Miller | KE648703 | Owner Manual | Miller D-64M WIRE FEEDER User manual

Miller D-64M WIRE FEEDER User manual
Miller
June 1994
Form:
OM-1587A
Effective With Serial No. KE648703
OWNERS
MANUAL
D-64M Wire Feeder
Microprocessor Controlled Constant Speed Dual
Multi-Power Source
For
Wire Feeder
Compatible
GMAW, GMAW-P, And FCAW Welding
For .023 To 1/8 In
(0.6
Standard Wire Feed
Programmable
To 3.2
mm) Wires
Speed Of
50 To 780 1PM
(1.3 To
19.8
MPM)
Pulse Weld Parameters
See Rear Cover For
Options
And Accessories
Read and follow these instructions and all
blocks carefully.
Give this manual to the operator.
safety
Have
and qualified persons
service this unit.
only trained
install, operate,
or
For
Call your distributor if you do not understand
the directions.
cover
1/94
ST-800 179
'
1994 MILLEA EleCtriC
or:
help,
call
sour distributor
MILLER Electric Mfg. Co., P.O. Box 1079,
WI 54912
414-734-9821
Appleton,
141g. Co.
PRINTED IN USA
I
TRUE
MILLERS
BLUETM LIMITED WARRANTY
Effective
with
(Equipment
-1~
________________
________________
a
January 1, 1992
preface of KC
serial number
This limited warranty supersedes all previous MILLER warranties and is exclusive with
newer)
other guarantees
or
warranties
expressed
or
implied.
Remote Controls
LIMITED WARRANTY Subject to the terms and conditions below, MILLER Electric
Mtg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new
MILLER equipment sold after the effective date of this limited warranty Is tree of de
tects in material and workmanship at the time it is shipped by MILLER. THIS WAR
RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT
no
or
Accessory Kits
Replacement Parts
MILLERS
BIueTM
True
Umited
Warranty
shall not
apply
to;
NESS.
Items furnished
1.
warranty periods listed below, MILLER will repair or replace any war
ranted parts or components that tail due to such detects in material or workmanship.
MILLER must be notitied in writing within thirty (30) days of such defect or failure, at
which time MILLER wilt provide instructions on the warranty claim procedures to be
one
equipment wee delivered to the original
equipment is sent to the distributor.
year after the
retail
purchaser,
are
covered
by
by others,
such
as
the manufacturers
engines
or
wsrranty, if
any.
2.
Consumable components; such as contact tips,
and relays or parts that tall due to normal wear.
3.
by eny party other than MILLER, or equip
improperly installed, improperly operated or misused
based upon industry standards, or equipment which has not had reasonable
end necessary maintenance, or equipment which has been used tor operation
outside of the specifications br the equipment.
followed.
start on the date that the
but manufactured
trade accessories. These items
Within the
MILLER shall honor warranty claims on warranted equipment listed below in the
event ot such a failure within the wsrrenty time periods. All warranty time periods
by MILLER,
Equipment
cutting
nozzes, contaclors
that has been modified
ment that has been
or
5YearaParta-aYearsLabor
1.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BYCOMMER
Original
3 Years
2.
main power rectifiers
CIALJINDUSTRIAL USERS AND PERSONS TRAINED AND EXPCRtENCED IN
THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
Pans and Labor
Transformer/Rectifier Power Sources
In the event of
Plasma Arc
shall be, at MILLERS
Cutting
Power Sources
Semi-Automatic and Automatic Wire Feeders
Robots
3.
2 Years
Parts and Labor
Engine Driven Welding Generators
(NOTE; Engines are warranted separately by
for a period of two years.)
Air Compressors
1 Year
4,
vice
the
engine
manutecturer
Motor Driven Guns
*
Water Coolant
Process Controllers
Systems
Grids
Welders
Lcod Banks
SDX Transtormers
Running Gear/Trailers
Field Options
(NOTE;
Field
options
are
covered under True
warranty period of the product they
one
5.
6 Months
6.
90
year
tacility as determined by MILLER. Therefore no compensation
trsnsportation costs of any kind wilt be allowed.
whichever is
are
BIueTM
installed in,
or
tor the
remaining
br a minimum of
reimburse
greater.)
Some states in the U.S.A. do not allow limitations ot how long an implied warranty
lasts, or the exclusion of incidental, indirect, special or consequential damages, so
the above limitation or exclusion may not apply to you. This warranty provides spe
cific legal rights, and other rights may be available, but may vary from state to state.
Banenea
in Canada,
Days
or
ment for
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR
RANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY 0 ~HER LEGAL
THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, IN
CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILtTY OR FITNESS
FDR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.
HFUnits
Spot
warranty claim covered by this warranty, the exciesive remedies
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 CON
TRACt TORT OR ANY OTHER LEGAL THEORY.
Parts end Labor
*
a
option; (1) repair; or (2) replacement; or, where authorized in
writing by MILLER in appropriate cases, (3) the reasonable cost of repair or replace
ment at an authorized MILLER service station; or (4) payment of orciodit tor the pur
chase price (less reasonable depreciation based upon actual use) upon return ot the
goods at customers risk and expense. MILLERS option ot repair or replacement
will be FOB., Factory at Appleton, Wisconsin, or FOB. ate MILLER authorized ser
or
Pans end Labor
legislation
in
some
provinces provides forcertain
MIG Guns/TIG Torches
Plasma
Cutting
out above may not
Warranty provides specific legal rights, and other rights may
vary from province to province.
Torches
additional warranties
remedies other than as stated herein, and to the extent that
waived, the limitations end exclusions set
they may not be
apply. This Limited
be available, but mey
.1-
RECEIVING-HANDLING
unpacking equipment, check carton for any damage that may have occurred during shipment. File any claims for
delivering carrier. Assistance for filing or settling claims may be obtained from distributor and/or equipment
Transportation Department.
Before
loss
with the
manufacwrers
When
requesting information
Use the
or
about this
following spaces to record
equipment, always provide
Model
Model
Designation
and Serial
or
Style
or
damage
Number.
Designation and Serial or Style Number of your unit. The information is located on the rating
label
nameplate.
Model
_________
Serial
or
Style
No.
Date of Purchase
miller 9/93
ERRATA SHEET
After this manual
appearing
was
printed,
Parts List
as
87-40
**First
oroering
equipment design occurred.
This sheet lists
extra manuals.
exceptions to data
PLG1O,24
PARTS LIST
Part
No.
Dia.
.
Use above FORM number when
follows:
Mkps.
84-35
86-2
FORM: OM-1587A
later in this manual.
CHANG ES TO SIECTION 16
Change
refinements in
November 15, 1994
...
Replaced
With
Description
155 022
150 147
170 980
..
172 075
..
133 530
168 825
.
CABLE, ribbon 34 posn 12.000 in
CARRIER, drive roll w/components 24 pitch
(Eff w/KE754598)
DRIVE, pinion 40T 24P .376 bore
(Eff w/KE754598)
digit represents page no digits following dash represent item no.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Quantity
1
4
1
ARC WELDING SAFETY PRECAUTIONS
WARNING
ARC WELDING
be hazardous.
can
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information that will be found in the
Safety Standards listed on the next page. Read and follow all Safety Standards.
HAVE ALL INSTALLATION, OPERATION,
PEOPLE.
ELECTRIC SHOCK
can
MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
1.
2.
3.
4.
5.
Do not touch live electrical
parts.
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.
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input poweraccording
to OSHA 29 CFR 191 0.147 (see Safety Standards).
Properly install and ground this equipment according to its
Wear
Manual and national, state, and local codes.
Owners
6.
check and be
Always verify
the
power cord
ground wire is properly connected
(4~
..
supply ground
sure
that
to
input
ARC RAYS can burn eyes and skin;
NOISE can damage hearing; FLYING
SLAG OR SPARKS can injure eyes.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays that
can burn eyes and skin. Noise from some processes
can damage hearing. Chipping, grinding, and welds
cooling throw oft piece~s of metal or slag.
Use appr oved
~J
ear
plugs
or ear
muffs if noise level is
can
conductor first
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
9.
Turn off all
10.
2.
Keep your head cut of
If inside, ventilate the
remove
welding
11.
Do not
12.
If earth
with
and/or
use
exhaust at the
arc
4.
Read the Material Safety Data Sheets (MSDSs) and the
manufacturers instruction for metals, consumables, coatings,
use an
explode
if
damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
1.
2.
3.
poorly spliced
drape cables
over
your
body.
grounding of the workpiece is required, ground it directly
separate cable do not use work clamp or work cable.
a
Wear
only well.maintained equipment. Repair or replace
damaged parts at once. Maintain unit according to manual.
16.
a safety harness if working above floor level.
Keep all panels and covers securely in place.
17.
Clamp
work
workpiece
or
cable with
worktable as
good
near
metal-to-metal
the weld
as
contact
to
practical.
ARC RAYS
2.
Wear
a
welding
helmet fitted with
a
proper shade of filter to
protect your face and eyes when welding or watching (see ANSI
Z49.1 and Z87.1 listed in
Safety Standards).
approved safety glasses
3.
Wear
4.
Use
protective screens or barriers to protect others
and glare; warn others not to watch the arc.
5.
Wear
5.
Work in
approved air-supplied respirator.
can
or
15.
with side shields.
from flash
protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained
watchperson nearby. Welding fumes and gases can displace air
and lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
Do not weld 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 metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
weld area, the
area
is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
cleaners, and de~lreasers.
CYLINDERS
use.
damaged, undersized,
use
7.
If ventilation is poor,
when not in
14.
to
3.
worn,
Do not touch electrode if you are in contact with the work,
ground, or another electrode from a different machine.
the fumes. Do not breathe the fumes.
area
equipment
use
13.
be hazardous to your health..
fumes and gases.
Do not
cables.
6.
1.
double-check connections.
8.
high.
FUMES AND GASES can be hazardous
to yoi~r health.
Welding produces fumes and gases. Breathing these
fumes and gases
7.
ground
NOISE
1.
or that cord plug is connected to a
properly grounded receptacle outlet.
When making input connections, attach proper grounding
terminal in disconnect box
kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire wald~ng, the wire, wire reel, drive roll housing,
and all metal parts touchin9 the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
4.
5.
6.
7.
Never
drape
welding torch over a gas cylinder.
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.
Never allow
a
a
Protect
8.
Turn face away from valve outlet when opening cylinder valve.
mechanical shocks,
9.
Keep protective cap in place
compressed gas cylinders from excessive heat,
slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical
circuits.
in
10.
use or
connected for
over
valve
except when cylinder is
use.
Read and follow instructions
on compressed gas cylinders,
associatedequipment,andCGApublicationP-1 listed in Safety
Standards.
Sri .1.1 2194
WELDING
fire
can cause
explosion.
or
Welding on closed containers, such as tanks, drums,
or pipes, can cause them to blow up. Sparks can fly
off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
Be
6.
yourself
and others from
1.
Protect
2.
Do not weld where
3.
4.
5.
flying sparks
and hot metal.
strike flammable material.
flying sparks can
(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.
Engines produce
ENGINE
can
kill.
FUEL
can
fire
cause
or
explosion.
Engine
1.
2.
fuel is
highly
ceiling, floor, bulkhead,
closed containers such
on
Connect work cable to the work
or
partition
as
tanks, drums,
or
9.
Do not
as close to the welding area.as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
welder to thaw frozen
use
pipes.
10.
Remove stick electrode from holder
contact tip when not in use.
ii.
Wearoil-free
12.
Removeany combustibles, such as a butane lighteror matches,
from your person before doing any welding.
or
cut off
welding wire
at
protective garments such as leather gloves, heavy
shirt, cuff less trousers, high shoes, and a cap.
ENGINES
harmful exhaust gases.
on a
the hidden side.
on
8.
WARNING
ENGINE EXHAUST GASES
welding
pipes, unlessthey are properly prepared according toAWS F4.1
(see Safety Standards).
Remove all flammables within 35 ft
£~
fire
Do not weld
7.
burns. Accidental contact of electrode to metal
objects can cause sparks, explosion, overheating, or
fire. Check and be sure the area is safe before doing
any welding.
that
aware
can cause
can
be hazardous.
outside in open, well-ventilated
1.
Use
2.
If used in
closed area, vent engine exhaust outside and
away from any building air intakes.
3.
Do not overfill tank
4.
Do not
equipment
areas.
a
allow
If fuel is
spill fuel.
for fuel to
room
spilled,
expand.
clean up before
starting
engine.
flammable.
Stop engine and let it cool off before checking or adding fuel.
Do not add fuel while smoking or if unit is near any sparks or
MOVING PARTS
can cause
injury.
3.
Have
only qualified people
remove guards or
tioubleshooting as necessary.
To prevent accidental starting during servicing,
negative () battery cable from battery.
covers
for
maintenance and
Moving parts, such as fans, rotors, and belts can
fingers and hands and catch loose clothing.
4.
cut
5.
1.
Keep all doors, panels,
securely in place.
2.
Stop engine
before
covers,
installing
and
guards
closed and
6.
or
connecting
unit.
Keep hands, hair, loose clothing, and tools away from moving
parts.
Reinstall
panels
or
guards and close doors when servicing
starting engine.
1.
Always
2.
Stop engine
wear a
face shield when working
before
Do not allow tools to
4.
Do not
gases.
5.
Observe correct
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
1.
explosive
engine
is cold
disconnecting
or
on a
battery.
connecting battery
cables.
3.
It is best to check coolant level when
to avoid scalding.
is
finished and before
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin,
Batteries contain acid and generate
disconnect
If the
use
engine
is
sparks when working on a battery.
charge batteries or jump start vehicles.
cause
welder to
polarity (+ and )
warm
and
checking
on
batteries.
is needed, follow
steps 2
and 3.
2.
Wear
3.
Turn cap
safety glasses and gloves and put a rag over cap.
slightly and let pressure escape slowly before
completely removing cap.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49.1, from
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards,
American
OSHA 29 CFR 1910, from
dent of Documents, U.S. Government
D.C. 20402.
Superinten
Printing Office, Washington,
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, Ameri
can Welding Society Standard AWS F4. 1, from American Welding So
ciety,
550 N.W. LeJeune Rd. Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Pro
tection Association, Batterymarch Park, Quincy, MA 02269.
srl.1.1 2/94
Safe
Handling
of
Compressed Gases
in
Cylinders, CGA Pamphlet
P-i, from Compressed Gas Association, 1235 Jefferson Davis High
way, Suite 501, Arlington, VA 22202.
Code for
Safety in Welding and Cutting, GSA
Standard Wi 17.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou
levard, Rexdale, Ontario, Canada M9W 1 R3.
Safe Practices
ForoccupationAnd Educational Eye And Face Protec
tion, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting
And
Welding Processes, NFPA Standard 51 B, from National
Batterymarch Park, Quincy, MA 02269.
Fire Protection Association,
PRECAUTIONS
ISE
PROTEGEZ-VOUS,
ENFANTS
Le
DE
SECURITE
EN_GARDE
LE SOUDAGE
soudage,
AINSI QUE LES AUTRES, CONTRELES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAiSSEZ PAS LES
NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QUILS NAIENT CONSULTE UN MEDE~1N).
Is plupart des activitØs Industrielles, expose a certains risques. Le soudage nest pas dangereux lorsquon prend des
consignes de sØcuritØ suivantes ne font que rØsumer Iinformation contenue dans les normes ØnumØrØes ci-aprŁs. Lisez et
ces riormes.
SEULES DES PERSONNES
QUALIFEES
LELECTROCUTION
Une
DOIVENT FAIRE DES TRAVAUX DINSTALLATION,
peut Œtre mortelle.
et le circuit de soudage sont
tension au dØmarrage. Le circuit dentrØo et los
circuits internes des matØriels sont aussi sous tension
des Ia mise en marche. En soudage automatique ou
semi-automatique avec f ii, ce dernier, le support de
roquette, le logement des galets dentrainement et
toutes les piŁces metalliques en contact avec 10 fil de
soudacpe sont sous tension. Des matØriels mal
install~s ou mal mis a Ia terre sont dangereux.
sous
4.
Ne touchez pas a des piŁces sous tension.
Portez des gants et des vŒtements isolants, secs et non trouØs.
lsolez-vous de Ia tle a souder et de Ia mise a Ia terre au moyen
de petits tapis isclants ou autres.
DØconnectez Ia prise dentrØe des matØriels ou arrŁtez leur
moteur avant de les installer ou den faire lentretien.
La RAYONNEMENT DE LARC peut brQler les
yeux at Ia peau; le BRUIT peut endommager
1.
Protez
Acran filtrant do teinte
appropriØe (consultez Ia norme ANSI Z49 indiquØe ci-apres),
pour vous protØger to visage et les yeux Iorsque vous soudez ou
un
m.
~
I
=L~w
1.
2.
~!
casquce de soudeur
Las
VAPEURS
FUMEES
sont
ArrŒtez tous los matØriels apres utilisation.
7.
Nutilisez pas de cables uses,
calibre trop petits.
8.
Nenroulez
9.
Mettez ala terre Ia tle a souder
terre.
applicables.
10.
11.
Le
soudago dØgage des vapeurs
dangereux de respirer.
ot des fumØes
ou
do
pas de cables autour do votre corps.
Ne touchez pas a IØlectrode
circuit de soudage (terre).
Nutilisez que des matØriels
au
Si
en
moyen dune bonne prise do
vous
Œtes
bon Otat.
contact avec le
en
Reparez
ou
remplacez
Portez
Fermez solidement touS 10 panneaux et los capots.
2.
3.
un
hamais de sØcuritØ si
vous
travaillez
en
hautour.
que vous observez IexØcution dune soudure.
Portez des lunettes do sØcuritØ approuvØes. Des Øcrans latØraux
sont recommandØes.
Entourez laire do soudage do rideaux ou do cloisons do
contro los coups darc ou lØblouissement; avertissez
los observateurs do no pas rogarder larc.
protection
4.
Portoz dos vOtements en tissus
des chaussuros do sØcuritØ.
5.
Portoz un casque antibruit ou des bouchons dorellle
5~ 10 nivoau do bruit est ØlevØ.
5.
Ne travailloz dans
ignifugo
durable
(lame
et
cuir)
et
approuvØs
espace confine quo slI est bien ventilO;
Los gaz
do Iair et
causer des blossures ou Ia mort. Assurez-vous quo lair est
propre a Ia respiration.
un
sinon, portez un respirateur a adduction dair.
protecteurs do soudago peuvent dØplacer Ioxygene
6.
Ne soudoz pas a proximitØ doperations de dØgraissage, do
nettoyage ou de pulvØrisation. La chaleur et les rayons de larc
pouvent reagir avec des vapeurs et former des gaz hautement
toxiques et irritants.
7.
Ne soudez pas do tles galvanisØes ou plaquees en plÆmb ou on
cadmium sans los avoir grattees a fond, car ces mØtaux, et tout
revOtoment qui en contient, peuvent alors dØgager des tumØes
toxiques. Assurez-vous dune bonne ventilation et portez un
respirateur.adduction dair si cest nØcessairo.
ou
5.
MØfiez-vous des incendies et gardez
main.
Carc pioduit des Øtincelles et des projections. Avec Ia
chaleui intense degagee par Ia tOle et Ies matØriels,
elles pouvent causer un incendie et des brOlures. Le
contact accidentel de lØlectrode avec un objet
metallique peut provoquer des Øtincelles, un
Øchauffemont ou un incendie.
6.
Noublioz pas quune soudure sur un plafond, un plancher,
cloison ou une paroi peut en enflammer Iautre ctO.
4.
Lisez los fiches signaletiques et los consignes du fabricant
relatives aux mØtaux, aux produits consummables, aux
rovŒtements et aux produits nettoyants
La SOUDAGE
une
peut
un
rospirateur a adduction
causer un
Incendie
explosion.
7.
ProtØgoz-vous,
projections.
2.
des Øtincelles
Ne soudez pas dans un endroit o
atteindre des matØriaux inflammables.
8.
un
recipient fermØ,
extincteur a
comme un
portØe de
reservoir
Ia
une
ou un
Connectez le cable de
soudage le plus prŁs possible de Ia tle de
soudage pour empOcher le courant do suivro un parcours long et
et
inconnu, et prØvenir ainsi les risques dØlectrocution
dincendie.
peuvent
Enlevoz toutes los matiŁros inflammables dans un rayon de 10,7
metres autour de Iarc, ou couvroz-Ies soigneusomont avec des
bches approuvØes.
Ne soudez pas
un
tonneau.
ainsi que los autres, contre les Øtincelles et les
1.
9.
10.
Ne faites pas
Videz votre
tube-contact
degeler
des tuyaux
avec un
carquois porte-electrodes
apres
le
chalumeau.
ou
coupez le fil
au
soudage.
Portez des vØtements protecteurs non huileux, tels des gants en
une chemise epalsse, un pantalon sans revers, des
chaussures montantes et un casque.
MØfiez-vous des Øtincelles et des Øc~ats brOlants, susceptib~es
de pØnØtrer dans des aires adjacentes par de petites ouvertures
ou fissures.
It.
LES ETINCELLES ET LES PROJECTIONS
BRULANTES peuvent causer des blessures.
1.
Protez un Øcran facial ou des lunottes a coques
Øcrans latOraux sont recommandØs.
