 15.2
540
125
225
2.9
550 / 14.0
530
120
220
2.8
500 / 12.7
520
115
210
2.8
450 / 11.4
495
110
195
2.8
400 / 10.2
480
100
180
2.8
350 / 8.9
465
90
165
2.7
300 / 7.6
450
85
150
2.6
250 / 6.4
430
80
130
2.6
200 / 5.1
410
70
110
2.5
150 / 3.8
38270
55
90
2.5
100 / 2.5
360
48
70
2.4
50 / 1.3
360
48
70
2.4
OM-172 324 Page 22
COMMENTS
Program 5 – .035” ER 309, Argon - CO2
Wire Size/Type: .035” ER 309
Gas: Ar - CO2 / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
750 / 19.1
390
95
210
2.2
700 / 17.8
380
95
200
2.1
650 / 16.5
370
90
190
2.0
600 / 15.2
360
85
180
1.9
550 / 14.0
350
80
170
1.9
500 / 12.7
340
75
160
1.9
450 / 11.4
330
70
150
1.8
400 / 10.2
320
65
140
1.8
350 / 8.9
310
60
130
1.7
300 / 7.6
300
55
120
1.7
250 / 6.4
290
50
100
1.6
200 / 5.1
280
45
80
1.6
150 / 3.8
270
40
60
1.6
100 / 2.5
270
36
40
1.5
50 / 1.3
260
30
30
1.5
COMMENTS
Program 6 – .045” ER 309, Argon - CO2
Wire Size/Type: .045” ER 309
Gas: Ar - CO2 / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
750 / 19.1
490
110
260
2.3
700 / 17.8
480
110
260
2.3
650 / 16.5
470
105
260
2.2
600 / 15.2
460
100
240
2.1
550 / 14.0
450
100
240
2.0
500 / 12.7
440
95
220
1.9
450 / 11.4
430
95
200
1.9
400 / 10.2
420
95
180
1.9
350 / 8.9
410
95
160
1.8
300 / 7.6
400
90
140
1.8
250 / 6.4
380
85
120
1.8
200 / 5.1
360
80
100
1.7
150 / 3.8
340
70
80
1.6
100 / 2.5
320
50
60
1.6
50 / 1.3
320
45
45
1.6
COMMENTS
OM-172 324 Page 23
Program 7 – 3/64” ER 5356, Argon
Wire Size/Type: 3/64” ER 5356
Gas: Argon / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
750 / 19.1
540
130
190
2.9
700 / 17.8
520
125
190
2.8
650 / 16.5
500
120
180
2.8
600 / 15.2
480
115
170
2.8
550 / 14.0
460
110
160
2.7
500 / 12.7
440
100
150
2.7
450 / 11.4
420
90
140
2.7
400 / 10.2
390
85
130
2.6
350 / 8.9
370
70
120
2.4
300 / 7.6
355
55
110
2.3
250 / 6.4
335
45
100
2.2
200 / 5.1
310
35
90
2.2
150 / 3.8
272
33
90
2.0
100 / 2.5
262
24
60
2.0
50 / 1.3
230
18
40
1.8
COMMENTS
Program 8 – .035” SIB, Argon
Wire Size/Type: .035” SIB
Gas: Argon / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
750 / 19.1
375
160
270
1.8
700 / 17.8
375
150
260
1.8
650 / 16.5
375
140
245
1.8
600 / 15.2
375
130
230
1.7
550 / 14.0
375
120
210
1.7
500 / 12.7
375
110
200
1.6
450 / 11.4
375
100
185
1.5
400 / 10.2
375
90
163
1.5
350 / 8.9
360
82
145
1.5
300 / 7.6
345
80
134
1.4
250 / 6.4
330
60
124
1.4
200 / 5.1
315
50
100
1.4
150 / 3.8
300
44
90
1.3
100 / 2.5
283
37
78
1.2
50 / 1.3
265
30
65
1.2
OM-172 324 Page 24
COMMENTS
NOTE
The next 8 programs are available after changing software wiretype (see Section
10-13).
Program 1 – .035” ER 4043, Argon
Wire Size/Type: .035” ER 4043
Gas: Argon / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
750 / 19.1
450
140
155
2.0
730 / 18.5
445
135
150
1.9
720 / 18.3
440
130
145
1.9
710 / 18.0
430
130
140
1.8
655 / 16.6
415
120
135
1.7
600 / 15.2
400
118
125
1.7
545 / 13.8
395
115
115
1.6
490 / 12.4
370
100
105
1.5
435 / 11.0
350
90
100
1.4
380 / 9.7
320
78
95
1.3
325 / 8.3
285
72
80
1.2
270 / 6.9
265
60
75
1.1
215 / 5.5
245
48
70
1.1
160 / 4.1
205
41
49
1.0
140 / 3.6
200
38
46
1.0
COMMENTS
Program 2 – 3/64” ER 4043, Argon
Wire Size/Type: 3/64” ER 4043
Gas: Argon / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
750 / 19.1
530
170
270
3.0
740 / 18.8
515
168
265
3.0
720 / 18.3
500
160
260
2.9
710 / 18.0
480
155
252
2.8
655 / 16.6
450
150
245
2.7
600 / 15.2
420
143
240
2.6
545 / 13.8
396
135
235
2.5
490 / 12.4
372
128
230
2.4
435 / 11.0
350
120
225
2.3
380 / 9.7
325
114
205
2.2
325 / 8.3
295
105
187
2.1
270 / 6.9
275
87
160
2.0
215 / 5.5
243
71
152
1.9
COMMENTS
OM-172 324 Page 25
160 / 4.1
212
55
125
1.9
105 / 2.7
210
41
55
1.9
Program 3 – 1/16” ER 4043, Argon
Wire Size/Type: 1/16” ER 4043
Gas: Argon / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
770 / 19.6
560
251
294
2.7
730 / 18.5
560
251
294
2.7
710 / 18.0
560
251
294
2.7
655 / 16.6
560
251
294
2.7
600 / 15.2
558
251
290
2.7
545 / 13.8
540
251
275
2.6
490 / 12.4
520
251
250
2.5
435 / 11.0
495
251
225
2.4
380 / 9.7
470
251
190
2.2
325 / 8.3
455
240
150
2.0
270 / 6.9
420
218
112
1.8
215 / 5.5
380
168
90
1.7
160 / 4.1
340
115
80
1.6
105 / 2.7
295
73
55
1.5
70 / 1.8
290
45
50
1.5
COMMENTS
Program 4 – .035” ER 5356, Argon
Wire Size/Type: .035” ER 5356
Gas: Argon / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
760 / 19.1
300
118
140
3.6
740 / 18.8
295
114
145
3.5
720 / 18.3
290
110
140
3.4
710 / 18.0
286
103
128
3.3
655 / 16.6
276
95
124
3.2
600 / 15.2
268
86
115
3.2
545 / 13.8
250
80
107
3.1
490 / 12.4
238
78
105
3.0
435 / 11.0
230
73
100
2.9
380 / 9.7
215
65
90
2.8
325 / 8.3
195
63
80
2.7
270 / 6.9
180
58
70
2.5
215 / 5.5
178
45
56
2.4
OM-172 324 Page 26
COMMENTS
160 / 4.1
175
33
45
2.3
105 / 2.7
175
25
29
2.2
Program 5 – 3/64” ER 5356, Argon
Wire Size/Type: 3/64” ER 5356
Gas: Argon / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
755 / 19.2
465
138
270
3.0
730 / 18.5
445
130
265
2.9
700 / 17.8
425
128
255
2.8
680 / 17.3
405
120
245
2.7
655 / 16.6
385
110
235
2.6
600 / 15.2
365
100
228
2.5
545 / 13.8
345
92
215
2.5
490 / 12.4
330
85
200
2.4
435 / 11.0
320
80
193
2.3
380 / 9.7
310
78
186
2.2
325 / 8.3
300
75
158
2.1
270 / 6.9
272
65
130
2.0
215 / 5.5
245
53
110
1.9
160 / 4.1
236
47
67
1.8
105 / 2.7
231
22
62
1.8
COMMENTS
Program 6 – 1/16” ER 5356, Argon
Wire Size/Type: 1/16” ER 5356
Gas: Argon / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
770 / 19.6
560
251
294
2.7
735 / 18.7
560
251
294
2.7
710 / 18.0
560
251
294
2.7
655 / 16.6
545
251
294
2.7
600 / 15.2
515
251
270
2.6
545 / 13.8
480
251
224
2.5
490 / 12.4
447
251
175
2.3
435 / 11.0
427
240
155
2.1
380 / 9.7
407
220
140
2.0
325 / 8.3
387
190
126
1.9
270 / 6.9
367
160
112
1.8
215 / 5.5
354
124
92
1.7
160 / 4.1
328
95
68
1.6
COMMENTS
OM-172 324 Page 27
105 / 2.7
315
51
58
1.6
75 / 1.9
311
35
58
1.5
Program 7 – 3/64” ER 5356, Argon
Wire Size/Type: 3/64” ER 5356
Gas: Argon / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
750 / 19.1
465
138
270
3.0
720 / 18.3
445
130
265
2.9
700 / 17.8
425
125
255
2.8
680 / 17.3
402
120
244
2.7
655 / 16.6
382
110
235
2.6
600 / 15.2
360
99
225
2.5
545 / 13.8
340
92
215
2.5
490 / 12.4
325
85
200
2.4
435 / 11.0
315
80
177
2.3
380 / 9.7
305
76
168
2.2
325 / 8.3
290
60
145
2.1
270 / 6.9
270
55
125
2.0
215 / 5.5
247
50
100
1.9
160 / 4.1
225
41
68
1.8
105 / 2.7
225
19
58
1.8
COMMENTS
Program 8 – .035” ER 5356, Argon
Wire Size/Type: .035” ER 5356
Gas: Argon / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
770 / 19.6
300
120
150
3.6
740 / 18.8
295
114
145
3.5
720 / 18.3
290
110
140
3.4
710 / 18.0
286
103
133
3.3
655 / 16.6
275
93
124
3.2
600 / 15.2
267
85
117
3.2
545 / 13.8
250
80
107
3.1
490 / 12.4
235
78
100
3.0
435 / 11.0
222
71
90
2.9
380 / 9.7
207
65
83
2.8
325 / 8.3
190
64
72
2.6
270 / 6.9
185
52
65
2.4
215 / 5.5
182
40
58
2.2
OM-172 324 Page 28
COMMENTS
160 / 4.1
180
30
43
2.1
105 / 2.7
180
23
30
2.0
5-4. Pulse Panel Mode Select Button
Control circuit and interface operational power are On when
using or changing the microprocessor settings.
