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![Miller D-64M WIRE FEEDER CE Owner’s Manual | Manualzz Miller D-64M WIRE FEEDER CE Owner’s Manual | Manualzz](http://s3.manualzz.com/store/data/051900093_1-819a62b3b17f9ae2273d58acaf2e6bb1-360x466.png)
OM-1587 161 874X 2006−05 Processes MIG (GMAW) Welding Pulsed MIG (GMAW-P) Flux Cored (FCAW) Welding (Gas- and Self-Shielded) Description Wire Feeder (Use with CC/CV Power Sources) D-64M File: MIG (GMAW) Visit our website at www.MillerWelds.com From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929. This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The Miller is the first welding parts list will then help you to decide the equipment manufacturer in exact part you may need to fix the problem. the U.S.A. to be registered to the ISO 9001:2000 Quality Warranty and service information for your System Standard. particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web. Mil_Thank 4/05 Working as hard as you do − every power source from Miller is backed by the most hassle-free warranty in the business. TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. . . . . . . . . . . . 2-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Manufacturer’s Rating Label For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 − INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Site Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Equipment Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Rear Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Rotating The Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5. 14-Pin Plug Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6. Gun Recommendation Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7. Wire Type, Size, And Feed Speed Capability Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8. Installing And Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Pulse Welding Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4. Side And Rear Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 − SETTING SEQUENCE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Sequence Parameters In A Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 8 − SETTING DUAL SCHEDULE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Selecting Dual Schedule Pair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Optional Dual Schedule Switch Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 9 − USING THE OPTIONAL DATA CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. Data Card Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2. Installing Data Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3. Card Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4. Entering Access Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5. Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 10 − SYSTEM SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1. Accessing The Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2. System Setup Display Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 3 3 4 4 5 5 5 7 8 8 9 9 10 10 11 11 11 11 12 13 13 14 14 14 15 17 17 17 18 19 20 20 21 21 22 23 23 23 24 25 26 27 27 28 TABLE OF CONTENTS SECTION 11 − STANDARD PULSE WELDING PROGRAMS FOR PHOENIX/INVISION 456 INVERTER WELDING POWER SOURCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1. Program 1 − Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2. Program 2 − Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3. Program 3 − Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4. Program 4 − Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5. Program 5 − Stainless Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6. Program 6 − Stainless Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7. Program 7 − Metal Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8. Program 8 − Metal Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 12 − STANDARD PULSE WELDING PROGRAMS FOR XMT 304 INVERTER WELDING POWER SOURCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1. Program 1 − Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2. Program 2 − Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3. Program 3 − Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4. Program 4 − Stainless Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5. Program 5 − Stainless Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6. Program 6 − Stainless Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7. Program 7 − Nickel Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8. Program 8 − Metal Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 13 − SETTING SharpArcE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1. Selecting And Adjusting SharpArcE Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 14 − TEACH POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1. Teach Using 15 Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2. Redefining Teach Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 15 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2. Motor Start Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-3. Error Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 16 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 17 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONS AND ACCESSORIES WARRANTY 29 29 29 29 30 30 30 30 30 31 31 31 31 32 32 32 32 32 33 33 34 34 35 37 37 37 38 39 40 42 Declaration of Conformity for European Community (CE) Products Note This information is provided for units with CE certification (see rating label on unit). Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W. Spencer Street Appleton, WI 54914 USA Manufacturer’s Address: Declares that the product: D-64M conforms to the following Directives and Standards: Directives Low Voltage Directive: 73/23/EEC Electromagnetic Compatibility (EMC) Directive: 89/336/EEC Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC Standards Arc Welding Equipment Part I: Welding Power Sources: IEC 60974-1 (September 1998 − Second Edition) Arc Welding Equipment: Wirefeed Systems: IEC 974-5 (September 1997 − Draft Revision) Degrees of Protection Provided By Enclosures (IP Code): IEC 529 (November 1989 − First Edition) Insulation Coordination For Equipment With Low-Voltage Systems: Part I: Principles, Requirements and Tests: IEC 664-1 (October 1992 − First Edition) Electromagnetic Compatibility, (EMC): EN 50199 (August 1995) European Contact: Telephone: Fax: dec_con1_11/02 Mr. Danilo Fedolfi, Managing Director ITW WELDING PRODUCTS ITALY S.r.l. Via Privata Iseo 6/E 20098 San Giuliano Milanese, Italy 39(02)98290-1 39(02)98290-203 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. 1-2. Arc Welding Hazards Y The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards. Y Only qualified persons should install, operate, maintain, and repair this unit. D D D D D D Y During operation, keep everybody, especially children, away. ELECTRIC SHOCK can kill. Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard. D Do not touch live electrical parts. D Wear dry, hole-free insulating gloves and body protection. D Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. D Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling. D Use AC output ONLY if required for the welding process. D If AC output is required, use remote output control if present on unit. D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! D Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards). D Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. D Always verify the supply ground − check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet. D When making input connections, attach proper grounding conductor first − double-check connections. D Frequently inspect input power cord for damage or bare wiring − replace cord immediately if damaged − bare wiring can kill. D D D D D D Turn off all equipment when not in use. Do not use worn, damaged, undersized, or poorly spliced cables. Do not drape cables over your body. If earth grounding of the workpiece is required, ground it directly with a separate cable. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be present. Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. Wear a safety harness if working above floor level. Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. Insulate work clamp when not connected to workpiece to prevent contact with any metal object. Do not connect more than one electrode or work cable to any single weld output terminal. SIGNIFICANT DC VOLTAGE exists in inverter-type welding power sources after removal of input power. D Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts. FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poor, wear an approved air-supplied respirator. D Read and understand the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers. D Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. D 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. D 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 while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. OM-1587 Page 1 ARC RAYS can burn eyes and skin. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. D Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). D Wear approved safety glasses with side shields under your helmet. D Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc. D Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection. WELDING can cause fire or explosion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. D Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. D Do not weld where flying sparks can strike flammable material. D Protect yourself and others from flying sparks and hot metal. D Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. D Watch for fire, and keep a fire extinguisher nearby. D Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. D Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWS F4.1 (see Safety Standards). D Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock, sparks, and fire hazards. D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use. D Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. D Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby. FLYING METAL can injure eyes. D Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. D Wear approved safety glasses with side shields even under your welding helmet. OM-1587 Page 2 BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. D Always ventilate confined spaces or use approved air-supplied respirator. HOT PARTS can cause severe burns. D Do not touch hot parts bare handed. D Allow cooling period before working on gun or torch. D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns. MAGNETIC FIELDS can affect pacemakers. D Pacemaker wearers keep away. D Wearers should consult their doctor before going near arc welding, gouging, or spot welding operations. NOISE can damage hearing. Noise from some processes or equipment can damage hearing. D Wear approved ear protection if noise level is high. CYLINDERS can explode if damaged. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs. D Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. D Keep cylinders away from any welding or other electrical circuits. D Never drape a welding torch over a gas cylinder. D Never allow a welding electrode to touch any cylinder. D Never weld on a pressurized cylinder − explosion will result. D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. D Turn face away from valve outlet when opening cylinder valve. D Keep protective cap in place over valve except when cylinder is in use or connected for use. D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders. D Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards. 