I

H

H

Miller

The Power ofBlue.

OM-1 588

October 1999

161 875L

Processes

MIG (GMAW) Welding

Pulsed MIG (GMAW-P)

Flux Cored (FCAW) Welding

Description

Wire Feeder

(Use with CC/CV Power Sources)

DS-64M

Swingarc

I

F

0

Visft our webs~te at www

MiHerWelds corn

12 and 16 Foot

OWNERS MANUAL

0

From Miller

to

You

Thank you and

congratulations

on

choosing

Miller. Now you can

get

the

job

done and

get

it done

right.

We know you dont have time to do it any other way.

Thats

why

when Niels Miller first started

building

arc welders in

1929,

he made sure his

products

offered

long-lasting

value and

superior quality.

Like you, his customers couldnt afford

anything

less. Miller

products

had to be more than the best

they

could be.

They

had to be the best you could

buy.

Today,

the

people

that build and sell Miller

products

continue the tradition.

Theyre just

as committed to

providing equipment

and service that meets the

high

standards of

quality

and value established in 1929.

This Owners 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. Weve iEiIIi1IIIi p

IREGISTERED

I QUALITY SYSTEM

______________

Miller is the first welding equipment manufacturer in the U.S.A. to be the ISO 9001 registered to

Quality System

Standard.

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,

theres a

Troubleshooting

section that will

help

you

figure

out what the

problem

is. The

parts

list will then

help

you to decide which exact

part

you may need to fix the

problem. Warranty

and service information for your

particular

model are also

provided.

.

~II~Wfl~

Working as hard as you do from

every power source

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 sucha

GMA~ V.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 call 1-800-4-A-Miller.

a

WARNING

This for product, when used welding or cutting, produces fumes or gases which contain chemicals known to the

State of California to cause birth defects and, in some cases, cancer.

(California Health &

Safety Code Section

25249.5

et seq.)

TABLE OF CONTENTS

SECTION 1

-

SAFETY PRECAUTIONS

-

READ BEFORE USING

1-1.

1-2.

1-3.

1-4.

1-5.

Symbol Usage

Arc Welding Hazards

Additional Symbols for Installation, Operation, and Maintenance

Principal Safety Standards

EMF Information

SECTION 1

-

CONSIGNES DE SECURITE

-

LIRE AVANT UTILISATION

1-1.

1-2.

1-3.

Signification des symboles

Dangers relatifs au soudage a arc

Dangers supplØmentaires en relation avec Iinstallation, le fonctionnement et Ia maintenance

1-4.

1-5.

Principales normes de sØcuritØ

Information sur

Ies champs electromagnØtiques

SECTION 2

-

INTRODUCTION

2-1.

Specifications

SECTION 3INSTALLATION

3-1.

3-2.

3-3.

3-4.

3-5.

3-6.

3-7.

3-8.

Installing Swivel Into Pipe Post

Installing Control Box And Adjusting Tilt

Installing Boom And Reel Support

Installing Wire Guide Extension

Equipment Connection Diagram

Connecting Weld Cables And Gas Hoses

Control Box Connections

3-9.

3-10.

3-11.

14-Pin Plug Information

Motor Start Control

Removing Safety Collar And Adjusting Boom

Gun Recommendation Table

3-12.

Wire Type, Size, And Feed Speed Capability Table

3-13.

Installing And Threading Welding Wire

SECTION 4OPERATION

4-1.

4-2.

4-3.

4-4.

Operational Terms

Pulse Welding Terms

Front Panel Control&

Side And Rear Panel Controls

SECTION 5- SETTING SEQUENCE PARAMETERS

5-1.

Sequence Parameters In A Program

SECTION 6

-

SETTING DUAL SCHEDULE PARAMETERS

6-1.

6-2.

Selecting Dual Schedule

Dual Schedule Switch

Pair

Diagrams

SECTION 7

-

USING THE OPTIONAL DATA CARD

7-1.

Data Card Terms

7-2.

7-3.

Installing Data Card

Card Displays

SECTION 8

-

SYSTEM SETUP

8-1.

System Setup Display Parameters

SECTION 9STANDARD PULSE WELDING PROGRAMS

9-1.

9-2.

9-3.

9-4.

9-5.

9-6.

9-7.

9-8.

Program 1

-

Steel

Program 2

-

Steel

Program 3

-

Steel

Program 4

-

Steel

Program 5

-

Stainless

Program 6

-

Stainless

Program 7

-

Nickel Alloy

Program 8

-

Silicon Bronze

SECTION 10

-

SETTING SharpArc CONTROL

10-1.

Selecting And Adjusting SharpArc Control

SECTiON 10TEACH POINTS

10-1.

Teach Using 15 Points

10-2.

Teach Using 4 Points

10-3.

Redefining Teach Points

SECTiON 11

-

MAINTENANCE AND TROUBLESHOOTiNG

11-1.

Routine Maintenance

11-2.

Error Displays

11-3.

Troubleshooting

SECTiON 12ELECTRICAL DIAGRAM

SECTION 13PARTS LIST

WARRANTY

OM-1588

11

12

13

14

10

10

9

9

14

15

15

16

16

17

18

18

18

19

20

9

9

7

8

8

24

24

24

25

26

26

27

28

28

28

28

27

27

27

27

21

21

22

22

23

.29

29

30

30

31

32

34

34

35

36

38

40

3

3

4

1

1

1

5

5

5

.

SECTION

1

-

SAFETY PRECAUTIONS

-

READ

BEFORE USING

som _nd_4/98

1-1.

Symbol Usage

4A Means Warning!

Watch Out!

There are possible hazards with this procedure!

The possible hazards are shown in the adjoining symbols.

A Marks a special safety message.

~ Means Note~ not safety related.

1-2.

Arc Welding Hazards

A The symbols shown below are used throughout this manual to call attention to and identity possible hazards. When you see the symbol, watch out, and followthe related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 -4. Read and follow all Safety Standards.

A Only qualified persons should install, operate, maintain, and repair this unit.

A During operation, keep everybody, especially children, away.

This group

ELECTRIC of symbols means

Warning!

Watch Out!

possible

SHOCK, MOVING PARTS, and HOT PARTS hazards.

Consult symbols and related instructions below for necessary actions to avoid the hazards.

If earth grounding of the workpiece is required, ground it directly with a separate cable.

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 replacedamaged parts at once.

Maintain unit according to manual.

Wear a safety harness if working above floor level.

Keep all panels and covers securely in place.

Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.

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.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work installed or circuit is

The electrically live whenever the output is on.

input power circuit and machine internal circuits are also live when automatic wire power is on.

In semiautomatic or welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live.

improperly grounded equipment is a hazard.

Incorrectly

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.

S

Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 191 0.147

(see Safety Standards).

Properly install and ground this equipment according to its

Owners Manual and national, state, and local codes.

Always verify the supply ground

check and be sure that input power cord in ground wire is properly disconnect box or that cord connected plug to ground is connected to a terminal 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 drape cables over your body.

FUMESAND GASES can behazardouS~

Welding produces these fumes and fumes gases can and gases.

Breathing be hazardous to your health.

Keep your head out of the fumes.

Do not breathe the fumes.

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 (MSDS5) and the manufacturers 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 lower the oxygen level fumes and gases causing injury or can displace death.

Be air and sure the breathing air is safe.

Do not weld in locations near degreasing, cleaning, or spraying operations.

The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

Do not weld on coated cadmium metals, such as galvanized, lead, or 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-1588 Page 1

ARC RAYS can bum eyes and skin

Arc rays from the welding visible and invisible process

(ultraviolet produce and intense infrared) rays that can burn eyes and skin.

Sparks fly off from the weld.

Wear awelding helmetfitted with a proper shade of filterto 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.

can

Sparks 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, area explosion, overheating, orfire.

Check and be surethe 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 unknown paths and welding current from traveling long, possibly 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 shirt, cuffless trousers, high shoes, and a cap.

gloves, heavy

Remove any from combustibles, your person before such doing as a any butane welding.

lighter or matches,

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.

BUILDUP OF

GAScan injure

or kill.

Shut off shielding gas supply when not in use.

Always ventilate confined spaces or use approved air-supplied respirator.

.

HOT PARTS cancausesevere burns.

Do not touch hot parts bare handed.

Allow cooling period before working on gun or torch.

MAGNETIC FIELDS can affect pace nakers.

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 damage hearing.

processes or equipment can

Wear approved ear protection if noise level is high.

CYLINDERS can

explode

if

damaged.

Shielding gas cylinders contain gas under high pressure.

Since gas

If damaged, cylinders are a cylinder normally part can of the explode.

welding process, be sure to treat them carefully.

Protect compressed gas mechanical shocks, slag, cylinders open from flames, sparks, excessive and arcs.

heat,

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 associated follow instructions on compressed gas cylinders, equipment, and CGA publication P-i listed in Safety

Standards.

.

.

OM-1588 Page 2

I -3.

Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

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.

MOVING PARTS can cause

injury.

Keep away from moving parts such as fans.

Keep all doors, panels, covers, and guards closed and securely in place.

FALUNG UNIT can cause

injury.

Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.

Use equipment of adequate capacity to support unit.

lift and

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.

H.F. RADIATiON can cause interference.

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 store, move, or ship PC boards.

boxes to

MOVING PARTS can cause

injury.

Keep away from moving parts.

Keep away from pinch points rolls.

such as drive

ARC WELDING can cause interference.

Electromagnetic energy can interfere with sensitive electronic equipment such as computers and such as robots.

computer-driven equipment

Be sure all equipment in the welding area is electromagnetically compatible.

To reduce possible interference, possible, close keep weld cables as short as together, and down low, such as on the floor.

Locate welding operation 100 meters from any sensitive elec tronic 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.

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.

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 Superinten dent of Documents, U.S. Government Printing Office, Washington,

D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and

Cutting of Containers That Have Held Hazardous Substances,

American Welding Society Standard AWS F4.1, from American

Welding Society, 550 N.W.

LeJeune Rd, Miami, FL 33126

National Electrical

Protection

Code, NFPA Standard 70, from National Fire

Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet

P-i, from Compressed Gas Association, 1235 Jefferson Davis

Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard Wi 17.2, from

Canadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1 R3.

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 SiB, from National

Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

OM-i588 Page 3

1-5

EMF Information

Considerations About

Electric And

Welding And The Effects Of Low Frequency

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 research, a special blue ribbon committee of the National

Council concluded that: ~The body of evidence, in the committees frequency judgment, has not demonstrated that exposure to powerelectric and magnetic fields is a human-health hazard.

However, studies are still examined.

going forth and evidence continues to be

Until the final conclusions of the research are reached, you may wish to minimize your exposure to welding or cutting.

electromagnetic fields when

To reduce procedures: magnetic fields in the workplace, use the following

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:

Pacemakerwearersconsultyourdoctorfirst.

If cleared byyourdoctor, then following the above procedures is recommended.

.

.

OM-1588 Page 4

SECTION 1

-

CONSIGNES DE SECURITE

-

LIRE AVANT

UTI LISATION

som _nd fre 4/98

1-1.

SignificatIon des symboles

4~ Signif~e Mise en garde! Soyezvigilant!

Cette procedure prØsente des risques de danger!

Ceux-ci sont identifies par des symboles adjacents aux directives.

A Identifie un message de sØcuritØ particulier.

~

Ce groupe de risques de symboles signifie Mise en garde !

Soyez vigilant! IIy a des danger relies aux

CHOCS ELECTRIQUES, aux

PIECES EN

MOUVEMENTetaux PIECESCHAUDES.

Reportez-vousauxsymboles etauxdirectives ci-dessous afinde connaItre les mesures a prendre pour

Øviter tout danger.

~ Signifie NOTA nest pas relatif A Ia sØcuritØ.

1-2

Dangers relatifs

au

soudage a Iarc

A Les symboles prØsentØs ci-aprŁs sont utilisØs tout au long du present manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant et suivez les directives mentionnØes atm dØviter tout danger.

normes

Les consignes de sØcuritØ prØsentØes ci-aprŁs ne font que rØsumer Iintormation contenue dans les

ØnumØrØes a Ia section 1-4. VeuiHez lire et normes respecter de sØcuritØ toutes ces de sØcuritØ.