1
Mode Display
2
Mode Select Button
Press Mode Select button to move
indicator in left window display.
Go to Section 5-5.
Pulse Panel
1
>P r o c e s s
Ca r d
Sequence
P r oces s
>C a r d
Sequence
> Pr g 1
Pu l s e
03 5 ” S t e e l
Ar g o n–Ox y
2
Ref. ST-154 109
OM-172 324 Page 29
5-5. Pulse Panel Parameter Select Button
Control circuit and interface operational power are On when
using or changing the microprocessor settings.
1
Parameter Display
2
Moving Line
Moving line is under value that can
be changed.
3
Pulse Panel Parameter Select
Button
Press pulse panel parameter select
button to move indicator in right window display.
Pulse Panel
1
2
>P r o c e s s
Ca r d
Sequence
> Pr
Pu
03
Ar
g 1
l se
5 ”S t ee l
g on – Ox y
P r
>P u
03
A r
g 1
l se
5 ”S t ee l
g on – Ox y
Pu
03
A r
>T e
l
5
g
a
se
”S t ee l
on – Ox y
c h Off
3
Ref. ST-154 109
OM-172 324 Page 30
5-6. Pulse Panel Parameter Increase And Decrease Buttons
Control circuit and interface operational power are On when
using or changing the microprocessor settings.
Use mode select button to select
mode to be changed (see Section
5-4).
Use pulse panel parameter select
button to select parameter to be
changed (see Section 5-5).
1 Increase Button
Press button to increase value that
is underlined by the moving line.
2 Decrease Button
Press button to decrease value that
is underlined by the moving line.
Pulse Panel
1
>P r
Pu
03
A r
g 1
l se
5 ”S t ee l
g o n –Ox y
>P r
Pu
04
A r
g 2
l se
5 ”S t ee l
g on – Ox y
Increase
Increase
2
>P r
Pu
05
A r
g 3
l se
2 ”S t ee l
g on – Ox y
Decrease
>P r
Pu
04
A r
g 2
l se
5 ”S t ee l
g on – Ox y
Ref. ST-154 109
OM-172 324 Page 31
SECTION 6 – GETTING STARTED FOR PULSE WELDING
6-1. Weld Cycle
Weld Time
Start Time
Weld Speed
Preflow Time
Weld
Start
Arc
Start
Burnback Time
Crater
Speed
Wire Speed
Crater Time
Start
Speed
Weld
Stop
Postflow Time
Arc
Out
Time
Ref. S-0271
NOTE
The type of robot being used is defined during the setup process (see Section 10).
The Robot type indicates which parts of the weld cycle the robot controls.
When the Robot type selected is Control of Power Source, Wire, Gas, & Analog,
there is only start condition programming capability and the robot controls the
remaining program sequences.
When the Robot type selected is Control of Arc On & Analog Inputs, only preflow
and postflow are programmable.
When the Robot type selected is Arc On & No Analog Inputs, preflow, weld, crater,
and postflow are programmable.
OM-172 324 Page 32
6-2. Setting Preflow Sequence Display
1
P r oces s
Ca r d
>S e q u e n c e
Mode Select Button
When unit is turned On, Process is
the default mode, at other times,
use mode select button to select
Sequence.
>P r e f l o w
0 . 0 Sec
2
Parameter Select Button
Use parameter select button to select parameters.
3
2
1
Preflow Parameters Display
Preflow can be adjusted from 0-9.9
seconds. If value set is zero (0),
there is no Preflow sequence.
Go to Section 6-3.
Parameter
Select
Mode Select
3
>P r e f l o w
0 . 0
Sec
P r e f l ow
>0 . 0
Sec
>P r e f l o w
1 . 2
Sec
Set Desired Time
Parameter
Select
Parameter
Select
Increase/
Decrease
Increase
Proceed to next figure.
6-3. Setting Weld Sequence Display
Set Desired Weld
Sequence Trim
1
We l d
>5 0
200
1
Weld Parameters Display
Parameter ranges are as follows:
Trim (Arc Length), 0-99
T r im
I PM
Wire Feed Speed, 50-780 Inches
Per Minute, IPM
Increase/
Decrease
Go to Section 6-4.
Parameter
Select
Set Desired Weld Sequence
Wire Feed Speed
We l d
60
>2 0 0
T r im
I PM
Increase/
Decrease
Parameter
Select
We l d
60
300
T r im
I PM
Increase
Proceed to next figure.
OM-172 324 Page 33
6-4. Setting Crater Sequence Display
1
1
Crater Parameters Display
Parameter ranges are as follows:
>C r a t e r
0 . 00 Sec
50
T r im
200
I PM
Set Desired
Time
Parameter
Select
Seconds, 0-2.50 Sec. If value set is
zero (0), there is no Crater
sequence.
Cr a t e r
0 . 20 Sec
T r im
>5 0
200
I PM
Cr a t e r
>0 . 0 0 S e c
50
T r im
200
I PM
Parameter
Select
Trim (Arc Length), 0-99
Wire Feed Speed, 50-780 Inches
Per Minute, IPM
Set Desired
Trim
Increase/
Decrease
Increase/
Decrease
>C r a t e r
0 . 20 Sec
60
T r im
150
I PM
Cr a t e r
0 . 20 Sec
60
T r im
>1 5 0
I PM
Go to Section 6-5.
Parameter
Select
Set Desired
Parameter Wire Feed Speed
Select
Increase
Proceed to next figure.
Increase/
Decrease
6-5. Setting Postflow Sequence Display
1
1
Po s t f l ow
>0 . 0
Sec
>P o s t f l o w
0 . 0
Sec
Parameter
Select
Set Desired Time
Increase/
Decrease
OM-172 324 Page 34
Postflow Parameters Display
Postflow can be adjusted from
0-9.9 seconds. If value set is zero
(0), there is no Postflow sequence.
>P o s t f l o w
1 . 2
Sec
Parameter
Select
Increase
Proceed to next figure.
SECTION 7 – TEACHING A PULSE WELDING PROGRAM
Control circuit and interface operational power are On
when using or changing the microprocessor settings.
NOTE
See GMAW-P (Pulsed MIG) Process Guide supplied with unit for more
information.
7-1. Pulse Waveforms And Explanation Of Terms
The interface, not the welding power source, controls weld output for
pulsed welds.
1
ApK – Peak Current Of
100-565 Amperes
ApK is the high pulse of welding
current. Peak current melts the
welding wire and forms a droplet.
The droplet is forced into the weld
puddle.
2
AbK – Background Current Of
10-200 Amperes
AbK is the low weld current. Background current preheats welding
wire and maintains the arc. When
background current is too low, the
arc is unstable and hard to
maintain.
3
Amps (Current)
3
PPS – Pulses Per Second Of
20-400
PPS, pulse rate, and frequency
(Hz) are used interchangeably. A
PPS or pulse rate of 60 Hz means
60 pulses of current are produced
each second.
4
1
2
4
Time
PWms – Pulse Width Of
1.0-5.0 Milliseconds
PWms is the time spent at peak current (1.2 ms is .0012 seconds). This
time must be long enough to form a
droplet of welding wire. The stiffness or fluidity of the molten weld
puddle is controlled by PWms.
Ref. S-0259
OM-172 324 Page 35
7-2. Typical Teach Point Settings And Resulting Synergic Setting
IPM
780
750
700
650
600
550
Example Of A Synergic
Setting For 425 IPM With
All Teach Points Set At
50 IPM Increments
500
450
400
350
300
250
200
ApK
AbK
150
PPS
100
PWms
50
150
10
30
1
180
20
55
210
30
80
240
40
105
270
50
130
2
The teach mode allows the user to create
custom pulse MIG welding programs. The
teach mode has 15 teach points. At each
teach point, the user can adjust four parameters: peak amperage (ApK), background amperage (AbK), pulses per second (PPS), and
pulse width in milliseconds (PWms) to shape
the pulse waveform of the weld output.
Wire feed speed teach points can range from
the minimum to the maximum wire feed
speed of the feeder. When using a standard
speed motor, wire feed speed teach points
typically range from 50 to 750 ipm. The feeder
uses pulse parameters at teach points to establish the pulse parameters at any wire feed
speed setting.
Below the wire feed speed of the lowest teach
OM-172 324 Page 36
300
60
160
330
70
185
360
80
210
3
370
90
235
420
100
260
450
110
290
point, and above the wire feed speed of the
highest teach point, the unit may limit wire
feed speed settings in pulse MIG to maintain
all pulse parameters within the capability of
the unit.
Pulse MIG programs made by the manufacturer have pulse waveform information entered for all 15 teach points. The operator can
relocate and modify the setting of one, or any
number of the 15 teach points if the factory
set information is not appropriate for a specific application.
After the parameters for each teach point are
established, an arc must be struck and maintained for at least 5 seconds in teach mode.
This allows the wire feeder to learn the arc
voltage length associated with the taught
480
120
315
4
510
130
340
540
140
365
565
150
400
5
ApK
AbK
PPS
PWms
pulse parameters. To ensure a proper arc
length reading, electrode stick-out must be
carefully maintained.
The taught arc length represents a Trim (arc
length) setting of 50. Increasing the value of
Trim, increases the actual arc length. Likewise, decreasing the value of Trim will
decrease actual arc length.
In the Pulse mode, the unit does not maintain
a constant arc length with variations in electrode stick-out. In the Adaptive Pulse mode,
the unit adjusts pulse frequency to maintain a
constant arc length regardless of variations
in electrode stick-out.
Proceed to next section to teach a pulse MIG
program.
7-3. Selecting Teach Point Wire Feed Speed
1
1
2
2
>P r o c e s s
Ca r d
Sequence
>P r
Pu
03
A r
Pu l se
035 ”S t ee l
g 1
l se
5 ”S t ee l
gon -Ox y
Mode
Select
>T e a c h
Of f
Parameter
Select
Increase/
Decrease
3
Process Display
When unit is first turned On, Process is the default screen, at other
times use mode select button to select Process.
Teach Display
Use parameter select button to select Teach.
Use increase/decrease buttons to
select On.
3
IPM (Teach Point)
The parameters associated with
this wire feed speed teach point can
be modified. The wire feed speed
value itself cannot be changed from
this unit.