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in place. D Have only qualified persons remove doors, panels, covers, or guards for maintenance as necessary. D Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power. FALLING UNIT can cause injury. D Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. D Use equipment of adequate capacity to lift and support unit. D If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit. READ INSTRUCTIONS. D Read Owner’s Manual before using or servicing unit. D Use only genuine Miller/Hobart replacement parts. H.F. RADIATION can cause interference. OVERUSE can cause OVERHEATING D Allow cooling period; follow rated duty cycle. D Reduce current or reduce duty cycle before starting to weld again. D Do not block or filter airflow to unit. D D STATIC (ESD) can damage PC boards. D Put on grounded wrist strap BEFORE handling boards or parts. D Use proper static-proof bags and boxes to store, move, or ship PC boards. D D D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. If notified by the FCC about interference, stop using the equipment at once. Have the installation regularly checked and maintained. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference. ARC WELDING can cause interference. MOVING PARTS can cause injury. D Keep away from moving parts. D Keep away from pinch points such as drive rolls. D WELDING WIRE can cause injury. D Do not press gun trigger until instructed to do so. D Do not point gun toward any part of the body, other people, or any metal when threading welding wire. D D D D Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots. D Be sure all equipment in the welding area is electromagnetically compatible. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area. 1-4. California Proposition 65 Warnings Y Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) For Gasoline Engines: Y Engine exhaust contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Y Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. For Diesel Engines: Y Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. OM-1587 Page 3 1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−international.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.1 from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 11 West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900, website: www.ansi.org). National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone: 617−770−3000, website: www.nfpa.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone: 617−770−3000,website: www.nfpa.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1735 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, website: www.cganet.com). Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there are 10 Regional Offices−−phone for Region 5, Chicago, is 312−353−2220,website: www.osha.gov). 1-6. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.” However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting. To reduce magnetic fields in the workplace, use the following procedures: OM-1587 Page 4 1. Keep cables close together by twisting or taping them. 2. Arrange cables to one side and away from the operator. 3. Do not coil or drape cables around your body. 4. Keep welding power source and cables as far away from operator as practical. 5. Connect work clamp to workpiece as close to the weld as possible. About Pacemakers: Pacemaker wearers consult your doctor before welding or going near welding operations. If cleared by your doctor, then following the above procedures is recommended. SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som _3/05 Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette procédure comporte des risques possibles ! Les dangers éventuels sont représentés par les symboles graphiques joints. Y Indique un message de sécurité particulier . Signifie NOTE ; n’est pas relatif à la sécurité. 2-2. Ce groupe de symboles signifie Avertissement ! Attention ! Risques d’ÉLECTROCUTION, ORGANES MOBILES et PARTIES CHAUDES. Consulter les symboles et les instructions afférentes ci-dessous concernant les mesures à prendre pour supprimer les dangers. Dangers relatifs au soudage à l’arc Y Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En présence de l’un de ces symboles, prendre garde et suivre les instructions afférentes pour éviter tout risque. Les instructions en matière de sécurité indiquées ci-dessous ne constituent qu’un sommaire des instructions de sécurité plus complètes fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité. Y Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil. Y Pendant le fonctionnement, maintenir à distance toutes les personnes, notamment les enfants de l’appareil. D Vérifier fréquemment le cordon d’alimentation afin de s’assurer qu’il D D D D D D UNE DÉCHARGE ÉLECTRIQUE peut entraîner la mort. D Le contact d’organes électriques sous tension peut provoquer des accidents mortels ou des brûlures graves. Le circuit de l’électrode et de la pièce est sous tension lorsque le courant est délivré à la sortie. Le circuit d’alimentation et les circuits internes de la machine sont également sous tension lorsque l’alimentation est sur Marche. Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de commande du rouleau et toutes les parties métalliques en contact avec le fil sont sous tension électrique. Un équipement installé ou mis à la terre de manière incorrecte ou impropre constitue un danger. D D D Ne pas toucher aux pièces électriques sous tension. D Porter des gants isolants et des vêtements de protection secs et sans D D D D D D D D D trous. S’isoler de la pièce à couper et du sol en utilisant des housses ou des tapis assez grands afin d’éviter tout contact physique avec la pièce à couper ou le sol. Ne pas se servir de source électrique à courant électrique dans les zones humides, dans les endroits confinés ou là où on risque de tomber. Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande. Si l’utilisation d’une source électrique à courant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé. D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement humide ou si l’on porte des vêtements mouillés ; sur des structures métalliques telles que sols, grilles ou échafaudages ; en position coincée comme assise, à genoux ou couchée ; ou s’il y a un risque élevé de contact inévitable ou accidentel avec la pièce à souder ou le sol. Dans ces conditions, utiliser les équipements suivants, dans l’ordre indiqué : 1) un poste à souder DC à tension constante (à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à souder AC à tension à vide réduite. Dans la plupart des situations, l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul ! Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité). Installer le poste correctement et le mettre à la terre convenablement selon les consignes du manuel de l’opérateur et les normes nationales, provinciales et locales. Toujours vérifier la terre du cordon d’alimentation. Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre. En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions. D D D n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est. Un fil à nu peut entraîner la mort. L’équipement doit être hors tension lorsqu’il n’est pas utilisé. Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés. Ne pas enrouler les câbles autour du corps. Si la pièce soudée doit être mise à la terre, le faire directement avec un câble distinct. Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou une électrode provenant d’une autre machine. Ne pas toucher des porte électrodes connectés à deux machines en même temps à cause de la présence d’une tension à vide doublée. N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel. Porter un harnais de sécurité si l’on doit travailler au-dessus du sol. S’assurer que tous les panneaux et couvercles sont correctement en place. Fixer le câble de retour de façon à obtenir un bon contact métal-métal avec la pièce à souder ou la table de travail, le plus près possible de la soudure. Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique. Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à une même borne de sortie de soudage. Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur quand on a coupé l’alimentation. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. LES FUMÉES ET LES GAZ peuvent être dangereux. Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereuse pour la santé. D Ne pas mettre sa tête au-dessus des vapeurs. Ne pas respirer ces vapeurs. D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de l’arc pour l’évacuation des fumées et des gaz de soudage. D Si la ventilation est médiocre, porter un respirateur anti-vapeurs approuvé. D Lire et comprendre les spécifications de sécurité des matériaux (MSDS) et les instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs. D Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant un respirateur à alimentation d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne présente aucun danger. D Ne pas souder dans des endroits situés à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants. D Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien ventilé et en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage. OM-1587 Page 5 LES RAYONS D’ARC peuvent entraîner des brûlures aux yeux et à la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. D Porter un casque de soudage approuvé muni de verres filtrants approprié pour protéger visage et yeux pendant le soudage (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité). D Porter des lunettes de sécurité avec écrans latéraux même sous votre casque. D Avoir recours à des écrans protecteurs ou à des rideaux pour protéger les autres contre les rayonnements les éblouissements et les étincelles ; prévenir toute personne sur les lieux de ne pas regarder l’arc. D Porter des vêtements confectionnés avec des matières résistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de protection. LE SOUDAGE peut provoquer un incendie ou une explosion. Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peuvent provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des objets métalliques peut provoquer des étincelles, une explosion, une surchauffe ou un incendie. Avant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger. D Déplacer toutes les substances inflammables à une distance de 10,7 m de l’arc de soudage. En cas d’impossibilité, les recouvrir soigneusement avec des protections homologuées. D Ne pas souder dans un endroit où des étincelles peuvent tomber sur des substances inflammables. D Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. D Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et des ouvertures. D Afin d’éliminer tout risque de feu, être vigilant et garder toujours un extincteur à la portée de main. D Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté. D Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les normes de sécurité). D Brancher le câble de masse sur la pièce le plus près possible de la zone de soudage pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie. D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées. D En cas de