A Linstallation, lutilisation, vent Œtre confiØs qu des lentretien et les personnes reparations ne doi qualifiees.

A Au coursde lutilisation, tenirtoute personne a lØcartet plus par ticuliŁrement les enfants.

UN CHOC ELECTRIQUE

peut

tuer

Un simple contact avec des piŁces Łlectriques peut provoquer une electrocution ou des blessures graves.

LŁlectrode et le circuit de soudage sont sous tension des que lappareil est sur ON. Le circuit dentrØe et les tension circuits internes de ace moment-l.

lappareil sont Øgalement sous

Ensoudagesemi-automatique ouautomatique, le fil, le dŁvidoir, le logement des galets dentraInement et les piŁces mØtalliques en contact avec le fil de soudage sont sous tension.

Des matØriels mal installØs ou mal mis a Ia terre prØsentent un danger.

Ne jamais toucher les piŁces Ølectriques sous tension.

Porter des gants et des vŒtements de protection secs ne comportant pas de trous.

Sisoler de Ia piŁce et de Ia terre au moyen de tapis ou dautres moyens isolants suffisamment grands pour empŒcher sique Łventuel avec Ia piŁce ou

Ia terre.

le contact phy

Ne pas se servir de source

Ølectrique courant humides, dans es endroits confines ou l o on

Ølectrique dans les zones risque de tomber.

Se seivir dune source Ølectrique procØdØ de soudage le demande.

courant electrique UNIQUEMENT si le

Si lutilisation dune source

Ølectrique courant Ølectrique savŁre nØces saire, se servir de Ia fonction de tØlØcommande Si lappareil en est Øquipe.

Couperialimentation ou arrŒterle moteuravantde procØderlinstal lation, a a reparation ou a lentretien de lappareil.

DŁverrouiller lalimentation selon Ia norme

OSRA29 CFR 1910.147

(voir normes de sŁcuritØ).

Installer et mettre a laterre correctement cet appareil conformØment son manuel dutilisation et aux codes nationaux, provinciaux et municipaux.

Toujours verifier Ia terre du cordon datimentation

-

Verifier et sassu rer que le fil de terre du cordon dalimentation est bien raccordŁ ala borne deterre du sectionneurou que a une prise correctement mise a

Ia fiche du cordon est raccordŁe

Ia terre.

En effectuant les raccordements dentrŁe fixer dabord le conducteur de mise a Ia terre approprie et contre-vŁriller les connexions.

Verifier frŁquemment le cordon dalimentation pour voir sil nest pas endommagØ oudŁnudØ

remplacer le cordon immŁdiatement sil est endommagŁ

un cable dŁnudØ peut provoquer une electrocution.

Mettre lappareil hors tension quand on ne

Iutilise pas.

Ne pas utiliser sante ou mal des cables uses,

ŁpissØs.

endommagŁs, de grosseur insuffi

Ne pas enrouler les cables autour du corps.

Si Ia piŁce soudŁe doit Œtre mise a laterre, le faire directement avec un cable distinct.

Ne pas toucher terre ou une lŁlectrode quand on est en contact avec electrode provenant dune autre machine.

Ia piŁce, Ia

Nutiliser quun materiel en bon Øtat.

RØparer ou remplacer sur-le champ les piŁces endommagŁes.

Entretenir lappareilconformØment a ce manuel.

Porter un harnais de sŁcuritŁ quand on travaille en hauteur.

Maintenir solidement en place tous les panneaux et capots.

Fixer le cable de retour de facon a obtenir un bon contact mŁtal-mŁtal avec

Ia piŁce a souderou latable detravail, le plus prŁs possible de Ia soudure.

Isoler Ia pince de masse quand pas mis a Ia piŁce pour Øviter le contact avec tout objet metallique.

Ily

a

DU COURANT CONTINU IMPORTANT dans les convertisseurs

aprŁs

Ia

suppression

de Ialimenta tion

Ølectrique.

ArrŁter les convertisseurs, dŁbrancher le courant electrique, et dŁ charger les condensateurs dalimentation selon les instructions indiquees dans Ia partie entretien avant de toucher les piŁces.

-~

LES FIJMEES ET LES GAZ

~

~ tredangereuL.

I peuvent

Le soudage inhalation gŁnŁre des fumŁes et des gas.

Leur peut Łtre dangereux pour votre sante.

=5

~

_____________

Eloigner votre tŒte des fumŁes.

Ne pas respirer les fumŁes.

A lintŁrieur, ventiler Ia zone etlou utiliser un echappement au ni veau de larc pour lŁvacuation des fumŁes et des gaz de soudage.

Si Ia ventilation est insuffisante, utiliser un tion dair homo!oguŁ.

respirateur a alimenta

Ure les spŁcificationsde sŁcuritŁ des matŁriaux (MSDSs) et les ins tructions du fabricant concernant les mŁtaux, les consommables, les revŒtements, les nettoyants et les dŁgraisseurs.

Travailler dans un en portant un espace fern,Ł seulement sil est bien ventilŁ ou respirateur a alimentation dair.

Demander toujours a un surveillant dOment formŁ de se tenir a proximitŁ.

Des fumŁes et des gaz de soudage peuvent dŁplacer lair et abaisser le niveau doxygŁne provoquant des blessures ou des accidents mortels.

Sassurer que lair de respiration ne prŁsente aucun danger.

Ne pas souder dans des endroits situŁs a proximitØ dopØrations de degraissage, de nettoyage ou de pulvŁrisation.

La chaleur et les rayons des gaz de larc peuvent hautement reagir toxiques en presence et irritants.

de vapeurs et former

Ne pas souder des mŁtaux munis dun revŒtement, tels que lacier galvanise, plaque en p10mb ou au cadmium a moms que le revŒte ment nait ŁtŁ enlevŁ dans Ia zone de soudure, que lendroit soil bien ventilŁ, et si nŁcessaire, en portant un respirateur a alimenta tion dair.

Les revŒtements et tous les mŁtaux renferniant ces

ØlØ ments peuvent degager des fumŁes toxiqueS en cas de soudage.

OM-1 588 Page 5

LES RAVONS DEL~ARC

peUvent

pro

:.~quer

des

bfl~tureSdans

les yeux et surla P~1

.1.

.:, des

Le gØnŁre des rayons visibles et invisibles intenses

(ultraviolets et infrarouges) susceptibles de provoquer brlures dans es rayonnement de Iarc du procØdØ de soudage yeux et sur Ia peau.

Des Øtincelles sont projetØes pendant le soudage.

Porter un casque de soudage muni dun Øcran defiltre appropriØ pour protØger votre visage et vos yeux pendant der le soudage ou pour regar

(voir ANSI Z49.

1 et Z87.

1 ØnumØrØ dans les normes de sØcuritØ).

Porter des protections approuves pour les oreilles Si le niveau sondre est trop ØlevØ.

Utiliser des Øcrans ou des barriŁres pour protØger des tiers de Øclair et de lØblouissement; demander aux autres personnes de ne pas re garder Iarc.

Porter des vŒtements de ble, resistant au feu protection constituØ dans une matiŁre dura

(cuir ou lame) et une protection des pieds.

m

(~.

~EJ

LE SOUDAGE

peut

provoquerun

~

incendie u une

explosion.

Le que souda~e des effectuØ sur des conteneurs fermØs tels reservoirs, tambours ou des conduites peut

provo9uerleurØclatement.

Des Øtincelles peuventØtre projetees de larc de soudure.

La projection dØtincel les, des piŁces chaudes et des Øquipements chauds peut provoquer des incendies et des brlures.

Le contact accidentel de lØlectrode avec des objets mØtalliques peut provoquer des

Łtincelles, une explosion, un surchauffement

Cu Ufl incendie.

Avant de commencer le soudage, verifier et sassurer que lendroit ne presente pas de danger.

Se protØger et dautres personnes de a projection dØtincelles et de metal chaud.

Ne pas sur des souder dans substances un endroit l inflammables.

o des Øtincelles peuvent tomber

DØplacertoutes les substances inflammables a une distance del 0,7 m de larcde soudage.

En cas dimpossibilitØ les recouvrirsoigneuse ment avec des protections homologuØs.

Des Øtincelles et des matØriaux chauds du ment passer dans dautres des ouvertures.

soudage peuvent facile zones en traversant de petites fissures et

SurveillertoutdŁclenchementdincendieettenirun mite.

extincteurproxi

Le soudage effectuŁ sur un plafond, plancher, paroi ou separation peut dØclencher un incendie de lautre ctØ.

Ne pas effectuer le soudage sur des conteneurs reservoirs, tambours, ou conduites, a moms fermØs tels que des quils naient ØtŁ prØpa rØs correctement conformŁment a AWS F4.i

(voir les normes de sØcuritØ).

Brancher le cable sur

Ia piŁce le plus prŁs possible de Ia zone de sou dage pour Øviter le transport du courant sur une longue distance par des chemins inconnus Øventuels en provoquant des risques dØlec trocution et dincendie.

Ne pas lees.

utiliser le poste de soudage pour dŁgeler des conduites ge

En cas de non electrode ou utilisation, enlever Ia couper le fil a Ia baguette dØlectrode du porte pointe de contact.

Porter des vØtements de protection dØpourvus dhuile tels que des gants en cuir, une chemise en matØriau lourd, des vers, des chaussures hautes et un couvre chef.

pantalons sans re

Avant de souder, retirer toute substance combustible de vos telles quun allumeur au butane ou des allumettes.

poches

DES PARTICIJLES VOL NTES

peUventblesser

tes yeux~

_____

Le soudage, lØcaillement, le passage de Ia piŁce a Ia brosse en fil defer, et le desØtincellesetdes meulage gŁnŁrent particules mŁtalliquesvolan tes. Pendant Ia pØriode de refroidissement des soudures, elles risquent de projeter du laitier.

Porter des lunettes de sØcuritØ avec

Øcrans latØraux cu un Øcran facial.

LES ACCUMULATIONS EDE GAz ris

quentde provoquerdØs

blessures:u

I

rnŒmelamort.

CJ

Fermer Ialimentation non utilisation.

du gaz protecteur en cas de

Veiller toujours a bien aØrer es espaces confines ou se servir dun respi rateur dadduction dair homologue.

DES

PI¨CES CHAUDESpØuvent

voquer des brOlures graves.

pro

Ne pas flues toucher des parties chaudes a mains

PrØvoir une dutiliser le pØriode de refroidissement avant pistolet ou

Ia torche.

LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs

cardiaques.

Porteurs de stimulateur cardiaque, restez a distance.

Les porteurs dun stimulateur cardiaque dabord consulter leur mØdecin avant de doivent sapprocher des operations de soudage a arc, de gougeage Cu de soudage par points.

LE BRUIT

peut

affecter louIe.

Le bruit des processus at des

IouIe.

equipements peut affecter

Porter des protections approuvØs pour les oreilles si le niveau sondre est trop ØlevØ.

Si des BOUTEILLES sont endomma

gØes,

elles

pourront exploser.

Des sous bouteilles de haute gaz protecteur contiennent du gaz pression.

Si une bouteille est endomma gee, elle peutexploser.

Du fait qua font normalement partie du las bouteilles degaz procØdŁ de soudage, es manipuler avec precaution.

Proteger les bouteilles de gaz comprimŁ dune chaleur excessive, des chocs mŁcaniques, du laitier, des flammes ouvertes, des Øtin celles et des arcs.

Placer les bouteilles debout en les fixant dans un naire ou dans un support station porte-bouteilles pour les empŒcher de tomber ou de se renverser.

Tenir les bouteilles ØloignŁes des circuits de soudage ou autres cir cuits electriques.

Ne jamais placer une torche de soudage sur une bouteille a gaz.

Une une electrode de soudage ne doit jamais entrer en contact avec bouteille.

Ne jamais souder une bouteille pressurisØe

risque dexplosion.

Utiliser seulement des bouteilles de gaz protecteur, tuyaux et raccords convenables pour les maintenir ainsi cette application que les ŁlŁments associØs en bon rØgulateurs, specifique; etat.

Ne pas tenir Ia bouteille.

tŒte en face de Ia sortie en ouvrant Ia soupape de Ia

Maintenir le chapeau de protection sur

Ia soupape, sauf en cas dutilisation ou de branchement de a bouteille.