To set or adjust teach point parameters, go to Section 7-4.
T e a c h On
>4 0 0
I PM
340
Apk
70
Abk
>T e a c h O n
400
I PM
340
Apk
70
Abk
Parameter
Select
OM-172 324 Page 37
7-4. Setting Teach Point Parameters On The Pulse Panel
Increase/
Decrease
>P r o c e s s
Ca r d
Sequence
T e a c h On
>4 5 0
I PM
340
Apk
70
Abk
T e a c h On
450
I PM
Apk
>3 4 0
70
Abk
Parameter
Select
Or
T e a c h On
450
I PM
>3 4 3
Apk
70
Abk
1
Parameter
Select
Increase/
Decrease
Increase/
Decrease
34
9
>2 8
1 .
3
2
0
9
Apk
Abk
PPS
P Wm s
34
9
>1 6
1 .
3
2
0
9
Apk
Abk
PPS
P Wm s
450
343
> 92
160
I PM
Apk
Abk
PPS
450
343
> 70
160
I PM
Apk
Abk
PPS
2
Parameter
Select
3
Parameter
Select
Increase/
Decrease
34
9
28
>1 .
3
2
0
9
Apk
Abk
PPS
P Wm s
34
9
28
>3 .
3
2
0
6
Apk
Abk
PPS
P Wm s
Weld for
5 seconds
Pu
03
A r
>T e
>T e a c h O n
450
I PM
343
Apk
92
Abk
l
5
g
a
se
”S t ee l
on -Ox y
ch Of f
Increase/
Decrease
Parameter
Select
4
Parameter
Select
5
P r
Pu
03
A r
When the Process Teach mode is On, and
one of the following pulse parameters is selected: ApK, AbK, PPS, or PWms, the pulse
panel displays the selected pulse parameter
instead of Trim (arc length). When the pulse
parameter is selected, the value can be
changed with the pulse panel controls as follows:
1
ApK Display
OM-172 324 Page 38
2
AbK Display
Turn Teach mode Off.
3
PPS Display
5
4
PWms Display
When values have been set for a teach point,
strike and maintain an arc for five seconds.
Repeat procedure at each teach point until
custom program is complete (see Section
7-2).
g
l
5
g
1
C
se
”S t ee l
on -Ox y
Custom Pulse Screen
The letter C will appear in the upper right corner of all customized programs.
Customized programs can be reverted back
to factory-set values through memory reset
(see Section 10-15).
NOTE
Make copies of this chart for future use.
Program #
Wire Size/Type
Gas
Program Name
Card #
Gun Model
Flowrate
IPM
ApK
AbK
PPS
PWms
CFH
COMMENTS
Preflow:
Sec.
Run-In Trim:
IPM:
Sec.:
Crater Trim:
IPM:
Sec.:
Postflow:
Sec.
OM-172 324 Page 39
7-5. Changing To Adaptive Pulse Welding
Welding parameters are the same
for both a Pulse and an Adaptive
Pulse welding program. While
welding adaptively, the unit uses
feedback to attempt to maintain a
constant arc length. To change to
Adaptive Pulse welding, proceed
as shown:
1
Mode Select
1
>P r o c e s s
Ca r d
Sequence
>P r
Pu
03
A r
g 1
l se
5 ”S t ee l
g o n –Ox y
Parameter
Select
>P r o c e s s
Ca r d
Sequence
P r
>P u
03
A r
g 1
l se
5 ”S t ee l
g o n –Ox y
Increase/
Decrease
>P r o c e s s
Ca r d
Sequence
OM-172 324 Page 40
Pulse Panel Display
Default display when unit is first
turned On, at other times use mode
select button to select Process.
P r
>A d
03
A r
g 1
a p tP u l s e
5 ”S t ee l
g o n –Ox y
SECTION 8 – TEACHING A MIG WELDING PROGRAM
Control circuit and interface operational power are On
when using or changing the microprocessor settings.
8-1. Weld Cycle
Weld Time
Crater Time
Start
Speed
Weld Speed
Preflow Time
Weld
Start
Arc
Start
Burnback Time
Crater
Speed
Wire Speed
Start Time
Weld
Stop
Postflow Time
Arc
Out
Time
Ref. S-0271
NOTE
The type of robot being used is defined during the setup process (see Section 10).
The Robot type indicates which parts of the weld cycle the robot controls.
When the Robot type selected is Control of Power Source, Wire, Gas, & Analog,
only the start time, level, and speed are programmable.
When the Robot type selected is Control of Arc On & Analog Inputs, preflow; start
time, level, and speed; burnback time and level; and postflow are programmable.
When the Robot type selected is Arc On & No Analog Inputs, preflow; start time,
level, and speed; weld level and speed; crater time, level, and speed; burnback
time and level; and postflow are programmable.
OM-172 324 Page 41
8-2. Changing To MIG In The Process Mode
1
Pulse Panel Display
Default display when unit is first
turned On, at other times use mode
select button to select Process.
Go to Section 8-3A.
Mode Select
1
>P r o c e s s
Ca r d
Sequence
>P r
Pu
03
A r
g 1
l se
5 ”S t ee l
g o n –Ox y
Parameter
Select
>P r o c e s s
Ca r d
Sequence
P r
>P u
03
A r
g 1
l se
5 ”S t ee l
g o n –Ox y
Increase/
Decrease
>P r o c e s s
Ca r d
Sequence
OM-172 324 Page 42
P r g
>M I G
1
8-3. Setting Sequence MIG Welding Parameters
Control circuit and interface operational power are On
when using or changing the microprocessor settings.
A. Setting Preflow Sequence Display
1
1
>P r o c e s s
Ca r d
Sequence
>P r g
MIG
1
2
Parameter Select Button
Use parameter select button to select parameters.
3
Preflow Parameters Display
Preflow can be adjusted from 0-9.9
seconds. If value set is zero (0),
there is no Preflow sequence.
2
Mode
Select
P r oces s
Ca r d
>S e q u e n c e
Pulse Panel Display
When unit is turned On, Process is
the default mode. Use mode select
button to select Sequence.
Go to Section 8-3B.
>P r e f l o w
0 . 0
Sec
Parameter
Select
3
P r e f l ow
>0 . 0
Sec
Set Desired Time
Increase/
Decrease
>P r e f l o w
1 . 2
Sec
Parameter
Select
Increase
Proceed to next figure.
OM-172 324 Page 43
B. Setting Start Sequence Display
1
1
>S t
0 .
24
9
Start Parameters Display
Parameter ranges are as follows:
a r t
2 Sec
. 0Vo l t
0 I PM
S t
>0 .
24
9
Parameter
Select
a r t
5 Sec
. 0Vo l t
0 I PM
S t
0 .
>1 8
9
Set Desired Time
Parameter
Select
Set Desired Voltage
Seconds, 0-2.5 Sec. If value set is
zero (0), there is no Run-In
sequence.
Volts, 10.0-38.0 Volts
Wire Feed Speed, 50-780 inches
per minute, IPM
Go on to Section 8-3C.
Increase/
Decrease
>S t
0 .
18
20
a r t
5 Sec
. 0Vo l t
0 I PM
Increase/
Decrease
a r t
5 Sec
. 0Vo l t
0 I PM
S t
0 .
18
>2 0
Increase
Proceed to next figure.
Parameter
Select
Parameter
Select
a r t
5 Sec
. 0Vo l t
0 I PM
Set Desired
Wire Feed Speed
Increase/
Decrease
C. Setting Weld Sequence Display
1
1
Set Desired Voltage
We l d
Volts, 10.0-38.0 Volts
Wire Feed Speed, 50-780 Inches
Per Minute, IPM
>1 8 . 0 V o l t
2 0 0 I PM
Go to Section 8-3D.
Increase/
Decrease
Parameter
Select
Set Desired Wire Feed Speed
We l d
20 . 0Vo l t
>2 0 0 I P M
Increase/
Decrease
Parameter
Select
>We l d
20 . 0Vo l t s
4 2 0 I PM
Increase
Proceed to next figure.
OM-172 324 Page 44
Weld Parameters Display
Parameter ranges are as follows:
D. Setting Crater Sequence Display
1
Crater Parameters Display
Parameter ranges are as follows:
1
Seconds, 0-2.50 Sec. If value set is
zero (0), there is no Crater
sequence.
>C r a t e r
0 . 02Se c
24 . 0Vo l t
9 0 I PM
Volts, 10.0-38.0 Volts.
Wire Feed Speed, 50 to 780 inches
per minute, IPM.
Go to Section 8-3E.
Parameter
Select
Cr a t e r
>0 . 1 2 S e c
24 . 0Vo l t
90
I PM
Set Desired Time
Cr
0 .
>1 8
9
a t e r
12Se c
. 0Vo l t
0 I PM
Set Desired
Voltage
Parameter
Select
Increase/
Decrease
Cr
0 .
18
>2 0
Parameter
Select
Increase/
Decrease
a t e r
12Se c
. 0Vo l t
0 I PM
Set Desired
Wire Feed Speed
Parameter
Select
Increase/
Decrease
>C r
0 .
18
20
a t e r
12Se c
. 0Vo l t
0 I PM
Increase
Proceed to next figure.
E. Setting Burnback Sequence Display
1
Burnback Parameters Display
Parameter ranges are as follows:
Volts, 10.0-38.0 Volts
Seconds, 0-0.25 seconds. If value
set is zero (0), there is no Burnback
sequence.
1
>B u r n b a c k
0 . 00 Sec
18 . 0 Vo l t
Go to Section 8-3F.
Bu r nbac k
>0 . 1 2 S e c
18 . 0 Vo l t
Parameter
Select
Set Desired Time
Increase/
Decrease
Bu r nbac k
0 . 12 Sec
>1 6 . 0 V o l t
Parameter
Select
Set Desired
Burnback Volts
Increase/
Decrease
>B u r n b a c k
0 . 12 Sec
16 . 0 Vo l t
Parameter
Select
Increase
Proceed to next figure.
OM-172 324 Page 45
F. Setting Postflow Sequence Display
1
1
>P o s t f l o w
0 . 0
Sec
Po s t f l ow
>0 . 0
Sec
Parameter
Select
Set Desired Time
Increase/
Decrease
OM-172 324 Page 46
>P o s t f l o w
1 . 2
Sec
Parameter
Select
Postflow Parameters Display
Postflow can be adjusted from
0-9.9 seconds. If value set is zero
(0), there is no Postflow sequence.