Le piqu age et le meulage produisent des Øclats de metal.
En refroidissant, Ia soudure pout projeter du laltier.
2.
Portez des vØtements de
>
Øpisses
13.
Ecartez le visage pour Øviter do respirer los fumØes.
A IintØrieur, assuroz-vous quo Iaire do soudage ost bien ventilØe
ou que les fumØes ot los vapeurs sont aspirØes a Iarc.
Si Ia ventilation est mauvaise, portez
dair approuvØ.
4.
mal
12.
quiI
3.
3.
endommages,
sur-le-champ los piŁces endommagØes.
dangareuses pour
ost
DENTRETIEN ET DESSAI
6.
avec
ET LES
Ia sante.
REPARATION,
Veillez a installer ces matOnels et a les mottre a Ia terre solon le
manuel dutilisation et les codes nationaux, provinciaux et locaux
Iouie.
Larc de soudage produit une chaleur et des rayons
ultraviclets intenses, susceptibles de brOler los yeux et
Ia poati. Le bruit cause par certains procØdØs peut
endom rnager louie.
DE
5.
dØcharge Ølectrique peut vous tuerou vous brQler
gravernent. LØloctrode
3.
dangereux.
est
comme
Les
respectez toutes
1.
A LARC
LARC
SAPPROCHER,
precautions.
2.
A
EN SOUDAGE
cuir,
approuvØes.
Des
protection indivlduelle apropriØs.
srl.1.2 5191
Lea BOUTEILLES
endommagees peuvent
exploser.
Les bouteilles contiennent des gaz protecteurs sous
haute pression.
Des bouteilles endommagØes
peuvent exploser. Comme les bouteilles font
normalement partie du procØdØ de soudage,
traitez-les avec soin.
1.
2.
Les bouteilles doivent Œtre protegees contre les sources de
chaleur intense, les chocs et les arcs de soudage.
3.
Eloignoz
4.
EmpŒchez
5.
Nutilisez que des bouteilles do gaz protecteur, des dØtondeurs,
des flexibles et des raccords conus pour chaquo application
spØcifique; ces matØriels et les piŁces connexes doivent Œtro en
bon Øtat.
6.
Ne mettez pas le
Iouvrant.
-
I
produisent
des
Le CARBURANT peut
une
gaz
incendie
ou
ArrŒtez le moteur avant do verifier le niveau do carburant
faire le plein.
2.
No faites pas le plein en fumant
d~~~~
dune flamme nue.
e
proche dune
ou
ou
de
soudage.
devant le robinet de bouteiUe
visage
chapeau
do bouteille
en
aprŁs utilisation.
dangereux.
dans dos aires ouvertes et
1.
Utilisez des machines a IextØrieur
bien ventilØes.
2.
Si vous utilisez des machines dans un endroit confine, les
fumØes dØchappement doivent Œtre envoyØes a iextØrieur, loin
des prises dair du btiment.
3.
Si cest possible, laissez lo moteur refroidir avant do faire le plein
de carburant
1.
do
electrode.
Remettez le
explosion,
Le carburant est hautement inflammable.
ou
une
Lisez et respectez los consignes relatives aux bouteilles do gaz
comprime et aux matØriels connexes, ainsi que Ia publication P-i
do Ia CGA, ØnumØrØes dans les normes ci-dessous.
dechappement
causer un
electrique
bouteille et
Les MOTEURS peuvent Œtre
Les GAZ DECHAPPEMENT D ES MOTEURS
PEU VENT ETRE MORTELS.
Les moteurs
nocifs.
une
8.
MISE EN GARDE
---4
tout contact entre
7.
EnchaInez verticalement les bouteillss a un support ou a un
cadre fixe pour les empŒcher do tomber ou dŒtre renversØes.
a
les bouteilles de tout circuit
ou
den
verifier le niveau
au
debut du
soudago.
4.
No faites pas le plein de carburant a
les pace p our son expansion.
5.
Faites attention de ne pas renverser do carburant. Nettoyez tout
carburant renversØ avant de faire dØmarrer le moteur.
3.
Seules
ras
bord:
prevoyez
de
source
~
PIECES
Des
causer
EN
MOUVEMENT
peuvent
des
personnes
qualifiees doivont dØmontor des
ou le depannage
protecteurs ou des capots pour faire lentretion
des blessures.
nØcessaire.
Des
piŁces en mouvement, telles des ventilateurs, des
pouvent couper los doigts et les
mains, ou accrocher des vØtemonts amples.
4.
Assurez-vous quo los portes, los panneaux, les
protecteurs sont bien fermØs.
capots
et los
Avant dinstaller
ou
de connecter
un
systŁme,
amples
arrŒtez-en le
moteur.
Des
ETINCELLES
oeuvent FAIRE EXPLOSER
DUN
ACCUMULATEUR peut brOler Ia peau et Ies
yeux.
Les accumulateurs contiennent do
des vapeurs explosives.
iØloctrolyte
ou
los cheveux de
piŁces
en
et des outils.
RØinstallez les capots ou les protecteurs et fermez les portes
aprŁs dos travaux dentrotien et avant do faire dØmarror le
Portez toujours
accumulateur.
un
Øcran
facial
en
travaillant
sur
do dØconnecter des
2.
ArrOtez le moteur avant de connecter
cAbles daccumulateur.
~
Nutilisez que des outils anti-Otincelles pour travailler
accumulateur.
~
Nutilisez
pas un poste
accumulateur ou connecter
5.
Utilisez Ia
ou
sur un
et
dØgagent
de soudage pour charger
provisoirement un vØhicule.
polarite
correcte
(+
et
-)
de laccumulateur.
1.
Ntez
pas le bouchon do radiateur tant que le moteur na
refroidi.
2.
Mettez des
pout Otre
3.
Laissez Ia
bouchon.
radiateur
un
un
LE
DE
VAPEUR
LIQUIDE
La
ET
REFROIDISSEMENT BRULANT SOUS PRESSION
peuvent brOler Ia peau et les yeux.
Le liquide do refroidissement dun
brUlant et sous pression.
PRINCIPALES NORMES DE
Safelyin WeldingandCutting, norme ANSI Z49.1 ,from American Weld
ing Society, 550 NW. LeJeune Rd, Miami FL 33128.
Safetyand Health Standards, OSHA29 CFR 1910, from Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme American Welding Socioty AWS F4.i,from American Welding Society, 550
N.W. LeJeune Rd. Miami, FL 33128.
National Elect rical Code, norme NFPA 70, from National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
Sri .1.2 9/91
pas les mains
motour.
UNACCUMULATEIJR; LELECTROLYTE
1.
Napprochez
mouvement; elles peuvent aussi accrocher des vŒtements
6.
2.
accidentel dun systŁme pendant
dØbranchez le cAble daccumulateur a Ia borne
empŒcher un demarrago
negative.
5.
1.
Pour
lentretien,
rotors et des courroies
pas
gants et posez un torchon sur le bouchon pour lter.
pression sechapper avant dter compiŁtement 10
SECURITE
Handling of Compressed Gases in Cylinders, CGA Pamphlet P-i,
Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Safe
from
Code for Safety in Welding and Cutting, norme CSA Wi 17.2, Associa
tion canadienne do normalisation, Standards Sales, 176 Rexdale Boule
yard, Rexdale, Ontario, Canada M9W 1 R3.
Safe Practices For Occupation And Educational Eye And Face Protec
tion, norme ANSI Z87.i, from American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cuffing And Welding Processes, norme NFPA 51 B, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
EMF INFORMATION
Considerations About
Magnetic Fields
NOTE ~
Welding And
The Effects Of Low
And
Frequency Electric
____________________
The
To reduce
of the U.S.
procedures:
following is a quotation from the General Conclusions Section
Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields
Backgmund Paper, OTA-BP-E-53 (Washington, DC: U.S.
Government Printing Office, May 1989):..
there is now a very
large volume of scientific findings based on experiments at the
cellular level and from studies with animals and people which clearly
establish that low frec~uency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific
understanding does riot yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible
risk or to offer clear science-based advice on strategies to minimize
or avoid potential risks.
magnetic fields
in the
workplace,
Keep cables close together by twisting
1.
Arrange
3.
Do not coil
4.
Keep welding power
practical.
5.
Connect work clamp to
one
or
the
following
taping them.
side and away from the
2.
cables to
use
operator.
.
or
drape cables
around the
source
body.
and cables
workpiece
as
as
far away
as
close to the weld
as
possible.
About Pacemakers:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your doctor for
complete information.
modloi 4193
TABLE OF CONTENTS
SECTION 1
SAFETY INFORMATION
1
SECTION 2
SPECIFICATIONS
1
SECTION 3- INSTALLATION
2
3-1.
Site Selection
3-2.
Connection
3-3.
Wire Guide And Drive Roll Installation
3-4.
Welding
3-5.
Moltor Start Control
3-6.
Control Connections
6
3-7.
Shielding Gas And Weld Cable Connections
Welding Wire Installation
Threading Welding Wire With Drive Assembly Horizontal
Threading Welding Wire And Rotating The Drive Assembly
7
3-8.
3-9.
3-10.
2
Diagram
3
4
Gun Connections
5
5
9
11
13
SECTION 4
GLOSSARY
15
SECTION 5
OPERATION
17
5-1.
Front Panel Controls
18
5-2.
Side Panel Controls
20
5-3.
Rear Panel Controls
5-4.
Setting
SECTION 6
Switches On 450
21
Ampere
Inverter Model
Welding
Power Source
STEPPING THROUGH THE MICROPROCESSOR CONTROLS
6-1.
Front Panel
6-2.
Side Panel
Controls
22
23
Microprocessor
Microprocessor Push Buttons
23
SECTION 7
STANDARD PULSE WELDING PROGRAMS
28
SECTION 8
GETTING STARTED
36
8-1.
8-2.
WeJlding With Only Front Panel Controls
Setting Sequence Pulse Welding Parameters
25
37
On Side Panel
SECTION 9- TEACHING A PULSE WELDING PROGRAM
9-1.
9-2.
9-3.
9-4.
Pulse Waveform
Explained
Explained
Teaching A Pulse Welding Program
Changing To Adaptive Pulse Welding
Teach Points
Display
38
42
42
43
44
47
OM-1587A-5194
SECTION 10TEACHING
10-1.
10-2.
A MIG WELDING PROGRAM
Changing to MIG Welding
Setting Sequence MIG Welding
48
48
Parameters On Side Panel
Display
49
SECTION 11
SETtiNG DUAL SCHEDULE PARAMETERS
52
SECTION 12
USING THE OPTIONAL DATA CARD
54
12-1.
12-2.
Installing Data Card
Using The Data Card
SECTION 13
13-1.
13-2.
13-3.
13-4.
13-5.
13-6.
13-7.
13-8.
13-9.
13-10.
13-11.
13-12.
13-13.
13-14.
13-15.
13-16.
13-17.
13-18.
13-19.
SETUP
Setup
Using Setup Displays
Selecting Process Capability
Selecting Welding Power Source Range
Selecting Security Lock
Selecting Or Changing Access Code
Selecting Voltage Correction
Selecting Voltage Sensing Method
Selecting Regular Or Hot Arc Start
Selecting Type Of Dual Schedule Switch
Selecting Trigger Program Select
Selecting Remote Increase/Decrease Capability
Resetting Arc Time
Using Self Test
Selecting Units For Wire Feed Speed And Motor Type
Selecting Bench Or Boom Model Type
Resetting Memory
Selecting Voltage Error Shutdown
Selecting Program Name Feature
13-20. Software Version Number
14-1.
54
58
Flow Chart
SECTION 14
54
MAINTENANCE & TROUBLESHOOTING
Routine Maintenance
The Hub
14-2.
Replacing
14-3.
Overload Protection
Assembly
58
59
59
60
61
62
63
63
64
64
65
66
66
67
68
68
69
69
70
70
71
71
72
72
14-4.
Error Screens
73
14-5.
Troubleshooting
74
SECTION 15- ELECTRICAL DIAGRAMS
SECTION 16
Figure
Figure
Figure
Figure
Figure
PARTS LIST
16-1. Main
80
Assembly
16-2. Control Box
16-3. Panel, Front
76
80
82
w/Components
Assembly, Wire
Panel, Side w/Components
85
16-4. Drive
86
16-5.
88
Table 16-1. Drive Roll And Wire Guide Kits
89
SECTION 1
-
SAFETY INFORMATION
modl.1 2/93
Read all
safety messages throughout this
Obey
safety messages
all
Learn the
meaning
to avoid
manual.
injury.
of WARNING and CAUTION.
2
1
Safety
Alert
2
Signal
Word
2
Symbol
WARNING means possible death
or serious injury can happen.
CAUTION
3
__
CAUTION
_____
_________
~
ELECTRIC SHOCK
can
~
kill
MOVING PARTS
nstsLlling
or
Input
power
servicing.
Injure
injury
beforeJj
~
Keep
all panels and covers closed
when
operating.
/
a
READ SAFETY BLOCKS at start of
SectIon 3-1 before proceedIng.
WA :I~II~~
Statement Of Hazard And
Result
4
Safety
NOTE
Er
Turn Off switch when
Instructions To Avoid
Hazard
5
Hazard
6
Safety
using high frequency.
NOTE
Special Instructions
ation
Figure
1-1.
SECTION 2
Symbol (If Available)
Banner
Read safety blocks for each sym
bol shown.
7
7H
means possible minor
equipment damage can
3
5
6
or
happen.
Keep away troth moving pans.
Do riot touch live etectflc~ pam.
Disconnect
can
for best oper
not related to
safety.
Safety Information
SPECIFICATIONS
Table 2-1. Wire Feeder
DescrIptIon
SpecIfication
Type Of Input
Power
From
Maximum Weld CircuiI~ Rating
Welding
Power Source
Wire Feed
Type
Speed Range
Wire Diameter
Range
Welding
Power Source:
Single-Phase
100 Volts, 750 Amperes, 100% Duty
24 Volts
AC, 10 Amperes, 50/60 Hertz
Cycle
Constant Voltage (CV) DC, With Contactor For GMAW Welding
Constant Current (CC) DC, With Contactor For GMAW-P Welding
Standard: 50 To 780 1pm (1.3 To 19.8 mpm)
High Speed: 92 To 1435 ipm (2.3 To 36.5 mpm)
Low Speed: 13 To 213 ipm (0.34 To 5.38 mpm)
.023 To 1/8 in
(0.6 To
3.2
mm)
(GMAW), Gas Metal
Gas Metal Arc
Input Power Cord
lOft
Overall Dimensions
Length: 32 in (812 mm); Width: 18 in (457 mm); Height:
Weight
Net: 74 lb
These
are
the wire feed
Arc
-
Pulse
(GMAW-P)
Welding Processes
And Flux Cored Arc
Welding (FCAW)
(3.1 m)
(33.6 kg); Ship:
speed ranges while GMAW welding.
82 lb
While Pulse
14 in
(356 mm)
(37.2 kg)
welding, the wire feed speed ranges may be more limited (see Section 9).
OM-1587 Page 1
SECTION 3- INSTALLATION
3-1.
Site Selection
a
WARNING
WARNING: FALLING WIRE FEEDER can
serious personal Injury and
cause
CYLINDERS
explode
away from
Keep cylinders
if
damaged.
welding and
other
electrical circuits.
equipment damage.
Never touch
Do not put wire feeder where it will
tip
Put all four rubber feet
flat surface.
solidly
can
on a
or
fall.
cylinder with welding electrode.
Always secure cylinder to running gear, wall,
other stationary support
ELECTRIC SHOCK
or
kill.
can
Do not touch live electrical
parts.
The welding wire, drive rolls, drive assembly, and all
metal parts touching the welding wire are electrically
live when
welding
or
1
Do not put feeder where
hits cylinder.
wire
using gun trigger.
Wire Feeder
2
Rubber Feet
3
Base Slot
If
welding wire
feeding
installing wire feeder over a lifting
eye on a welding power source, se
lect the slot that allows all four rub
ber feet on base of feeder to sit se
curely on top of welding power
source.
4
Wire
5
Gas
6
Welding Power Source
Spool/Reel
Cylinder (Customer
Supplied)
Position wire feeder
power
ing wire,
or
Figure
Page
2
3-1.
Installing
Wire Feeder
welding
that weld
wire spool/reel, does
not touch gas
OM-1587
on
source or cart so
cylinder.
3-2.
Connection
Diagram
N OTE ~j~
____________________
if
using
wire feeder with
switch in Run (high
Run/Idle position.
an engine-driven power source, place engine control
speed) position. Some wire feeders may work with switch in.
1
Welding Power Source
2
17-Pin Plug And
necting Cord
3
14-Pin
Plug
Intercon
And Intercon
necting Cord
4
Positive
(+) Weld Cable
5
Negative ()
6
Workpiece
7
Voltage Sensing
8
Gun
9
Wire Feeder
10
Gas Hose With Y~ Adapter
11
Gas
Weld Cable
Lead
Cylinder
2.
3
4
8
ST-162 129
Figure
3-2. Connection
Diagram
OM-1587
Page
3
3-3.
Wire Guide And Drive Roll Installation
a
WARNING
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Turn Off wire feeder and
welding power source, and disconnect input power before inspecting
or
installing.
wtwaml.1 2/93
A.
Wire Guide Installation
When
check
1
changing wire size or type,
guide size (see Table 16-1).
Drive Rolls
Remove drive rolls before installing
wire guides (see Figure 3-4).
2
Wire Guide
Loosen wire
3
Securing
guide
Screws
screws.
Antiwear Guide
Install antiwear guide onto inlet
guide, and secure with set
screw. Use existing antiwear guide
when changing inlet wire guide
size.
wire
4
Inlet Wire Guide
Install inlet guide so wire guide
screw is centered in groove in
guide.
5
Intermediate Wire Guide
intermediate guide until
flange on guide rests against cast
ing, and secure with guide screw.
Insert
Tools Needed:
Install drive rolls
(see Figure 3-4).
Repeat procedure for opposite
side of wire feeder.
5/64 in
1
Figure
B.
ST.153 1258 / ST-137 377.0
3-3. Wire Guide Installation
Drive Roll Installation
When
changing
drive
check
Table 16-1).
wire size or
roll
size
type,
(see
Shaft Carrier
1
Spring
2
Drive Roll Nut
3
Drive Roll Carrier
Turn nut one click until lobes of nut
line up with lobes of drive roll
carrier.
4
Drive Roll
Slide drive roll onto drive
carrier. Turn nut one click.
roll
Repeat procedure for all drive rolls.
5
Drive
Close
Assembly Cover
cover.
Repeat procedure
for
opposite
side of wire feeder.
4
ST-137 377-0
Figure
OM-1 587
Page
4
3-4. Drive Roll Installation
3-4.
Welding Gun Connections
WARNING
ELECTRIC SHOCK
can
Do not touch live electrical
Turn Off wire feeder and
kill.
parts.
welding
power source, and disconnect
input power before inspecting
installing.
or
wlwaml.1 2/93
Securing
1
Gun
2
Gun Block
3
Gun End
Knob
Loosen gun securing knob. Insert
end Into block. Position as close as
possible to drive rolls without
touching. Tighten knob.
4
Gun
Trigger Plug
5
Gun
Trigger Receptacle
plug
Insert
into
tighten threaded
6
Drive
Close
receptacle, and
collar.
Assembly Cover
cover.
Repeat procedure on opposite side
of wire feeder.
ST-162 183 / Ref. ST-187 703
Figure
3-5.
3-5. Gun And
Trigger
Lead Connections
Motor Start Control
WARNING
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Turn Off wire feeder and welding power source, and
disconnect input power before inspecting or
STATIC ELECTRICITY can
circuit boards.
damage parts
on
Put on
boards
grounded
or
wrist strap BEFORE
handling
parts.
installing.
wtwaml.r2/93
To change wire feed
proceed as follows:
starting speed
Turn Off wire feeder and
power
welding
source.
Remove wrapper.
1
Motor Board PCi
2
Motor Start Control Poten
tiometer R70
Turn
potentiometer clockwise to In
time it takes the motor to
ramp up to speed. Remove protec
tive white rubber cap before mak
crease
Tools Needed:
ing adjustment. Adjust potentiome
using a small nonconduc
ter R70
tive screwdriver.
1/4 in
3
_____
Reinstall wrapper.
Non-conductive
ST-162 132/ Ref. 5B148 882-D
Figure
3-6. Motor Start Control On Motor Control Board PCi
OM-1 587
Page
5
3-6.
Control Connections
1
1 7-Socket Receptacle
Table 3-1)
2
Keyway
(See
interconnecting cord to
receptacle, align keyway, insert
plug, and tighten threaded collar.
To connect
Weld Current Sensor Recep
tacle (For Use With Field Op
3
tion
Only)
35 ft (10.6
ing Lead
4
Connect to
m) Voltage Sens
workpiece
to read
arc
at the arc when
welding
power source has a 17-pin
tion (see Figure 3-2).
connec
voltage
5
Threaded Collar
6
14-Pin
Plug (See Table 3-2)
To connect plug to matching recep
tacle on welding power source,
align keyway, insert plug, and tight
en
threaded collar.
S-162 132 / Ref. S-o512 / S-0003-A / S-0628
Figure
3-7. Control Connections With Pin Information
Table 3-1. Remote 17 Socket Information
REMOTE 17
E/~
*The
remaining sockets
are
Socket*
Socket Information
C
CCICV select; +13 to +24 volts dc is CV, 0 volts dc is CC.