Lire et suivre les instructions concernant les bouteilles de gaz corn prime, les Łquipements associØs et les publications P-i CGA Ønu mØrØes dans les normes de sØcuritØ.

.

OM-1588 Page 6

1-3.

Dangers

supplØmentairesefl

etla maintenance relation

avec

Iinstallation, le fonctionnement

Risque

DINCENDIE OU

DEXPLOSION.

Ne pas placer lappareil sur, au-dessus proximitØ de surfaces infliammables.

ou a

Ne pas installer lappareil a proximitØ de produits inflammables

Ne pas surcharger linstallation electrique

sassurer que lalimen tation est correctement dimensionnØ et protØgØ avant de mettre lappareil en service.

LA CHUTE DE LAPPAREIL blesser.

peut

Utiliser lanneau de levage uniquement pour sou lever lappareil, NON PAS les chariot, es bouteil les de gaz ou tout autre accessoire.

Utiliser un engin dune capacitØ appropriØe pour soulever lappareil.

En utilisant des fourches de que lesfourches sont oppose de lappareil.

levage pour dØplacer lunitØ, sassurer suffisamment longues pour dØpasser du ctØ

L~EMPLOI EXCESSIF

SURCHAUFFER

peut

L~EQUIPEMENT.

PrØvoir une pØriode de refroidissement, respec ter le cycle opØratoire nominal.

RØduire le courant ou le cycle opØratoire avant de recommancer le soudage.

Ne pas obstruer les passages dair du poste.

LES CHARGES

ELECTROSTATIQUES

peuvent

endommager

lescircuits im

primes.

Etablir

Ia connexion avant de manipuler avec

Ia barrette des cartes ou des de terre pieces.

Utiliser des pochettes et des boites antistatiques pour stocker, circuits dØplacer imprimes.

ou expØdier des cartes de

DES :ORGANES

M9BILES peuvent

:pmvoquer:des

blesŁures..

Ne pas sapprocher des organes mobiles.

Ne tels pas que sapprocher des points de coincement des rouleaux de conimande.

LES FILS DE SOUDAGE

vquer;des peuvent

pro bIessUrØS.:~I ~

Ne pas appuyer sur recu linstruction.

Ia gachette avant den avoir

Ne pas diriger sonnes ou toute le pistolet vers soi, piŁce mecanique dautres en per engageant le fil de soudage.

DES ORGANES MOBILES

provoquerdes

blessures.

peuvent

Rester a lØcart des organes mobiles comme ventilateur.

le

MaintenirfermØsetfixementen place les portes, panneaux, protection.

recouvrements et dispositifs de

LE RAVONNEMENT HAUTE

FRE

QUENCE

(HF.) risque

de provoquer des interferences.

Lerayonnementhautefrequence peutprovoquer des interferences avec les Øquipements de ra dio-navigationetde communication, lesservices de sØcuritØ et les ordinateurs.

Demander seulement avec des a des personnes qualifiees familiarisØes

Øquipements Ølectroniques de faire fonctionner installa tion.

Lutilisateur est tenu de faire corriger rapidement par un

Ølectricien qualifie les interferences resultant de linstallation.

Si le FCC signale des interferences, arrŒter immØdiatement lappa reil.

Effectuer rØguliŁrement le contrle et lentretien de installation.

Maintenir sources soigneusement de haute fermØs es portes et les panneaux des frØquence, maintenirles Øclateurs une distance correcte et utiliser une terre et et un blindage pour rØduire es inter fØrences Øventuelles.

LE SOUDAGE

A

LARC

risque

de provoquer des interferences.

LØnergie provoquer

ØlectromagnØtique des interferences pour risque de lØquipement

Ølectronique sensible tel que les ordinateurs et tØquipement commandØ par ordinateur tel que es robots.

Veiller a Ce que tout patible lequipement de Ia zone de soudage soit com

ØlectromagnØtiquement.

Pour rØduire Ia possibilitØ dinterfØrence, maintenir les cables de soudage aussi courts bas que que possible, possible (ex.

par terre).

les grouper, et les poser aussi

Veiller a souder a une distance de 100 metres de tout Øquipement electronique sensible.

Veiller a ce que ce poste conformØment a ce mode de soudage demploi.

soit pose et mis a Ia terre

En cas dinterfØrences aprØs avoir pris les mesures prØcØdentes, 1 incombe a lutilisateur de prendre des mesures supplØmentaires telles que le dØplacement lutilisation de flltres de du ligne poste, ou lutilisation

Ia pose de de cables protecteurs blindØs, dans Ia zone de travail.

LES CHAMPS MAGNETIQUES peuvent affecter lØs :stimulateurs

cardiaques.

Porteurs de stimulateur cardiaque, restez a dis tance.

Les porteurs dun stimulateur cardiaque dabord consutter leur mØdecin avant de doivent sappro cher des operations de soudage a larc, de gou geage ou de soudage par points.

OM-1 588 Page 7

1-4

Principales

normes

de

securite

Safetyin Welding and Cutting, norme

ANSI Z49.

1, de American Wel ding Society, 550 N.W.

Lejeune Rd, Miami FL 33126

Safetyand Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practice for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances, norme

AWS F4.

1, de American Welding Society, 550 N.W.

Lejeune Rd, Mia mi FL 33126

National Electrical Code, NFPA Standard 70, de Ia National Fire Pro tection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet

P-i, de Ia Compressed Gas Association, 1235 Jefferson Davis High way, Suite

501, Arlington, VA 22202.

RŁgles de sØcuritØ en soudage, coupage etprocØdØs connexes, norme CSA Wi 17.2, de lAssociation canadiennede normalisation, vente de normes, 178 Rexdale Boulevard, flexdale (Ontario) Canada M9W

1R3.

.

Safe Practices ForOccupationAnd Educational EyeAnd Face Protec tion, norme

ANSI Z87.1, de lAmerican National Standards Institute,

1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, norme

NFPA SiB, de Ia National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

1-5.

fnformation

sur

les champs

ØlectromagnØtiques

DonnØes sur le soudage electrique et sur les effets, pour lorganisme, des champs magnØtiques basse frequence

Le courant de soudage, pendant son passage dans es cables de sou dage, causera des champs electromagnetiques.

II y a eu et il y a encore un certain souci avoir examine a propos de tels plus de 500 etudes qui ont champs. Cependant, aprŁs

ØtØ faites pendant une pe node de recherche de 17 ans, un comitØ special ruban bleu du

National Research Council a conclu: Laccumulation de preuves, sui vant le jugement du comitØ, na pas dØmontrØ que lexposition aux champs magnØtiques et champs Ølectriques a haute frequence reprØ sente un risque a Ia sante humaine.

Toutefois, des etudes sont toujours en cours et les preuves continuent a Œtre examinØes.

En at tendant que es conclusions finales de Ia recherche soient Øtablies, il vous serait souhaitable de rØduire votre exposition aux champs Ølec tromagnØtiques pendant le soudage ou le coupage.

2

3

Afin de rØduire les champs ØlectromagnØtiques dans Ienvironnement de travail, respecter les consignes suivantes

1 Garder les cables ensembles en les torsadant ou en les attachant avec du ruban adhØsif.

4

5

Mettre tous es cables du ctØ oppose de IopØrateur.

Ne pas courber votre corps.

pas et ne pas entourer pas es cables autour de

Garder le poste de soudage et les cables le plus loin possible de vous.

Relier a pince de masse le plus prŁs possible de Ia zone de soudure.

Consignes relatives aux stimulateurs cardiaques

Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur.

est alors

Si vous

Œtes dØclarØ apte par votre docteur, il recommandØ de respecter les consignes ci-dessus.

.

.

OM-1 588 Page 8

SECTION 2INTRODUCTION

2-1.

Specifications

Type of Input

Power

24 Volts AC

Single-Phase

10 Amperes

50/60 Hertz

Welding Power

Source Type

Constant Voltage (CV)

DC For GMAW Or

Constant Voltage (CV) /

Constant Current (CC) DC

For GMAW-P

All Need 14-Pin And

Contactor Control

Wire Feed Speed

Range

Standard: 50 To 780 ipm (1.3

To 19.8

mpm)

Optional High Speed:

92 To 1435 ipm (2.3

To

36.5

mpm)

Wire Diameter

Range

.023 To 1/8 in

To 3.2

mm)

(0.6

Max Spool Weight:

60 lb (27 kg)

Welding Circuit

Rating

100 Volts,

750 Amperes,

100% Duty Cycle

Weight

12 ft

207 lb

(3.7 m):

(94 kg)

16 ft (4.9 m):

280 lb (127 kg)

Maximum Height With 4 ft (1.2

m) Post

Vertical Uft Of Boom

12 ft (3.7 m) Boom

17 ft (5.2

m)

Horizontal to 60 Above Horizontal

16 ft (4.9 m) Boom

21 ft (6.4

m)

Horizontal to 60 Above Horizontal

SE CTION 3INSTALLAT ION

3-1.

Installing Swivel Into Pipe Post

2

5

4

1

2

3

Swingpak Base or

CBC Cart

Pipe Post With Base

Steel Bolt

Secure as shown mum using as a mini

1/2 in diameter SAE grades steel bolts.

4 Swivel Assembly

Insert into swivel.

pipe post.

Lubricate

5 Safety Collar

A Do not remove instructed to.

until

3

Tools Needed:

~ 3/4in

ST-152 382

OM-1 588 Page 9

3-2.

Installing Control Box

And

Adjusting

Tilt

I

4

6~

Tools Needed:

~:==~ 3/8, 3/4 in

OM-1588 Page 10

3

7

1

2

Swivel Plates

Yoke

Remove hardware from swivel plates and yoke.

3 Boom

Set boom into swivel as shown.

4 Yoke Pin

Install pin through yoke.

Install cot ter pin and spread ends.

5 Bolt

Install bolt, washers, and nut.

Tighten hardware, and back bolt oft one half turn.

6

7

Locking Knob

Install tighten.

locking knob but do not

Reel Support

Install reel support.

.

2

ST-153 170

3-4.

Installing

Wire

Guide Extension

4

3

4

1

2

Wire Guide Fitting

Bolt

Monocoil Liner

Wire Guide Extension

Tighten bolt to secure liner in wire guide fitting.

Do not overtighten bolt and crush liner.

Repeat procedure for opposite side.

Tools Needed:

EI~ZJ1i

3/8 in

ST-152 383

OM-1 588 Page 11

3-5.

Equipment Connection Diagram

INDUCTANCE/DIG

SCRATCH

PULSED

0

PANEL

REMOTE

V/A CONTROL

300/400 Ampere Model

CC/CV lnverter Welding

Power Source

I

2

6

7

8

Use settings shown for both pulse MIG welding and MIG welding.

450 Ampere Model CV

Inverter Welding Power

Source

3 14-Pin Cord

4

5

Positive (+) Weld Cable

Negative (-) Weld Cable

Be sure weld cables are sized properly for peak amperage if pulse welding (see welding power source

Owners Manual).

Workpiece

Voltage Sensing Lead

(Optional Use)

Gun

Be sure perage if gun is rated for pulse welding.

peak

Install am ac cording to its Owners Manual.

9 Wire Feeder

For connections see Section 3-7.

10

11

12

Shielding Gas Supply

Supplied Y Adapter

Gas Hose From Boom

OM-1588 Page 12

ST-8O1 806 / Ref. ST-175 086 / Ref. ST-iSO 311-8

3-6.

Connecting

Weld

Cables And Gas Hoses

The weld cables and shielding gas hoses extend lOft (3 m) from the boom.

Route weld cables from boom through reed relays, if applicable.

If the welding power source or gas supply are further from the boom, extend cables or hoses as follows:

1 Weld Cable

2

3

Insulated Sleeving

Bolt together weld cables from welding power source and boom.

Use electrical tape and insulated sleeving to cover connection.

Shielding Gas Hose

Connect hose to gas supply or ex tension hose. The hose from the boom threads.

has 5/8-18 right-hand

Tools Needed:

5/8in

Ret. ST-801 806 / Ref. 5T-152 800-A

OM-1588 Page 13

3-7.