SECTION 9 – USING THE OPTIONAL DATA CARD
9-1. Installing Data Card
Label
1
2
3
4
5
7
6
8
9
11
10
12
13
14
1
Peel backing from label and apply
to data card with THIS SIDE UP by
metal pins.
THIS SIDE UP
Write the names of the programs
stored on the card on the label.
Write the name of the piece of
equipment the card is used with on
the label.
2
Data Card
3
Card Slot
Insert card into slot. To format card,
turn On power to the unit. Select
Card from menu. Data card formats
when unit enters Card mode. Exit
Card mode and turn Off power.
60-M Data Card
3
2
1
ST-156 266-B / Ref. S-155 823
9-2. Data Card Displays
1
P r oces s
>C a r d
Sequence
P r ess
Be l ow
Use Mode Select button to select
Card.
1
Card Display
2
Write
Used to transfer program data from
unit to card. The program card can
hold up to 32 programs. When writing to the card, the next available
program number is automatically
assigned.
3
Parameter
Select Once
4
2
Read
Used to transfer program data from
card to unit.
Delete
Used to delete program data from
card.
>W r
Re
De
Do
3
4
i
a
l
n
t e
d
e t e
e
# 1 Pu l se
035 ”S t ee l
A r g o n –Ox y
P r ess
5
Done
Used to exit card display.
6
Moving Line
Moving line is under value that can
be changed.
5
6
OM-172 324 Page 47
9-3. Naming Programs And Writing To Card
NOTE
All program types (Pulse, Adaptive Pulse, and MIG) can be stored on a data card
and retrieved.
1
1
P r oces s
>C a r d
Sequence
2
P r es s
Be l ow
Parameter
Select
2
i
a
l
n
t e
d
e t e
e
Moving Line
Moving line is under value that can
be changed. Use increase or
decrease button to change value.
3
>W r
Re
De
Do
Card Display
Use Mode Select button to select
Card.
Name Display
If no name is desired, press
Parameter Select button to continue the write procedure.
#1 Pu l se
035 ”S t ee l
A r g o n –Ox y
P r ess
Allowable characters include: 0 thru 9, :, ;, <, =,
>, ?, @, A thru Z, [, , ], ^, _,‘, a thru z , blank , !, ”,
#, $, %, &, ’, (, ), *, +, –, ., /,
3
Parameter
Select
N ame ? N o
035 ”S t ee l
A r g o n –Ox y
P r es s
Increase/
Decrease
N ame ? Y e s
035 ”S t ee l
A r g o n –Ox y
P r ess
Yes
N ame ? Y e s
035 ”S t ee l
A r g o n –Ox y
⇒P r e s s
N ame ? Y e s
5007992
F r ame
_
⇒P r e s s
Increase
No
Parameter
Select
Parameter
Select
Parameter
Select
Wr i t eDo n e
P r g 1 t o
Ca r dP r g 1
P r es s
Wr i t eDo n e
P r g1 t o
Ca r d P r g1
P r ess
N ame ?
No
5007992
F r ame
P r ess
Increase
Parameter
Select
Parameter
Select
#1 Pu l se
035 ”S t ee l
A r g o n –Ox y
P r es s
OM-172 324 Page 48
N ame ? Y e s
5007992
F r ame
P r ess
Parameter
Select
#1 Pu l se
5007992
F r ame
P r ess
9-4. Reading From Card
1
P r ocess
>C a r d
Sequence
Use Mode Select button to select
Card.
P r es s
Be l ow
t e
d
e t e
e
Parameter
Select Once
# 1 Pu l se
035 ”S t ee l
A r g o n –Ox y
P r ess
P r g1 Wi l l
Be Los t
Lose? Yes
P r ess
Read Display
Use increase or decrease button to
select feeder program number
where the card program goes.
3
Read Ca r d
t o Feede r
P r g 1
P r ess
Parameter
Select
WA R N I N G :
Moving Line
Moving line is under value that can
be changed. Use increase or decrease button to select program
number to read from card to feeder.
2
i
a
l
n
Card Display
2
3
Mode
Select
Twice
Wr
>R e
De
Do
1
Parameter
Select
P r g1 Wi l l
Be Los t
Lo s e? No
P r ess
No
Yes
# 1 Pu l se
035 ”S t ee l
A r g o n –Ox y
P r ess
Increase
Parameter
Select
Parameter
Select
Read Done
Ca r d P r g1
t o P r g 1
P r ess
Parameter
Select
# 1 Pu l se
035 ”S t ee l
A r g o n –Ox y
P r ess
9-5. Reading (Or Deleting) From An Empty Card
1
1
Wr
>R e
De
Do
i
a
l
n
t e
d
e t e
e
Warning Display
If there are no programs on the
card, this series of displays appear.
WA R N I N G :
C a r d Emp t y
P r ess
Be l ow
Parameter
Select Once
Wr
Re
De
>D o
i
a
l
n
t e
d
e t e
e
>P r o c e s s
Ca r d
Sequence
>P r g
MIG
2
P r es s
Parameter
Select
OM-172 324 Page 49
9-6. Deleting Programs From Card
Use Mode Select button to select
Card.
1
P r ess
Be l ow
Mode
Select
Twice
i
a
l
n
Card Display
2
Moving Line
Moving line is under value that can
be changed.
P r oces s
>C a r d
Sequence
Wr
Re
>D e
Do
1
3
Delete Display
Select program number to be deleted from card.
Parameter
Select Once
t e
d
e t e
e
#
2
MIG
WA R N I N G :
P r ess
Parameter
Select
2
3
De l e t e
Ca r d P r g2
Lose? Yes
P r ess
De l e t e
Ca r d P r g2
Lo s e? No
P r ess
No
Increase
Yes
#3
P r ess
P r ess
Parameter
Select
OM-172 324 Page 50
MIG
MIG
P r ess
Parameter
Select
Parameter
Select
Ca r d P r g2
De l e t ed
#2
SECTION 10 – SETUP
10-1. Setup Flow Chart
1
Display Selections
2
Features
2
3
Settings
3
To set up features that customize
operation, use the setup displays.
Features that can be customized
are as follows:
1
>R a
Se
Ac
Mi
nge
cu r i t y
ces s
g Type
Vo l t
10 . 0
Mi n
Vo l t
Example Of Pulse Panel Setup Display
Display
Selection
>Range
Features
Settings
Volt Min
0.0 - 25.0 V
Volt Max
25.0 - 99.9 V
Amp Min
0 - 50 A
Amp Max
50 - 999 A
Section
Display
Selection
Features
Section
Hardwire/Softwire
10-13
Actual
Amps
Command
10-14
10-3
>Wiretype
Wire Type
In Feeder
>Display
Press Mode Select
To Go To Next Setup Display
>Memory
>Security
Settings
Program
Number
Lock
Off/On
>Access
Code
Off/On
10-5
>Mig Type
Voltage
Correction
DVC On/Off
10-6
>Inductance
Level
0.0 - 99
10-7
>Purge
Button
Timer
0.0 - 25.0
10-8
>Voltage
Control
Feedback
17-Pin
Volt Sense
10-9
>Arc Start
Arc Start Type
Standard
Hot Start
Soft Start
10-10
0–9999.99 Hours
0–999,999 Cycles
10-11
No Reset
10-15
10-4
Program Reset
Memory Reset
>Shutdown
Arc Start/
Volt Sense
Off/On
10-16
>Name
Card Programs
Off/On
10-17
>Program
Remote
Program
Off/On
10-18
>Stick
Stick Check
Off/On
10-19
>Jog IPM
IPM
50 - 780
10-20
>Robot
>Arc Time
Run Hours
>Monitor
10-21
Arc Volt Error
Off/On
Range
0.1 - 9.9
Sec
0.1 - 25
10-22
No Reset
>Software
Version Number
10-23
Reset
>Wire Feed
Display
IPM/MPM
Motor Type
Standard
Low Speed
High Speed
10-12
OM-172 324 Page 51
10-2. Using Setup Displays
1
2
3
Mode
Select
Front Panel Setup Display
Front panel display during setup.
Parameter
Select
2
Pulse Panel Mode And Parameter Select Buttons
3
Power Switch On Rear Panel
Press and hold down both buttons
while turning On unit.
4
Pulse Panel Setup Display
Follow this procedure any time access is required. Once in the setup
displays, use the Mode Select button to select a particular display.
To save any or all of the changes
made while in the setup displays,
and/or to exit the setup displays,
turn power to the unit Off and back
On.
1
4
S e t u p
Front Panel Display
>R a
Se
Ac
Mi
nge
cu r i t y
cess
g
Type
Vo l t
10 . 0
Pulse Panel Display
OM-172 324 Page 52
Mi n
Vo l t
10-3. Selecting Welding Power Source Range
NOTE
Welding power source minimum and maximum voltage values are always
required. Amperage values are required for pulse welding.
1
>R a
Se
Ac
Mi
Access
Setup
Display
nge
cu r i t y
cess
g
Type
1
>V o l t M i n
10 . 0Vo l t
Range Display
See welding power source Owner’s
Manual for voltage and amperage
ranges. Set values to match welding power source ranges.
2
Minimum Voltage Display
Range is 0 to 25.0 volts.
3
Press Mode
Select
Maximum Voltage Display
Range is 25.0 to 99.9 volts.
4
Parameter
Select
Minimum Amperage Display
(Available When System Set
For Pulse/Mig)
Range is 0 to 50 amperes.
Default values are for 450 Ampere Inverter Model.
Do not change values if using 450 Ampere
Inverter Model.
5
Vo l t Mi n
>1 0 . 0 V o l t
Maximum Amperage Display
(Available When System Set
For Pulse/Mig)
Range is 150 to 999 amperes.
2
Increase/Decrease
Vo l t Mi n
> 8 . 0Vo l t
Parameter
Select
Increase
>V o l t M a x
38 . 0Vo l t
*Use Parameter Select button to
select voltage or amperage.
Use Increase/Decrease buttons
to change value.
5*
>A m p
565
3*
Parameter
Select
Ma x
Amp
>A m p
10
Mi n
Amp
4*
Parameter
Select
OM-172 324 Page 53
10-4. Selecting Security Lock
NOTE
Security lock works only when a data card is inserted (see Section 9).
1
Security Display
Use this display to lock a program’s
weld parameters so that changes
can not be made using pulse panel
controls.
Access
Setup
Display
1
2
2
Program Number
Choose the program number (1
through 8) to be locked.