G
Arc control/inductance
E
Actual weld current output signal; +1 volt dc is 100 amps.
M
Actual weld
F
Current feedback from
H
feedback from
Voltage
control; 0
to +10 volts dc.
voltage output signal;
+1 volt dc is 10 volts dc.
welding power
welding
source; 0 to +10 volts dc, 1 volt per 100 amperes.
power source; 0 to +10 volts
dc,
1 volt per 10 arc volts.
not used.
Table 3-2. Remote 14 Pin information
REMOTE 14
OUTPUT
Pin Information
Pin*
A
24 volts
B
Contact closure to A completes 24 volts
G
Circuit
C
+10 volts dc
ac.
ac
contactor control circuit.
(CONTACTOR)
A Al
MIV
*The
AMPERAGE
VOLTAGE
remaining pins
OM-1 587
Page
6
are
not used.
common
for 24 volts
input
ac
circuits.
to remote control.
D
Remote control circuit
E
0 to +10 volts dc
common.
output command signal from feeder voltage control.
3-7.
Shielding
Gas And Weld Cable Connections
WARNING
CYLINDERS
can
explode
away from
Keep cylinders
if
~
damaged.
welding
E LECTRIC SHOCK
and other
electrical circuits.
Never touch
cylinder with welding
Turn Off wire feeder and welding power source, and
disconnect Input power before inspecting or
electrode.
Always secure cylinder to running gear, wall,
other stationary support.
installing.
or
BUILDUP OF SHIELDING GAS
health or kill.
H
A.
Shielding
Gas Connections To
kill.
can
Do not touch live electrical parts.
Shut off
shielding gas supply
can
when not in
wam4.19/91
harm
use.
/wtwaml.1 2/93
Regulator/Flowmeter
Obtain gas cylinder and chain to
running gear, wall, or other station
ary support so cylinder cannot fall
and break off valve.
1
Cap
2
Cylinder
Valve
Remove cap, stand to side of
valve, and open valve slightly. Gas
flow blows dust and dirt from valve.
Close valve.
1
3
Cylinder
4
Regulator/Flowmeter
Install
so
face is vertical.
.2
5
Gas Hose Connection
Fitting has 5/8-18 right-hand
threads. Obtain gas hose and In
stall between cylinder and ~Y
F-
adapter (see Figure 3-9).
3
6
Flow
Adjust
Check wire manufacturers
mended flow rate.
Make
when
recom
flow adjust is closed
opening cylinder to avoid
damage to the flowmeter.
OR
Argon Gas
2
4
sure
7
CO2 Adapter
8
0-Ring
adapter with 0-ring between
regulator/flowmeter and
CO2
cylinder.
Install
L
3
7
8
CO2 Gas
Tools Needed:
~ 1-1/8,5/8 in
ssb3.V 5/94 -ST-158 697-A
Figure
3-8.
TypIcal Regulator/Flowmeter
Installation
OM-1587
Page
7
B.
Shielding
Gas And Weld Cable Connections At Feeder
1
V
2
Shielding
Adapter Hose (Supplied)
When
Gas
Fitting
of shield
using
ing gas, route and connect~Y
adapter and gas hose as shown.
one source
If two
sources of shielding gas are
being used, obtain two gas hoses
with 5/8.18 right-hand threaded fit
tings. Route a hose from each
shielding gas source under spool
support arm, and connect to appro
priate shielding
gas
fitting.
3
Weld Cable Terminal
4
Jumper Weld Cable
Install
one end of jumper weld
cable to each weld cable terminal.
5
Weld Cable
(Customer
Supplied)
Select and prepare weld cables ac
to welding power source
Owners Manual.
cording
When
under
possible, route weld cable
spool support arm, and con
nect to either weld cable terminal.
If there is not enough
spool support
and/or hoses
support
arm,
room
under
route cables
along side
of
spool
arm.
1
5
Connect To
Regulator/
Flowmeter
Connect To Positive (+)
Weld Output Terminal On
Welding Power Source For
Direct Current Electrode
Positive (DCEP), Or Con
nect To Negative () Weld
Output Terminal On Weld
ing Power Source For Di
rect Current Electrode Neg
ative (DCEN)
Tools Needed:
~ 9/16,5/8 in
Ref. 5T-152 567-A
Figure
OM-1 587
Page
8
3-9.
Shielding Gas And
Weld Cable Connections
3-8.
A.
Welding
Wire Installation
Positioning Spool Support
Arm
Wire feeder is shipped from factory
with spool support arm installed to
handle a wire spool/reel up to 12
inches in diameter. If a larger spoov
reel is to be used, reposition spool
support arm as instructed.
1
Base
2
SpoolSupport
3
Self-Tapping Securing
Arm
Screws
Install spool support arm in the po
sition that allows the spool/reel to
turn without touching the wire feed
er or gas cylinder, while allowing
the
welding wire to
run
the
est line from the wire
through
straight
spool/reel,
the drive rolls,
Tools Needed:
~
3/8in
ST-152 565
Figure
B.
Installation Of
Spool-Type
3-10.
Positioning
The
Spool Support
Arm
Wire
1
7
Hex Nut
Remove hex nut.
8
2
HubSupportShaft
3
Holes For Positioning Hub
Support Shaft
Install shaft into hole that allows
to run the straightest
line from wire spool, through the
drive rolls. Reinstall hex nut.
6
welding wire
2
4
Spacer
5
Hub Pin
6
Hub
7
Spool
8
Retaining Ring
Remove retaining ring, and slide
wire spool onto hub (wire may feed
from top or bottom of spool, see
Figure 3-14 and Figure 3-16). Turn
spool until hub pin fits hole in spool.
Reinstall
9
retaining ring.
Hub Bracket
Repeat procedure using hub
bracket to install spool-type wire
onto right side of wire feeder.
Tools Needed:
15/Thin
ST-152 564-A
Figure
3-11. Installation Of
Spool-Type Wire
OM-1 587
Page
9
C.
Installation Of
Optional
Wire Reel And Reel
Type
Wire
1
Hub
2
Hex Nut
.9
12
SupportShaft
Remove hex nut.
3
7
Holes For Positioning Hub
Support Shaft
Install shaft into hole that allows
wire to run the straightest
line from wire spool, through the
drive rolls without touching the wire
feeder or gas cylinder. Reinstall
hex nut.
welding
4
6
5
Spacer
5
Hub Pin
6
Hub
7
Wire Reel
8
Wire
~
Wire Retainer
10
Spanner
11
Lock
12
Retaining Ring
Nut
Remove retaining ring. Pull lock
and turn. Remove spanner nut,
wire retainer, and wire reel from
hub.
Lay wire reel assembly
face, and install wire
flat sur
shown
(wire may be installed to feed from
top or bottom of reel).
on
as
Tighten spanner nut until lock is in
position over hole in wire retainer.
Pull lock and turn to insert locking
pin into wire retainer.
Slide wire reel assembly onto hub,
and turn assembly until hub pin is
seated in hole in reel. Reinstall re
/
taining ring.
13
Hub Bracket
procedure using hub
bracket to install reel-type wire
onto right side of wire feeder.
Repeat
Wire Installation
Tools Needed:
15/l6in
ST-i 52 563-B 1ST-i 52 463/ Ret. ST-i 57 999-A
Figure
D.
3-12. Installation Of
Optional
Wire Reel And Reel
Type
Wire
Adjusting Hub Tension
Turn Off wire feeder and
power
welding
source.
1
Hex Nut
2
Spool
Grasp spool in one hand and turn
while using a wrench to adjust hex
nut. When a slight force is needed
to turn spool, tension is set.
Repeat procedure to adjust hub
on right side of wire feeder.
tension
Tools Needed:
r
15/l6in
ST-i52 562-A
Figure
OM-1 587
Page
10
3-13.
Adjusting
Hub Tension
3-9.
Threading Welding
Wire With Drive
Assembly
Horizontal
WARNING
CYLIINDERS
can
Keep cylinders
explode
away from
if
damaged.
welding
and
other
electrical circuits.
Never touch
WELDING WIRE
wounds.
Do not press gun
cylinder with welding electrode.
Always secure cylinder to running gear, wall,
other stationary support.
ELECTRIC SHOCK
9
can
or
can
cause
puncture
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.
kill.
Do not touch live electrical parts.
The welding wire, drive rolls, drive assembly, and all
metal parts touching the welding wire are electrically
live when welding or feeding wire using gun trigger.
HOT SURFACES
can
Allow gun to cool before
burn skin.
touching.
wlwam2.1 /wfwaml.1
9/91
OM-1587 Page 11
Spool/Reel
1
Wire
2
Wire Guide
3
Pressure
4
Drive Rolls
5
Spring
Close
Adjustment Knob
Shaft Carrier
spring
shaft carrier.
6
Drive Roll Pressure Indicator
Scale
7
Jog
8
Gun Conduit Cable
Button
Lay
gun conduit cable out
9
Drive
straight.
Assembly Cover
Repeat procedure for opposite side
of wire feeder. If desired, either side
drive assembly may be rotated (see
Figure 3-15).
I~I
Hold wire
from
tightly to keep it
unraveling.
See Figure 5-13 for
switch positions of 450
a
ampere inverter model
welding power source
see welding power
-*
or
Owners Manual
for other models.
source
OFF
Wire Feeder
(see Figure 5-10)
Welding
Power Source
Set switches.
Pull and hold wire; cutoff end.
JOG
~
o1o
-,5~
Push wire thru guides up to drive rolls;
continue to hold welding wire.
-~
Press Select button (see Figure 5-6)
to choose active side of wire feeder.
Press Jog button (see Figure 5-8)
until drive rolls grab wire.
-*
-*
Press Jog button until wire
comes out gun.
Adjust tension until wire does not
slip. Indicator is for reference only.
Cut off wire.
Feed wire to check drive roll
pressure. Adjust knob enough
to
Close
cover.
prevent slipping.
Ref. ST.153 091 / Ref. ST-iSO 922 / Ret. ST-161 713 / S-0627.A
Figure
OM-1587
Page
12
3-14.
Threading Welding
Wire With Drive
Assembly
Horizontal
3-10.
Threading Welding
Wire And
Rotating
The Drive
Assembly
WARNING
CYLINDERS
can
Keep cylinders
explode
away
from
if
WELDING WIRE
wounds.
damaged.
welding
and other
electrical circuits.
Never touch
Do not press gun
cylinder with welding electrode.
Always secure cylinder to running gear, wall,
other stationary support.
ELECTRIC SHOCK
can
cause
can
puncture
until instructed to do
trigger
so.
Do not
point gun toward any part of the body, other
people, or any metal when threading welding wire.
or
kill.
HOT SURFACES
Do not touch live electrical parts.
The welding wire, drive rolls, drive assembly, and all
metal parts touching the welding wire are electrically
live when welding or feeding wire using gun trigger.
burn skin.
can
Allow gun to cool before
touching.
wtwam2.1 I wtwam7.V 9/91
A.
Rotating
Drive
Assembly
Feeder is
in
sembly
shipped
a
rotate drive
follows:
with drive as
horizontal position. To
assembly, proceed
as
Remove screws (6) from front edge
of wrapper, and loosen screws on
back edge of wrapper.
1
Front Panel
Remove screw from upper left cor
ner of nameplate, and open hinged
front panel.
2
Drive Assembly Rotation
justment Openings
3
Drive Assembly
4
Wire
Ad
SpooL/Reel
Insert 3/16 in allen wrench into
opening, and loosen alien bolt.
Turn drive assembly to a position
that allows welding wire to run the
straightest line from spooL/reel,
through the drive rolls (wire may
feed from top or bottom of spooV
reel, see Section 3-8.). lighten
bolt.
4
Close and secure front panel, and
go to Figure 3-16.
3
Tools Needed:
j
3/16 in
Ref. ST-153 093/ ST800 289
Figure
3-15.
Rotating
The Drive
Assembly
OM-1587
Page
13
B.
Threading Welding
Wire With Drive
Assembly
Rotated
1
Wire
2
Wire Guide
3
Pressure Adjustment Knob
4
Spring
Spool/Reel
Shaft Gamer
Close spring shaft carrier.
5
Drive Roll Pressure Indicator
Scale
6
Jog
7
Gun Conduit Cable
8
Drive Rolls
9
Drive
Assembly
10
Drive
Assembly Cover
Button
If
position of drive assembly needs
adjusting, go back to
Figure 3-15.
further
_______
fIII~
_______
Hold
wire
tightly
to
Tools Needed:
See Figure 5.13 for
switch positions of 450
ampere inverter model
ON
9
~
welding power source
see welding power
or
....~
Owners Manual
for other models.
source
OFF
Wire Feeder
(see Figure 5-10)
Welding
Power Source
Set switches.
Pull and hold wire; cut offend.
JOG
4~
Push wire thru guides up to drive rolls;
continue to hold welding wire.
do
Press Select button (see Figure 5-6)
to choose active side of wire feeder.
Press Jog button (see Figure 5-8)
until drive rolls grab wire.
Adjust tension until wire does not
slip, Indicator is for reference only.
-,
Press
Jog
button until wire
comes out
Cut off wire.
Close cover.
Feed wire to check drive roll
pressure. Adjust knob enough
gun.
to
prevent slipping.
Ref. sT-i 53 093 / Ref. ST-ISO 922 / Ref. ST.161 713/ s-0627-A
Figure
OM-1587
Page
14
3-16.
Threading Welding
Wire With Drive
Assembly
Rotated
SECTION 4- GLOSSARY
The
following
is
a
list of terms and their definitions
as
they apply
to this wire feeder:
General Term~
Adaptive
Pulse
When the
adaptive pulse welding process is selected, the unit will automatically
regulate pulse frequency in order to maintain a constant arc length, regardless of
change in welding wire stickout.
Current
Background
The lower of the two current levels in the
Inductance
In short circuit
welding,
an
pulsing
waveform.
increase in inductance will decrease the number of short
circuit metal transfers per second (provided no other changes are made) and in
crease the arc-on time. The increased arc-on time makes the pool more fluid.
Peak Current
The
Pulses Per Second
Number of
(PPS
Or Pulse
Pulse Width
higher
of the two current levels in the
peak
current
pulses which
pulsing waveform.
occur
in
one
second of time.
Frequency)
(Or
Peak
Time)
Trim
Duration of the
peak
current level.
Term used to represent arc length adjustments in pulse programs. Increasing trim
increases the actual arc length. Likewise, decreasing trim shortens arc length. Trim
is replaced by volts in MIG programs.
Synergic
Synergic refers to the units ability to use preprogrammed pulse parameters in order
pulse settings of Peak Amperage, Background Amperage,
Pulse Frequency and Pulse Width at any specific wire feed speed setting.
to determine the actual
Front Panel Terms
Display
Control Knob
Is used for all
adjustable front panel displays.
Digital Display
2-line
Gas
Allows the gas line and gun to be
Purge
Control
Parameter Select Button
Trigger
Wire
Hold Control
Jog Control
by 16-character liquid crystal display
Is used to select
a
variety
purged
without
of parameters that
When selected, allows the system to remain
hold the gun trigger.
Allows the wire to feed without
gas valve. The wire jog
played
on
the front
with built-in LED
speed
panel.
is
can
energizing
be set
on
backlight.
the wire feeder.
the front
panel display.
energized without the operator having to
energizing the welding power source contactor and
independent from actual wire feed speed, and is dis
Side Panel Terj~
Digital Display
4-line
Dual Schedule
Allows two weld programs to be linked together when two different
tions, such as hotter and colder, are required on one wire.
Process Mode
by
20-character
liquid crystal display
with built-in LED
Is used to select the type of process to be used,
backlight.
welding
condi
including Pulse, Adaptive Pulse,
or
Mig.
OM-1 587
Page
15
Remote Parameter
When this
Increase/Decrease
decrease
Sequence
Mode
feature
is
turned
on,
the
operator
selected weld parameter with the
momentary-contact switch.
a
use
can
of the
remotely increase and
optional DSS-1 0 2-pole
a variety of sequences to be used within a weld program if required.~ Se
quences include, preflow gas control from 0 to 9.9 seconds, run-in control of voltage
or trim and wire feed speed from 0 to 2.5 seconds, weld time from 0 to 25 seconds,
Allows
crater control of
voltage or trim and wire feed speed from 0 to 2.5 seconds, burnback
postf low gas control from 0 to 9.9 seconds.
time from 0 to 0.25 seconds, and
Setup
Screen Terms
Access Mode
A three-letter code
can be programmed in the access mode which restricts unautho
personnel from changing any of the security/set-up screens. NOTE: The
optional Data Card is required to activate this feature.
rized
Arc Start
Provides the
option
Arc Time
Allows actual
time up to 9,999.99 hours and weld cycles up to 999,999 to be accu
displayed on the digital display, and can be reset to zero as required.
mulated and
Dual Schedule
of
a
higher arc starting
amperage for
large
wires.
arc
Is used to select the type of dual schedule switch that will be used when the dual
schedule feature is selected.
Mig Type
Selects whether
Model
Allows selection of
voltage
correction is used
feeder
boom-type
or
or not.
bench mount feeder
pulse program
parameters.
Name Feature
Program
Reset
When using the optional Data Card and turning the name feature on, customized pro
grams written to the card can be identified by name, number, job number, etc.
By selecting program reset in the memory reset mode,
factory program settings for the program last active.
the unit defaults to
original
The wire feeder
requires that the voltage and amperage range of the welding power
be entered. Obtain this information from the welding power source Owners
Manual.
Range
source
Remote Parameter
When the Remote Parameter Inc/Dec is on, a dual schedule switch can also be used
increasing or decreasing weld parameters when the front panel display cursor is
at Trim, Volts, or 1PM.
for
Is used to limit what the operator can control. This includes
Security
accessing the
number of
the program, 1 through 8, and also the range of welding parameters within the pro
gram selected. NOTE: The optional Data Card is required to activate this feature.
Software Screen
Selection of this function will
System
This unit
can
display
be used either with
pulse GMAW (Pulse/Mig)
Only) welding only.
and
System
OM-1587
Reset
Page
16
a
or
the software version of the unit.
welding power source capable of regular GMAW
a welding power source capable of GMAW (Mig
By selecting system reset in the memory reset mode, the unit defaults to original fac
tory settings for all programs and all set up excluding System, Arc Time, and Model
Type.
Trigger Program
Allows programs to be selected
Select
Self Test Mode
Voltage
Control Feedback
remotely
with the gun
trigger.
A built-in
diagnostic feature to check a variety of wire feeder and
tions if
a
malfunction
Allows
voltage to
power source func
occurs.
be monitored at the output terminals by two methods. This can be.
17-pin cord connection if the welding power source has a 17-pin
through the use of the units optional external voltage sense lead.
selected through the
receptacle,
Voltage
Sense Shutdown
or
When this feature is on, the system immediately shuts down if no arc is initiated upon
gun trigger actuation. When this feature is off, the system (wire feeder), when actu
ated by the gun trigger, feeds wire for approximately three seconds at set welding
speed
and then
automatically switches to cold wire jog speed for approximately one
normally selected to allow threading wire with the gun
minute. The off feature is
trigger.
Wire Feed Mode
Allows the selection of inches per minute or meters per minute for wire feed speed.
This mode is also used to select motor type; standard speed, low speed, or high
speed. High and low speed motors are available as factory options.
SECTION 5-OPERATION
WARNING
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Always
wear
Insulate
Keep
all
panels and
work and
covers
FUMES AND GASES
to your health.
Keep
I
:9,.~
dry insulating gloves.
yourself from
in
or use
can cause
Do not weld
Watch for
near
fire
0
Do not weld
or
Keep all doors, panels,
and securely in place.
on
Allow work and
as
covers, and
drive rolls.
guards
closed
Pacemaker
wearers
keep away.
Wearers should consult their doctor before
~
,~
near
any
going
welding operations.
combustible surfaces.
See Safety Precautions at beginning of manual for ba
sic welding safety information.
closed containers.
equipment
to cool before
handling.
wlwam3.1 8/92
Wear the
2
~~
injury.
such
MAGNETIC FIELDS FROM HIGH CUR
RENTS can affect pacemaker operation.
explosion.
flammable material.
over
can cause
device.
fire; keep extinguisher nearby.
Do not locate unit
body protection.
Keep away from pinch points
Read Material Safety Data Sheets (MSDS5) and
manufacturers instructions for material used.
WELDING
helmet with correct shade of filter.
MOVING PARTS
0
be hazardous
breathing
welding
Wear correct eye, ear, and
place
your head out of the fumes.
Ventilate area,
Wear
~-~-
ground.
securely
can
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
p
3
~o
1
following
Dry, Insulating
while
welding:
Gloves
Safety Glasses
With Side
Shields
:
Welding
Helmet With Correct
Shade Of Filter (See ANSI
Z49.1)
ob3.11/94
Figure
5-1.
Safety Equipment
OM-1587
Page
17
1
Clamp
Work
Connect work clamp to a clean,
paint-free location on workpiece,
as close to weld area as possible.
Use wire brush or sandpaper to
clean metal at weld joint area. Use
chipping hammer to remove slag
after welding.
Tools Needed:
2
Voltage Sensing Clamp
Connectto workpiece, if applicable
(see Figure 3-2).
sb4.1 2/93
Figure
5-1.