Control Box Connections

2

3

4

5

6

Optional Reed Relay

Connection

Wire Feed Motor And Gas

Valve Control Receptacle

Wire Feed Motor And Gas

Valve Control

Boom

Plug From

14-Pin Cord

Volt Sense Lead (Optional

Use)

Gun Trigger Plug From Boom

.

0 p

0

ST-800 177-A / Ref. ST-800 17S

3-8.

14-Pin

Plug Information

Pin Information

24 volts ac with respect to socket G.

Contact closure to A completes 24 volts ac contactor control circuit.

Circuit common for 24 volts AC circuit.

+10 volts dc output to remote control with respect to socket D.

Remote control circuit common.

0 to +10 volts dc input command signal from remote control with respect to socket D.

Voltage feedback; 0 to +10 volts dc, 1 volt per 10 arc volts.

Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes.

CC/CV Select (+24 V

=

CV)

Inductance (0-10 V)

*The remaining pins are not used.

.

OM-1588 Page 14

3-9.

Motor Start Control

To change wire feed starting speed proceed as follows:

Turn Off wire feeder and welding power source.

Remove wrapper.

1 Motor Board PCi

2 Motor Start Control Poten tiometer R70

Turn potentiometerclockwiseto in crease time it takes the motor to ramp up to speed.

Remove protec tive white rubber cap before mak ing adjustment. Adjust potentiome ter R70 using a small nonconduc tive screwdriver.

Reinstall wrapper.

Tools Needed:

Non-Conductive

-

___

c1j=o

1/4 in

ST-162 132/Ref.

SA-183 121-B

3-10.

Removing Safety Collar And Adjusting Boom

3

Tools Needed:

1-1/8 in

2

E

0

I

Rod

.3

Increasing Spring

Pressure For A

Heavy Gun

2

Decreasing Spring

Pressure For A

Ughter Gun

4

1 Locking Knob

Tighten knob to prevent boom movement.

Loosen knob to allow boom movement.

Change knob position to limit upward movement.

Pull boom down move slightly and re safety collar.

Boom should balance in any zontal to 60 position from hori degrees above hori zontal.

If necessary, as follows: adjust boom

2

3

Threaded Rod

JamNut

Loosen jam nut and turn threaded rod until boom balances.

Tighten jam nut.

Be sure several full threads are through yoke to pre vent boom falling.

4 Yoke

Retain safety collar for use in dis assembling or moving boom.

ST-142 599-B

OM-1588 Page 15

3-11.

Gun Recommendation Table

Process

GMAW-P

-

Hard or

Cored Wires

GMAW

-

Hard or

Cored Wires

FCAW

-

Self-Shielding Wires

Gun

GW-500 Or GW-600

M25, M40, Or GA-50C

GA-4OGL Or GA-5OGL

3-12. Wire

Type, Size, And Feed Speed Capability Table

Motor Speed

Standard

Standard

Standard

OpUon:l High

Wire Type

All

All

All

Wire Size

.023 To 5/64 in (0.6

To 2 mm)

3/32 To 7/64 in (2.4

To 2.8

mm)

1/8 in (3.2

mm)

All .023 To 5/64 in (0.6

To 2 mm)

Feed Speed Capability

50 To 780 ipm (1.3

To 19.8

mpm)

50 To 700 ipm (1.3

To 17.8

mpm)

50 To 300 ipm (1.3

To 7.6

mpm)

92 To 1440 ipm (2.3

To 35.6

mpm)

.

.

OM-1588 Page 16

3-13.

Installing And Threading Welding

Wire r1~:~d *4 Tools Needed:

~

3/16,5/64in

~ 15/16,3/81n

Install wire spool.

Adjust tension nut so wire is taut when wire feed stops.

JO

4-

Install drive rolls.

-,

NONCONDUCTIVE

SURFACE

No Wire Slip

NONCONDUCTIVE

SURFACE

Wire Slips

UJ~ Be sure that outlet cable has proper size liner for the

When welding wire size.

installing gun, position liner extending from outlet wire guide as close as possible to drive rolls without touching.

Install to gun.

Lay gun cable out straight.

Cut offend of wire. Push wire through guides up drive rolls; continue to hold wire. Press

Jog button to feed wire out gun.

0:7 Forsoft wire orsmall diameterstainless steel wire, use

2 drive rolls and set drive roll pressure from

0 to a maximum of 4 on the pressure indicator scale (so that only the inner spring is compressed).

This setting will generally give the best performance for these types of wires.

To adjust drive roll pressure, hold nozzle about 2 in (51 mm) from nonconductive surface and press gun trigger to feed wire against surface.

Tighten knob so wire does not slip.

Do not overtighten.

If contact tip is completely blocked, wire should slip at the feeder (see pressure adjustment above).

Cut wire off.

Close cover.

Repeat for other side.

ST-152 564-B I Ref. ST-156 929 / Ref. SC-150 922 / Ref. ST-156 930/ S-0627-A

OM-1 588 Page 17

SECTION 4OPERATION

4-1.

Operational Terms

Note 1EI~

See Menu Guide for detailed

programming

steps.

The following is a list of terms and their definitions as they apply to this wire feeder:

General Terms:

Adaptive Pulse Welding

Cold Wire

Inductance

Trim

Synergic

Jog

The wire feeder less of automatically regulates pulse frequency to maintain a constant arc length, regard change in welding wire stickout.

When weld

Then the amperage is not present, wire feeds for about three seconds at set wire feed speed.

welding power source contactor deenergizes and wire continues to feed at the wire jog speed.

As inductance increases, arc on time increases, and the weld puddle becomes more fluid.

Arc length adjustment in pulse welding. Increasing trim increases the actual arc length.

Trim is re placed by volts in MIG programs.

The the operator programs pulse parameters for a pulse parameters between these wire feed specific wire feed speed.

The wire feeder determines speed increments.

Side Panel Terms:

Process Mode

Sequence Mode

Dual Schedule Mode

Card Mode

Security Mode

Is used to select the type of process to be used, including Pulse, Adaptive Pulse, or Mig.

Is used to select and program the weld preflow, and run-in.

sequences which include weld, crater, burnback, postflow,

Is used to select a pair of programs that can be used together.

Is used to select use of the optional data card storage and retrieval capabilities.

Only functions with a data card. Allows using the lock feature for restricting range of program pa rameter changing.

.

4-2.

Pulse Welding Terms

Amps

/\

1

3

2

1 Apk

=

Peak Amperage

Increasing Apk increases penetra tion.

Vpk

=

Peak Voltage

Arc voltage during peak current phase of the pulse waveform. This determines arc length during adaptive pulse welding.

2 Abk

=

Background Amperage

Maintains arc between pulses.

3 PPS

=

Pulses Per Second

Increasing PPS increases travel speed.

4 PWms

=

Pulse Width In

Milliseconds

Increasing PWms increases bead width.

/

Time

.

OM-1588 Page 18

4-3.

Front Panel Controls

2

3

8

7

4

4

5 6 5

ST-162 127

1

2

Display

Parameter Select Button

Press button to move > on display.

3 Display Control

Turn control to change value pointed to by>.

Turning control one click causes

Trim (arc length) to increase/decrease by one or

Volt to increase/decrease by 0.1.

When 1PM is selected, click causes wire feed turning control one speed (1PM) to in crease/decrease by one.

When MPM is selected, turning control three clicks causes wire feed speed (MPM) to in crease by 0.1.

When Prg # is selected, turning control one click causes program number (Prg #) to in crease/decrease by one.

The program number cannot be changed while welding, with exception of Dual Sched ule Mode (see Section 6).

Pulse is a default setting.

To change type of process side

(Pulse, Adaptive panel controls (see

Pulse, or

Section

MIG)

4-4).

use

4

5

Active Side Indicator Ught

Trigger Hold Button And Indicator Light

Trigger Hold can be set on a per program ba sis.

Indicator light comes on for programs where this feature is active.

To weld without holding gun trigger through out turn weld cycle, press and release button to feature on (indicator light turns on).

To start weld trigger within three seconds after an arc has been struck.

To end weld cycle, press and release gun cycle, press and release gun trigger.

6 Side Select Button

The feeder remembers the last used pro gram for each side and retums to that pro gram when the active side is changed.

The gun trigger may be used to change active side of the feeder.

7 Jog Button

Push to momentarily feed welding wire with out gas energizing welding circuit or shielding valve.

Jog speed is varied using the Display Con trol while Jog button is pressed.

Default set ting is 200 1PM.

8 Purge Button

Push to without momentarily energize gas valve energizing the welding circuit.

lET Jog and Purge only work on the active side of the feeder.

Holding the Jog and Purge buttons at the same time displays pulse parameters on the side panel display and voltage on front panel display.

OM-1 588 Page 19

4-4.

Side

And

Rear Panel Controls

2

4

5

6

1

2

Mode Display

Mode Select Button

3

4

Press button to move> in display.

Parameter Display

Parameter Select Button

6

7

8

Press button to move > in display.

5 Parameter Increase Button

Parameter Decrease Button

Power Switch

Circuit Breaker CB1

CB1 protects the wire feeder from overload.

Ref. ST-162 128/ Ret. ST-i 62 133

.

.

OM-1 588 Page 20

SECTION 5

-

SETTING SEQUENCE PARAMETERS

OM-1 588 Page 21

SECTION 6SETTING DUAL SCHEDULE PARAMETERS

6-1.

Selecting Dual Schedule Pair

_______

Dual Schedule is used with two consecutive weld

3&4, 5&6, programs

1 & 2, or7&8.Anyprogram

type (MIG, Adaptive Pulse, or

Pulse) can be combined in dual schedule.

1 Side Panel Display

Use side panel to turn feature on.

See Menu Guide for detailed programming steps.

2 Front Panel Display

Press front panel parameter select button to select program number.

3

4

Front Panel Display Control

Dual Schedule Switch (See

Section 6-2)

U7 Switch type is set in System

Setup.

5 Welding Gun Trigger

Selecting dual schedule program

A or

B is done by using Display Con trol, dual schedule switch, or gun trigger (depending on system setup).

When program

B is active, turn

Display Control one click clock wise to select another pair of dual schedule programs.

~ Programs can be rearranged in desired order using the data card. See Section 7.

.

2

V

>Prg

Dual

2

B

Display

Control

I>Prg

Dual

31

Al

Display

Control

OM-1 588 Page 22

6-2.

Dual Schedule Switch Diagrams

1

>

2

>

A

O

/

77

(_--0-

B

2

>

1

3

>

-1

4

A

~

B

1

2

>

2

>

3

>

4

2

I

p

TR~

I

IBO

A\~

I

3

>>

Adapter

>

>>~

3 3

>>

>

>

3

I I

TR

4 p

___

I

4 4

>

1

2

3

4

Momen 2P

(Momentary-Contact 2-Pole

Switch)

Maint 2P (Maintained-Contact

2-Pole Switch)

Maint 1 P

1-Pole

(Maintained-Contact

Switch)

Trigger

Allows dual scheduling after estab lishing a welding arc.

U~ If trigger is used for dual schedule switch, Trigger Hold is disabled.

PM-i 588 Page 23

SECTION 7USING THE OPTIONAL DATA CARD

7-1.