Ra
>S e
Ac
Mi
nge
cu r i t y
ces s
g
Type
>P r o g
Lock
1
Of f
3
When lock is off a program, the operator can change all weld parameters of that program without
restriction.
Press Mode
Select
Increase
P r og
>L o c k
T r im
I PM
2
On
0
0
P r og
>L o c k
2
Of f
Increase
>P r o g
Lock
Parameter
Select
2
Of f
3
Parameter
Select
P r og
Lock
>T r i m
I PM
P r og
Loc k
>T r i m
I PM
2
On
0
0
2
On
10
0
Increase/
Decrease
P r og
Loc k
T r im
>I PM
2
On
10
0
Parameter
Select
Increase/
Decrease
>P r o g
Lock
3
Of f
>P r o g
Loc k
T r im
I PM
Increase
OM-172 324 Page 54
2
On
10
100
P r og
Lock
T r im
>I PM
Parameter
Select
Program Lock Display
2
On
10
100
With lock on a program, the operator can change parameters of that
program but the range of change is
restricted.
In the example displays in this figure, the operator could change the
value of trim ±10% and wire feed
speed ±100 ipm from programmed
values. If the settings are left at 0,
the operator cannot change values
from those programmed.
10-5. Selecting Or Changing Access Code
NOTE
Access code works only when a data card is inserted (see Section 9).
1
Access
Setup
Display
Code Display
With code off, access to the setup
displays is not restricted.
1
With code on, the operator must
know and enter the access code to
access or change any of the setup
displays.
Ra
Se
>A c
Mi
nge
cu r i t y
ces s
g Type
Co d e
>O f f
2
Access Display
With a code set, this display appears when power is turned on
while holding the pulse panel Mode
and Parameter Select buttons.
Press Mode
Select
Press Parameter Select button to
enter access code. When the correct letter is entered, the indicator
automatically moves to the next
character. When the final access
code letter is entered, the display
automatically changes to the initial
setup display.
Increase
Code
>O n
AAA
Parameter
Select
Co d e
On
>A A A
⇒P r e s s
Increase/Decrease
To Set Code
Parameter Select
To Move
Indicator
Co d e
On
>Z WX
⇒P r e s s
Turn Power Off And Back On
And Access Security Display
2
En t e r
Ac ces s
Code
>C o d e
⇒P r
AAA
ess
OM-172 324 Page 55
10-6. Selecting Voltage Correction
1
Mig Type Display
With DVC Voltage Correction On,
the unit uses closed-loop feedback
from the 17-pin cord or voltage
sensing leads to maintain set voltage parameters.
With DVC Voltage Correction Off,
feedback from the arc is not used
for closed-loop feedback to maintain voltage parameters. Feedback
from the arc is still used for other
functions.
Be sure voltage sensing leads are
connected or voltage feedback is
available through the 17-pin receptacle via the welding power source.
1
Access
Setup
Display
Press
Mode Select
Se
Ac
>M i
I n
cu r i t y
ces s
g Type
duc t .
Vo l t a g e
Co r r e c t i o n
>D V C O n
Vo l t a g e
Co r r e c t i o n
>D V C O f f
Increase
10-7. Selecting Inductance
1
1
Access
Setup
Display
Press
Mode Select
Ac c
Mi
>I n
Pu
ess
g Type
duc t .
r ge
Inductance Display
The inductance level can be varied
between 0 (zero) and 99.
Increase
Le v e l
30
Le v e l
99
10-8. Selecting Purge Time
1
Use Purge only when a weld
program is not running.
Access
Setup
Display
OM-172 324 Page 56
Press
Mode Select
1
Mi
I n
>P u
Vo l
g Type
duc t .
r ge
t age
Ti me
0 . 0
Purge Display
The purge time can be varied between 0.0 (zero) and 25.0 seconds.
Increase
Ti me
25 . 0
10-9. Selecting Voltage Sensing Method
1
Voltage Feedback Display
When using the 17 Pin setting, arc
voltage feedback is through the
welding power source and the feedback signal is sent through the
17-pin cord to the feeder.
If the 17 Pin setting is used, it is recommended that the voltage sensing terminals on the welding power
source be used to monitor arc voltage at the workpiece.
When using the V. Sense setting,
arc voltage feedback is through the
voltage sense leads connected to
the feeder. Use this setting when
there is more than 50 ft (15 m) of
weld cable used.
1
Access
Setup
Display
Press
Mode Select
I n
Pu
>V o
A r
duc t .
r ge
l t age
cS t a r t
Co n t r o l
Fe e d b a c k
>1 7 P i n
Increase
Co n t r o l
Fe e d b a c k
>V . S e n s e
10-10.Selecting Arc Start Method
NOTE
Arc Start selection is not used when welding in non-pulsed MIG.
Do not use the Hot Start setting for .035 in (9 mm) or smaller wire.
1
1
Access
Setup
Display
Press
Mode Select
Pu
Vo
>A r
A r
r ge
l t age
cS t a r t
c T i me
Pu l se
Ar c S t a r t
>S t a n d a r d
Ar c S t a r t
Ty p e
>H o t S t a r t
Arc Start Display
Use the Hot Start mode for pulse
welding with 450 Ampere Inverter
Model when high initial weld current
is necessary to start large diameter
welding wires. When in Hot Start,
the 450 Ampere Inverter Model
starts the arc in the CV mode and
switches to CC once the arc is
started. Do not use Hot Start unless
using 450 Ampere Inverter Model.
Increase
Ar c S t a r t
Ty p e
>S o f t S t a r t
OM-172 324 Page 57
10-11.Resetting Arc Time
1
Arc Time Display
The unit accumulates arc hours up
to 9999.99 hours or 999999 weld
cycles before rolling over to zero
(0). The arc timer can be reset using
this display.
1
Press
Mode Select
Access
Setup
Display
Vo
A r
>A r
Wi
l t age
c S t a r t
c T i me
r e f eed
0 . 0 0H r s
0Cy c l
>N o R e s e t
0 . 0 0H r s
0Cy c l
>R e s e t
P r ess
Increase
10-12.Selecting Units For Wire Feed Speed And Motor Type
1
Wire Feed Display
The displayed unit of wire speed
(IPM or MPM) can be changed
along with the wire feed motor type
(Standard, Low Speed, or High
Speed).
1
Access
Setup
Display
Press
Mode Select
A r
A r
>W i
Wi
cS t a r t
c T i me
r e f eed
r e t ype
Di s p l a y
>I PM
Mo t o r T y p e
S t anda r d
Increase
Di s p l a y
I PM
Mo t o r T y p e
>L o w S p d
Di s p l a y
I PM
Mo t o r T y p e
>H i g h S p d
Increase
OM-172 324 Page 58
Di s p l a y
I PM
Mo t o r T y p e
>S t a n d a r d
Increase
Di s p l a y
>MP M
Mo t o r T y p e
S t anda r d
Parameter Decrease
Select
10-13.Selecting Wire Type
NOTE
If wire type is changed, perform a memory reset (see Section 10-15) immediately
after selecting wire type to bring up the correct welding programs.
1
Wire Type Display
Select soft wire when using aluminum wire in the wire feeder. Select
hard wire when using any other kind
of wire.
1
Access
Setup
Display
Press
Mode Select
A r
Wi
>W i
D i
c T i me
r e f eed
r e t ype
sp l ay
Wi r e Type
I n Feede r
>H a r d w i r e
Wi r e Type
I n Feede r
>S o f t w i r e
Increase
10-14.Selecting Display
1
1
Display Select Display
The display can show amps, actual
reading or print out command.
Access
Setup
Display
Press
Mode Select
Wi r e
Wi r e
>D i s p
Memo
f
t
l
r
eed
ype
ay
y
C o mm a n d
Increase
Ac t ua l
Increase
Amp s
OM-172 324 Page 59
10-15.Resetting Memory
1
No Reset
Memory cannot be reset.
Press
Mode Select
Access
Setup
Display
1
Wi r e
D i sp
>M e m o
Shu t
t
l
r
d
ype
ay
y
own
>N o
2
Re s e t
3
Increase/
Decrease
>P r o g r a m
Re s e t
4
>P r
Pu
03
A r
g 1
l se
5 ”S t ee l
gon Ox y
System Reset
Press Parameter Select button to
reset programs and setup to original factory settings. System, Arc
Time, and Model Type settings are
not affected by the system reset.
1
4
P r ess
>P r o c e s s
Sequence
Ca r d
Program Reset
Press Parameter Select button to
reset last active program to original
factory program settings. All other
program and setup information remains the same.
Reset (Default) Displays
2
Parameter
Select
Increase/
Decrease
3
>S y s t e m
Re s e t
P r ess
Parameter
Select
10-16.Selecting Arc Start/Volt Sense Error Shutdown
1
Voltage Shutdown Display
With Arc Start/Volt Sense on, the
unit shuts down when no arc voltage is sensed. If the unit shuts
down, an error message appears
(see Section 12-3).
With Arc Start/Volt Sense off, the
unit continues to feed wire even
when there is no arc voltage
sensed.
1
Access
Setup
Display
OM-172 324 Page 60
Press
Mode Select
D i sp l ay
Memo r y
>S h u t d o w n
N ame
Ar c S t a r t /
Vo l t S e n s e
>O n
Increase
Ar c S t a r t /
Vo l t S e n s e
>O f f
10-17.Selecting Program Name Feature
1
1
Access
Setup
Display
Press
Mode Select
Memo r y
Sh u t d own
>N a m e
P r o g r am
Name Display
When a data card is used, the programs written from the unit to the
card can be named.
Ca r d
Pr o g r a m s
>O n
Ca r d
Pr o g r a m s
>O f f
Increase
10-18.Remote Program Select
NOTE
Remote Program Select is in binary code, with “A” the least significant bit, and “C”
the most significant bit.
1
1
Access
Setup
Display
Press
Mode Select
Sh u t d own
N ame
>P r o g r a m
S t i c k
Program Display
When Program is On, a remote device may be used to select programs. When Off, program selection must be done from robot Teach
Pendant or interface pulse panel.
Re m o t e
Pr o g r a m
>O f f
Re m o t e
Pr o g r a m
>O n
Increase
10-19.Stick Check Selection
1
Stick Check Display
When stick check is On, a stick
check routine is performed at the
end of each weld. When Off, no
stick check is done.