5-2. Work And
/ Ret. ST~156 931-A
Voltage Sensing Clamps
Front Panel Controls
2
1
Display
2
Parameter Select Button
3
Display Control Knob
4
Right Side
5
Right Side Trigger Hold
Button And Indicator Light
6
Side Select Button
7
Left Side
Indicator
Light
Trigger Hold
Light
Button
And Indicator
3
4
8
Left Side Indicator
9
Jog Button
10
Purge
Light
Button
See Section 6 for information
using microprocessor controls.
on
ST-162 127
Figure
5-3. Front Panel Controls
1
Parameter Select Button
Press button to
move
indicator
on
display.
Ref. ST-167 703
Figure
OM-1 587
Page
18
5-4. Parameter Select Button
1
Display Control Knob
Turn
knob
selected.
to
Spin
quickly change pa
slowly by
knob to
change
value
rameters or move knob
parameters.
clicks to fine tune
Figure
5-5.
Display Control Knob
2
2
a~
~o
1
Side Select Button
2
Side Indicator
Light
Push button to select active side of
wire feeder. indicator light is on for
active side.
The feeder remembers the last
used program for each side, and
returns to that program when the
active side is changed.
TRIGGER
r
HOLD
Gun trigger may also be used to se
lect or change active side of wire
feeder.
0
RECEPTACLE
Figure
5-6. Select Button And Side Indicator
2
0
Lights
Hold Button
1
Trigger
2
Indicator
Ught
To weld without holding gun trigger
throughout weld cycle, press and
release button to turn on indicator
light and hold circuit.
To start weld
cycle and feed weld
ing wire, press and release gun
trigger within the first three sec
TRIGGER
onds after
an arc
has been struck.
If gun trigger is not released within
the first three seconds after arc ml-
tiation, trigger hold stops, but is still
active for next weld cycle. To end
weld cycle, press and release gun
trigger.
Trigger
hold cannot be started
while gun trigger is pressed.
If the Trigger hold button is pushed
for the nonactive side of the feeder
RECEPTACLE
(see Figure 5-6), the trigger hold
indicator light turns on, but Trigger
I-told does not become active until
that side is selected.
Figure
5-7.
Trigger
Hold Button
OM-1587
Page
19
I
Jog Push Button
Jog
side
works
of
on
active,
selected
or
feeder
only
(see
Figure 5-6). Separate jog speeds
~
PURGE
be set for each side of the
feeder.
can
1
JOG
Push to
O+O~
2
momentarily
feed
welding
wire without energizing welding cir
cuit or shielding gas valve.
~~~1
~o
Jog speed is varied using the Dis
play Control knob while Jog button
is pressed. Default setting is 200
1pm.
Jog button is released, unit
displays preset wire feed speed,
and previously selected parameter
When
~,
-.
is active.
Jog does not work when gun trigger
is pulled.
Jog
2
50
Tr
im
I
PM
Prg
Purge Push Button
Purge works on active, or selected
of
feeder
only
(see
Figure 5-6).
side
>200
Jog
>50
260
Jog
Tr
im
Prg
I
PM
Pulse
Push to momentarily energize gas
valve. This allows purging of air
from gun shielding gas line, and ad
justing shielding gas regulator
without energizing the welding
circuit.
Front panel controls, side panel
controls, and gun trigger do not
work when
Jog
or
Purge
button is
pressed.
FIgure
5-2.
5-8.
Jog And Purge Buttons
Side Panel Controls
1
4
2
1
Parameter Increase Button
2
Parameter Decrease Button
3
Parameter Select Button
4
Mode Select Button
5
Mode
6
Parameter
Display
Display
See Section 6 for information
on
using microprocessor controls.
3
Ref. 5T-162 133
Figure
OM-1587
Page
20
5-9. SIde Panel Controls
5-3.
Rear Panel Controls
1
2
1
/
I
Power Switch
Use power switch to turn unit On
and Off.
2
Circuit Breaker (See Section
14-3)
000
o
o
b
I
ST-162 128
Figure
5-10. Power Switch
WARNING
BUILDUP OF SHIELDING GAS
Shut off
shielding
gas
supply
can
harm health
or
kill.
when not in use.
waml.1 2/93
1
Shielding
2
Valve
3
Gun
Gas
Cylinder
Trigger
Open valve
welding.
on
Gun
turns weld
and oft.
trigger
gas flow
on
Close valve on
Ished welding.
cylinder just before
output and
cylinder when
fin
3
ob5.1 6/92-S-0621-C
Figure
5-11.
Shielding
Gas
OM-1 587
Page
21
CAUTION
4A
HIGH FREQUENCY will
Turn off
high frequency
Completely
J
using
this unit.
this unit.
disconnect this unit from power
Install &
Connect
Wire Feeder
source
when
using high frequency.
Install Welding \\
Turn On
Set Al~\
Put On
\~\Turn On Shieldin~\ \
Gas
Controls
System
J )
) J Personal Safety J J Wire Feeder And J )
) )
J J (See Figure 3-2) J J
Equipm~~JJ Power Source J I (If Applicabj~,/ J (See Figure 5-13)1
~\
Begin
)
Welding
Figure
5-4.
damage
when
5-12.
Sequence
Setting Switches
Of Gas Metal Arc (GMAW), Gas Metal Arc
And Flux Cored Arc Welding (FCAW)
On 450
Ampere Inverter Model Welding
Pulse
(GMAW-P),
Power Source
Always use switch settings shown for
all welding processes when using this
wire feeder.
A/V
0
PANEL
ON
G*OUTPUIcONTftCTCR
0
PANEL
ARC FCR~E /INDUcTANcE
AND GC/CV
Ref. ST~15O 171-C / Ref. SC-154 197
Figure
OM-1587
Page
22
5-13.
Setting
Switches On 450
Ampere
Inverter Model
Welding
Power Source
SECTION 6- STEPPING THROUGH THE
MICROPROCESSOR CONTROLS
WARNING
ELECTRIC SHOCK
.
kill.
can
WELDING WIRE
wounds.
Do not touch live electrical parts.
settings.
equipped with eight (8) pulse welding programs (see Section 7). When
This unit is
comes
illustrated throughout this manuaL Instructions are
Section 9) on how to select or change a program.
Front Panel
puncture
The welding wire is electrically live and moves out of
the gun whenever the power switch is On and the gun
trigger is pressed.
the unit is turned On for the first time program 1
6-1.
cause
Do not point gun towards any part of the body, other
people, or any metal when programming.
Control circuit and feeder operational power are On
when using or changing the microprocessor
N OT E
can
up, therefore, program us
this manual (see
given later in
Microprocessor Controls
Turn On welding power source and
wire feeder. Follow along with the
controls as shown.
1
\
1
Front Panel
2
Parameter Select Button
Display
Press parameter select button to
indicator.
move
The indicator points to parameters
that are selected for change.
00
0
0
0
0 000
Parameter select button can move
indicator between Trim (arc length)
and 1PM while welding.
0
Go to
0
Prg
Figure
6-2.
1
Pulse
Tr
50
>2 00
im
1PM
Prg
1
Pulse
ST.162 127
Figure
6-1
-
Front Panel Parameter Select Button
OM-1587
Page
23
1
Front Panel
Display
Select parameter to be changed
(see Figure 6-1).
2
0
__.
Display Control
Knob
Turning knob one click causes,the
following changes to selected
2
setting:
00
Trim
00
00
(arc length) increases/de
by one.
creases
00000
The trim
(arc length) value being
changed also changes on the side
panel parameter display (see
Figure 8-3).
Wire feed speed (1PM) increases/
decreases by one inch per minute.
>50
200
Trim
The wire feed speed value being
changed also changes on the side
Prg
1PM
panel parameter
Figure 8-3).
Pulse
Program
number
ses/decreases by
display
(Prg #)
(see
increa
one.
The
number
being
program
changed also changes on the side
panel parameter display (see
Figure 6-5).
>55
200
Trim
Prg
1PM
Pulse
c
55
>200
The program number cannot be
changed while welding, with ex
ception of Dual Schedule Mode
(see Section 11).
Trim
All
accessible
are
programs
either side of the feeder,
and any program is available to ei
ther side of the feeder at the same
time.
Front Panel
Parameter
through
Select
Display Control knob can be used
Jog speed when Jog button
is pressed (see Figure 5-8).
Prg
1PM
to set
Pulse
Pulse is a default setting. To
change type of program (Pulse,
Adaptive Pulse, or MIG) use side
controls (see Sections 9-4 and
10-1).
Go to
Trim
~300
Figure
6-3.
Prg
1PM
Pulse
0 Front Panel
c
55
300
50
200
Trim
1PM
Trim
1PM
Parameter
Select
>Prg
Pulse
>Prg
2
Pulse
ST-162 127
FIgure
OM-1587
Page
24
6-2. Front Panel
Display
Control Knob
6-2.
Side Panel
Microprocessor
Push Buttons
____
1
Mode
2
Mode Select Button
Display
Press mode select button to move
indicator In left window display.
Go to
Figure
6-4.
L1H~
t~c~
9
Side Panel
1
P
r 0 C e S S
S
e
C
a r
q u e n C e
>Dua I Schd
d
Ref. ST-154 109
Figure
6-3. Mode Select Button
OM-1 587
Page
25
I
1
Parameter
2
Moving
Moving line is
changed.
I
Display
Line
under value that
can
be
3
Side Panel Parameter
Button
Sel~ct
Press side panel parameter select
button to move indicator in right
window display.
9
Side Panel
Prg
1
>E uI
a e
O35~St eel
ArgonO
xy
Pulse
L
J
~
035Steel
ArgonOxy
>Teach
Qff
Ref. ST-154 109
Figure
OM-1587 Page 26
6-4. Side Panel Parameter Select Button
Use mode select button to select
mode
be
to
changed (see
Figure 6-3).
I
Use side panel parameter select
button to select parameter to be
~
changed (see Figure 6-4).
1
Increase Button
Press button to increase value that
is underlined by the moving line.
Decrease Button
2
Press button to decrease value
that is underlined by the moving
line.
Side Panel
I
Increase
>Prg
a_
Pulse
052St
ArgonO
eel
xy
Decrease
>Prg
2_
Pulse
045St
eel
ArgonO
xy
Ref. ST.154 109
Figure
6-5. Side Panel Parameter Increase And Decrease Buttons
OM-1587
Page
27
SECTION 7- STANDARD PULSE WELDING PROGRAMS
following eight (8) pulse welding programs are in the memory of the wire feeder. Use this information to change a
standard program, or as a basis to build a custom program. To revert back to the standard program in the wire feeder
memory, see Section 13-17, Resetting Memory.
The
Program
Wire Size I
Program
# 1
Program
Name: .035
Steel, Argon
Type:
-
.035
1
S-3
Gas: 98 Ar
-
2
Oxy
or
95Ar
-
5
Oxy
Card #_________________________
Oxy
Gun Model: MILLER GW
Flowrate: 40 CFH
1PM / MPM
ApK
AbK
PPS
PWms
750/19.1
470
100
160
2.3
700/17.8
460
100
150
2.3
650/16.5
450
100
145
2.3
600/15.2
440
100
140
2.3
550/14.0
430
95
135
2.3
500/12.7
420
90
130
2.2
450/11.4
410
85
125
2.1
400/10.2
400
80
120
2.0
350 / 8.9
390
75
110
2.0
300/7.6
370
70
100
1.9
250 / 6.4
350
65
90
COMMENTS
.
1.8
.
200/5.1
330
60
80
1.7
150/3.8
320
55
60
1.6
100/2.5
300
45
40
1.6
80/2.0
290
40
35
1.5
Pref low: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:_________________________
Crater Trim: 50
1PM: 200
Sec.:__________________________
Postf low: 0 Sec.
OM-1587
Page
28
Program
Program
# 2
Wire Size /
Program
Name: 045
Steel, Argon
Type:
-
.045
2
S-3
Gas: 98Ar
Oxy
-
2
Oxy
or
95 Ar
-
5
Oxy
Card #________________________
Gun Model: MILL.ER GW
Flowrate: 40 CFH
1PM I MPM
ApK
AbK
PPS
PWms
750/19.1
540
120
220
3.2
700/17.8
530
120
210
3.2
650 / 16.5
520
120
200
3.1
600/15.2
510
115
190
3.0
550/14.0
500
115
180
3.0
500/12.7
490
115
170
2.9
450/11.4
480
110
160
2.8
400 / 10.2
470
105
150
2.7
350/8.9
460
100
140
2.6
300 / 7.6
450
95
130
2.5
250 / 6.4
440
85
120
2.4
200/5.1
420
80
100
2.3
150/3.8
400
75
80
2.2
100/2.5
350
62
60
2.1
80/2.0
320
60
50
2.1
COMMENTS
.
.
Preflow: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:_____________________
Crater Trim: 50
1PM: 200
Sec.:_________________________
Postf low: 0 Sec.
OM-1 587
Page
29
Program
Wire Size /
Program
# 3
Program
Name: .052
Steel, Argon
Type:
-
.052
3
S-3
Gas: 98Ar
-
2
Oxy
or
95 Ar
-
5
Oxy
Card #_________________________
Oxy
Gun Model: MILLER GW
Flowrate: 40 CFH
1PM / MPM
ApK
AbK
PPS
PWms
750/19.1
565
145
260
3.1
700/17.8
565
140
260
3.1
650/16.5
560
135
260
3.1
600/15.2
560
130
255
3.1
550/14.0
560
125
240
3.1
500/12.7
550
120
225
3.0
450/11.4
540
115
210
2.9
400/10.2
530
110
195
2.9
350/8.9
520
105
170
2.8
300/7.6
510
100
155
2.8
250 / 6.4
500
95
140
2.7
200/5.1
480
90
120
2.6
150/3.8
460
70
100
2.5
100/2.5
420
50
80
2.4
50/1.3
350
35
50
2.4
COMMENTS
.
.
Preflow: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:__________________________
Crater Trim: 50
1PM: 200
Sec.:__________________________
Postf low: 0 Sec.
OM-1587
Page
30
Program
Program
Wire Size I
#4
.035
Program Name:
309, Argon
Type: .Q35
-
4
309
Gas: 98 Ar
-
2
CO2
or
95Ar
-
5
CO2
Card #_________________________
CO2
Gun Model: MILL.ER GW
Flowrate: 40 CFH
1PM / MPM
ApK
AbK
PPS
PWms
750/19.1
390
95
210
2.2
700 / 17.8
380
95
200
2.1
650 / 16.5
370
90
190
2.0
600 / 15.2
360
85
180
1.9
550/14.0
350
80
170
1.9
500/12.7
340
75
160
1.9
COMMENTS
,
.
450/11.4
330
70
150
1.8
400/10.2
320
65
140
1.8
350/8.9
310
60
130
1.7
300 / 7.6
300
55
120
1.7
250 / 6.4
290
50
100
1.6
200 / 5.1
280
45
80
1.6
150/3.8
270
40
60
1.6
100/2.5
270
36
40
1.5
80/2.0
260
30
30
1.5
Preflow: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:__________________________
CraterTrim:50
1PM: 200
Sec.:_____________________
Postflow: 0 Sec.
OM-1 587
Page
31
Program
Wire Size /
Program
# 5
Program
Name: .045
.045
Type:
Steel, 309, Argon
-
5
Gas: 98 Ar
309
-
2
CO2
or
95Ar
-
5
CO2
Card #_________________________
CO2
Flowrate: 40 CFH
Gun Model: MILLER GW
1PM I MPM
ApK
AbK
PPS
PWms
750 /19.1
490
110
260
2.3
700/17.8
480
110
260
2.3
650/16.5
470
105
260
2.2
600/15.2
460
100
240
2.1
550/14.0
450
100
240
2.0
500/12.7
440
95
220
1.9
450/11.4
430
95
200
1.9
400/10.2
420
95
180
1.9
350/8.9
410
95
160
1.8
300/7.6
400
90
140
1.8
250/6.4
380
85
120
1.8
200/5.1
360
80
100
1.7
150/3.8
340
70
80
1.6
100/2.5
320
50
60
1.6
50/1.3
320
45
45
1.6
COMMENTS
.
.
Preflow: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:__________________________
Crater Trim: 50
1PM: 200
Sec.:__________________________
Postflow: 0 Sec.
OM-1587
Page
32
Program
Wire Size /
Program
# 6
Program
Name: 3/64
Type:
3/64
6
4043
Gas:
Argon
Card #_________________________
4043, Argon
Flowrate: 40 CFH
Gun Model: MILLER GW
1PM / MPM
ApK
AbK
PPS
PWms
750/19.1
510
145
190
3.5
700/17.8
500
145
180
3.5
650/16.5
480
140
180
3.4
600 / 15.2
470
140
180
3.3
550 / 14.0
460
140
170
3.2
500/12.7
440
135
160
.3.0
450/11.4
420
130
150
3.0
400/10.2
:380
130
140
2.9
350 / 8.9
:350
115
130
2.8
300 / 7.6
320
105
120
2.7
250 / 6.4
280
93
110
2.6
200/5.1
250
73
100
2.4
150/3.8
230
52
90
2.2
100/2.5
:205
32
80
2.2
80/2.0
190
25
45
2.2
COMMENTS
.
.
Preflow: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:__________________________
Crater Trim: 50
1PM: 200
Sec.:__________________________
Postf low: 0 Sec.
OM-1 587
Page 33
Program
Wire Size /
Program
#7
Program
Name: 3/64
Type:
3/64
7
5356
Gas:
5356; Argon
Argon
Card #_________________________
Gun Model: MILLER GW
Flowrate: 40 CFH
1PM / MPM
ApK
AbK
PPS
PWms
750/ 19.1
540
130
190
2.9
700/17.8
520
125
190
2.8
650/16.5
500
120
180
2.8
600/15.2
480
115
170
2.8
550 /14.0
460
110
160
2.7
500 / 12.7
440
100
150
2.7
450./ 11.4
420
90
140
400 / 10.2
390
85
130
2.6
350/8.9
370
70
120
2.4
300/7.6
355
55
110
2.3
250 / 6.4
335
45
100
2.2
200 / 5.1
310
35
90
2.2
150/3.8
272
33
90
2.0
100/2.5
262
24
60
2.0
50/1.3
230
18
40
1.8
COMMENTS
.
.
2.7
Preflow: 0 Sec.
Run-In Trim: 50
IPM: 200
Sec.:__________________________
CraterTrim:50
1PM: 200
Sec.:_____________________
Postflow: 0 Sec.
OM-1 587 Page 34
Program
Program
Wire Size /
# 8
Program Name:
035
NickI, Argon
Type:
-
.035
8
Gas: 75 Ar
NickI
-
25 He
Card #________________________
He
Gun Model: MILLER GW
Flowrate: 40 CFH
1PM I MPM
ApK
AbK
PPS
PWms
750/19.1
:390
110
130
3.5
700 / 17.8
380
105
130
3.5
650 / 16.5
370
100
125
3.4
600 / 15.2
:360
90
120
3.4
550/14.0
350
85
115
3.3
500/12.7
345
80
110
3.3
450 / 11.4
340
75
105
3.3
400 / 10.2
330
70
95
3.3
350 / 8.9
320
65
85
3.3
300/7.6
310
60
75
3.2
250 / 6.4
300
55
65
3.1
200/5.1
290
48
55
3.1
150/3.8
275
42
45
3.1
100/2.5
250
31
35
2.9
50/1.3
220
25
30
2.8
COMMENTS
.
.
Pref low: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:__________________________
CraterTrim:50
1PM: 200
Sec.:_____________________
Postf low: 0 Sec.
OM-1587
Page
35
SECTION 8- GETTING STARTED
WARNING
4A
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Always
wear
Insulate
dry insulating gloves.
yourself from
Keep all panels and
work and
covers
FUMES AND GASES
to your health.
Keep your
,~
ground.
securely
can
in
~
~
or use
0
~
near
Do not weld
on
Allow work and
NOTE ~
OM-1 587
Page
36
explosion.
extinguisher nearby.
over
body protection.
combustible surfaces.
closed containers.
equipment to cool before handling.
can cause
injury.
MAGNETIC FIELDS FROM HIGH CUR
RENTS can affect pacemaker operation.
flammable material.
Watch for fire; keep
Do not locate unit
fire or
helmet with correct shade of filter.
Keep away from pinch points such as drive rolls.
Keep all doors, panels, covers, and guards closed
and securely in place.
breathing device.
can cause
Do not weld
welding
Wear correct eye, ear, and
MOVING PARTS
be hazardous
Read Material Safety Data Sheets (MSDS5) and
manufacturers instructions for material used.
WELDING
Wear
S
place
head out of the fumes.
Ventilate area,
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
.
..
~
S
Pacemaker
S
Wearers should consult their doctor before
near arc
wearers
keep away.
welding, gouging,
or
going
spot welding opera
tions.
See Safety Precautions at beginning of manual for ba
sic welding safety information.
wfwam6.1 8192
Set up equipment according to Figure 5-12. Use the standard pulse welding
program in Section 7 that is closest to your appilcation (by wire type and size and
gas type) when setting up.
8-1.
Welding
With
Only
Front Panel Controls
Turn On welding power source,
wire feeder, and gas.
Use Select button or gun tnggej to
select active side of feeder.