Data Card Terms

CARD SCREEN TERMS

WRITE Programs To Card

>Wr i t e

Read

Delete

Done

READ Programs From Card

Amperage

PULSE MIG TERMS

PPS

(Pulses Per

Second)

PWms

~ (Pulse Width In

Milliseconds)

-r

Apk (Peak

Amperage)

~~~1

Abk

(Background

Amperage)

Time

SA-158 435

.

7-2.

Installing

Data

Card

1

2

3~

1 Label

Apply label to data card. Write pro gram information on label.

2

3

Data Card

Card Slot

For Blank Data Card:

Insert card into slot. Toformat card, turn On menu.

power.

Select Card from

Data card formats when unit enters Card mode.

For Power Source Data Card:

Insert card into slot. Turn On er.

Push pow

Parameter Select button within 3 seconds and the 8 pro grams and setup information read into the wire feeder are memory.

Unit is ready to use when Please

Wait front message panel disappears display.

from

ST-156 266-B

.

OM-1 588 Page 24

7-3.

Card Displays

4

5

Sequence

Dual Schd

>Card

Security

Pr ess

Below

Side Panel

Parameter

Select Once

1f7 See Menu Guide for detailed programming steps.

Security mode only functions with a data card.

1

2

Card Display

Moving Line

Moving line is under value that can be changed.

3 Write

Transfers program data from unit to card. The program card can hold up to 32 programs.

When writing to the card, the next available pro gram number is automatically as signed.

4 Read

Transfers program data from card to unit.

5 Delete

Deletes program data from card.

6 Done

Exits card display.

OM-1588 Page 25

SECTION 8SYSTEM SETUP

8-1.

System Setup Display Parameters

Note ~

See Menu Guide for detailed

programming steps.

DISPLAY SETflNG

>System *

>Range *

>Access$

>Mig Type

>Voltage

>Arc Start~

>Dual Schedule

>Trigger

>Remote

>Arc Time

>Wire Feed

>Memory

>ShutdoWn

>Teach

>Gas Flow

>Software

NOTES

Select the process the welding power source is able to do.

Welding power source minimum and maximum voltage values are always needed.

Amperage values are required for pulse welding.

Set values to match welding power source ranges.

When on, restricts use of setup screens.

Default is Off. Set to On only for older CV welding power source without voltage feedback at 14-socket receptacle.

Default is 14-pin receptacle.

Use V.

Sense when more than 50 ft (1 5m) of weld cable is used (including gun cable length).

Use Hot Start switches to only with Inverter Model welding power source and large diameter wires.

The arc starts in CV and

CC.

See Section 6-2.

When on, grammed.

trigger can be used to switch between programs that have at least 0.2

seconds of preflow time pro

When on, a dual schedule switch can be used to panel display> is.

change Volts or

Trim, 1PM, or Prg depending on where the front

Displays accumulated arc time and cycles.

Choose to display inches per minute or meters per minute and motor type, but installed motor must match selection.

No Reset: allows operator to exit memory reset parameter without resetting any data.

Program Reset: unit defaults to original factory setting for the last active program.

Setup information does not change.

If setup card is in card slot, program will be loaded from card.

System Reset: unit defaults to original factory settings for all programs and setup excluding System and Arc Time. If setup card is in card slot, program will be loaded from card.

Total Reset: unit defaults to original factory settings for all programs and setup including System and Arc Time. If setup card is in card slot, program will be loaded from card.

When on, the system age is sensed.

immediately shuts down if no arc voltage is sensed. When off, wire feeds even if no arc volt

Default is 15 points, but can be set to 4 points.

Setting must be Meter Off if option is not installed.

Know this when talking with service personnel.

* Automatically set if power source data card is used.

--

Can be used only when optional data card is inserted.

Selection does not appear

Must remain set to Meter on

Off display if when option is

MIG not

Only is installed to

System choice.

prevent system error.

OM-1 588 Page 26

SECTION 9STANDARD PULSE WELDING PROGRAMS

Note ~

Apk

=

Peak

Amperage, Vpk

=

Peak

Voltage,

Abk

=

Background Amperage,

PPS

=

Pulses Per Second, PWms

=

Pulse Width

(milliseconds).

Four teach

points

were use d for

factory

set programs.

If selection is set for fifteen teach

points,

the

remaining points interpolations

from the 4

taught points.

are

9-1.

Program

1

-Steel

Wire Size/Type: .035

1PM / MPM Apk

700/17.8

400/10.2

200/5.1

100/2.5

440

385

335

328

Vpk

36.7

32.4

28.7

27.4

Gas: Ar

-

CO2 or Ar

-

Oxy /40 CFH (19 L/m)

Abk PPS PWms

180 2.9

160

108 126 2.3

61

37

81

47

2.0

1.7

COMMENTS

9-2.

Program

2

-

Steel

Wire Size/Type: .045

1PM / MPM Apk

518 700 / 17.8

400/10.2

466

412 200/5.1

100/2.5

375

Vpk

35.0

31.3

28.5

26.5

9-3.

Program

3

-

Steel

Wire Size/Type: .052

1PM / MPM

625 / 15.9

400/10.2

Apk

560

525

200/5.1

100/2.5

475

445

Vpk

39.3

36.2

31.7

29.6

Gas: Ar

-

CO2 or

Ar

-

Oxy / 40 CFH (19 L/m)

Abk PPS PWms

205 3.6

195

147 158 2.9

93

50

106

66

2.4

2.2

Gas: Ar

-

CO2 or

Ar

-

Oxy / 40 CFH (19 L/m)

Abk PPS PWms

200 229 3.6

148

102

50

189

131

80

3.5

2.7

2.4

COMMENTS

COMMENTS

9-4.

Program

4

-

Steel

Wire Size/Type: .062

1PM / MPM Apk

550 400/10.2

300/7.6

510

480 200/5.1

100/2.5

460

Vpk

36.8

36.3

31.6

28.7

Gas: Ar -CO2 or

Ar

-

Oxy / 40 CFH (19 Urn)

Abk PPS PWms

4.1

200

145

195

175 3.8

110

69

155

94

3.2

2.6

COMMENTS

OM-1 588 Page 27

9-5.

Program

5

-

Stainless

Wire Size/Type: .035

1PM / MPM

700/17.8

Apk

403

318 400 /10.2

200/5.1

100/2.5

295

280

Vpk

33.9

31.6

28.5

26.0

Gas: Ar

-

He

-

CO2 /40 CFH (19 L/m)

Abk PPS PWms

132

87

53

32

191

146

94

45

2.8

2.4

1.9

1.8

9-6.

Program

6

-

Stainless

Wire Size/Type: .045

1PM / MPM Apk

480 700/17.8

400 / 10.2

425

200/5.1

100 / 2.5

360

350

Vpk

39.0

32.4

28.0

26.2

Gas: Ar

.

He

-

CO2 / 40 CFH (19 L/m)

Abk PPS PWms

200 227 3.2

155

100

40

185

115

70

2.5

2.0

2.0

9-7.

Program

7

-

Nickel Alloy

Wire Size/Type: .035

Nickel Alloy

1PM / MPM Apk

350 700/17.8

400/10.2

310

Vpk

34.5

30.0

280 200/5.1

100/2.5

260

27.5

25.1

Gas: Ar

-

He / 40 CFH (19 L/m)

Abk PPS

130

80

48

28

144

105

55

36

PWms

3.7

3.3

2.9

2.5

9-8.

Program

8

-

Silicon Bronze

Wire Size/Type: .035

SiBr

1PM / MPM

510/13.0

Apk

340

400/ 10.2

310

200/5.1

277

242

Vpk

30.7

29.8

26.6

25.2

Gas: Argon / 40 CFH (19 Urn)

Abk PPS

100

83

48

31

125

97

55

31

PWms

3.7

3.4

3.0

3.0

COMMENTS

COMMENTS

COMMENTS

COMMENTS

.

.

OM-1 588 Page 28

SECTION 10SETTING SharpArcTM CONTROL

10-1.

Selecting And Adjusting SharpArc~ Control

______________________

5 0 T ri m

200 1PM

_________________

>Prg

1

0 3 5 S t

1 Arc

SharpArc is Arc on the display.

It is used to adjust arc cone width and arc characteristics.

Use front panel parameter select button to move> to select Arc. Use

Display Control to adjust Arc setting.

SharpArc~ setting range is from 0 to 20. The factory default is set at zero (0).

When Arc value is increased toward 20, the arc cone narrows and the weld puddle becomes less fluid.

Parameter

Select

50

200

Tr rn

I PM

Prg

>

iL

01

/

5 0

200

Tr im

I PM

Prg

>

A r c

2 lU

01

Ref. S-0259

OM-1 588 Page 29

SECTION 11

-

TEACH POINTS

11-1.

Teach Using

15

Points

*4

L~

A

E

0

Apk

=

Peak Amperage

Vpk

=

Peak Voltage

Abk

=

Background Amperage

PPS

=

Pulses Per Second

PWms

=

Pulse Width (Milliseconds)

1PM / MPM

780 / 19.8

750/19.1

700/17.8

650/16.5

600/15.2

550/14.0

500 / 12.7

450/11.4

400/10.2

350/8.9

300/7.6

Example Of A Synergic

Setting For 425 1PM With

All Teach Points Set At 50

1PM (1.3

MPM) Increments

250/6.4

200/5.1

150/3.8

100/2.5

50/1.3

Apk

Vpk

Abk

PPs

PWms

100

10

10

20

180

18

20

55

210

21

30

80

240

24

40

105

2

270

27

50

130

300

30

60

160

330

33

70

185

360

36

80

210

3

370

37

90

235

420

42

100

260

450

45

110

290

4

480

48

120

315

510

51

130

340

540

54

140

365

565

56

200

400

5

Apk

Vpk

Abk

PPS

PWms

.

The teach mode allows the user to create custom pulse programs.

selection for 15 teach

The teach mode points gives a more defined curve for a specific range.

At each teach point, the user can adjust five param eters to weld shape the pulse waveform of the output.

The six parameters are:

1PM

(MPM), Apk, Vpk, Abk, PPS, and PWms.

Apk, Vpk, Abk, PPS, and PWms acting Undersomeconditions,thewirefeederlim together provide the energy necessary to its wire feed speed to maintain all pulse paburn off welding wire at a set wire feed rameterswithinthecapabilityofthesystem.

speed.

The feed speed graph below shows that increases, energy as wire increases

(Apk, Vpk, Abk, PPS, and PWms acting synergically).

OM-1 588 Page 30

11-2.

Teach Using

4

Points

L~

A

U

0

Apk

=

Peak Amperage

Vpk

=

Peak Voltage

Abk

=

Background Amperage

PPS

=

Pulses Per Second

PWms

=

Pulse Width (Milliseconds)

PM / MPM

780/19.8

750/19.1

700/17.8

650/16.5

600/ 15.2

550/14.0

500/12.7

450/11.4

400/10.2

350/8.9

300 / 7.6

250/6.4

200/5.1

150/3.8

100 /2.5

Example Of A

Intervals Of 100

Synergic

Setting For 425 1PM With

Teach Points Set At

(2.5), 200

(5.1), 400 (10.2), And 700

1PM (17.8 MPM)

Increments

50/1.3

Apk

Vpk

Abk

100

10

10

PPS

PWms

20

180

18

20

55

210

21

30

80

240

24

40

105

2

270

27

50

130

300

30

60

160

330

33

70

185

360

36

80

210

3

370

37

90

235

420

42

100

260

450

45

110

290

4

480

48

120

315

510

51

130

340

540

54

140

365

565

56

200

400

5

Apk

Vpk

Abk

PPS

PWms

The teach mode allows the user to create custom pulse programs. The teach mode selection for 4 teach points gives the whole welding range quickly.

At each teach point, the user can adjust five parameters to shape the pulse waveform of the weld output.

The six parameters are:

1PM (MPM),

Apk, Vpk, Abk, PPS, and PWms.

Apk, Vpk, Abk, PPS, and PWms acting Undersomeconditions,thewirefeederlim together provide the energy necessary to its wire feed speed to maintain all pulse paburn off welding wire at a set wire feed rameterswithinthecapabilityofthesystem.

speed.

The graph below shows that as wire feed speed increases, energy increases

(Apk, Vpk, Abk, PPS, and PWms acting synergically).

OM-1 588 Page 31

11-3.

Redefining Teach Points

Redefining 1PM Teach Point

50 Trim

Prg

1

>4 5 0 1PM

_________________

Pulse

________________

Purge

~ Arid

____________________

50 Trim

>460 1PM

________________

Prg

1

Pulse

Redefining Pulse Parameters

2