1
Access
Setup
Display
Press
Mode Select
N ame
P r o g r am
>S t i c k
J o g I PM
St i c k
Ch e c k
>O n
St i c k
Ch e c k
>O f f
Increase
OM-172 324 Page 61
10-20.Jog Wire Feed Speed Selection
1
This feature is only used with
arc-On style robots.
Jog IPM Display
Jog wire feed speed can be varied
between 50 and 780 inches per
minute, IPM.
1
Press
Mode Select
Access
Setup
Display
P r
S t
>J o
Ro
o g r am
i c k
g I PM
bo t
I PM
>5 0
I PM
>7 8 0
Increase
10-21.Robot Type Selection
1
1
Access
Setup
Display
Press
Mode Select
S t
Jo
>R o
A r
i c k
g I PM
bo t
c Fa i l
Co n t r o l o f
>A r c O n
&An a l o g
I npu t s
Increase
Co n t r o l o f
>A r c O n
NoAna l og
I npu t s
Increase
Co n t r o l o f
>P S, W i r e ,
Ga s &
Ana l og
OM-172 324 Page 62
Robot Type Display
This interface can be programmed
to work with three different types of
robot controllers.
The robot has control of arc on but
the interface has control of weld sequences. There are two analog
channel for the robot to use.
The robot has control of arc on but
the interface has control of weld sequences. There are no analog
channels for the robot to use.
The robot has control of arc on, the
welding power source contactor,
wire feed speed, gas valve and two
analog channels.
The setting of robot type affects the
programming capabilities of the interface. See Sections 6 and 8.
10-22.Arc Voltage Error Selection
1
When a system reset is done, Monitor is set to Off.
Access
Setup
Display
Press
Mode Select
When this feature is off, arc voltage
or arc length variations will not
cause an error or shut the unit
down.
1
Ro
A r
>M o
So
bo t
c Fa i l
n i t o r
f t wa r e
Monitor Display
Provides a means to enable/disable the arc voltage error feature
and to set an acceptable range of
deviation from set arc voltage or arc
length (trim) before the error will actuate.
Ar c V o l t s
>O n
2 . 0 Vo l t s
1 . 0 Sec
A r c
>O f f
When this feature is on and a range
of deviation is set (±0.1 – 9.9 volts
from desired weld voltage), arc voltage or arc length variations outside
of the range for a period of time
longer than that set by the Arc Error
timer, causes either the error relay
to energize or the unit to shut down
depending on the Arc Start/Volt
Sense shutdown error setting.
Vo l t s
Increase
10-23.Software Version Number
1
Access
Setup
Display
Press
Mode Select
Ro
A r
Mo
>S o
bo t
c Fa i l
n i t o r
f t wa r e
Ve r s i o n
#1 2 3 4 5 6 Z
1
Example Version Number Display
When talking with service personnel, this number may be required.
(Check actual unit display for number.) The factory keeps this number
on file with the serial number of the
unit.
OM-172 324 Page 63
SECTION 11 – CONTROL MENU
The control menu allows the user access to rise time setting that controls rise and fall time of the pulse square wave.
Changing the rise time setting changes the square wave shape by rounding off the corners, and makes it possible to
quiet the pulse arc by just changing the rise time.
11-1. Using Menu Display
1
2
Front Panel Control Display
Front panel display during control
setting.
3
Increase
Button
2
Pulse Panel Increase And Decrease Buttons
3
Power Switch On Rear Panel
Press and hold down both buttons
while turning On unit. Release buttons when Control appears on the
front panel display.
4
Decrease
Button
Pulse Panel Control Display
Follow this procedure any time access is required. To save any
changes made while in the control
display, and/or to exit the control
display, press Reset button on front
panel.
1
4
C o n t r o l
>R i s e
T i me
>1 2 5 0
Front Panel Display
Pulse Panel Display
OM-172 324 Page 64
A / ms
11-2. Setting Rise Time
NOTE
Maximum Rise Time setting will make the welding power source go to its
maximum output.
1
1
Access
Control
Display
>R i s e
T i me
>1 2 5 0
A / ms
Rise Time Display
Setting is depend on desired arc
characteristics. Make a sample
weld after each setting until desired
arc characteristics are obtained.
Use Increase or decrease button to
change setting.
Range is 250 to 1250 A/ms.
Press Reset button to save setting
and exit Control menu.
Increase/Decrease
> 255
A / ms
Reset
>P r o c e s s
Sequence
Ca r d
>P r
Pu
03
A r
g 1
l se
5 ”S t ee l
gon Ox y
OM-172 324 Page 65
SECTION 12 – MAINTENANCE & TROUBLESHOOTING
12-1. Routine Maintenance
Turn Off all power before maintaining.
3 Months
3 Months
6 Months
Tape Or
Replace
Cracked
Weld
Cable
Replace
Unreadable
Labels
Blow Out
Or
Vacuum
Inside
OR
During Heavy Service,
Clean Monthly
Replace
Cracked
Parts
14-Pin Cord
Gas Hose
Gun Cable
12-2. Overload Protection
1
Turn Off robot, interface, and welding power source.
1
Circuit Breaker CB1
CB1 protects the interface from
overload. If CB1 trips, the unit shuts
down.
Allow cooling period and manually
reset breaker.
2
Fuse F1
F1 protects the interface from overload. If F1 opens, the unit shuts
down.
Replace F1 with fuse of the same
type, size, and rating.
2
OM-172 324 Page 66
ST-800 962-A
12-3. Front Panel Error Displays
1
Memory CRC Error Display
Corrupted program data has been
detected or loaded. The “X” value indicates the program number.
1
Memo r y
P r g
X
CRC
E r r o r
2
Memo r y
P r g
X
R a n g e
E r r o r
3
May be caused by incompatible information on the data card or bad
memory.
2
May be caused by improper range
settings or improper data loaded into
the interface unit.
3
N o
E r r o r
4
May be caused by an inability to establish an arc in the pulse schedule,
or a lack of voltage feedback.
4
N o
T a c h
S e n s e d
E r r o r
5
May be caused by obstructions in the
wire feed system or a faulty wire drive
system.
Arc Stop Error Display
Trouble is occurring at arc end.
E r r o r
6
May be caused by obstructions in the
wire feed system or a faulty wire drive
system.
6
A r c
S t a r t
No Tach Sensed Error Display
The motor tachometer feedback is
not reaching the control.
5
A r c
S t o p
No Volt Sensed Error Display
The arc voltage sense circuit did not
receive feedback within the required
time after an arc was established.
V o l t
S e n s e d
Memory Range Error Display
Improper welding power source
range is selected. The “X” value indicates the program number.
Arc Start Error Display
Trouble is occurring at arc start.
E r r o r
May be caused by obstructions in the
wire feed system or a faulty wire drive
system.
OM-172 324 Page 67
12-4. Error Displays (Continued)
1
1
S t o p
We l d
E r r o r
C y c l e
D e t e c t e d
2
2
Error Card Read Display
The card reader is not working
properly.
May be caused by a bad data card, a
bad data card reader, a faulty microprocessor circuit board, or a wiring
problem.
E r r o r
C a r d
R e a d
3
Robot E-Stop Display
The robot E-Stop is active. The interface unit will remain in a locked stated
until the E-Stop is released.
3
R o b o t
4
E – S t o p
Ground Current Detect Error
Display
Weld current has been detected in
the earth ground connection.
4
G r o u n d
C u r r e n t
D e t e c t
E r r o r
5
May be caused by a conductor making connection to the unit chassis.
5
Wire Stick Error Display
The welding wire has stuck to the
workpiece at the end of the weld.
May be caused by poor weld
conditions.
W i r e
6
S t i c k
An arc was not established within the
allotted time.
E r r o r
6
A r c
T i me
OM-172 324 Page 68
Stop Weld Cycle Error Display
An error has been detected and the
robot hasn’t stopped the weld cycle,
causing the interface unit to stop the
weld cycle and wait for the robot to
stop.
May be caused by an inoperable wire
drive, absence of shield gas, or improperly operating welding power
source.
F a i l
O u t
Arc Fail Time Out Error Display
E r r o r
12-5. Interface Board PC5 Diagnostic LED’s
1
Diagnostic LED’s Cover
Remove cover.
2
Interface Board PC5
Diagnostic LED’s are visible inside
unit, located on edge of Interface
Board PC5 facing front of unit.
Refer to Section 12-6 for information
on diagnostic LED’s.
1
Reinstall cover after checking diagnostic LED’s.
LED5
LED4
LED3
LED6 LED7 LED8 LED9
LED2
LED1
2
ST-800 755-B / ST-801 094
12-6. Diagnostic LED’s On Interface Board PC5
LED
Status
1
On
Indicates +15 volts dc present on interface board PC5 with respect to power source common.
Off
If LED 1 is off and LED’s 2 thru 5 are on, replace interface board PC5. If LED 1 is off and LED’s 2 thru 5
are off, check Power switch S1, integrated rectifier SR1, and motor board PC3. Replace S1, SR1, and
PC1 if necessary.
On
Indicates –15 volts dc present on interface board PC5 with respect to power source common.
Off
If LED 2 is off and LED’s 1, 3, 4, and 5 are on, replace interface board PC5. If LED 2 is off and LED’s 1,
3, 4, and 5 are off, check Power switch S1, integrated rectifier SR1, and motor board PC3. Replace S1,
SR1, and PC1 if necessary.
On
Indicates +15 volts dc present on interface board PC5 with respect to dc circuit common.
Off
If LED 3 is off and LED’s 1, 2, 4, and 5 are on, replace interface board PC5. If LED 3 is off and LED’s 1,
2, 4, and 5 are off, check Power switch S1, integrated rectifier SR1, and motor board PC3. Replace S1,
SR1, and PC1 if necessary.
On
Indicates –15 volts dc present on interface board PC5 with respect to dc circuit common.
Off
If LED 4 is off and LED’s 1, 2, 3, and 5 are on, replace interface board PC5. If LED 4 is off and LED’s 1,
2, 3, and 5 are off, check Power switch S1, integrated rectifier SR1, and motor board PC3. Replace S1,
SR1, and PC1 if necessary.
On
Indicates +5 volts dc present on interface board PC5 with respect to dc circuit common.
Off
If LED 5 is off and LED’s 1 thru 4 are on, replace interface board PC5. If LED 5 is off and LED’s 1 thru 4
are off, check Power switch S1, integrated rectifier SR1, and motor board PC3. Replace S1, SR1, and
PC1 if necessary.
On
Indicates contactor is not energized, normal standby mode.
Off
Indicates contactor is energized.
On
Indicates CV mode is selected.