1
1
Front Panel
the first time the unit is turned on,
at other times the last program
1
>Prg
number selected is
displayed. Use
panel parameter select
select the Prg #.
the front
200
Pulse
button to
2
Control
Prg3
Select the weld program from
Section 7 (1 through 8) which Is
closest to the application (by wire
and gas).
Display
2
Strike an
Trim
50
200
P
u
I
3
3
>Prg
1PM
s
If
el
If
Front Panel
Parameter
Select
Trim
>50
200
200
select
1PM,
and
arc.
3
3
3
Prg
1PM
55
Trim~
I
necessary,
Front Panel
Parameter
Select
>200
> 5 0
1PM
Pulse
Trim
55
necessary, select Trim, and
to achieve the best arc.
Go to Section 8-2.
Prg
1PM
~
Length)
Pulse
Trim
>55
and try a sample weld.
adjust to achieve the best
Prg
1PM
arc
Trim (Arc
adjust
4
U
Display
1 is the default program
Program
Pulse
PM~
3
Prg
P
u
I
s
e
7
FIgure
8-1.
Welding
With
Only
Front Panel Controls
OM-1 587
Page
37
8-2.
Pulse
Setting Sequence
Welding Parameters On Side
Display
WARNING
a
ELECTRIC SHOCK
can
kill.
WELDING WIRE
wounds.
Do not touch live electrical parts.
I
Panel
can
cause
puncture
Do not point gun towards any part of the body, other
people, or any metal when programming.
The welding wire is electrically live and moves out of
Control circuit and feeder operational power are On
when using or changing the microprocessor
settings.
the gun whenever the power switch is On and the gun
trigger is pressed.
NOTE ~
Figure 8-2 is a graphic layout of a weld cycle. Follow examples in Figure
through Figure 8-8 to adjust sequence welding parameters to fit your needs.
8-3
Weld lime 0-25 Sec.
Run-In Time
0-2.5 Sec.
Run-In
a,
a)
Speed
~
I
I
Preflow
0-9.9 Sec.
Crater Time
0-2.5 Sec.
Bumback Time
0-0.25 Sec.
a,
a,
/
Cl)
a,
I
Tim~
Trigger
I
I
Arc
Start
U
/~
Postflow lime
0-9.9 Sec.
o u~
.
~.
Trigger
Released
Arc
Ou
lime
Pressed
Ref. S-0271
Figure
OM-1 587
Page
38
8-2. Weld
Cycle
1
Process
>S
Mode Select Button
When unit is turned On, Process is
the default mode, at other times,
>W~ I d
mode select button to select
50.
Trim
Dual Schd
250
1PM
Sequence.
Card
0.0
Sec
2
e
U e n C e
q
use
Side Panel Parameter Select
Button
Use side
panel parameter select
button to select parameters.
2
3
Weld Parameters
.1
Parameter ranges
Trim
follows:
(Arc Length), 0-99
Changes
are
Display
are as
also
Sequence
to Weld
displayed
on
Trim
front panel
display.
Wire Feed Speed, 50-780 Inches
Per Minute, 1PM
Changes
are
also
to Weld
displayed
Sequence 1PM
on front panel
display.
Set Desired Weld
Sequence Voltage
Seconds, 0-25.0 Sec. If value set Is
(0), welding will continue until
welding gun trigger Is released.
zero
3
Or
use
front
D
panel parameter
lncrease/
Decrease
select to move
indicator to trim.
Go to
Figure
8-4.
Trim
can be fine tuned
while welding,
see Figure 6-2.
Set Desired Weld Sequence
Wire Feed Speed
(r~
~
Or
use
front
panel parameter
select to move
indicator to 1PM.
lncrease/
Decrease
1PM can be fine
tuned while welding,
see Figure 6-2.
Set Desired Weld Sequence
Time, If Applicable
Increase/
Decrease
Increase
Proceed to next
Figure
8-3.
figure.
Setting
Weld
Sequence Display
OM-1 587
Page
39
1
1
>~ra1er
I
I 50
Trim1
I 200
1PM H
0.00
Crater
Sec
Crater
Trim1
>~
200
1PM
0.00
Sec
I
1PM
>2~Q
0.00
I
0-99
H1
Wire Feed Speed, 50-780 Inches
Per Minute, 1PM
(Arc Length),
Seconds, 0-2.50 Sec. If value set is
Sec
(0),
zero
Side Panel
Parameter
Select
Side Panel
Parameter
Select
Set Desired
Trim
follows:
are as
Trim
Trim
60
Crater Parameters Display
Parameter ranges
Set Desired
Wire Feed Speed
there
is
Crater
no
sequence.
Go to
Figure
8-5.
Side Panel
Increase!
Decrease
I
I
>Qralar
60
TrimI
150
1PM
0.20
Sec
f~
J
Increase
Proceed to next figure.
8-4.
Select
j
Crater
TrimLJ
60
~
Side Panel
Parameter
Select
Figure
~ Parameter
Increase!
Decrease
150
1PM
>
Sec
Set Desired
Time
Increase/
Decrease
SettIng Crater Sequence Display
1
1
l>~urnba~k
Bu rnback
>~tlrn~aQk
I
Bumback Parameters
Display
Bumback can be adjusted from
0-0.25 seconds. If value set is zero
(0), there is no Bumback
sequence.
Go to
0.00
Sec
>Q,QQ
Sec
0.12
Sec
Figure
8-6.
____________
Side Panel
Parameter
Select
Set Desired Time
Side Panel
Parameter
Select
Increase
Proceed to next
lncrease/
Decrease
Figure
8-5.
Setting
Burnback
figure.
Sequence Display
1
1
______/
______
>EQ~tf1Qw
0.0
Sec_F ~
Side Panel
Parameter
Select
______
Posttlow
Sec_F
Set Desired Time
Go to
1.2
OM-1 587 Page 40
8-6.
Setting
Sec
Side Panel
Parameter
Select
Increase
Proceed to next
Increase!
Decrease
Figure
Postf low Parameters
Postflow
figure.
Sequence Display
Display
Postflow can be adjusted from
0-9.9 seconds. If value set is zero
(0), there is no Postflow sequence.
Figure
8-7.
Pref low Parameters
1
Display
Pref low can be adjusted from 0-9.9
seconds. If value set is zero (0),
there is no Preflow sequence.
Go to
Figure
8-8.
/
______
______
Preflow
>~sf!~w
0.D
Sec_F ~
Sec_F ~
Side Panel
Set Desired Time
Increase!
Decrease
8-7.
Preflow
Setting
1.2
Sec
Side Panel
Parameter
Select
Parameter
Select
Figure
>~refIQw
Increase
Proceed to next figure.
Sequence Display
Run-In Parameters
1
Parameter ranges
Display
are as
follows:
Trim, 0-99.
Wire Feed
Speed,
50-780 inches
per minute, 1PM
Seconds, 0-2.5 Sec. If value
zero
in
150.
Trim
200
1PM
10.0
Sec
there
is
no
set Is
Run-In
sequence.
1
I >fiun
(0),
I
__
__
Run in
Side Panel
Parameter
Select
Runin
Trim
>~Q
Trim
55
200
1PM
>20Q
1PM
0.0
Sec
0.0
Sec
Side Panel
Parameter
Select
Set Desired Trim
F1
Set Desired
Wire Feed Speed
Increase!
_____________________________________________________________________________
>We I ~
>Bun!n
Trim
~
Trim
250
1PM
150
1PM
0.0
Sec
1.1
Sec
I
_____________________________________________________________________________
I
50
Side Panel
Parameter
Select
Increase!
Decrease
Decrease
Runin
Trim
55
I
Side Panel
Parameter
Select
Increase
I
I
150
1PM
~
Sec
Set Desired Time
Increase!
Decrease
Figure
8-8.
Setting
Run-In
Sequence Display
OM-1587
Page
41
SECTION 9- TEACHING A PULSE WELDING PROGRAM
WARNING
a
ELECTRIC SHOCK
can
WELDING WIRE
wounds.
kill.
Do not touch live electrical parts.
can
cause
puncture
Do not point gun towards any part of the body, other
people, or any metal when programming.
The welding wire is electrically live and moves out of
Control circuit and feeder operational power are On
when using or changing the microprocessor
settings.
the gun whenever the power switch is On and the gun
trigger is pressed.
____________________________________________
NOTE iI~
See GMAW-P
information.
___________
(Pulsed MIG)
Process Guide
supplied
with unit for
more
_____________________
9-1.
Pulse Waveform
Explained
The wire feeder, not the welding
power source, controls weld output
for pulsed welds.
1
Peak Current Of
100-565 Amperes
ApK
ApK is the high pulse of welding
current.
Peak current melts the
welding wire and forms a droplet.
The droplet is forced into the weld
puddle.
2
AbK
Background Current
Amperes
Of 10-200
AbK is the low weld current. Back
ground
current preheats welding
wire and maintains the arc. When
/
background current
is
arc
C
is too
and
low, the
hard
to
maintain.
3
0
E
unstable
1
2
*
I
PPS
Pulses Per Second Of
20-400
PPS, pulse rate, and frequency
(Hz)
lime
/
are used interchangeably. A
PPS or pulse rate of 60 Hz means
60 pulses of current are produced
each second.
4
PWms Pulse Width Of
1.0-5.0 Milliseconds
PWms is the time spent at peak
(1 .2 ms Is .0012 seconds).
This time must be long enough to
form a droplet of welding wire. The
stiffness or fluidity of the molten
weld puddle is controlled by
PWms.
current
R&. S-0259
Figure
OM-1 587 Page 42
9-1. Pulse Waveforms And
Explanation Of Terms
Teach Points
9-2.
Explained
1PM
780
750
700
650
600
550
Example Of A Synergic
Setting For 425 1PM With
500
All Teach Points Set At
50 1PM Increments
450
400
350
300
250
200
ApK
o
AbK
o
pps
S
PWms
150
100
50
100
181)
210
240
270
300
330
360
370
420
450
480
510
540
565
ApK
10
2Ci
30
40
50
60
70
80
90
100
110
120
130
140
200
AbK
20
55
80
105
130
160
185
210
235
260
290
315
340
365
400
1
2
The teach mode allows the user to create
custom pulse MIG welding programs. The
teach mode has 15 teach points. At each
teach point, the user can adjustfourparame
peak amperage (ApK), background
amperage (AbK), pulses per second (PPS),
and pulse width in milliseconds (PWms) to
shape the pulse waveform of the weld
ters:
output.
Wire teed speed teach
points can range from
the minimum to this maximum wire feed
speed of the feeder. When using a standard
speed motor, wire feed speed teach points
from 50 to 750 ipm. The wire
feed speed of a teach point can be redefined
to any wire speed setting between adjacent
teach points (see Section 9-3). The feeder
uses pulse parameters at teach points to es
tablish the pulse parameters at any wire feed
typically range
speed setting.
Figure
9-2.
Typical
3
Below the wire feed
teach
4
speed
point, and above
of the lowest
the wire feed
speed
of the
highest teach point, the unit may limit
speed settings in pulse MIG to
maintain all pulse parameters within the Capability of the unit.
wire feed
PPS
5
To
ensure a
proper
PWms
length reading,
arc
trode stick-out must be carefully
elec
maintained,
and the weld must be terminated by releas
Ing the gun trigger, not by pulling the welding
gun away from the workplece.
The
Pulse MIG programs made by the manufacturer have pulse waveform information entered for all 15 teach
points. The operator
and modify the setting of one, or
any number of the 15 teach points if the factory set information is not appropriate for a
can relocate
taught arc length represents a Trim (arc
length) selling of 50. Increasing the value of
Trim, increases the actual arc length. Like
wise, decreasing the value of Trim will de
crease actual arc length.
established, an arc must be struck and main-
In the Pulse mode, the unit does not maintain
a constant arc length with variations in elec
trode stick-out. In the Adaptive Pulse mode,
the unit adjusts pulse frequency to maintain
a constant arc length regardless of varia
tions In electrode stick-out.
tamed for at least 5 seconds. This allows the
wire feederto learn the arc voltage length associated with the taught pulse parameters.
program.
specific application.
Afterthe
parametersforeach teach point are
Teach Point
Settings
And
Proceed to next
figure
to teach a
pulse MIG
Resulting Synergic Setting
OM-1 587
Page
43
9-3.
Teaching
A Pulse
Welding Program
READ SAFETY BLOCKS at start of
Section 9 before proceeding.
A.
Selecting
And/Or
Redefining
Teach Point Wire Feed
Speed
1
point (1PM) can be selected on either the side pane! or front pane! displays,
but the wire feed speed of a teach point can only be redefined with the Purge button
and Display Control knob while 1PM is selected on the front panel display.
Process
A teach
Selecting
2
A Teach Point
1
Display
When unit is first turned On, Pro
cess is the default screen, at other
times use mode select button to se
lect Process.
Teach Display
Use parameter select button to
lect Teach.
2
se
Use increase/decrease buttons to
select On.
3
1PM
(Teach Point)
You can also select a teach point
with the front panel Display Control
knob if the cursor on the front panel
display is pointing at 1PM.
Side Panel
Mode Select
To redefine the wire feed speed of
a teach point, proceed as follows:
4
Front Panel
Display
Use parameter select button to
lect 1PM (teach point).
Press and hold
se
Purge
button while
Control knob to re
define the teach point wire feed
speed. For example, if teach points
reside at 150, 200, and 250 ipm,
the teach point at 200 can be ad
justed to a wire feed speed of 151
to 249 ipm.
turning Display
Repeat the procedure for as many
of the 15 teach points as desired.
To
set
or
adjust teach point
to Figure 9-4.
parameters, go
Redefining
A Teach Point
5 0
450
Tr
im
1PM
Front Panel
Parameter
Select
50
>460
Figure
OM-1587 Page 44
9-3.
Trim
I
PM
Selecting And/Or Redefining
iL
Prg
Pu
I
s
4
A Teach Point
B.
Setting Teach
Point Parameters On The Side Panel
lncrease/
Decrease
Side Panel
Parameter
Select
lncrease/
Decrease
lncrease/
Decrease
I
~
I
Apk
92
Abk
PPS
1.9
PWms
2
Side Panel
I Parameter
11_J
Select
lncrease/
Decrease
I
Apk
L~
92
Abk
280
PPS
>
PWm
9
_______
343
I
Apk
Or~
280
PPS
~
PWm
$
~j>Teach
Abk-
92
Pulse
0n
460
1PM
~
Apk
92
Abk
035~SteelI
Argon-Oxyl
>Teach
____
Side Panel
Parameter
Select
lncrease/
Decrease
I
4
rJ
Side Panel
Parameter
Select
5
I
I
Prg
1
Pulse
O35Steel
Argon-Oxyj
When the Process Teach mode is On, and
one of the following pulse parameters is se
lected: ApK, AbK, PPS, or PWrns, the front
panel displays the selected pulse parameter
instead of Trim (arc length). When the pulse
parameter Is selected on the front panel, the
value can be changed with the front panel
Display Control knob, or on the side panel as
follows:
Figure
9-4.
1
ApK Display
2
AbK
Display
3
PPS
Display
4
PWms
custom
program
is
complete
(see
Figure 9-2).
Turn Teach mode Off.
Display
When values have been set for a teach point,
strike and maintain an arc for five seconds.
Repeat procedure at each teach point until
SettIng
5
Custom Pulse Screen
The letter C will appear In the upper right cor
ner of all customized programs.
To set Sequence
Section 8-2.
Welding Parameters,
see
Teach Point Parameters On The Side Panel
OM-1 587
Page
45
N OTE
~
Program #__________
Make
Wire
copies
of this chart for future
use.
Size/Type________________________ Gas__________________________
Program Name____________________________________________
Card #________________________
Gun Model_____________________________________________ Flowrate
1PM
ApK
AbK
PPS
PWms
CFH
COMMENTS
Preflow:__________________ Sec.
Run-In Trim:______________ 1PM:__________________________ Sec.:________________________
Crater Trim:______________ 1PM:________________________ Sec.:______________________
Postf low:________________ Sec.
OM-1587
Page
46
9-4.
£~
Changing
WARNI
Adaptive Pulse Welding
To
I
READ SAFETY BLOCKS at start of
Section 9 before proceeding.
Welding parameters
are the same
for both a Pulse and an Adaptive
Pulse welding program. While
welding adaptively, the unit uses
feedback to attempt to maintain a
constant arc length. To change to
Adaptive Pulse welding, proceed
as shown:
1
Mode Select
Side Panel
Display
Default display when unit is first
turned On, at other times use mode
select button to select Process.
2
>Process
>Prg
Sequence
1_
Pulse
DualSchd
O35Steel
Card
ArgonOxy
Side Panel
Parameter
Select
I
>Process
1
Prg
Sequence
>EMISO
DualSchd
O35~Steel
Card
ArgonOxy
I
U
lncrease/
Decrease
I
>Process
Prg I
>~dapt~uL&e
Sequence
DualSchd
O35~Steel
Card
ArgonOxy
Figure
9-5.
Changing
To
Adaptive
Pulse
Welding
OM-1587
Page
47
SECTION 10-TEACHING A MIG WELDING PROGRAM
£~
WARNING
ELECTRIC SHOCK
can
Do not touch live electrical
kill.
WELDING WIRE
Control circuit and feeder operational power are On
when
using
settings.
changing
or
the
can
cause
puncture
wounds.
parts.
Do not point gun towards any part of the body, other
people, or any metal when programming.
The welding wire is electrically live and moves out of
microprocessor
the gun whenever the power switch is On and the gun
trigger is
pressed.____________________
10-1.
Changing
To MIG
Welding
1
Side Panel Display
Default display when unit is first
turned On, at other times use mode
select button to select Process.
Mode Select
Go to
>Process
1
Prg
Sequence
>Eulse
DualSchd
O35~Steel
Card
ArgonOxy
U
Increase/
Decrease
+
Prg
>Process
1
>M1~
Sequence
Dual Schd
Card
Figure
OM-1587
Page
48
10-1.
Changing
To MIG In The Process Mode
Figure
10-2.
10-2.
Setting Sequence
MIG
Welding Parameters On Side
Panel
Display
1
Side Panel
Display
When unit Is turned On, Process Is
the default mode. Use mode seject
Sequence.
button to select
2
>Process
>Prg
D
u a
1
MIG
Sequence
Side Panel Parameter Select
Button
Use side
I Sc h d
panel parameter
select
button to select parameters.
Card
3
Weld Parameters
Parameter ranges
Display
are as
follows:
Volts, 10.0-38.0 Volts
fl
Wire Feed
Mode
Select
Speed, 50-780 Inches
Per Minute, 1PM
Seconds, 0-25.0 Sec. If value set Is
(0), welding continues until
zero
welding gun trigger
Process
Inductance, 0-99 %
>WeI
>Sequence
is released,
Changes
to voltage and wire teed
speed (1PM) parameters in the
weld sequence are also displayed
on front panel display.
18. OVol t
DualSchd
200
1PM
Card
0.0
Sec
Go to
Set Desired
Figure
10-3.
3
Voltage
We I d
>1~.QVol
Increase!
Decrease
Set Desired Weld Time,
If Applicable
Weld Sequence
Volts can be fine
tuned while welding
Weld
0.0
Sec
t
lncrease/
Decrease
Set Desired Wire Feed
~Weld
1PM
>2QQ
1PM
0.0
Sec
Increase!
Decrease
Side Panel
I
Weld
Sequence
1PM
be fine tuned
while welding
can
Parameter
Select
Side Panel
Parameter
Select
Speed
20.OVolt
Sec
30%Induc
lncrecse/
Decrease
1PM
Side Panel
Parameter
Select
I 420
I>~~
Set Desired Inductance,
If Applicable
200
Weld
1420
1PM
20.OVoltsI
I
Sec
420
1PM
2.2
Sec
2.2
>
Side Panel
Parameter
Select
Figure
10-2.
Setting
Weld
Increase
Proceed to next
figure.
Sequence Display
OM-1 587
Page
49
1
Crater Parameters
Parameter ranges are
1
Display
as
follows:
Volts, 10.0-38.0 Volts
Wire Feed
Speed, 50-780
Inches
Per Minute, 1PM
Seconds, 0-2.50 Sec. If value set is
zero
(0),
there
is
Crater
no
sequence.
Go to
Figure
1 0-4.
Crater
24.OVoIt
~~
Set Desired
Voltage
Side Panel
Parameter
Set Desired
Wire Feed Speed
Select
Increase!
Decrease
400
1PM
~Q~QQSec
Side Panel
Parameter
Select
Set Desired Time
lncrease/
Increase!
Decrease
Decrease
a I a r
24. OVo It
400
1PM
1.l2Sec
Side Panel
Parameter
Select
Increase
Proceed to next
Figure
10-3.
Setting
Crater
figure.
Sequence Display
1
Bumback Parameters
Parameter ranges
are as
Display
follows:
Volts, 10.0-38.0 Volts
Seconds, 0-0.25 seconds. If value
set is zero
(0), there is no Bumback
sequence.
Go to
/
___
___
18.0
Volt
0.00
Sec
>16~Q
Vol
0.00
Sec
___
16.0
>Q.12
Volt
16.0
Sec
0.12
_________
_________
Parameter
Select
Set Desired
Bumback Volts
Side Panel
Parameter
Select
Figure
50
10-4.
Setting
Set Desired
Bumback Time
Increase!
Decrease
Increase!