IPMC erminestheweld metal tieposition rate.

UT Redefining 1PM is not normally required unless special wire or unusual joint design is needed.

Use front panel parameter select buttontomove >toselectlPM. Use

Display Control to select teach point value.

Press and hold Purge button while turning Display Control to redefine the pm teach point.

For example: there are teach points at 150, 200, and 250 ipm; the teach point at 200 can be adjusted to a wire feed speed of 151 to 249 ipm.

2 Vpk

-

Peak Voltage

Arc voltage during peak current phase of the pulse waveform. This determines arc adaptive pulse length during welding.

3

4

Apk

-

Peak Amperage

Abk

-

Background Amperage

Peak and background amperage depend on the range of the welding power source.

5 PPS

-

Pulses Per Second Of

20-400

6 PWms

-

Pulse Width Of

1.0-5.0 Milliseconds

Use side panel controls to change pulse parameters.

See Menu

Guide for detailed programming steps.

After values are set, strike and maintain an arc for five seconds.

Do this for each teach point.

End weld by releasing gun trigger, not by pulling gun out of weld. Re peat for each custom teach point.

The taught arc length represents a

Trim (arc length) setting of 50.

Once the teach points are set, the wire feeder adjusts parameters be tween teach points synergically.

.

___y3

400 1PM

32.4

>385

Vpk

Apk

108 Abk

___________

32.4

385

>108

Vpk

Apk

Abk

126 PPS

___________

4

385

108

>126

2.3

Apk

Abk

PPS

PWms

5

385

108

Apk

Abk

126 PPS

>2.3

PWms

OM-1 588 Page 32

Ref S-0259/Ref.

ST-154 109

Date

Gas

Program Number_ Wire SizejType_

Flowrate______

Equipment Used

-

Power Source

Wire Feeder

Serial Number___________________________

Serial Number

Gun Model_____________________ Weld Cable

-

Negative

Wire Manufacturer________________ Mfg.

Date_______________________________

1PM / MPM Vpk Apk Abk PPS PWms

Positive______

COMMENTS

_CFH(L/min)

Preflow Seconds:________

Run-In TrimNolts:________ 1PM / MPM:___________________________________ Seconds:____________________________

Crater Volts:_____________________ 1PM I MPM:_____________________________ Seconds:_____________________________

Postf low Seconds:________

OM-1588 Page 33

SECTION 12

-

MAINTENANCE AND TROUBLESHOOTING

12-1.

Routine Maintenance

i~5~1~

A Disconnect power before maintaining.

.

Repair or replace cracked weld cable.

Replace cracked parts.

a

6 Months

Blow out or vacuum inside.

During heavy service, clean monthly.

Check

cord.~

Check gas hose and fittings.

14-pin

Or

A

Check gun cable.

OM-1 588 Page 34

12-2.

Error Displays

3

2

Release

I r i gge r

No Volt

Sensed

1Error

I

Memory

CRC

Prg

Error

Memory

Range

Prg

Error

5

\

No Tach

Sensed

1Er ror

6

Arc

Start

1Er ror

7

Arc

Stop

1Error

8

9

Mi n

C F H x x

Ga s

F I o w

1Er ror

Ma x

C F H x x

Gas F I ow

10

\~

Gas

Out

Lo

f R a n g e

11

1Error

1Er ror

12

\

Coo It

Flow

Unlocked

Program

1Er ror

1Er ror

~fIlfl

00

1 Release Trigger Error Display

This appears if the trigger is closed when the unit power is turned on, or if the trigger is stuck or defective.

2 No Volt Sensed Error Display

The arc voltage sense circuit is not receiving feedback. Check voltage sensing connections.

Check connections at 14-position plugs!

receptacles at the unit and welding power source.

Turn unit off and back on after correcting problem.

If this error continues to occur when pulse welding, it may help to select Hot Start.

3 Memory CRC Error Display

The data in the program indicated is not the same data that was saved.

Perform a system reset.

4 Memory Range Error Display

The data in the program is out of usable range.

indicated

Go through pulse parameters to make sure they do not exceed settings of the Range display or perform a system reset.

5 No Tach Sensed Error

Display

The motor tach feedback is not reaching the control.

Check connections.

Press front panel Parameter

Select to clear error.

6 Arc Start Error Display

This appears when pulse welding and current is detected but the arc cannot be started.

Check and correct and program pulse parameters voltage settings.

Check voltage sensing connections.

Press front panel Parameter

Select to clear error.

7 Arc Stop Error Display

This appears when pulse and the motor does not welding stop at the end of the weld.

If there is high frequency being used in the area, turn it off.

A motor brake circuit problem can also cause this error.

Press front panel Parameter

Select to clear error.

8 Minimum Gas Flow Error

This appears when gas flow falls below the minimum CFH set (xx in example). Adjust gas flow to bring it above set value.

Press front panel Parameter

Select to clear error.

9 Maximum Gas Flow Error

This appears when gas flow above the maximum CFH set (xx is in example). Adjust gas flow to bring it below set value.

Press front panel Parameter

Select to clear error.

10 Gas Out Of Range Error

This appears when gas flow is greater than 100 CFH.

To protect the internal sensor, the unit shuts down until the gas flow can be adjusted below 100 CFH.

11 Coolant Flow Error

This appears flow switch only when coolant option is installed.

Check coolant recirculating system.

12 Unlocked Program Error

Display

This appears run an when unlocked attempting program to while other programs are locked. Either lock the unlocked select a program or different program that is locked.

Ref. ST-i 55 222

OM-1588 Page 35

12-3.

Troubleshooting

A Disconnect power before troubleshooting

~t~j1~

Trouble Remedy

Wire feeds, shielding gas flows, but electrode wire is not energized.

Checkinterconnectingcordconnections.

If secure, checkcordforcontinuityandrepairorreplace(see

Sections 3-5 and 3-7).

Wire up, feeder is on, motor does not meter(s) do not run, gas light valve and welding power source contactor do not pull in.

Check and reset CB1 (see Section 4-4).

Electrode wire feeding stops or feeds erratically during welding.

Check gun trigger connection.

See gun Owners Manual.

Check gun trigger.

See gun Owners Manual.

Readjust hub tension and drive roll pressure

(see Section 3-13).

Change to correct size drive roll (see Table 13-1).

Clean or replace dirty or worn drive roll.

Incorrect size or worn wire guides.

Replace contact tip or liner.

See gun Owners Manual.

Motor runs slowly.

Remove weld spatter or foreign matter from around nozzle opening.

Have Factory Authorized Service Agency check drive motor or motor control board PCi.

Check for correct input voltage.

Wire does notfeed until trigger is pulled, but continues to feed after trigger is released, and trigger hold is not on.

Check for a short between welding gun trigger leads and weld cable.

Repair short or replace welding gun.

Gas valve in feeder is rattling loudly along with possible erratic or slow wire feed speed.

Check for a short between welding gun trigger leads and weld cable.

Repair short or replace welding gun.

Unit does not switch out of Run-In

Speed.

Install, reconnect, or replace voltage sensing lead.

Wire feeder power is on, up, but unit is inoperative.

displays light Check welding gun trigger leads for continuity, and repair leads or replace gun.

.

OM-1 588 Page 36

Notes

OM-1 588 Page 37

SECTION 13ELECTRICAL DIAGRAM

~

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_________

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p

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Figure

13-1.

Circuit

Diagram

OM-1 588 Page 38

I

I

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OM-1 588 Page 39

rrr Hardware is common and not available unless listed.

SECTION 14PARTS LIST

(0

(0

IL)

C) ii-

(0

0) r (0 0) a,

UcJ

OM-1588 Page 40 r

CIJ

=

Figure

13-1. Main

Assembly

C,)

C)

LL

C)

U-

ST-800 272-B

.

2

3

3

1

1

10

.10

11

12

13

13

13

13

8

9

6

7

4

5

5

PLG21 ,23

PLG28,29

..

149251

149252

079 878

079531

605156

..

080 328

SeeNote

164475

164474

PLG27,28,37,38 047 636

079 739

163519

159297

139600

139599

600324

602243

602213

601872

080947

151626

132053

Fig

13-2

149838

149839

078264

079216

14

14

15

20

..21

...22

GS1,2

075078

079217

16

17....

18...

19...

Figl3-8

605227

RC27,37...

047637

048144

PLG11,17

PLG33,34

115092

135409

139813

125785

139816

...23

...24

...25

...26

...27

28

...29

...29

31

...32

159647

156243

159360

159646

145639

134834

167774

167776

157295

604612

082050

164969

167780

167782

Item

No.

Dia.

Mkgs.

Part

No.

Quantity

Model

12 16

Description

Figure

13-1.

Main

Assembly

CABLE,

trigger (consisting of)

CABLE,

trigger (consisting

CONNECTOR&PINS

of)

CONNECTOR, circ

clamp

str rif sz

11

Amp

206358-2

CABLE, port No.

184/c

(order

CONNECTORw/SOCKETS

by ft)

CONTROL BOX,

CABLE,

(Fig 13-4) interconnecting (consisting of)

CABLE,

interconnecting (consisting of)

CONNECTOR&PINS

CONNECTOR, circ

CABLE,

clamp

str rlf sz

17-20

Amp

206322-2

port

No.

18/14 8/c

(order by ft)

HOSE ASSEMBLY, gas

HOSE, gas

HOSE, gas

CABLE, weld cop strd No.

4/0

(order by ft)

WASHER, flat stl std .375

WASHER, lock stl

split

.375

NUT, stl hex full .375-16

BRACKET,

BRACKET,

spring retaining spring retaining

SCREW, cap stl hexhd .375-16 x

1.500

SUPPORT, hub & reel

lg

PIPE POS1 4ft w/base or

PIPE POST, 6ftw/base

PIPE POST, 4ftw/base or

PIPE POST, 6ft w/base

PIPE POS1

PIPE

4ftw/o base

POST, 6ft w/o base

BOOM ASSEMBLY

NU1

nyl

hex

jam

.75ONPST

CONNECTOR &SOCKETS

CONNECTOR, circ

pin plug keying Amp

200821-1

CONNECTOR &SOCKETS

CONNECTOR&PINS

COVER, protector motor

VALVE, 24VAC 2 way custom port 1/8 on

PANEL, end cover

INSULATOR, motor

clamp

CLAMP, motor top

INSULATOR, screw machine

CLAMP, motor base

STRIP buna N

compressed

sheet .062

x

4.000sq

HOSE,SAE.187IDx.4100D(orderbyft)

DRIVE ASSEMBLY, wire RH

(Fig 13-5)

DRIVE ASSEMBLY, wire RH

(high speed) (Fig 13-5)

GUIDE, monocoil

SCREW, set stl sch 8-32 x

.125

cup

LINER, monocoil inlet wire

point

BUS BAR,

connecting

weld current

DRIVE

ASSEMBLY,

wire LH

(Fig 13-5)

DRIVE ASSEMBLY, wire LH

(high speed) (Fig 13-5)

1

1

4

1

2

1

2

1

2

2

2

2

2

8

2

1

1

1

2

1

1

1

2 2

3ft 3ft

1 1

1

4 4

2

1

1

2

1

1

2

1

2

1

2

2

2

2

2

8

2

1

1

2

1

1

1

1

4

1

2

1

2

1

....

2

17ft

....

..

2

21ft

1

1

....

1

1

....

2

2

..

2

2

....

2

2

....

17ft

1

2

..

....

21ft

1

26ft

8

4

4

1

..

2

30ft

8

4

4

NOTE: When

ordering

Control Box contact

Factory

Service

Department

for proper number.

OPTIONAL

To maintain the

factory original performance

of your

equipment,

use

only

Manufacturers

Suggested

Replacement

Parts. Model and serial number

required