Off
Indicates CC mode is selected.
On
Indicates gas valve GS1 is not energized, normal standby mode.
Off
Indicates gas valve GS1 is energized.
On
Indicates wire feed motor M1 is not running, normal standby mode.
Off
Indicates wire feed motor M1 is running.
2
3
4
5
6
7
8
9
Diagnosis
OM-172 324 Page 69
12-7. Customer Interface Board PC4 Diagnostic LED’s
1
Robotic Interface II
2
Customer Interface Board PC4
Diagnostic LED’s are visible inside
unit, located on PC4 mounted to center panel facing front of unit.
Refer to Section 12-8 for information
on diagnostic LED’s.
Reinstall top cover after checking
diagnostic LED’s.
LED12
LED23
LED25
LED26
LED22
LED24 LED8 LED9
LED7
LED4
LED3 LED10 LED5
LED1
LED11 LED2 LED6
LED13
LED14
LED15
LED19
LED16
LED17
LED18
2
LED21 LED20
1
Ref. ST-801 124-B
OM-172 324 Page 70
12-8. Diagnostic LED’s On Interface Board PC4
LED
1
2
3
4
5
6
7
8
9
10
11
12 to 21
22
23
24
25
26
Status
Diagnosis
On
Input signal On for RPS8-A.
Off
Input signal Off for RPS8-A.
On
Input signal On from robot for shielding gas valve.
Off
Input signal Off from robot for shielding gas valve.
On
Input signal On for welding power source contactor.
Off
Input signal Off for welding power source contactor.
On
Input signal On for RPS8-C.
Off
Input signal Off for RPS8-C.
On
Input signal On for shielding gas purge.
Off
Input signal Off for shielding gas purge.
On
Input signal On for Jog retract.
Off
Input signal Off for Jog retract.
On
Indicates +24 volts dc present on customer interface board PC4 with respect to power source common.
Off
No +24 volts dc at customer interface board PC4.
On
Indicates –15 volts dc present on interface board PC4 with respect to dc circuit common.
Off
No –15 volts dc at customer interface board PC4.
On
Indicates +15 volts dc present on interface board PC4 with respect to dc circuit common.
Off
No +15 volts dc present at customer interface board PC4.
On
Input signal On for Jog advance.
Off
Input signal Off for Jog advance.
On
Input signal On for RPS8-B.
Off
Input signal Off for RPS8-B.
Not used
On
Output signal On to indicate that wire is stuck.
Off
Output signal Off indicates wire not stuck.
On
Output signal On indicates ABB robot jog signal.
Off
Output signal Off indicates no ABB robot jog signal.
On
Output signal On indicates weld current detected.
Off
Output signal Off indicates no weld current detected.
On
Output signal On indicates an arc failure.
Off
Output signal Off indicates no arc failure.
On
Output signal On indicates welding power source is ready.
Off
Output signal Off indicates welding power source not ready.
OM-172 324 Page 71
SECTION 13 – ELECTRICAL DIAGRAMS
Figure 13-1. Circuit Diagram For Robotic Interface Unit
OM-172 324 Page 72
SD-185 806
OM-172 324 Page 73
Figure 13-2. Circuit Diagram For Microprocessor Board PC1
OM-172 324 Page 74
SD-161 039-A
OM-172 324 Page 75
Figure 13-3. Circuit Diagram For Motor Board PC3
OM-172 324 Page 76
SD-083 388-B
OM-172 324 Page 77
Figure 13-4. Circuit Diagram For Customer Interface Board PC4 (Part 1 of 2)
OM-172 324 Page 78
SD-180 191 (Part 1 of 2)
OM-172 324 Page 79
Figure 13-5. Circuit Diagram For Customer Interface Board PC4 (Part 2 of 2)
OM-172 324 Page 80
SD-180 191 (Part 2 of 2)
OM-172 324 Page 81
Figure 13-6. Circuit Diagram For Interface Board PC5
OM-172 324 Page 82
SD-165 466
OM-172 324 Page 83
SB-179 739
Figure 13-7. Circuit Diagram For Filter Board PC6
OM-172 324 Page 84
SC-165 462-A
Figure 13-8. Circuit Diagram For Display Board PC7
OM-172 324 Page 85
SA-156 626-A
Figure 13-9. Circuit Diagram For Data Card Board PC8
SA-158 163
Figure 13-10. Circuit Diagram For Pulse Display Board PC9
OM-172 324 Page 86
SC-176 534
Figure 13-11. Circuit Diagram For Junction Board PC10
OM-172 324 Page 87
SECTION 14 – PARTS LIST
Hardware is common and
not available unless listed.
1
2
7
6
3
5
24
13
4
14
8
23
9
10
22
15
12
11
16
17
21
20
2
19
18
ST-801 142
Figure 14-1. Case Section w/Components
OM-172 324 Page 88
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-1. Case Section w/Components
. . . 1 . . . . PC3 . . . . . 071 642 . . CIRCUIT CARD ASSEMBLY, motor speed control . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . 098 691 . . STAND-OFF, No. 6-32 x .500 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . 3 . . . . . C1 . . . . . . 031 692 . . CAPACITOR, elctlt 750uf 200VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . 006 426 . . CLAMP, capacitor 2.000dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . R3 . . . . . . 079 497 . . RESISTOR, WW fxd 25W 2K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . 605 741 . . CLIP, mtg resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 7 . . . . . R2 . . . . . . 030 941 . . RESISTOR, WW fxd 100W 5 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . R1 . . . . . . 030 651 . . RESISTOR, WW fxd 25W 10 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . 166 357 . . CASE SECTION, bottom/sides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . +166 512 . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 134 327 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . PLG7 . . . . . 165 897 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 111 030 . . . . CONNECTOR, edge skt 20-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
. . . 11 . . . . . . . . . . . . . . . 009 335 . . STAND-OFF, No. 4-40 x .625 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . . . 155 022 . . CABLE, ribbon 34posn 12.000 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . 169 923 . . CABLE, ribbon 24posn 14.000 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . PC1 . . . . . 171 525 . . CIRCUIT CARD ASSEMBLY, processor w/prom . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG11 . . . . 115 092 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 113 746 . . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . PLG13 . . . . 163 467 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 147 995 . . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
. . . . . . . . . PLG15 . . . . 153 501 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 147 995 . . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . PLG17 . . . . 115 093 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 113 746 . . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . PLG18 . . . . 162 382 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 113 746 . . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
. . . 15 . . . . . . . . . . . . . . . 155 629 . . CABLE, ribbon 14posn 3.000 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . 126 689 . . STAND-OFF, No. 6-32 x 1.500 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 17 . . . . PC5 . . . . . 165 463 . . CIRCUIT CARD ASSEMBLY, I/O interface . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG51 . . . . 158 720 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 147 995 . . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . . . . . . PLG52,58 . . . 158 719 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 147 995 . . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . PLG53 . . . . 131 204 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 113 746 . . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . PLG54 . . . . 148 439 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 147 995 . . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
. . . . . . . . . PLG55 . . . . 115 092 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 113 746 . . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . . . . . . . . PLG56 . . . . 115 093 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 113 746 . . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . PLG57 . . . . 164 900 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 147 995 . . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 18 . . . . . . . . . . . . . . . 019 663 . . MOUNT, nprn 15/16 OD x 3/8rec 3/16 x 3/8 . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 19 . . . . . T2 . . . . . . 090 465 . . XFMR, signal 115V 24VCT 4A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . T1 . . . . . . 169 063 . . XFMR, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . SR1,SR2 . . . 035 704 . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 22 . . . . . C2 . . . . . . 169 080 . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . 1T . . . . . . 157 169 . . BLOCK, term 20A 16 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 601 219 . . LINK, jumper term blk 20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 24 . . . . CR1 . . . . . 109 006 . . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . D1 . . . . . . 171 386 . . DIODE, w/leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PC10 . . . . . 176 536 . . CIRCUIT CARD ASSEMBLY, junction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG6 . . . . . 163 467 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG166 . . . 131 052 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . C3 . . . . . . 179 217 . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-172 324 Page 89
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-2. Panel, Front w/Components
. . . 1 . . DSPL1 . . . 165 459 . . CIRCUIT CARD ASSEMBLY, display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . 166 355 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 057 359 . . BLANK, snap-in nyl .375mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 3 . . . . . . . . . . . . . 164 757 . . GASKET, meter lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . 169 419 . . COVER, troubleshooting lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . . . . . . . . . . . . 154 109 . . PLATE, ident inner control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . . . 155 024 . . LENS, clear anti glare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . . . . . . . . . . . . 168 337 . . PANEL, control inner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . PC8 . . . . . 156 623 . . CIRCUIT CARD ASSEMBLY, data card . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . PLG60 . . . 153 501 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 147 995 . . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . DSPL2 . . . 158 160 . . CIRCUIT CARD ASSEMBLY, side display . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . . . . . . . . . 144 844 . . STAND-OFF, No. 6-32 x .875 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial No.) . . . . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . . . . 168 459 . . DOOR, access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 13 . . . . . . . . . . . . . 089 899 . . LATCH, slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . . . . 153 169 . . ACTUATOR, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . . . . 089 032 . . LENS, LED 4341 red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
2
1
1
1
6
1
8
1
1
1
8
3
Hardware is common and
not available unless listed.
8
3
7
4
6
1
9
5
2
10
11
15
14
13
12
ST-801 143-A
Figure 14-2. Panel, Front w/Components
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-172 324 Page 90
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-3. Panel, Center w/Components
. . . 1 . . . . . . . . . . . . . 099 037
. . . 2 . . . . . 2T . . . . 157 169
. . . 3 . . . . . . . . . . . . . 038 839
. . . . . . . . . . . . . . . . . . . 601 219
. . . 4 . . . . CR2 . . . 052 964
. . . 5 . . . . . . . . . . . . . 134 201
. . . 6 . . . . . . . . . . . . . 166 354
. . . 7 . . . . PC4 . . . 180 189
. . . . . . . . . . . . . . . . . . . 012 633
. . . . . . . . . . PLG3 . . . 158 768
. . . . . . . . . . . . . . . . . . . . 113 746
. . . . . . . . . . PLG6 . . . 164 467
. . . . . . . . . . . . . . . . . . . 147 995
. . . . . . . . . PLG70 . . . 115 092
. . . . . . . . . . . . . . . . . . . . 113 746
. . EDGE TRIM, style 62-1/16 black w/clips (order by ft) . . . . . . . . . . . . . . . . .