Decrease
Page
Sec
_________
_________
Side Panel
OM-1587
10-5.
Volt~
Burnback~~>~urnbaQkI
I>~urnba~k~~Burnback
I
Figure
Burnback
Sequence Display
Side Panel
Parameter
Select
Increase
Proceed to next figure.
1
1
________________
________________
________________
I
~ ~ ~
0
Sec
0
.
Po
~
S t
f I
Sec
~
Side Panel
Parameter
Select
ow
~
Figure
10-6.
Sec
2
.
Increase
Proceed to next
Increase!
Decrease
Setting
10-5.
~ ~
Goto
1
Display
Side Panel
Parameter
Select
Set Desired Time
Figure
i
~
Posttlow Parameters
Postflow can be adjusted from
0-9.9 seconds. If value set is zero
(0), there is no Postf low sequence.
Postf low
figure.
Sequence Display
1
Pref low Parameters
Display
1
Pref low
>ELQI IQW
0. 0
Sec
Sec
> Q
Side Panel
Parameter
Select
~
Goto
1
Setting
Pref low
Sequence Display
1
1
~ ~
I
1 8
.
0 V
200
0
.
0
o
I
t
1PM
S
e c
10-7.
Sec
2
.
Figure
Increase
Proceed to next figure.
lncrease/
Decrease
10-6.
Q W
Side Panel
Parameter
Select
Set Desired Time
Figure
I I
~
Pref low can be adjusted from 0-9.9
seconds. If value set is zero (0),
there is no Pref low sequence.
Run-In Parameters
Parameter ranges
I
Display
are as
follows:
Volts, 10.0-38.0 Volts
A
Runin
_________~
~
>1 8.. 0 V
o
200
1PM
0
S
.
0
Wire Feed
I
2 0
.
>200
0
e c
.
0
0 V
0
I t
Speed, 50-780 inches
per minute, 1PM
1PM
5
l
e c
Seconds, 0-2.5 Sec. If value set Is
zero
(0), there is no Run-In
_________
Side Panel
Parameter
Select
Set Desired
Voltage
Side Panel
Parameter
Select
Increase!
Decrease
>WQIcA
I
20.OVoIt
I
420
1PM
2.2
Sec
0.5
Sec
F _
I
20.OVolt
Side Panel
Parameter
Select
Increase
Side Panel
Parameter
Select
Increase!
Decrease
I>a~nin
I 20.OVolt
H 150 1PM
]~
sequence.
Set Desired
Wire Feed Speed
150
1PM
>
Sec
Set Desired Time
Increase!
Decrease
Figure
10-7.
SettIng
Run-In
Sequence Display
OM-1 587
Page
51
SETTING DUAL SCHEDULE PARAMETERS
SECTION 11
WARNING
£~
ELECTRIC SHOCK
can
kill.
.
Do not touch live electrical parts.
.
Control circuit and feeder operational power are On
when
using
or
changing
the
L_~
~
~ I~
microprocessor
I
settings.
WELDING WIRE
wounds.
can
cause
puncture
Do not
point gun towards any part of the body, other
people, or any metal when programming.
The welding wire is electrically live and moves out of
S
the gun whenever the power switch is On and the gun
trigger is pressed.
Dual Schedule can only be used
consecutive weld pro
grams such as: 1 & 2, 3 & 4, 5 & 6,
or 7 & 8. Any program type MIG,
Adaptive Pulse, or Pulse can be
combined in dual schedule. For ex
ample, Prg 1 is MIG, Prg 2 is Pulse,
or Prg 1 is Adaptive Pulse, and Prg
2 is Pulse, etc.
with two
2
3
1
Mode Select Button
2
Mode
Display
Use mode select button to select
Dual Schedule, then proceed as
shown:
3
Dual Schedule Parameters
Display
Use side
panel increase/decrease
Display Control knob
(see Figure 11-2) to select dua
buttons,
schedule
On
. 1&2~.~~
Prg
1&2~
Side Panel
Parameter
Select
Display
Control
If the two desired welding programs are not in the proper program order (1 & 2, or
etc.), the most common method to get them in the proper order would be to
write one program to a data cam, and then read the program from the card into the
desired program number. See Section 12 for data card information.
3 & 4,
FIgure
OM-1587 Page 52
11-1.
Setting Dual Schedule Pairs On Side
Panel
Display
or
pairs.
1
1
Front Panel Parameter Select
Button
2
Front Panel
Display
2
~eter
Fr~anl5 -i
Press parameter select button to
select program number on front
I
panel display.
3
24.
I>Prg
OV
I
250
P M
ii
I
liDual Al
4
I
~
I
Display
Control
Knob
OR
>Prg
31
Display Control
Welding Gun Trigger, Or
DSS-Type Switch
The dual schedule programs can
be alternately selected between
I
Welding Gun
Tngger
Front Panel
Knob
~,
active programs A or B by turning
the Display Control knob one click
clockwise or counterclockwise, or
by squeezing and releasing the
welding gun trigger, or by an exter
nal mounted DSS-type switch on
the welding gun. See Section
13-10 for specific switch-type In
structions.The settings shown on
the front panel display are for the
active weld program.
When program B is active, turn Dis
play Control knob one click clock
Dual__A~~j
wise to select another pair of dual
schedule programs.
Display
Control
Knob
When dual schedule is On, and Process is selected Cr, the
side panel display, then the side panel increase/decrease
buttons can be used to change program numbers.
Figure
11-2.
Selecting
Between Active Dual Schedule
Programs
A And B On Front Panel
Display
OM-1587 Page 53
SECTION 12- USING THE OPTIONAL DATA CARD
12-1.
Installing
Data Card
1
Label
Peel
backing from label and apply
by
metal pins.
to data card with THIS SIDE UP
Write the names of the programs
stored on the card on the label.
Write the name of the piece of
equipment the card is used with on
the label.
2
Data Card
3
Card Slot
Insert card into slot. To format card,
turn On power to the unit. Select
Card from menu. Data card for
mats when unit enters Card mode.
Exit Card mode and turn Off power.
1
51-156 266-B / Ref. S-155 823
Figure
12-2.
Using
12-1.
Installing
Data Card
The Data Card
Use Mode Select button to select
Card.
1
Card
2
Write
Display
Process
Sequence
D
>C
u a
a
r
I S
c
h d
d
P
r e s s
B
e
I
Usedtotransferprogramdatafrom
unit to card. The program card can
hold up to 32 programs. When writ
ing to the card, the next available
program number is automatically
o~
I
assigned.
3
Read
Used to transfer program data from
card to unit.
4
Delete
Used to delete program data from
card.
3
5
Done
Us ed to exit card
display.
4
6
5
Page
54
Line
Moving line is
changed.
6
be
Figure
OM-1 587
Moving
12-2. Card
Displays
under value that
can
N OTE ~
All program
types (Pulse, Adaptive Pulse, and MIG)
can
be stored
on a
data card
and retrieved.
Card Display
1
Use Mode Select button to select
Card.
Moving Line
2
Moving line is under value that can
changed. Use increase or de
crease button to change value.
be
3
If
Name
Display
no name
Is desIred, press side
panel Parameter Select button
continue the write procedure.
2
#11~ulse
>Write
Read
035Steel
Delete
ArgonOxy
Done
Press
to
Side Panel
When
Pa~ane~er
panel Display Control knob can be
used
to
speed selection of
naming
a
program, the front
characters.
0-
--I
Allowable characters include: 0 thru 9, :, ;, <,=,
>,?, @, Athru Z, f,], A,
I,
%, &,, (, ), ., +, ,
,, athru
z,
I,, #, $,
.,
lncrease/
Decrease
Side Panel
Parameter
Select
Yes
Increase
No
O
Side Panel
Parameter
Select
Side Panel
Parameter
Select
Wr i teDone
to
Prg 1
CardPrg
1
Press
Increase
Side Panel
Parameter
Select
Side Panel
Parameter
Select
3
Pulse
#1
035St
eel
ArgonOx
y
Press
Figure
12-3.
Naming Programs
And
Writing
To Card
OM-1 587
Page
55
Use Mode Select button to select
Card.
.
1
Card
2
Moving Line
Process
Sequence
Pr
DualSchd
Moving line is under value that can
changed. Use increase or de
ess
be
Be low
>Card
Display
button to select program
numberto read from card to feeder.
crease
3
Side Panel
Parameter
Select Once
Mode
Select
Once
L
Increase
LrJ
________________
I
I
Read
Card
I
to
Side Panel
Parameter
Select
________________
I
I
#
1
Pu I
sel
Done~ 4~~O35Steel,
Prgl
Prg 1
ArgonOxyl
Press
Figure
Press
12-4.
Reading
From Card
1
Warning Display
If there
Writ
e
WARNING:
Ca
>Read
Press
Done
Below
c~
Side Panel
Parameter
Select Once
>Process
e
Read
Del
Sequence
Dual Schd
e t e
>Done
Card
Press
Side Panel
Parameter
Select
Figure 12-5. Reading (Or Deleting) From
OM-1 587
Page
56
are no
programs
on
the
card, this series of displays appear.
rdEmpty
Dele te
Wr i t
Display
Side Panel
Parameter
Select
I
Side Panel
Parameter
Select
Read
Use increase or decrease button to
select feeder program number
where the card program goes.
An
Empty Card
>Prg
MIG
2
Use Mode Select button to select
Card.
1
Card
2
Moving
Display
Line
Moving line is under value that pan
be changed.
Process
Sequence
3
Pr
DualSchd
>Card
Delete
Display
ess
Select program number to be de
leted from card.
Be low
-t~-Side Panel
Parameter
Select
2
I
Increase
Yes
Side Panel
Parameter
Select
Side Panel
Parameter
Select
#,~
MIG
Press
Side Panel
Parameter
Select
Figure
12-6.
Deleting Programs
From Card
OM-1 587
Page
57
SECTION 13- SETUP
13-1.
Flow Chart
Setup
2
r#
J~
i~J~tIIIIII1_
>s y
A a
s
t em
n
g
e
Sec
u
r
A
p
i t y
>P
u
I
b
Features
/ M
s e
Display
1
Selection
>System
3
Settings
Panel
Section
Settings
Features
To set up features that customize
operation, usethe setupdisplays.
Features that can be customized
are as follows:
i
c c e ~
Example Of Setup Display On Side
Display
Display
ocess
a
Selections
1
2
Settings
Features
Section
Selection
Process
Capability
Pulse/Mig
Mig Only
>Remote
13-3
Parameter
Off/On
13-12
Increase!
Decrease
Press Mode Select
To Go To Next
I
Setup Display
>Arc Time
Run Hours
e
>Range
Volt Mm
0.0 -25.0 V
Volt Max
25.0
AmpMin
0-50A
AmpMax
50-999A
-
13-4
09999.99
Hours
0999,999
Cycles
13-13
No Reset
99.9 V
Reset
.
I
>Self Test
e
13-14
I
>Security
Program
Number
Lock
Off/On
Code
Off/On
Voltage
DVC On/Off
13-5
>Wire Feed
IPM/MPM
Display
Motor
Type
Standard
Low
+
>Access
j
13-6
13-15
Speed
High Speed
e
I
>Mig Type
13-7
>Model
Model
Type
Correction
>Voltage
Bench
13-16
Boom
Control
17-Pin
Feedback
Volt Sense
13-8
>Memory
No Reset
13-17
Reset
I
t
__________________________________________________________________
>Arc Start
Arc Start
Type
13-9
Standard
Hot Start
>Shutdown
No Volt Sense
Off/On
13-18
>Name
Card
Off/On
13-19
I
I
__________________________________
__________________________________________________________________
>Dual Schedule
______________________________________________________________
Switch
Type
____________________________________________________________________
Momentary 2-Pole
13-10
Programs
Maintained 2-Pole
I
Maintained 1-Pole
>Software
Trigger
Program Select Off/On
>Trigger
13-11
Figure
OM-1 587
Page
58
13-1.
Setup
Flow Chart
Version
Numberl
13-20
13-2.
Using Setup Displays
1
Front Panel
Front
Setup Display
panel display during setup.
2
Side Panel Mode And Para
meter Select Buttons
3
Power Switch On Rear Panel
Press and hold down both buttons
while turning On unit.
4
Side Panel Setup
Display
Follow this procedure any time ac
cess is required. Once in the setup
displays, use the Mode Select but
ton to select a particular display.
To
save any or all of the changes
made while in the setup displays,
and/or to exit the setup displays,
turn power to the unit oft and back
on or
trigger to return
display.
press the gun
to the Process
4
Side Panel
Figure
13-3.
Selecting
N OTE ~
Process
13-2.
Display
AccessIng Setup Displays
Capability
This selection allows the wire feeder to be used with
a variety of welding power
This selection also determines whether Gas Metal Arc Welding Pulse
(Pulse/Mig) GMA W-P is available.
sources.
1
Example Welding Power Sources:
Pulse/Mig 450 Ampere Inverter Model
Mig Only 450 Ampere Non-Inverter Model
=
=
System Display
When Process Capability is Pulse/
Mig, the wire feeder works with the
welding
power source to produce
either pulse GMAW-P or regular
GMAW welds.
When in
Mig Only,
works
with
source
to
the wire feeder
welding power
produce regular GMAW
the
welds.
Select the process the welding
power source is able to do.
When
Mig Only
setup choices
is selected,
are
some
automatically
made and are not available for
lection by the operator.
Figure
13-3.
se
System Display
OM-1 587
Page
59
13-4.
Selecting Welding
N OTE ~
Power Source
Range
Welding power source minimum and maximum voltage values
required. Amperage values are required for pulse welding.
1
are
always
Range Display
See welding power source Own
ers Manual for voltage and amper
age ranges. Set values to match
welding power
2
Minimum
Range IsO
3
Press Mode
Select
4
Default values
are for 450 Ampere lnverter
Models. Do not change values if using 450
Ampere Inverter Models.
Amperage Display
(Available When System Set
For Pulse/Mig)
Side Panel
Parameter
Select
Increase
3*
4*
5*
*Use side panel Parameter Select
button to select voltage or amperage.
Use Increase/Decrease buttons to change value.
Figure
OM-1 587
Page
60
13-4.
Range Display
is 0 to 50 amperes.
Maximum
Amperage Display
(Available When System Set
For Pulse/Mig)
Range
2
Voltage Display
is 25.0 to 99.9 volts.
Minimum
Range
5
ranges.
to 25.0 volts.
Maximum
Range
source
Voltage Display
is 150 to 999 amperes.
13-5.
Selecting Security
NOTE ~
Lock
Security lock
works
only
when
a
data card is inserted
(see
1
Section
12-1).
Security Display
Use this display to lock a programs
weld parameters so that changes
can not be made using front panel
controls.
2
Program Number
Choose the program number (1
through 8) to be locked. A program
can be locked on one or both sides.
3
Program
Lock
When lock is off of
Increase
Press Mode
Select
Display
program, the
all weld pa
rameters of that program without
restriction. The operator can also
change sides without restriction.
operator
can
With lock
on a
a
change
program, the opera
change parameters of that
program but the range of change is
restricted. If only one side Is
tor can
locked,
the
operator cannot
sides or program number.
If both sides are locked, the opera
change
change sides but
change program number.
tor can
In the
cannot
example displays in this fig
operator could change the
ure, the
value of trim –10% and wire feed
speed –100 ipm from programmed
values. If the settings are left at 0,
the operator cannot change values
from those programmed. If both
sides are locked, they automatical
ly have the same range of change.
Increase
6
~
Side Panel
Parameter
Select
If dual schedule is on, the paired
are locked and unlocked
programs
l
Iprog
L..J
Lock
together.
2
On
>Trim
1PM
0
lncrease/
Decrease
>Prog
a
Lock
Off
Side Panel
Parameter
Select
Side Panel
Parameter
Select
Increase
Figure
13-5.
Security Display
OM-1 587
Page
61
13-6.
Selecting Or Changing Access Code
NOTE ~
Access code works
only
when
a
data card is inserted
(see Section 12-1).
1
Code
Display
With code off, access to the setup
displays is not restricted.
With code on, the
know and enter the
access or
change
must
code to
any of the setup
operator
access
displays.
2
Access
With
Display
code set, this display ap
pears when power is turned on
while holding the side panel Mode
Press Mode
Select
a
and Parameter Select buttons.
Press side
panel Parameter Select
button to enter access code. When
the correct letter is entered, the in
dicator automatically moves to the
next character. When the final ac
code letter is entered, the dis
cess
play automatically changes
initial setup display.
Turn Power Off And Back On
And Access Security Display
2
J
I
Enter
>Code
AAA
Access
Code
~P_r_e_s_s
Figure
OM-1587
Page
62
13-6. Access Code
Display
to the
13-7.
Selecting Voltage Correction
1
Mig Type Display
With DVC Voltage Correction On,
the unit uses closed-loop feedback
from the 17-pin cord or voltage
sensing leads to maintain set volt
age parameters.
With DVC Voltage Correction Off,
feedback from the arc is not used
for closed-loop feedback to main
tain voltage parameters. Feedback
from the arc Is stIll used for other
functions.
Be sure voltage sensing leads are
connected or voltage feedback Is
availablethrough the 17-pin recep
tacle via the welding power source.
Figure
13-8.
Selecting Voltage Sensing
N OTE ~
13-7.
Mig Type Display
Method
Voltage sensing feedback
setting is Mig Only.
is automatica Ily set for V. Sense when the
System
~J
.
1
Voltage Feedback Display
using the 17 Pin setting, arc
voltage feedback is through the
welding power source, and the
feedback signal is sent through the
17-pin cord to the feeder.
When
If the 17 Pin setting is used, it Is rec
ommended that the voltage sens
ing terminals on the welding power
source be used to monitor arc volt
age at the workplece.
When
using the V. Sense setting,
voltage feedback is through the
voltage sense leads connected to
the feeder. Use this setting when
there is more than 50 ft (15 m) of
arc
weld cable used.
Figure
13-8.
Voltage
Feedback
Display
OM-1587
Page
63
13-9.
Selecting Regular
NOTE ~
Or Hot Arc Start
Arc Start selection is not available when the
Do not
use
the Hot Start
setting
for .035 in
System setting
(9 mm)
or
is
Mig Only.
smaller wire.
1
Arc Start
Display
Use the Hot Start mode for pulse
welding with 450 Ampere Inverter
Model when high initial weld cur
rent is necessary to start large di
ameterwelding wires. When in Hot
Start, the 450 Ampere Inverter
Model starts the arc in the CV mode
and switches to CC once the arc is
started. Do not use Hot Start un
less using 450 Ampere Inverter
Model.
3~~: rDuaISChd
Figure
13-10.
Selecting Type
1~
13-9. Arc Start
lnc~asetart~
Display
Of Dual Schedule Switch
1
Dual Schedule
Display
Choose type of external dual
schedule switch or use of the trig
ger as the dual schedule switch.
1
Increase
L~
Increase
Figure
OM-1587
Page
64
13-10. Dual Schedule
Displays
1
(DSS-l0)
1
1
(0SS9M)
~
>
1
>
2
2
2
2
Maint 2P
(Maintained-Contact
DSS-9M)
2-Pole Switch Or
2
>
>
Momen 2P (Momentary
Contact 2-Pole Switch Or
DSS-1 0)
3
Maint 1 P Or
Trigger (Maintai
ned-Contact 1 -Pole Switch Or
DSS-9 Or DSS-8)
A
3
2
1
0--
A
3
4
0-
3
1
(DSS9)
1
(DSS-8)
1
2
2
2
A~4
3
l\_________
I
3
2
>
3
3
3
>
>
4
4
>
>
Figure
13-11
Selecting Trigger Program
-
Dual Schedule Switch
1
>
2
TB
3
Adapter
1
>
>
13-11.
1
>~
>
2
Adapter
1
Diagrams
Select
1
Trigger Display
When
Program Select is On, the
trigger
can
be used to switch be
tween programs that have at least
0.2 seconds of preflow time.
Briefly pressing and releasing the
gun trigger switches programs. For
example: If programs 1, 2, and 6
have preflowtime of at least 0.2 se
conds, pressing the trigger will
switch from program ito 2, 2 to 6,
and 6 to 1.
:1
Figure
13-12.
Trigger Display
OM-1 587
Page
65
13-12.
Selecting
Remote Increase/Decrease
Capability
1
Remote
Display
When Parameter Inc/Dec is On,
the
dual
momentary-contact
schedule switch can be used for
changing weld parameters as well
for
between
as
switching
programs.
For example: when the cursor on
the front panel display is on Trim or
Volts, the dual schedule switch can
be used to remotely change the
value. When the front panel param
eter select is on Prg, the dual
schedule switch can be used to
the program number. A
DSS-1O dual schedule switch is
recommended for this purpose.
change
I
Press
Mode Select
I
D
u a
I Sc h d
Tn
Setup
gger
>Remote
Arc
Pa
r ame
t
Inc IDe
c
e
~incIDec
Pa
r
_~_
>Qf I
Time
r ame
t e r
Increase
Figure
13-13.
Resetting
13-13. Remote
Display
Arc Time
1
Arc Time
Display
The unit accumulates arc hours up
to 9999.99 hours or 999999 weld
cycles before rolling over to zero
(0). The arc timer can be reset us
ing this display.