when

ordering parts

from your local distributor.

OM-1588 Page 41

Item

No.

Part

No.

1

2

....

....

058427

136684

3

4

5

....

....

605941

010233

6

7

....

....

057971

010191

058628

....

8

9

....

058428

080393

....

10...

t108008

11....

124900

12...

+168104

166594

13....

168103

Description

Figure

13-2.

Support,

Hub & Reel

(Fig

13-1 Item

12)

RING,

retaining spool

NUT, sti

slflkg

hex reg

.625-11

w/nyl

insert

WASHER, flat stl .640 ID x

1.000 OD x

l4ga

thk

SPRING, cprsn

.970

OD x

.120 wire x

1.250

WASHER, flat stl

keyed

1.SOOdia

x

.l2Sthk

WASHER, fbr .656 ID x

1.500

OD x

.l2Sthk

WASHER, brake stl

HUB,

spool

SUPPORT,

reel

REEL, wire 60 lb

(consisting of)

SUPPORT, reel

spool

RETAINER,

spool

support

LABEL, caution

falling

(consisting

wire reel

of)

can cause

damage

NUT, spanner

retaining

IEY~ Hardware is common and not available unless listed.

Quantity

1

1

2

1

2

4

4

2

1

2

2

1~

.3

4

.5

6

S

.8

7

10

ST-081 760-C

Figure

13-2.

Support,

Hub & Reel

OPTIONAL

+When

ordering

a component

originally displaying

a

precautionary

label, the label should also be ordered.

To maintain the

factory original performance

of your

equipment,

use

only

Manufacturers

Suggested

Replacement

Parts. Model and serial number

required

when

ordering parts

from your local distributor.

S

OM-1588 Page 42

1

3

.4

.6

.7

Item

No.

Dia.

Mkgs.

PC2O,30

PLG25

PLG24

10

11

12

13

117 Hardware is common and not available unless listed.

Part

No.

Description

Figure

13-3.

Panel,

Front

w/Components (Fig

13-4 Item

28)

167 697

147 139

164 842

144 844

171 814

165 484

159 264

167 633

089 032

153 169

010 291

167 700

..

..

..

..

..

..

..

..

..

..

..

..

NAMEPLATE,

PANEL, front

(order by

model and serial

number)

TAPE, adh

acrylic

double sided .010

x

.500

x

3.000

METER LENS,

w/gasket

STAND-OFF,

6-32 x

.875

Ig

CIRCUIT CARD, schd front

CONNECTOR & SOCKETS

(RC5)

See

Figure

13.4 Item 35

(RC24)

RING, ext .625

shaft grv x

.O45thk

E

WASHER, shldr .612 ID

style

LENS, LED 4341 red

panel mtg

ACTUATOR, switch

WASHER, flat .625 ID

nylafil

KNOB,

pointer

Quantity

1

9

1

1

1

2

1

2

9

13 12

11 10

Figure

13-3.

Panel, Front

w/Components

ST-800 1 12-C

To maintain the

factory original performance

of your

equipment,

use

only

Manufacturers

Suggested

Replacement

Parts. Model and serial number

required

when

ordering parts

from your local distributor.

OM-1588 Page 43

U~ Hardware is common and not available unless listed.

S c~) cJ

0)

N cJ

S

OM-1588 Page 44

0) cJ

C)

C,)

C)

LL

N

C,,

C,)

Figure

13-4.

Control Box cJ

C) C)

0

C,)

ST-800 273-B

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure

13-4.

Control Box

(Fig

13-1 Item

2)

Quantity

2

11

...22

...23

24

...25

...26

29...

...32

....

RC3O,40

35...

36...

PCi

PLG1

PLG2

PLG4

PLG6

CB1.

Si..

PC8O

PLG81

PLG82

PLG89

PLG9O

PLG9

RC7O

CR101

SRi.

PLG12,50

PC5O

PLG51

PLG52

PLG53

PLG54

PLG55

PC1O

PLG11

PLG15

PLG17

PLG18

PLG1O,24

PLG16,41

145948

Fig

13-3

155629

154938

097132

189124

158720

158719

131 204

148439

115092

126689

191 996

115092

153501

115093

162382

170980

155023

Fig

13-7

010 146

162253

047637

048144

134201

198037

115092

115093

115091

136810

184824

083432

111997..

182403

115093

158720

131054..

153501

073756

151187..

+162 364

010290

134464

163520

141162..

079739

601222..

176089

600399

138044

107983

048282

000527

072817

035704

030170

PANEL, side lower

CONNECTOR & SOCKETS

CONNECTOR,

circ

pin

STAND-OFF

plug keying

in sockets

SUPPORT, PC card .312/.375

Amp

200821-1

CIRCUIT CARD, motor control

CONNECTOR&SOCKETS(RC1)

CONNECTOR & SOCKETS

(RC2)

CONNECTOR & SOCKETS

CONNECTOR & SOCKETS

(RC4)

(RC6)

CASE SECTION, bottom/rear

CIRCUIT BREAKER, man reset 1P 10A250V

SWITCH, rocker SPST 1OA 25OVAC

CIRCUIT CARD, HF filter dual

CONNECTOR & SOCKETS

(RC81)

CONNECTOR & SOCKETS

(RC82)

CONNECTOR & SOCKETS

CONNECTOR & SOCKETS

(RC89)

(RC9O)

STAND-OFF, 6-32 x

.625

Ig

LATCH, slide flush

mtg

hole 1.000 wide x

1.500

Ig

WRAPPER

BUSHING, strain relief 1.030 ID

LABEL,

warning general precautionary

CABLE, port No.

18/14 11/c

CONNECTOR & PINS,

(order

(consisting byft) of)

CONNECTOR, circ

clamp

str rlf sz

17-20

Amp

206322-2

CLAMP, Univ 50A

TUBING,

plstc

PVC .250 ID x

.375

OD x

9.000

WIRE, strd

l4ga

blk 600V 105c

(order by

BUSHING, strain relief .120/150 ID x

ft)

.SOOmtg

hole

BLANK,

snap-in nyl .500mtg

hole

CONNECTOR w/SOCKETS

BLANK,

snap-in nyl .875mtg

hole

RELAY, end

24VAC DPDT

RECTIFIER, integ

40A 800V

BUSHING,

snap-in nyl

.750 ID x

1.000mtg

hole

BRACKET, mtg control box

PANEL, front

w/components

CABLE, ribbon 1 4posn

STRIP~ mtg PC card

(RC1

STAND-OFF, 6-32 x

.375

CIRCUIT CARD, interface

Ig

2) (RC5O)

CONNECTOR & SOCKETS

(RC51)

CONNECTOR & SOCKETS

(RC52)

CONNECTOR & SOCKETS

(RC53)

CONNECTOR & SOCKETS

(RC54)

CONNECTOR & SOCKETS

(RC55)

STAND-OFF, 6-32 x

1.500

Ig

CIRCUIT CARD, processor

w/proms (16 MEG)

CONNECTOR & SOCKETS

(RC11)

CONNECTOR & SOCKETS

(RC15)

CONNECTOR & SOCKETS

(RC17)

CONNECTOR & SOCKETS

(RC18)

CABLE, ribbon 34posn

CABLE, ribbon 24posn

(RC1O) (RC24)

(RC16) (RC41)

PANEL, side

CLAMP

w/components nyl

.625dia

1

1

1

1

1

1

4

1

1

17ft

1

1

1

1

1

1

1

1

1

1

1

1

1

2

4

10

1

35ft

1

1

1

1

1

1

1

1

1

1

1

1

1

4

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

Manufacturers

Suggested

Replacement

Parts. Model and serial number

required

when

ordering

parts from your local distributor.

OM-1 588 Page 45

Hardware is common and not available unless listed.

See Table 13-1 For

Drive Roll & Wire Guide Kits

16

18

20

21

6

8

9

10

26

27

~94

38

36~~

33

32

30

29

Figure

13-5.

Drive

Assembly,

Wire

~~f

ST-8O1 456-A

.

OM-1588 Page 46

Rem

No.

Dia.

Mkgs.

Part

No.

Description Quantity

Figure

13-5. Drive

Assembly,

Wire

(Fig

13-1 Items 29 &

33)

.4

.5

.6

.7

.8

.9

10

11

12

12

.14

15

.16

17

.18

.19

.20

.21

...22

...23

...24

.25

...26

27

1

13

28

...29

..31

...32

.33

.34

.35

...36

.37

...38

.39

41

...42

010668..

172075..

149962.:

149486..

163282..

165798..

165799..

SCREW, cap sti sch .250-20 x

1.500

CARRIER, drive roll

w/components

24

pitch

SPACER, carrier drive roll

PIN, rotation arm rocker

NUT, .250-28 stl

SPRING, pressure arm

WASHER, flat .257 ID sti

retaining

132750..

150520..

133493

133350

M1,2 156354

M1,2....

156353

153491

153492

*153 493

155098

153550

155099

155100..

154031

133493

184136..

182414..

182415

137248..

129351

602200..

604772..

182156..

182155..

132746..

181522..

132747..

133739..

ARM, pressure

SPACER, rotation

pin

RING, retaining

ext .250 shaft x

.O2Sthk

PIN,

hinge

MOTOR, gear

1/8hp

24VDC 272RPM

(consisting of)

MOTOR, gear

KIT, brush

1/8hp

24VDC 500RPM

replacement (consisting

(consisting of) of)

CAP, brush

BRUSH, carbon

KIT, cover motor

COVER, motor

gearbox (consisting of) gearbox (consisting of)

GASKET,

cover

SCREW,

cover

SPACER, locating

RING,

rtngext.2soshaftgrvx.O25thk

KIT, brush holder

WASHER, flat

PIN, cotter hair

SPRING, indicator

SCREW, hexwhd-slt stl

slffmg

8-32 x

.500

WASHER, lock stl

split

No.

8

WASHER, flatstl SAE No.8

SPRING, cprsn

SPRING, cprsn

BUSHING,

spring

SHAFT,

spring

CARRIER, shaft

WASHER, flat .375 ID x

.625

OD x

.062

183330..

PC51 153631

PLG57 131 204

604311

PLG58....

131 203

132611

KNOB, extension

CIRCUIT

CARD, digital

tach

(consisting

CONNECTOR & SOCKETS

of)

GROMMET,

rbr .250 ID x

.375mtg

hole

CONNECTOR&PINS

OPTICAL ENCODER DISC

149959..

179265..

108940

604538..

151437..

128237..

+179263

178937..

601872..

602213..

602243..

601966..

167387..

168825

133308..

FITTING, brs barbed M

3/l6tbg

x

.312-24

ADAPTER,

gun/feeder

LH

SCREW, cap stl hexwhd .250-20 x

.750

WASHER, flat stl SAE .312

KNOB,

plstcT 1.1251gx

.312-18x 1.500 bar

SCREW, hexwhd-slt stl

slffmg

10-32 x

.500

COVER, drive roll

(consisting of)

LABEL,

warning

electric shock and

pinch

NUT, stl hex full .375-16

WASHER, lock stl

split

.375

WASHER, flat stl .375

SCREW, cap stl hexhd .375-16 x

1.250

SPACER,

DRIVE,

locating pinion

40T 24P .376 bore

RING,

retaining

ext .375

shaft x

.O2Sthk

Part of 132 129

Optional High Speed

Motor

*Recommended

Spare

Parts.

+When

ordering

a component

originally displaying

a

precautionary

label, the label should also be ordered.

To maintain the

factory original performance

of your

equipment,

use

only

Manufacturers

Suggested

Replacement

Parts. Model and serial number

required

when

ordering

parts from your local distributor.

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

2

1

1

1

1

2

1

1

2

1

1

1

1

1

1

1

5

2

1

1

1

1

1

1

2

2

1

1

1

2

2

2

2

2

4

2

2

4

4

OM-1588 Page 47

Wire Size

Fraction Metric

.~

E~5

-(~ a,

~

E~

~c,

~

Table 13-1.

Drive Roll and Wire Guide Kits

V-GROOVE

4 RoIl

Kit

Drive

Roll

U-GROOVE

4 RoIl

Kit

Drive

Roll

VK-GROOVE

4 RoIl

Kit

Drive

Roll

UC-GROOVE

4 Roll

Kit

Drive

Roll

S

.023-025 in 0.6mm

150 993 149 518 151 024 087 130

.030 in.

0.8

mm 150 993 149 518 151 025 053 695

.035 in.

0.9

mm 150993 149518 151 026 053700 151 036 072000 151 052 132958

.040 in.

1.0

mm

150993 149518 161 189 053696

.045 in.

1.1/1.2mn

150994 149519 151 027 053697 151 037 053701 151 053 132957 151 070 083489

.052 in.

1.3/1.4mn

150994 149519 151 028 053698 151 038 053702 151 054 132956 151 071 083490

1.6

mm 150995 149520 151 029 053699 151 039 053706 151 055 132955 151 072 053708

.068-.072in

1.8mm

150995 149520

5/64 in.

(.079 in.)

2.0

mm

150995 149520

(.094

in.)

2.4mm

150 996 149 521 fl)

2.8

mm

150 996 149 521

151056 132959

151 040 053704 151 057 132960 151 073 053710

.

151 041 053 703 151 058 132 961 151 074 053 709

151 042 053 705 151 059 132 962 151 075 053 711

(isi)

3.2mm

150 997 149 522 151 043 053 707 151 060 132 963 151 076 053 712

Each Kit Contains An Inlet Guide, Intermediate Guide, And 045 233 Antiwear Guide With 604612 Setscrew 8-32 x .125,

With 4 Drive Rolls.

Along

2 Kits Required For Dual Models.

S0549-D

OM-1588 Page 48

..

..

..

3

4

1

2

..

..

..

..

..

5

6

7

8

Item

No.

Dia.

Mkg

s.

PC6O

PLG6O

PLG41

PC4O

Hardware is common and not available unless listed.

Part

No.

Description

Figure

13-6.

Panel,

Side

w/Components (Fig

13-4 Item

37)

147 139

155 024

154 933

156 623

153 501

158 160

144 844

154 109

153 169

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