. . BLOCK, term 20A 16 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLOCK, term 20A 5 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LINK, jumper term blk 20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RELAY, encl 24VDC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF SUPPORT, pc card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, mtg cmpts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSEMBLY, interface (consisting of) . . . . . . . . . . . . . . . .
. . . . FUSE, mintr gl 1A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR, rect 24P/S 2 row plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hardware is common and
2ft
1
1
2
1
4
1
1
1
1
24
1
9
1
8
2
not available unless listed.
1
3
4
5
6
7
ST-801 144
Figure 14-3. Panel, Center w/Components
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-172 324 Page 91
Hardware is common and
not available unless listed.
3
2
4
3
1
5
13
6
12
10
9
8
7
11
ST-801 145
Figure 14-4. Panel, Rear w/Components
OM-172 324 Page 92
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 14-4. Panel, Rear w/Components
. . . 1 . . . . . . . . . . . . . 171 363
. . . 2 . . . . . S1 . . . . . 111 997
. . . 3 . . . . . . . . . . . . . 046 432
. . . 4 . . . . . F1 . . . . 012 655
. . . 5 . . . . . . . . . . . . . 139 042
. . . 6 . . . . . . . . . . . . . 171 367
. . . . . . . . . . PC2 . . . 134 560
. . . . . . . . . . . R4 . . . . . 074 110
. . . . . . . . . . RC21 . . . 076 624
. . . 7 . . . . RC9 . . . 152 492
. . . . . . . . . . . . . . . . . . . 134 731
. . . 8 . . . . RC8 . . . 153 884
. . . 9 . . . . CB1 . . . . 011 991
. . . 10 . . . . . . . . . . . . . 073 756
. . . 11 . . . . PC6 . . . 179 741
. . . . . . . . . PLG89 . . 131 204
. . . . . . . . . . . . . . . . . . . . 113 746
. . . . . . . . . PLG82 . . 158 720
. . . . . . . . . . . . . . . . . . . 147 995
. . . 12 . . . . RC20 . . . 139 268
. . . 13 . . . . . FL1 . . . 084 171
. . . . . . . . . . . . . . . . . . . 176 872
. . . . . . . . . . . . . . . . . . . 153 886
. . . . . . . . . . . . . . . . . . . 039 734
. . . . . . . . . . . . . . . . . . . 600 798
. . . . . . . . . . . . . . . . . . . 071 892
. . . . . . . . . . . . . . . . . . . 079 534
. . . . . . . . . . . . . . . . . . . 079 739
. . . . . . . . . . . . . . . . . . . 158 373
. . . . . . . . . . . . . . . . . . . 097 868
. . . . . . . . . . . . . . . . . . . . 116 964
. . . . . . . . . . . . . . . . . . . 600 343
. . . . . . . . . . . . . . . . . . . 097 866
. . . . . . . . . . . . . . . . . . . . 175 115
. . . . . . . . . . . . . . . . . . . 141 162
. . . . . . . . . . . . . . . . . . . 134 731
. . . . . . . . . . . . . . . . . . . 079 739
. . . . . . . . . . . . . . . . . . . 121 274
. . . . . . . . . . . . . . . . . . . 152 370
. . . . . . . . . . . . . . . . . . . 079 534
. . . . . . . . . . . . . . . . . . . 079 739
. . . . . . . . . . . . . . . . . . . 133 866
. . . . . . . . . . . . . . . . . . . 073 686
. . . . . . . . . . . . . . . . . . . 039 828
. . . . . . . . . . . . . . . . . . . 133 859
. . . . . . . . . PLG150 . 131 054
. . . . . . . . . . . . . . . . . . . . 113 746
. . . . . . . . . . CR3 . . . 178 503
. . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . SWITCH, rocker spst 10A 250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . HOLDER, fuse mintr .250 x 1.250 panel mtg . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FUSE, mintr cer 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . BUSHING, strain relief .270/.480 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . RECEPTACLE, w/components (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CIRCUIT CARD, filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . RESISTOR, c 1W 10K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR, circ 4 pin rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . CONNECTOR, circ pin 14-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . CONNECTOR, circ 19skt rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CIRCUIT BREAKER, man reset 1P 1.5A 250VAC . . . . . . . . . . . . . . . . . . . 1
. . STAND-OFF, No. 6-32 x .625 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CIRCUIT CARD ASSEMBLY, filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR, rect skt 22-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . CONNECTOR, circ 10skt rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . FILTER, line pwr 115/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CABLE, motor/gas (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR, circ 19 pin plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR, circ clamp str rlf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CABLE, port No. 16 10/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30ft
. . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . CONNECTOR, circ skt 14-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . . CONNECTOR, circ clamp str rlf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CABLE, interconnecting power 10ft (consisting of) . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR, circ 17skt plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR, circ clamp str rlf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . CABLE, port No. 16 5/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10ft
. . . . CONNECTOR, circ 17 pin plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CABLE, interconnecting 10ft (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . CONNECTOR, circ pin 14-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . CONNECTOR, circ clamp str rlf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CABLE, port No. 18 12/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10ft
. . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . CONNECTOR, circ skt 14-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . CONNECTOR, circ clamp str rlf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . CABLE, volt sense 35ft (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR, circ 4skt plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR, circ clamp str rlf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CABLE, shld No. 18ga 1/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . 70ft
. . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . SWITCH, reed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-172 324 Page 93
Hardware is common and
31
36
37
38
39
40
41
35
34
2
3
4
5
6
7
8
33
9
32
1
14
16
15
10 11 12 Includes
Items
13-16
34
33
17
13
32
14
18
19
20
21
22
24
25
30
26
23
27
28
29
29
not available unless listed.
ST-801 153
Figure 14-5. Motor & Drive Assembly
OM-172 324 Page 94
Item
No.
Part
No.
Description
Quantity
Figure 14-5. Motor & Drive Assembly
. . . 1 . . . . . 046 779 . . DRIVE ASSEMBLY, wire (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . 602 154 . . . . SCREW, cap stl hexhd .250-20 x .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . 010 224 . . . . PIN, spring CS .187 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 4 . . . . . 166 337 . . . . HOUSING, adapter gun/feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . 085 242 . . . . FASTENER, pinned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . 085 244 . . . . WASHER, cupped stl .328 ID x .812 OD x .125 lip . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . 010 231 . . . . SPRING, cprsn .770 OD x .105 wire x 1.225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 8 . . . . . 085 243 . . . . KNOB, adjustment tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . . 166 071 . . . . LEVER, mtg pressure gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . 079 634 . . . . PIN, hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . 151 828 . . . . PIN, cotter hair .054 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . 166 338 . . . . LEVER, mtg pressure gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . 144 172 . . . . FITTING, brs barbed M 3/16tbg x .250-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . 166 072 . . . . SPACER, gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . 604 538 . . . . WASHER, flat stl SAE .312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . 079 772 . . . . KNOB, plstc T 1.500 lg x .312-18 x 2.000 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . 070 397 . . INSULATION, motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . 173 128 . . BRACKET, mtg motor/gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . 075 150 . . WASHER, shldr nyl 1.000 OD x .375 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 20 . . . . . 010 910 . . WASHER, flat stl SAE .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 21 . . . . . 602 213 . . WASHER, lock stl split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 22 . . . . . 079 624 . . SCREW, cap stl hexhd slflkg .375-16 x 2.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 23 . . . . . 173 145 . . MOTOR, gear (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . 047 636 . . . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 079 535 . . . . . . CONNECTOR, circ pin push-in 14-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . 25 . . . . . 079 739 . . CLAMP, cable strain relief sz 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . 172 996 . . CABLE, motor 12.000 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . 132 611 . . OPTICAL ENCODER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . 153 631 . . CIRCUIT CARD, digital tach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 131 203 . . CONNECTOR & PINS (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 114 656 . . . . CONNECTOR, rect pin 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 29 . . . . +172 807 . . MOTOR, gear 1/8hp 115VDC 2000RPM (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 153 491 . . . . KIT, brush replacement (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 153 492 . . . . . . CAP, brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . 153 493 . . . . . . BRUSH CARBON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 30 . . . . . 092 865 . . KEY, stl .1215/.1230 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . 133 873 . . VALVE, 24VDC 2 way custom port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 605 227 . . NUT, .750-14 knurled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 134 834 . . HOSE, SAE .187 ID x .410 OD (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1ft
. . . . . . . . . . . 149 332 . . CLAMP, hose .405-.485clp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 604 525 . . CABLE, port No. 18 2/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3ft
. . . . . . . . . . . 026 202 . . DIODE, rect 1A 400V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . 053 842 . . GEAR, spur insulated w/bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 33 . . . . . 079 626 . . SCREW, mach stl filh 10-32 x .875 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
. . . 34 . . . . . 605 518 . . SCREW, cap stl hexhd .250-20 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 35 . . . . . 072 010 . . WASHER, shldr nyl .437 OD x .316 ID x .187 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 36 . . . . . 079 625 . . WASHER, spring stl .500 shakeproof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 37 . . . . . 000 418 . . SCREW, cap stl hexhd slflkg .250-20 x .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . 602 241 . . WASHER, flat stl SAE .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . 093 664 . . GEAR, spur insulated drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . 601 872 . . NUT, stl hex full .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 41 . . . . . 602 243 . . WASHER, flat stl std .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . 168 589 . . BUSHING, insulating 1.500dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 168 590 . . BUSHING, insulating .750dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . 080 438 . . BRACKET, ball clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 079 872 . . BRACKET, mtg pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 080 439 . . BRACKET, ball clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 045 767 . . BAR, mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-172 324 Page 95
Notes
OM-172 324 Page 96
Effective January 1, 2000
(Equipment with a serial number preface of “LA” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
*
LIMITED WARRANTY – Subject to the terms and conditions
below, Miller Electric Mfg. 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 LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
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
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
1.
5 Years Parts – 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
185 & Spoolmate 250)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
HF Units
Grids
Maxstar 140
Spot Welders
Load Banks
Miller Cyclomatic Equipment
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
*
MIG Guns/TIG Torches
Induction Heating Coils and Blankets
*
*
*
*
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate 185 & Spoolmate 250
Canvas Covers
Miller’s True Blue Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
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.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
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 customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION,
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.
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 in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.
miller_warr 7/00
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters–USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier for:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.
PRINTED IN USA
 2001 Miller Electric Mfg. Co.
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