FIgure
CM-i 587
Page
66
13-14. Arc Time
Display
13-14.
a
Using
Self Test
1
Have
only Factory-Authorized persons
perform tests or replace parts.
Switch A
This checks the gun switch in
crease
2
Access
Setup
Display
This checks the gun switch docrease
3
~
position.
Switch B
position.
Trigger
This checks the gun
Press
Mode
Select
4
trigger.
Wire Feed
This checks the wire feed motor.
5
Gas
This checks the gas valve.
6
Contactor
This checks the
source
7
welding
power
contactor.
CVICC
This tests the pin at the 1 7-pin re
ceptacle that controls whether the
unit is in CC (constant current) or
CV (constant voltage).
T~er
>1
r
I g g
5
Increase
~ £
On~
I~~
~ ~
~ ~
I
Increase
I..-
a
I
o
Press
~
I >GQ a
The
welding wire and all metal parts In contact with
Itcarryweldoutputwhentheweldlngpowersource
contactor Is energIzed.
r e s s
Side Panel
Parameter
Select6
I
t a
oni
p
I ~ r
Increase
I
>CV
Side Panel
Parameter
Select
On~
_______________
Press
___
___
Figure
13-15. Self Test Procedure
OM-1587
Page
67
13-15.
Units For Wire Feed
Selecting
Speed
And Motor
Type
Wirefeed
1
Display
displayed unit of wire speed
(1PM or MPM) can be chanped
along with the wire feed motor type
(Standard, Low Speed, or High
Speed).
The
~
Di
$
p I
a
Di
y
$
p I
a
Increase
y
I PM
Motor
>1:11gb
iMotor
Type
~
Type
Standard
Increase
Parameter Decrease
Increase
Select
Figure
13-16.
Selecting
__NOTE
~7)
13-16. Wirefeed
Bench Or Boom Model
Display
Type
This selection is not available when the
System setting
1
is
Mig Only.
Model
The unit is
Type Display
shipped from the factory
set to Bench for bench
feeders or Boom for
Swingarc model feeders. The set
ting loads the proper pulse param
eters into memory for the model
used.
properly
model
This selection does not change
when a memory reset is done.
1
Figure
OM-1587
Page
68
13-17. Model
Type Display
13-17.
Resetting Memory
1
No Reset
Memory
2
cannot be reset.
Program
Reset
Press Parameter Select button to
reset last active program to
original
factory
program settings. All other
program and setup information re
mains the same.
3
System
Reset
Press Parameter Select button to
reset programs and setup to oilgi
nal factory settings. System, Arc
Time, and Model Type settings are
not affected by the system reset.
rami
(Default) Displays
4
Reset
1
Voltage Shutdown Display
Reset
Press
>Process1
Sequence
>Prg
SidePanel
Parameter
Select
1
I
I
Pulse
DualSchd
O35~Steel
Card
Argon
Increase!
Decrease
Oxy
~yatem
Reset
L___~___
Press
Side Panel
Parameter
Select
Figure
13-18.
Selecting Voltage
13-18.
Resetting Memory
Error Shutdown
With Arc StartNolt Sense on, the
unit shuts down when no arc volt
age is sensed. If the unit shuts
down,
an error
message appears
(see Section 14-4).
With Arc StartNolt Sense off, the
unit continues to feed wire even
when there is no arc voltage
sensed.
Figure
13-19.
Voltage
Shutdown
Display
OM-1 587
Page
69
13-19.
Selecting Program
Name Feature
Name
1
Display
data card is used, the pro
grams written from the unit to the
card can be named.
When
Figure
13-20.
13-20.
a
Naming Card Programs
Software Version Number
1
Example Version Number
Display
When talking with service person
nel, this number may be required.
(Check actual unit display for num
ber.)The factory keeps this number
on file with the serial number of the
unit.
1
Figure
OM-1587
Page
70
13-21. Version Number
Display
SECTIC)N 14- MAINTENANCE & TROUBLESHOOTING
WARNING
_______
ELECTRIC SHOCK can kill.
Do not touch live electrical
parts.
Turn Oft wire feeder and welding power source, and
di~connect
input power before inspecting,
maintaining,
or
servicing.
MOVING PARTS
Keep away
from
can cause
Allow
can cause severe
cooling period before
burns.
servicing gun
or
unit.
Aæi~Liti,
injury.
moving parts.
Maintenance
away from pinch points such
Keep
S
H OT PARTS
as
drive rolls.
to
be
persons.
performed only by qualified
wtwam4.1 8/92
14-1. Routine Maintenance
a
Turn
Off
before
all
=
power
3 Months
-
6 Months
maintaInIng.
Tape Or
Replace
-~
Cracked
Weld
Cable
3 Months
WARNII~J~
Replace
Unreadable
Labels
See
Section
Replace
~
Cracked
Parts
16
14-Pin Cord
Clean
And
lighten
________
_________
3-7
Weld
Terminals
Gas Hose
Figure
Gun Cable
14-1. Maintenance Schedule
OM-1567
Page
71
14-2.
Replacing
The Hub
Assembly
READ SAFETY BLOCKS at start of
Section 14 before proceeding.
____
Turn Off wire feeder and welding
power source. Retract wire onto reel
and remove. Take hub apart as
shown.
1
Retaining Ring
2
Spanner Nut (Optional)
3
Wire Retainer
4
Wire Reel
5
CClip
6
Washer
7
Hub
8
Spring
9
Keyed Washer
10
Fiber Washer
11
Brake Washer
(Optional)
(Optional)
Support Shaft
12
Hub
13
Spacer
14
Hex Nut
Replace worn or broken parts, and
slide parts onto shaft in order shown.
hex nut until a slight force is
needed to turn hub, Install welding
wire (see Section 3-8).
Tighten
7
9
10
11
11
10
13
Tools Needed:
14
~ 15/161n
ST.152 56~-B
Figure
14-2. Hub
Assembly
14-3. Overload Protection
I
~
READ SAFETY BLOCKS at start of
Section 14 before proceeding.
Turn Off wire feeder and
power
1
welding
source.
Circuit Breaker CB1
CB1 protects the wire feeder from
overload. If CB1 trips, the wire
feeder shuts down.
Allow
cooling period and manually
reset breaker.
Rel. ST-162 ~2S
Figure
OM-1 587
Page
72
14-3. Circuit Breaker CB1
14-4. Error
Displays
1
Release
Trigger
Error
Display
This appears it the trigger is closed
when the unit power Is turned on, or
If the trigger is stuck or defective.
2
The
No Volt Sensed Error
Display
voltage sense circuit is not
receiving feedback. Check voltage
sensing connections. Check con
nections at 17-position plugs/recep
tacles at the unit and welding power
arc
source.
1\
Turn unit off and back
on
after
cor
recting problem.
A
T
e
r
I
I
e
a
g g
s
e
e
If this
r
pulse welding, It may help to select
Hot Start (see Section 13-9).
2
3
No
~
Volt
Sensed
error
continues to
occur
when
Memory CRC Error Display
The data in the program indicated is
not the same data that was saved.
1Error
]EJ
Perform
4
3
a
system
reset.
Memory Range Error Display
The data in the prqgram indicated Is
out of usable range.
M
e m 0
r
y
CRC
Prg
Er
1
00
ror
4
Go through pulse parameters to
make sure they do not exceed set
tings of the Range display (see Sec
tion 13-4 and Section 7) or perform a
system reset.
M
e m o
.r
y
5
1
Prg
No Tach Sensed Error
The
A
a
n
~
e
reaching
Error
Display
tach
feedback is not
the control. Check connec
motor
tions.
5
Press front
panel Parameter Select
to clear error.
No
Tach
Sensed
6
Arc
S t
.a
r
7
Arc
Stop
t
1Error
1Error ~
1Error
6
Arc Start Error
Display
This appears when pulse welding
and current Is detected but the arc
cannot be started. Check and correct
program pulse parameters and volt
age settings. Check voltage sensing
connections.
Press front panel Parameter Select
to clear
7
Arc
error.
Stop
Error
Display
This appears when pulse welding
and the motor does not stop at the
end of the weld. If there Is high fre
quency 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.
Ref. ST-155 222
Figure
14-4. Error
Displays
OM-1587
Page
73
14-5.
Troubleshooting
WARNING
AA
ELECTRIC SHOCK
S
kill.
can
HOT PARTS
Do not touch live electrical parts.
Allow
can cause severe
cooling period
before
burns~
servicing gun
or
Lnit.
Turn Off wire feeder and welding power source, and
disconnect
input power before inspecting,
maintaining,
or
servicing.
MOVING PARTS
Keep
away from
Keep away
from
can cause
injury.
moving parts.
shooting
pinch points such
as
to be
performed only by qualified
drive rolls.
Table 14-1.
wfwam4.1 8192
Troubleshooting
Trouble
Section
Remedy
Wire feeds, shielding gas flows, but
electrode wire is not energized.
~
-~
Check interconnecting cord connections. If secure, check cord for
~
continuity
I
and
repair
or
replace.
3-6
-~
_____________
Wire feeder is on, meter(s) do not light
up, motor does not run, gas valve and
welding power source contactor do not
pull In.
~
-.
Check and reset CB1.
Electrode wire feeding stops
erratically during welding.
H.
-~
Check gun
trigger connection.
Check gun
trigger.
or
feeds
14-3
-~
3-4
--~
--
I
See gun Owners
Readjust
drive roll pressure.
Readjust
hub tension.
Change
Clean
Manual.
3-9,3-10
-~
3-8
to correct size drive roll.
or
replace dirty
Incorrect size
Replace
or worn
contact
tip
or
or worn
wire
3-3B
3-3A
guides.
Manual.
--~
matter from around nozzle
--~
liner. See gun Owners
Remove weld spatter
or
3-3B
drive roll.
foreign
opening.
Have Factory Authorized Service Station/Service Distributor
check drive motor or motor control board PCi.
Motor
runs
1---
slowly
Wire does not feed until trigger is pulled,
but continues to feed after trigger is re
leased, and trigger hold is not on.
Gas valve in feeder Is rattling loudly
along with possible erratic or slow wire
feed
--.
J
-.
Check for correct input
--~
--
]
voltage.
Check for a short between welding gun trigger leads and weld
cable. Repair short or replace welding gun.
Check for a short between welding gun trigger leads and weld
cable. Repair short or replace welding gun.
-
-----1__-~
~
-~
speed.
Unit does not switch out of Run-In
}.
Speed.
I
Install, reconnect,
or
replace voltage sensing lead.
3-6
____________________________________________________
Wire feeder power is on, displays
up, but unit is inoperative.
light
~
(
-~
Check welding gun trigger leads for continuity, and repair leads
replace gun.
or
i
-~
I
_____________
OM-1587
Page
74
NOTES
OM-1 587
Page
75
SECTION 15
ELECTRICAL DIAGRAMS
-
r~T~~JST~
I
COJECTIGH FOW REICTE
I
SEE FIELD DOTRLCTIGH)
PP~AM
DSPL2
SIDE DISPLAY
DC
I
I
I
i~1-1~.-j~i~*.
SELECT
A~GH
I
I
ii
IOOTO
6
6
ii
6
6
6
23456
DSPL I
FRONT DISPLAY
DATA CARD
:
J
RC6I
RCIOO-l>
i
I
I
I
PC6O
I
RCSO/PLD6O
I
vvvvvvvvvvvvvv
I
~
I
0
0
P941
~
0
0
P942
I
~
PC6~DATACASO
~
RCIOO-2>)--
~cRE)N1
IP~ONT
P
B
FIL~B~3AR0
RCIOO/PLGIOO
RCIOI/PtGIOI
RCIOO-3>>RCIOO-6>>-
I
PCI
3-5
v_v_v_v_v
PARAITEP
SELECT
PC3O
P~
UP
A/\AAAAAAAA
w~
LEFT/RIGHT
SELECT
00
P825
_______
~
0000
P921
P922
LEFT
TRIGGER
~D
91041
MROGESSOW BOARD
dO
Rd24
PCI 0/PLO 10
PCI I/PLGI I
TRIGGER
~D
PC 12/PLO 12
PCI 5/PLC IS
0000
wr~ ~m
1 r
ANT FLOW
5wI#GA~C ~
Icciao.
~T.
4
I IPLG8I
P1.023
~ 14
3>)113
>
>
~I ~
01
I
-
I
PLG63
J
~
(~TI04AL)
~
allY,1 4>
~>Ij
~~~)2>
4
2
~
wr~ 1~j-~
,.kTAo.cNr
r r
~ ~
~PTI04A1..)
I IPLG8I
P1.0831
I
1
~
>..~J
13
2
>)J
2
>
>
1P3-D
PCI I-I
LED
LED
PCI
LEFT
RIGHT
SELECT
PC 17/PIG IT
>121>
I_2>)~~_~!~
RCII~6>>_~!5~
PCII-3>>~55
LED
~
4
2
I
I
r
L.__...J
I.OED WITH SWIIEARC
OW XTAO4~IT
I
h
-<I
2
E~~-<
7
*-~< 74~-~7 ~ 7.
3
~34~)3
(I
2E-~I2
>~-<I~
I
4
GSI<>
i
I
5
5
.E~~--<
5~~5
>.<
2
E~-(
2E-)2
~
I
7
~ 7~7 >~<
~-~- 3<.~(I
3
~<i
6
PLG57/PLGS7
CO~ 24~_.(I
E~(
34~)3 >~~-<I ~.
RIGHT
I
~
4_~L<1 I.E-~-).I ~
4~-<6E~~+6
~
<._L_< ~ >
2
6<~ .
6
I
I.
FIgure
Page
76
15-1. Circuit
>2~<ii
6
~<I
GS2~
OM-1587
RCII-4>>~0~
RCI I-8>>--~~
>
PCI
>
____
PLG29
RC27>
I
I
~~>I4
~
RC26
SELECT
LED
___j
PLG25
P923
RIGHT
TRIGGER
3
__________
_______
I
PC 16/PLC lb
P924
LEFT
TRIGGER
~fl-O
Diagram
_I
For Wire Feeder
-l
REICTE PEICANT
pPs-8
I
(OPTION)
I
I
RPS-B
I
SWITCH BOARD
I
I
PCI I0.Pl_SI
I
10
I
.%~
I
ISIIELO
I
<CRC1I0-*
NIT
I
at,
Iii
~pyIII
I
<<PCI
ID-I
<<PCI
ID-S
I
PE1CANT
I
I
CCRCIIO-3
__________________________________
I
~C<RCIIO-2
SLk,Lo~Iio
PCBO
L
FILTER BOARD
RCB2/PL082
RCB9/PLO7D
RC9D/PLOPO
SCSI-F >
F
I
I
C
I
IIV/IODAII E>?c
E
I
I
O)~>
0
I
I
~)~> N4r25
I.24V-CV)
RCBI-E > Q.PPDU FE~AOC
RCBI-G > IpcxTna
)~>
C)~~>
IF
17 PIN ~4O4
RCBI-C > ICICV
ID-IDA)
RCBI-M> VEIJAGE FEEDBAD( IIV/IDV)
I
I
I
(IFAPPLICASLE)J
L
r
WELD ELEIRENT SE1C~l
PC5O
INTERFACE BOARD
1!Q~LNSLR~&TL~E!
RCSO/PL050
-I
SCSI/PLOD I
L
Rt52/PLGD2
Rt53/PLOD3
5c54/PLGDA
/0
*~
-~<
DUVE ASSY
PID(-LP(PIQITI
ScssiPu~e
PC55-5
L<<RC~o,
~IVE ASSY
PID(-LPILEFT)
corn
2
~
a-Aw
NPlC
STUD
r
IA
-I
PIN PLLS
I
IOV
IXI44APC
P_S_
~
I
PLO9
I
au
I
~tOi
I
I
I
) F
I
I
I>~
PCI
MOTOR BOARD
COBECT
TO POWER
PCI/PLO I
RD2/PLG2
RC3/PLG3
RC4/PL.G4
RcD/VLIZ
0
SD-164 539-B
OM-1 587
Page
77
pc25,
~G25
PC2O
FRONT DISPLAY
PLG57
&
~IVE
Figure
OM-1 587
Page
78
15-2.
Wiring Diagram
For Wire Feeder
SD-164 481-B
OM-1 587 Page 79
SECTION 16- PARTS LIST
.r-.
c~)
CLI
cJ
LI)
cJ
CD
(I
/
/
CLI
C~)
CD
E
0
a,
V
0
CLI
CD
0)
ST-800 084-C
Figure
OM-1 587
Page
80
16-1. Main
Assembly
Item
No.
Part
No.
Figure
1
.108 008..
..
2
168 103.
..
3
..
+168 104
16-1. Main
Assembly
REEL, wire 60 lb (consisting of)
NUT, spanner retaining
RETAINER, spool support (consisting of)
LABEL, caution falling wire reel can cause damage
SUPPORT, reel spool
HUB & SPINDLE ASSEMBLY, (consisting of)
RING, retaining spool
RING, rtng ext .625 shaft grv x .O5Othk
WASHER, fIat .640 ID x 1.000 OD x .O75thk stl
1
.
..
1
.
.
..
1
.
166 594
..
4
124 900
.
..
..
5
..
6
143 160..
058 427.
.
..
..
7
141 700.
.
..
..
8
605 941
.
..
..
9
142 837.
..
10
..
11
010233.
057971
..
12
010191
....
..
13
058 628
.
..
14
..
15
..
16
..
17
058428.... HUG,spool
071 730
TUBING, stl .875 OD x l2ga wall x 2.375
135 205
NUT, .625-11 .94hex .77 high stl elastic stop
601964.. SCREW,.375-16x.75ohexhd
.
.
.
..
.
..
.
..
.
..
.
.
..
.
.
..
1
1
1
1
1
1
SHAFT support spool
SPRING, cprsn .970 OD x .120 wire x 1.250
WASHER, fIat .632 IDx 1.5000Dx .l25thkstl
1
1
2
WASHER,flat.656lDx1.5000Dx.l25thkfbr
WASHER, brake sti
..
18
..
19
..
20
..
21
..
22
SUPPORT, spool
FOOT, rubber 1 .25Odia x 1 .375high
142 838.. BRACKET, mtg spool RH
602213.. WASHER, lock .380 ID x .683 OD x .ll5thk stl split
601 872.. NUT, .375-16 .56hex .34 high stl
..
23
139226..
BASE
..
24
083639..
..
25
159 360..
..
26
159 646..
..
27
159647..
..
28
139752..
..
29
167768..
..
29
.167 770..
..
29
.167 772..
..
30
156243..
..
31
145 639..
..
32
134834..
..
33
167762..
..
33
.167 764..
..
33
.167 766..
WEATHERSTRIPPING,adh .125x 1.500 (order by ft)
INSULATOR, screw machine
CLAMP, motor base
INSULATOR, motor clamp
SPACER, stl .500 OD x l2ga wall x 3.750
DRIVE ASSEMBLY, wire RH (Fig 16-4)
DRIVE ASSEMBLY, wire RH (high speed) (Fig 16-4)
DRIVE ASSEMBLY, wire RH (low speed) (Fig 16-4)
CLAMP, motor top
STRIP, buna N compressed sheet .062 x 4.000 x 4.000
HOSE, SAE .187 ID x .410 OD (order by ft)
DRIVE ASSEMBLY, wire LH (Fig 16-4)
DRIVE ASSEMBLY, wire LH (high speed) (Fig 16-4)
DRIVE ASSEMBLY, wire LH (low speed) (Fig 16-4)
..
34
141 411
Quantity
Description
2
2
1
1
1
2
1
..
134 306..
.
Fig
16-2..
600 324..
4
1
2
2
1
ift
8
2
2
1
1
1
1
2
2
5ft
1
1
1
CONTROL BOX
1
3ft
CABLE, weld cop strd No. 4/0 (order by ft)
OPTIONAL
+When
ordering
a
component originally displaying
BE SURE TO PRDVIDE
a
precautionary label,
the label should also be ordered.
MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1 587
Page
81
/
U)
cJ
0)
0)
/
(0
I
/
/
\
\
/
/
/
/
/
/
/
/
/
/
/
/
/
0)
C
C~)
a
Iz
(0
0
C.)
C.)
ST800 111-a
Figure
OM-1587
Page
82
16-2. Control Box
Item
No.
Dia.
Mkps.
Part
No.
FIgure
1
2
GS1 ,2
3
(Fig
16-1 Item
34)
PANEL, side lower
VALVE, 24VAC 2 way custom port 1/8 orf
STAND-OFF SUPPORT, PC card .3121.375
134 201
155114.. CIRCUIT CARD, motor control
115092.. CONNECTOR & SOCKETS, (consisting of)
113746.... CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
115 093.. CONNECTOR & SOCKETS, (consisting of)
113746.... CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
115 091
113746.... CONNECTOR, rect skt 24-1 Bga Molex 39-00-0038
136 810.. CONNECTOR & SOCKETS, (consisting of)
114066.... CONNECTOR, rect skt 20-l4ga Amp 350536-1
161 706.. CASE SECTION, bottom/rear
083432.. CIRCUIT BREAKER, man reset 1P 1OA 250V
111 997.. SWITCH, rocker SPST 1OA 25OVAC
CIRCUIT CARD, HF filter dual
163921
1
.
125 785..
2
10
..
PCi
PLG1
PLG2
PLC44
PLG6
5
6
7
..
CB1
Si
PC8O, RC81
131 204..