.

TAPE, adh

acrylic

double sided .010

x

LENS, clear

anti-glare

.

500 x

3.000

PANEL, inner control

CIRCUIT CARD, data card

CONNECTOR & SOCKETS

See

Fig

13-3, Item 40

(RC41)

CIRCUIT CARD, side

display

STAND-OFF, 6-32 x

.875

Ig

PLATE, ident inner control

(RC6O)

ACTUATOR, switch

.

.

5

6

Quantity

1

4

1

4

1

1

2

1

1

2

7

-S

8

ST-800 113-B

Figure

13-6.

Panel,

Side

wlComponents

To maintain the

factory original pertormance

of your

equipment,

use

only

Manufacturers

Suggested

Replacement

Parts. Model and serial number

required

when

ordering parts

from your local distributor.

OM-1 588 Page 49

U~ Hardware is common and not available unless listed.

V

\

\

\__~

\

\

\

\

\

~

OM-1 588 Page 50

CD

L)

C.)

CJ

Figure

13-7.

Boom

Assembly

CD

0)

CJ

ST-142 306-C

.

Item

No.

Part

No.

Description

Figure

13-7.

Boom

Assembly (Fig

13-1 Item

15)

16

17

18

18

12

13

14

15

19

20

21

22

23

7

8

9

10

10

11

.1.010313..

2 010910..

3

4

079622..

079621..

6

7

5

5

079667..

080812..

079632..

079665..

080811..

079664..

139633..

159999..

160513..

073742

24

073741

079029..

075462..

602250..

079020..

155335

149858..

151625..

150258

024605

075101..

079030..

174754

080157..

174688..

142804

134327

073666..

25

26

27

28

29

047224..

602246..

010493..

139818..

PIN, coffer hair .072

x

1.437

WASHER, flat stl SAE .375

WASHER, shld .381 ID x

.750 OD

PULLEY, V

sgl

grv

7.7SOdia

x

8.000P

x

.625

bore

PIPE,

plstc

.500

x

133.750

PIPE,

plstc

.500x 181 .750

BOLT, U stl .250-20 x

.875 wide x

1.375

deep.

GUIDE, wire

GUIDE, wire

GUIDE, wire inlet

LINER, monocoil 3/32-1/8 wire x

15.687

BOOM,

dual

BOOM, dual

PIN, clevis .750

OD x

2.156

Ig

CLEVIS, .812

yoke

6.062

Ig

NUT, stl hex full fnsh .750-16

.750-l6thd

SHAFT, boom counterbalance

WASHER, flat stl SAE .750

NUT, stl hex elastic stop .750-16

PIPE, blk 3.000

x

.875

SPRING, cprsn 3.750 OD x

.625 wire x

36.000

SPRING, cprsn 3.750

OD x

.640 wire x

36.000

RETAINER,

spring

BEARING, ball thr

sgl

row

.750

x

1.625

x

.625

NUT, stl hex

special

.750-16 x

1.250

WASHER, lock stl ext tooth .750

BASE, swivel boom

FITTING, grease

1/8NPT

BRACKET,

mtg

control tilt

LABEL,

Swingarc

(consisting of)

caution

heavy spring

LABEL,

warning general precautionary

BOLT, mach stl hexhd .750-16 x

2.750

KNOB, T-bar .500-l3thd

WASHER, flat stl std .500

BUSHING,

snap-in nyl

.625 ID x

.875mtg

hole

GUARD, motor protector

Quantity

12

Model

I

16

4....

6....

2....

2....

2

4

6

2

2

2

1....

1....

2....

1....

2....

1....

1

2

1

2

1

1

1

1

1

1

2

2

2

1

1....

1

1....

1

1....

1

1....

1

1....

1

1....

1

1....

1

1....1

1....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

Manufacturers

Suggested

Replacement

Parts.

Model and serial number

required

when

ordering parts

from your local distributor.

OM-1588 Page 51

Notes

OM-1 588 Page 52

.

Notes

OM-1 588 Page 53

Notes

__

OM-1 588 Page 54

.

.

~k ~II

miner

~

SERVICE TRAINING

FROM MILLER ELECTRIC

-

These Service Videos will tenance,

help

you learn about main

troubleshooting,

and

servicing specific

Miller

equipment.

Also, if you are a

Miller Certified Service Technician, these videos can

help

you

recertify. Passing

the included test will earn five

points

towards the

forty points

needed.

You will find each of these

professionally produced

videos to be very informative and a valuable part of your Service Video

Library.

SER VICE VIDEOS

: XMT 304 Video Kit

(#197 018)

324-1035

Additional XMT 304 Test Sheet

(#197 019)

324-1008

$86.00

$3.00

11

Feeder Series

Package

(2 videos

-

S-62& S-54 & 60M)

(#197 006)

324-1009 $126.00

L1

Bobcat 225 NT Video Kit

(#197 007)

324-1014 $86.00

S-62 & 5-64 Series Video Kit

(#197 012)

324-1030

Additional S-62 & S-64 Test Sheet

(#197 014)

324-1016

$86.00

$3.00

Additional Bobcat 225 NT Test Sheet

(#197 009)

324-1018

LI

Deltaweld 452 Video Kit

(#197 010)

324-1032

LI

Additional Deltaweld Test Sheet

(#197 011)

324-1019

S-MM Video Kit

(#197 015)

324-1031

Additional S-MM Test Sheet

(#197 017)

324-1017

$86.00

$3.00

Payment

Information

Check or

Money Order Send check or money order payable to: Neenah Printing

Attn: Literature Distribution Center

P0. Box 506

Neenah, WI 54957-0506

Purchase Order

_______________

Mastercard Visa

$3.00

$86.00

$3.00

Name of Card holder

__________________________________________________

Account #__________________________________ Exp.

Date

__________

Cardholders signature

To Order call 920-751-2120 or

Fax 920-751-2121

Distributor Name Customer #_________________

Miller

~

WELDING EQUIPMENT

SER VICE ENGINEERING

SELF-PACED

TRAINING COURSE

FROM MILLER ELECTRIC

-

Learn the basics of

Welding equipment troubleshooting

and

servicing

With this three module course

designed

for home

study,

industrial and educational use.

This course

Will

provide

the basic

knowledge

to

begin

a career in

servicing welding equipment,

act as a refresher, or

provide

a

welding

salesman or technician service and

troubleshooting techniques.

A certificate of

completion

is awarded

by

the Miller

Training Department

upon successful

completion

of the course.

MODULE

1

Visual

Inspection

High Frequency

Safety

MODULE

2

Volt-ohm Meter

Operation

Load Bank

Operation

MODULE

3

Electronic

Symbols

Component

Identification

Troubleshooting

U

Welding Equipment

Service

Engineering Training

Course

(Includes text, videotape, exams, and

(#145 870)

$60.00

registered answer card.)

U

Additional Text

(Includes text and registered answer card.)

Payment

Information

J

Check or

Money Order Send check or money order payable to: Neenah Printing

Attn: Literature Distribution Center

P0. Box 506

Neenah, WI 54957-0506

II]

Purchase Order

______________

Mastercard

LI

Visa

Name of Card holder

Account #__________

Cardholders signature

To Order call 920-751-2120 or

Fax 920-751-2121

Distributor Name

Exp.

Date

Customer #

(#145 871)

$35.00

.

V

/

~

/ o~

:~t

/

7

40

/

/

......:c4;, // .7.,:0 V:

7

/

/

/

/

.0~

/

/

Warranty

Questions9

/ Call

1

-800-4-A-MILLER

for your local

Miller

distributor

a

U.

0:

C

.

Your thstrtbutor also gives you..~

Service

~ get the fast, reliable response you

-parts can-bØin your ttandsin24hptirs.

Support.

Need fast answers to the

:togh welding questions?

Contact your distributor::

The.expettise

of the distributor and Miller is there io.help

you,: every stepoftheway.

:~

H

Effective January 1,

1999

(Equipment

with a

serial number preface of KK

or

newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied.

LIMITED WARRANTY

-

Subject to the terms and conditions below, Miller Electric to its original retail

Mfg. Co., Appleton, Wisconsin, warrants 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.

2.

3.

4.

5.

5 Years Parts

-

3 Years Labor

*

*

Original main power rectifiers

Inverters (input and output rectifiers only)

3 Years

*

Parts and Labor

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

Motor

185)

Driven Guns (w/exception of Spoolmate

* Process Controllers

* Positioners and Controllers

*

*

Automatic Motion Devices

Robots

*

*

*

*

*

*

RFCS Foot Controls

IHPS Power Sources

Water Coolant Systems

HF Units

Grids

Maxstar 140

*

*

*

*

*

*

*

Spot Welders

Load Banks

SDX Transformers

Miller Cyclomatic Equipment

Running Gear/Trailers

Plasma Cutting Torches (except APT, ZIPCUT &

PLAZCUT Models)

Field Options

(NOTE: Field options are covered under True

Bluefi for the remaining warranty period of the product they are installed in, or for a minimum of one year whichever is greater.)

6 Months Batteries

90 Days

*

Parts

MIG Guns/TIG Torches

*

* APT, ZIPCUT & PLAZCUT Model Plasma

Torches

Culling

Remote Controls

*

*

*

Accessory Kits

Replacement Parts (No labor)

Spoolmate lBS

Millers True Bluefi Limited Warranty shall not apply to:

1.

2.

Items furnished such as engines by Miller, but manutactured by others, or trade accessories. These items are covered by the manutacturers warranty, if any.

Consumable components; such as contact tips, cuHing nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear.

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 which has been used for maintenance, or operation equipment outside of the specitications 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 Millers option: (1) repair; or(2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost ot repair or replacement at an authorized Miller service station; or

(4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customers risk and expense. Millers option of repair or replacement will be FOB., Factory atAppleton, Wisconsin, or

FOB.

at a

Miller authorized service facility as determined by

Miller.

Therefore no compensation or reimbursement for transportation costs of any kind will be 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,

OPERATION OF

MIGHT

LAW,

ARISE BY IMPLICATION,

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 provides specific legal rights, apply to you. This warranty and other available, but may vary from state to state.

rights may be

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

Warranty provides specific legal rights, apply.

This and other

Limited rights may be available, but may vary from province to province.

miller_warr 9/ag

Owners Record

Please

complete

and retain with your

personal

records.

Model Name

Purchase Date

Distributor

Address

City

State

Serial/Style

Number

(Date which equipment was delivered to original customer.)

Zip

...~.

.

.

.~..

..

..

,...

~ I.

~

Resources Available

Always provide

Model Name and

Serial/Style

Number.

Contact your Distributor for:

To locate a distributor or service near you, call agency

1-800-4-A-Miller or visit our website at www.MillerWelds.com

Welding Supplies

and Consumables

Options

and Accessories

Personal

Safety Equipment

Service and

Repair

Replacement

Parts

Training (Schools,

Videos,

Books)

Technical Manuals and

Parts)

(Servicing

Information

Circuit

Diagrams

Welding

Process Handbooks

Contact the

Delivering

Carrier for:

For assistance in filing or settling claims, contact your distributor manufacturers and/or equipment

Transportation Department.

PRINTED IN USA

/

/

Co

H

..

.

(

...

k~temahon

.

H

-

UnIted K3ngdom;~

Phone: 44

FAX 44(0)

(0) f~(}4593493

1204~598D66

~.

.

www

~HerWeJdscom

.,.:

.~

File a claim for loss or

damage during shipment.

'

1999 Miller Etethic Mfg.

co.

9/99

p//A illet.~

~

.~

H