PLG82
113746.... CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
158 720.. CONNECTOR & SOCKETS, (consisting of)
PLG9O
153 501
9
..
1
6
1
10
1
4
1
1
1
CONNECTOR & SOCKETS,
1
CONNECTOR,
rect skt
(consisting of)
22-l8ga Amp
1
3
1
770904-3
12
CONNECTOR & SOCKETS, (consisting of)
.
1
147995....
6
073 756..
CONNECTOR, rect skt 22-l8ga Amp 770904-3
STAND-OFF, 6-32 x .625 Ig
2
11
151 187..
+161 710..
12
010 325..
13
14
134 464..
163519..
PLG9
1
8
..
PLG75
10
1
..
147995....
15
16-2. Control Box
161 707..
....
4
8
Quantity
Description
LATCH,slideflushmtgholel.000widexl.5001g
1
WRAPPER
1
BUSHING, strain relief .840 ID x .875mtg hole
LABEL, warning general precautionary
1
1
CABLE,portNo.18/148/c(orderbyft)
l2ft
18
CONNECTOR & PINS, (consisting of)
CONNECTOR, circ pin push-in 14-l8ga Amp 21 3603-1
158719.. CONNECTOR & SOCKETS, (consisting of)
147995.... CONNECTOR, rect skt 22-l8ga Amp 770904-3
079739.... CONNECTOR, circ clamp str rif sz 17-20 Amp 206322-2
601222.. CLAMP, univ5oA
603 106.. HOSE, nprn brd No. 1 x .250 ID (order by ft)
19
600399..
ift
35ft
20
138044..
1
141 162..
134731
PLG19
16
17
1
14
....
1
2
1
1
WIRE, strd l4ga bik 600V 105c (order by ft)
BUSHING, strain relief .120/.150 ID x .500mtg hole
21
107 983.. BLANK, snap-in nyl .500mtg hole
22
RC7O
048 282.. CONNECTOR w/SOCKETS, (consisting of)
079 534.... CONNECTOR, circ skt push-in 14-l8ga Amp 66358-6
23
000 527.. BLANK, snap-in nyl .875mtg hole
24
605 227.. NUT, .750-14 knurled 1 .68dia .41 high nyl
25.... CR101
072 817.. RELAY, end 24VAC DPDT
26
SRi
035 704.. RECTIFIER, integ 40A 800V
27
030 170.. BUSHING, snap-in nyl .750 ID x 1.000mtg hole
28
Fig 16-3.. PANEL, front w/components
29... PLG12,50 155629.. CABLE, ribbon l4posn
30
154 938.. STRIP, mtg PC card
31
097 132.. STAND-OFF, 6-32 x .375 Ig
32
PC5O
163917.. CIRCUIT CARD, interface
PLG51
158720.. CONNECTOR & SOCKETS, (consisting of)
147995.... CONNECTOR, rect skt 22-l8ga Amp 770904-3
PLG52
158 719.. CONNECTOR & SOCKETS, (consisting of)
147 995.... CONNECTOR, rect skt 22-1 8ga Amp 770904-3
PLG53
131 204.. CONNECTOR & SOCKETS, (consisting of)
113746.... CONNECTOR, rect skt 24-i8ga Molex 39-00-0038
PLG54 148 439.. CONNECTOR & SOCKETS, (consisting of)
147 995
CONNECTOR, rect skt 22-i8ga Amp 770904-3
1
1
4
1
2
1
1
3
1
1
1
4
1
1
12
1
2
1
3
1
10
....
OM-1587
Page
83
Item
No.
Dia.
Part
No.
Mkgs.
Figure
PLG55....115092
113746
126689
Quantity
Description
16-2. Control Box
(Fig
16-1 Item
34) (Continued)
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
STAND-OFF, 6-32 x 1.500 Ig
CIRCUIT CARD, processor w/proms
CONNECTOR & SOCKETS, (consisting of)
..115092
113746
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
PLG15... 153501
CONNECTOR & SOCKETS, (consisting of)
147995
CONNECTOR, rect skt 22-l8ga Amp 770904-3
PLG17
CONNECTOR & SOCKETS, (consisting of)
..115 093
113746
CONNECTOR, rect skt 24-lBga Molex 39-00-0038
35 PLG1O,24.. 155 022.. CABLE, ribbon 34posn
36 PLG16,41
155 023.. CABLE, ribbon 24posn
37
Fig 16-5.. PANEL, side w/components
158 373.. CABLE, interconnecting pwr (consisting of)
097868.... CONNECTOR, circ l7skt plug Amphenol MS-3106A-20-29S
116964.... CONNECTOR, circ clamp slf sz 20-22 Amphenol MS-3057-1012
600 343.... CABLE, port No. 16 5/c (order by ft)
097 866.... CONNECTOR, circ 17 pin plug Amphenol MS-3106A-20-29P
059 712.. CLIP, component .437dia mtg adh back
010 145.. CLAMP, nyl .500 clamp dia
164 059.. HOSE ASSEMBLY, gas (consisting of)
056 851
FITTING, hose brs barbed nipple 3/1 6tbg
010606.... FITTING, hose brs nut .625-18RH
056 108.... FITTING, hose brsferrule .450 ID x .718 Ig
134 834.... HOSE, SAE .187 ID x .410 OD (order byft)
073433.... FITTING, brs barbed M 3/l6tbg x 1/4NPT
044 858.... FITTING, pipe brs Y short 1/8NPT ml x 1/4NPT
073 432.... FITTING, brs barbed M 3/l6tbg x 1/8NPT
079 196.... FITTING, brs barbed fem 3/l6tbg x 1/4NPT
010604.... FITTING, hose brs bushing 1/4NPTx .625-18RH
33
POlO
PLG11
34
...
161781
..
..
....
+When
ordering
a
component originally displaying
a
precautionary label,
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1587
Page
84
1
,
8
4
1
1
8
1
6
1
6
1
1
1
1
1
2
lOft
1
2
1
1
2
2
6
4ft
2
1
1
1
1
a
Dia.
Item
No.
Mkgs.
Part
No.
Description
Figure
167697..
147139..
164842..
144844..
6
...
PC2O,30
PLG25.
7....
160804..
165484..
147995..
PLG24....
167633..
089 032..
153169..
010291
167700..
10
11
12
13
Panel, Front w/Components (Fig
16-2 Item
28)
NAMEPLATE, (order by model and serial number)
PANEL, front
TAPE, adh acrylic double sided .010 x .500 x 3.000
METER LENS, w/gasket
STAND-OFF, 6-32 x .875 Ig
CIRCUIT CARD, schd front
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-l8ga Amp 770904-3
See
159264..
16-3.
Quantity
Figure
1
2
1
9
1
1
8
16-2 Item 35
RING, ext .625 shaft grv x .O45thk E style
WASHER, shldr .612 ID
LENS, LED 4341 red panel mtg
ACTUATOR, switch
WASHER, flat .625 ID nylafil
KNOB, pointer
3
1
4
2
9
13
12
ST-800 112.C
Figure
16-3. Panel, Front
w/Components
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1587
Page
85
Item
No.
Dia.
Mkgs.
Part
No.
Figure
..
1
010 668
.
.
..
2
150 147
.
.
..
3
149 962
.
.
..
4
.
.
..
5
.
.
..
6
149 486
163 282
163 281
.
.
165 798
165 799
.
.
..
6
7
.
.
..
8
132 750
.
.
..
9
150 520
.
.
..
Quantity
Description
16-4. Drive
Assembly,
Wire
(Fig
16-1 Items 29 &
33)
SCREW, cap sti sch .250-20 x 1.500
CARRIER, drive roll w/components
SPACER, carrier drive roll
PIN, rotation arm rocker
NUT, .250-28 stl
SPRING, pressure arm retaining LH
SPRING, pressure arm retaining RH
WASHER, flat .257 ID stl
ARM, pressure
2
2
2
2
2
2
2
SPACER, rotation pin
7
19
20
See Table 16-1 For
Drive Roll & Wire Guide Kits
21
16
15
9
10
2
1
24
25
26
S.
S.
27
A
31
30
7
29
3
2
1
Figure
OM-1 587
Page
86
16-4. Drive
Assembly,
Wire
ST-152 711-D
Item
No.
Dia.
Part
No.
Mkgs.
Description
Figure 16-4.
(Continued)
10
133493
11
133350
12
12
M1,2
M1,2
156354
156353
153491
153492
153493
13
155098
153550
155099
155100
154031
133493
PLG11,17... 115092
113746
PLG51,57... 131 203
114656
RC7,8
....
135409
114656
010837
Drive
Assembly,
Quantity
Wire
(Fig
16-1 Items 29 &
RING, retaining ext .250 shaft x .O25thk
PIN, hinge
MOTOR, gear 1/8hp 24VDC 272RPM (consisting of)
MOTOR, gear 1/8hp 24VDC 500RPM (consisting of)
KIT, brush replacement (consisting of)
CAP, brush
BRUSH, carbon
KIT, cover motor gearbox (consisting of)
COVER, motor gearbox (consisting of)
GASKET, cover
SCREW, cover
SPACER, locating
RING, rtng ext .250 shaft grv x .O25thk
CONNECTOR & SOCKETS,
CONNECTOR,
rect skt 24-1
8ga
CONNECTOR,
rect
pin 24-1 8ga Molex
(consisting of)
pin 24-1 8ga Molex
CARRIER, shaft
153631
131 204
26
113746
604311
132611
27
149959
28
28
149746
29
108940
149745
30
604538
..31
151437
32
33
34
128237
149527
601872
35
602213
36
602243
37
38
149964
601966
39
167387
40
133530
41
133308
Optional High Speed
2
1
2
8
3
1
132747
152241
..
1
5
8
1
22
....
1
2
SHAF1
25.. TK1,2/PC51
PLG57
1
39-00-0040
132824
133739
2
CONNECTOR & PINS,
21
23
24
1
2
2
165934
132746
17
2
Molex 39-00-0038
604772
137248
129351
602200
16
1
2
CONNECTOR & PINS, (consisting of)
18
19
20
15
.2
(consisting of)
39-00-0040
CONNECTOR, rect
PIN, spring CS .093 x .625
SPRING, indicator
SCREW, hexwhd-slt stl slffmg 8-32 x .500
WASHER, lock stl split No. 8
WASHER, flatstl SAE No.8
SPRING, cprsn .573 00 x .088 wire x 1.062 Ig
BUSHING, spring
14
33)
1
1
1
1
2
2
spring
KNOB, extension
WASHER, flat .375 ID
1
1
x
.625 OD
x
.062
1
CIRCUIT CARD, digital tach (consisting of)
CONNECTOR & SOCKETS, (consisting of)
2
1
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
GROMMET, rbr .250 ID x .375mtg hole
3
1
OPTICAL ENCODER DISC
2
FITTING, brs barbed M 3/l6tbg x .312-24
ADAPTER, gun/feeder LH
ADAPTER, gun/feeder RH
SCREW, cap stl hexwhd .250-20 x .750
WASHER, flat stl SAE .312
KNOB, plstcT 1.125 Ig x .312-18 x 1.500 bar
SCREW, hexwhd-slt sti slffmg 10-32 x .500
COVER, drive roll
NUT, stl hex full .375-16
WASHER, lock stl split .375
WASHER, flat stl .375
PIN, groove .250d1a x .500 Ig
SCREW, cap stl hexhd .375-16 x 1.250
SPACER, locating
DRIVE, pinion
RING, retaining ext .375 shaft x .O25thk
1
1
1
4
1
1
2
1
1
1
1
2
1
2
1
1
Motor
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1 587
Page
87
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure
1...
PC6O
PLG6O
w/Components (Fig
16-2 Item
37)
TAPE, adh acrylic double sided .010 x .500 x 3.000
LENS, clear anti-glare
154 933.. PANEL, inner control
156 623.. CIRCUIT CARD, data card
153501.. CONNECTOR & SOCKETS, (consisting of)
147995.
CONNECTOR, rect skt 22-l8ga Amp 770904-3
147 139..
2
155024..
1
.
PLG41
PC4O
16-5. Panel, Side
Quantity
1
1
1
6
..
See
158 160..
144 844..
8...
154 109..
9.
153 169..
Figure 16-2, Item 36
CIRCUIT CARD, side display
STAND-OFF, 6-32 x .875 Ig
PLATE, ident inner control
ACTUATOR, switch
1
4
1
4
1
7
99
8
ST800 113-B
Figure
16-5.
Panel, Side wiComponents
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1587 Page 88
Table 16-1. DrIve Roll And Wire Guide Kits
4)
~
Wire Size
E~
~
V-GROOVE
U-GROOVE
VK-GROOVE
~
4 RoIl
Kit
Drive
Roll
4 Roll
KIt
Drive
Roll
053700
151036
072000
151052
132958
151027
053697
151037
053701
151053
149519
151028
053698
151038
053702
150995
149520
151029
053699
151039
053706
1.8mm
150995
149520
(.079 in.)
2.0mm
150995
149520
151 040
(094in:)
2.4mm
150996
149521
(~)
2.8mm
150996
(15)
3.2mm
150997
4 Roll
Kit
Drliie
Roll
132957
151070
083489
151054
132956
151071
083490
151055
132955
151072
053708
151 056
132959
053704
151 057
132960
151 073
053710
151041
053703
151058
132961
151074
053709
149521
151042
053705
151059
132962
151075
053711
149522
151043
053707
151060
132963
151076
053712
4 Roll
Kit
Drive
Roll
149518
151024
087130
150993
149518
151025
053695
0.9mm
150993
149518
151026
.045in.
1.1mm
150994
149519
.052in.
1.3mm
150994
1.6mm
Fraction
Metric
.023-.025in
0.6mm
150993
.030in.
0.8mm
.035in.
.068-.072in
UC-GROOVE
E~
.S
5/64 in.
S-0549-C
Each Kit Contains An Inlet Guide, Intermediate Guide, And 045 233 Antiwear Guide With 604 612 Setscrew 8-32
With 4 Drive Rolls.
2 Kits Required For Dual Models.
x
.125, Along
OM-1587
Page
89
OPTIONS AND ACCESSORIES
WELD CURRENT SENSOR
(#160 963)
Required when using
the 64M
feeder with Miller conventional MIG
power sources that do not have
17pin receptacle.
POWER SOURCE DATA CARDS
Data card is inserted into feeder,
and with a push of a button, the
feeder is
automal:ically
programmed for 1:he power
being
source
eight factorywritten
Fieldinstalled
wire
for Dimensionfi 650
for XMTfi 200 CC/CV
For .035
-
.045 in.
(0.9
-
1.1
mm)
-
1/8 in.
(1.6-3.2 mm)
single
and
side of dual
models.
129) Factory only
(#132
For left side of dual wire models.
(#132 130) Factory only
Provides wire speed range of 90
1400 1PM (2.3 35.6 m/min.). Not
recommended for wire sizes larger
than 5/64 in. (2.0 mm).
-
-
Argon/Oxygen shielding
gas
.035 in. 309L stainless steel
using Argon/CO shielding
gas
.045 in. 309L stainless steel wire
using Argon/CO shielding gas
3/64 in. 4043 aluminum wire
using Argon shielding
gas
3/64 in. 5356 aluminum wire
using Argon shielding gas
.035 in. nickel wire using
Argon/Helium shielding gas
.035 in. silicon bronze wire using
Argon shielding gas
64M DATA CARD
one
lmportant:Same speed
used
on
motor must be
each side of the dual wire
models.
Factorywritten synergic Pulse
M1G programs will not operate with
highspeed
motor.
WATER HOSE KIT
For
benchstyle feeders
(#096 746)10 ft. (3 m)
For 12 ft. (3 m) Swingarc style
programs to other 64M feeders.
welding
For .10 ft.
(3 m) gun
(#041 792)
For 15 ft. (4.6 m) gun
(#041 793)
Twoposition slide switch that
attaches to the welding gun.
Selects welding condition when
utilizing the dual schedule feature.
Gun trigger operates as standard
trigger.
(#042 749)
Twoposition, momentary
(#159288)23 ft. (7 m)
For 16 ft. (4.9 m)Swingarc style
feeders
DSS-9M
DSS10 REMOTE INCREASE!
DECREASE SWITCH
feeders
(#155 910) Blank Card
Stores up to 32 complete weld
programs. Ideal for saving custom
programs and transferring
down
(3 m) gun
(#079 691)
For 15 ft. (3 m) gun
(#079 693)
Requires adapter cord (#157 364).
Twoposition trigger switch that
easily attaches to the welding gun.
Used in place of the standard
trigger for dual scheduling.
tip.
MOTOR
.045 in. steel wire with
feeder. Connects both kits to
water coolant system.
For 10 ft.
Reduces cast in wire. Improves
wire feeding performance and
right
Argon/Oxygen shielding gas
water hose
DSS-8
For
eight synergic pulse
a
dual wire
DUAL SCHEDULE SWITCHES
(#141 581)
HIGHSPEED
programs:
.035 in. steel wire with
a
overheating by shutting
wire
Conventional MuG Power
Source:
includes
each side of
Used with the water hose kits.
Protects water-cooled gun from
increases life of gun liner and
XMT 300 CC/CV data card
on
WATER FLOW SAFETY SWITCH
(#141 580)
For 1/16
contact
for )(MTfi 300 CC/CV
WATER HOSE KIT
system if water does not flow.
Data Card for Pulse MIG and
(#164 166)
Y
(#164 583)
Data Cards for Conventional
MIG Power Sources:
164)
165)
the
feeder control module from the
wire drive assembly and base.
WIRE STRAIGHTENER
162) for Deltaweldfi 300
161) for Deltaweldfi 451
160) for Deltaweldfi 651
163) for Dimensionfi 400
safety
Note:lf water kit is to be used on both
sides of a dual wire feeder, a kit must be
ordered for EACH side of the feeder.
kit
25 ft.
(7.6 m)
only.
only. Separates
water flow
(#165 491)
Required when using
CONTROL DETACHMENT KIT
(#134 934) 10 ft. (3m)
(#134 935)
optional
switch.
(#160 977)
Eight-position rotary switch used
to remotely select weld programs.
Includes a 33 ft. (10 m) cord.
programs and 24 unused spaces
for customerdeveloped programs.
(#164
(#164
(#164
(#164
(#164
(#164
without
For 64M bench models
used. Each data card
contains
RPS-8 AEMOTE PROGRAM
SELECTOR
contact
switch that attaches to the welding
gun. Used with the Remote
Parameter Increase/Decrease
(#159 289)
27 ft.
(8.2 m)
Used with Miller coolant systems
and GW Series watercooled
guns. Can be used with
or
feature to fine tune parameters at
the welding gun while welding.
Gun trigger operates
trigger.
as
standard
11101
OPTIONS AND ACCESSORIES
WIRE REEL ASSEMBLY
HANGING BAIL
(#108 008)
Accommodates 60 lb.
(27 kg)
coil
of wire.
MILLER GMAW
(#058 435)
Electrically isolated. Suspends
feeder
over
work
area.
REEL COVERS
(#058 256)
right side of
For
D64M
dual wire
TURNTABLE ASSEMBLY
(#146 236)
strain and
of gun cable.
bending
WATER COOLANT SYSTEMS
Radiator 1A, 115 VAC
(#042 492)
gal. (5.7 L)tank capacity.
contaminants.
ADJUSTABLE SPOOL CARRIER
(#096 075)
SPOOL COVERS
Fits a 12 in. (304 mm)
spool
wire. For left side of D64M
of
dual
wire model.
(#057 607)
For right side
of D64M
dual wire
model.
(#090 389)
CARRYING CART
(#056 301)
Radiator 2A, 230 VAC
only with Swingarc models
with 6 ft. (1.8 m) pipe post
mounted on Swingpak base.
Replaces standard spool
assembly. Positions welding wire
lower for easier loading and
unloading.
WatermateTM
EXTENSION CORDS
4
For
miscellaneous
extend 64M feeder
disassembled.
(#142 382)
Lowprofile, creeper
disassembled.
optimum performance,
(18 m)
14Pin
from power
cart.
Shipped
17Pin
more
do not
than 60 ft.
(#042 493)
gal. (5.7 L)
1.5
(#042 495)
2 gal. (7.6 L)
tank
capacity.
1 A, 115 VAC
tank
capacity.
CooImate~ 4, 115 VAC
(#042 288)
gal. (15.1 L)
tank
capacity.
Refer to Water Coolant
Systems
literature, Index No. AY/7.2.
source.
Extension Cord
(#122 973)
(#122 974)
FEEDER CART
1.5
Used
Carries wire feeder and
welding supplies.
Height: 34 in (863 mm). Lower tray
height: 9 in. (228 mm). Shipped
Guns
Refer to literature Index No. M/9.0.
Allows feeder to rotate as operator
changes work position. Reduces
model. Protects wire from
(#091 668)
GUNS
WaterCooled Guns
Refer to literature Index No.
Mu 3.4.
AirCooled
Accommodates 60 lb. (27 kg) coil
of wire. For left side of D64M dual
wire model.
(MIG)
25 ft.
50 ft.
(7.6 m)
(15 m)
Extension Cord
(#042 120)
25 ft.
(7.6 m)
COOLANT SOLUTION
(For Extra Freezing Protection)
(#128 705)
Resists freezing to 0 F (18
C).
Important: Distilled
water is recommended.
11/93
______
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