non-utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact. D Porter des vêtements de protection exempts d’huile tels que des gants en cuir, une veste résistante, des pantalons sans revers, des bottes et un casque. D Avant de souder, retirer toute substance combustible de ses poches telles qu’un allumeur au butane ou des allumettes. D Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA 51B pour travaux de soudage et prévoir un détecteur d’incendie et un extincteur à proximité. DES PARTICULES VOLANTES peuvent blesser les yeux. D Le soudage, l’écaillement, le passage de la pièce à la brosse en fil de fer, et le meulage génèrent des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier. D Porter des lunettes de sécurité avec écrans latéraux ou un écran facial. OM-1587 Page 6 LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué. DES PIÈCES CHAUDES peuvent provoquer des brûlures graves. D Ne pas toucher des parties chaudes à mains nues. D Prévoir une période de refroidissement avant d’utiliser le pistolet ou la torche. D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour éviter les brûlures. LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques. D Porteurs de stimulateur cardiaque, rester à distance. D Les porteurs d’un stimulateur cardiaque doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points. LE BRUIT peut endommager l’ouïe. Le bruit des processus et des équipements peut affecter l’ouïe. D Porter des protections approuvées pour les oreilles si le niveau sonore est trop élevé. LES BOUTEILLES peuvent exploser si elles sont endommagées. Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution. D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs. D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser. D Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques. D Ne jamais placer une torche de soudage sur une bouteille à gaz. D Une électrode de soudage ne doit jamais entrer en contact avec une bouteille. D Ne jamais souder une bouteille pressurisée − risque d’explosion. D Utiliser seulement des bouteilles de gaz protecteur, régulateurs, tuyaux et raccords convenables pour cette application spécifique ; les maintenir ainsi que les éléments associés en bon état. D Détourner votre visage du détendeur-régulateur lorsque vous ouvrez la soupape de la bouteille. D Le couvercle du détendeur doit toujours être en place, sauf lorsque la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur. D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles. D Lire et suivre les instructions sur les bouteilles de gaz comprimé, l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas Association) mentionné dans les principales normes de sécurité. 2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. DES ORGANES MOBILES peuvent provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre l’appareil en service. D S’abstenir de toucher des organes mobiles tels que des ventilateurs. D Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispositifs de protection. D Seules des personnes qualifiées sont autorisées à enlever les portes, panneaux, recouvrements ou dispositifs de protection pour l’entretien. D Remettre les portes, panneaux, recouvrements ou dispositifs de protection quand l’entretien est terminé et avant de rebrancher l’alimentation électrique. LA CHUTE DE L’APPAREIL peut blesser. LIRE LES INSTRUCTIONS. D Utiliser l’anneau de levage uniquement pour soulever l’appareil, NON PAS les chariots, les bouteilles de gaz ou tout autre accessoire. D Utiliser un équipement de levage de capacité suffisante pour lever l’appareil. D En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil. L’EMPLOI EXCESSIF peut CHAUFFER L’ÉQUIPEMENT. D Lire le manuel d’utilisation avant d’utiliser ou d’intervenir sur l’appareil. D Utiliser uniquement des pièces de rechange Miller/Hobart. LE RAYONNEMENT HAUTE FRÉQUENCE (HF) risque de provoquer des interférences. SUR- D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal. D Réduire le courant ou le facteur de marche avant de poursuivre le soudage. D Ne pas obstruer les passages d’air du poste. D D D LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés. D D D Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces. D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes PC. LE SOUDAGE À L’ARC risque de provoquer des interférences. DES ORGANES MOBILES peuvent provoquer des blessures. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement tels que des rouleaux de commande. D D LES FILS DE SOUDAGE peuvent provoquer des blessures. D D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage. 2-4. D Le rayonnement haute fréquence (HF) peut provoquer des interférences avec les équipements de radio-navigation et de communication, les services de sécurité et les ordinateurs. Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation. L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation. Si le FCC signale des interférences, arrêter immédiatement l’appareil. Effectuer régulièrement le contrôle et l’entretien de l’installation. Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les interférences éventuelles. D D L’énergie électromagnétique peut gêner le fonctionnement d’appareils électroniques comme des ordinateurs et des robots. D Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement. Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre). Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible. Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi. En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail. Proposition californienne 65 Avertissements Y Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de Californie, chapitre 25249.5 et suivants) Pour les moteurs à essence : Y Les gaz d’échappement des moteurs contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres problèmes de procréation. Y Les batteries, les bornes et autres accessoires contiennent du plomb et des composés à base de plomb, produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des cancers et des malformations congénitales ou autres problèmes de procréation. Se laver les mains après manipulation. Pour les moteurs diesel : Y Les gaz d’échappement des moteurs diesel et certains de leurs composants sont reconnus par l’État de Californie comme provoquant des cancers et des malformations congénitales ou autres problèmes de procréation. OM-1587 Page 7 2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com). Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site Internet : www.csa-international.org). Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard AWS F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com). Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, de American National Standards Institute, 11 West 42nd Street, New York, NY 10036-8002 (téléphone : 212-642-4900, site Internet : www.ansi.org). National Electrical Code, NFPA Standard 70, de National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (téléphone : 617-770-3000, site Internet : www.nfpa.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, de National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (téléphone : 617-770-3000, site Internet : www.nfpa.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de Compressed Gas Association, 1735 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202-4102 (téléphone : 703-412-0900, site Internet : www.cganet.com). Code for Safety in Welding and Cutting, CSA Standard W117.2, de Canadian Standards Association, Standards Sales, 178 Rexdale 2-6. OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, de U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10 bureaux régionaux−−le téléphone de la région 5, Chicago, est 312-353-2220, site Internet : www.osha.gov). Information EMF Considérations sur le soudage et les effets de basse fréquence et des champs magnétiques et électriques. Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu : « L’accumulation de preuves, suivant le jugement du comité, n’a pas démontré que l’exposition aux champs magnétiques et champs électriques à haute fréquence représente un risque à la santé humaine ». Toutefois, des études sont toujours en cours et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage. Pour réduire les champs magnétiques sur le poste de travail, appliquer les procédures suivantes : OM-1587 Page 8 1. Maintenir les câbles ensemble en les tordant ou en les enveloppant. 2. Disposer les câbles d’un côté et à distance de l’opérateur. 3. Ne pas courber pas et ne pas entourer pas les câbles autour de votre corps. 4. Garder le poste de soudage et les câbles le plus loin possible de vous. 5. Connecter la pince sur la pièce aussi près que possible de la soudure. En ce qui concerne les stimulateurs cardiaques Les porteurs de stimulateur cardiaque doivent consulter leur médecin avant de souder ou d’approcher des opérations de soudage. Si le médecin approuve, il est recommandé de suivre les procédures précédentes. SECTION 3 − DEFINITIONS 3-1. Warning Label Definitions A B 1 1.1 2 2.1 3 3.1 4 4.1 1.2 2.2 + 1.3 2.3 3.2 + 5 C 3.3 + + 6 S-178 936 1. Warning! Watch Out! There are possible hazards as shown by the symbols. 2. Drive rolls can injure fingers 3. Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects clear. 1 Electric shock can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1.2 Protect yourself from electric shock by insulating yourself from work and ground. 1.3 Disconnect input plug or power before working on machine. 2 Breathing welding fumes can be hazardous to your health. 2.1 Keep your head out of the fumes. 2.2 Use forced ventilation or local exhaust to remove the fumes. 2.3 Use ventilating fan to remove fumes. 3 Welding sparks can cause explosion or fire. 3.1 Keep flammables away from welding. Don’t weld near flammables. 3.2 Welding sparks can cause fires. Have a fire extinguisher nearby and have a watch person ready to use it. 3.3 Do not weld on drums or any closed containers. 4 Arc rays can burn eyes and injure skin. 4.1 Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection. 5 Become trained and read the instructions before working on the machine or welding. 6 Do not remove or paint over (cover) the label. OM-1587 Page 9 3-2. Manufacturer’s Rating Label For CE Products For label location see Section 5-3. S/N: U1 24 V =I1= 10.0A U2 100 V = 1 I2= 750 A 50/60 Hz IP 21 X 100 % ST-178 794-A 3-3. Symbols And Definitions Note Some symbols are found only on CE products. Output Off U2 X Duty Cycle A IP Amperes Degree Of Protection V Hz Volts Hertz Jog Parameter Select Trigger Line Connection Purge Read Instructions Trigger Hold On Trigger Hold Off Increase Trigger Hold On Indicator Light Trigger Hold Off Indicator Light Load Voltage Single Phase OM-1587 Page 10 Alternating Current I1 Primary Current I2 Rated Current U1 Primary Voltage Percent SECTION 4 − INTRODUCTION 4-1. Specifications Type of Input Power Welding Power Source Type 24 Volts AC Single-Phase 10 Amperes 50/60 Hertz Constant Voltage (CV) DC For GMAW Or Constant Voltage(CV) / Constant Current (CC) DC For GMAW-P All Need 14-Pin And Contactor Control Wire Feed Speed Range Standard: 50 To 780 ipm (1.3 To 19.8 mpm) Optional High Speed: 92 To 1435 ipm (2.3 To 36.5 mpm) Wire Diameter Range Welding Circuit Rating .023 To 1/8 in (0.6 To 3.2 mm) 100 Volts, 750 Amperes, 100% Duty Cycle Max Spool Weight: 60 lb (27 kg) IP Rating Overall Dimensions Weight Length: 32 in (812 mm) IP 21 Width: 18 in (457 mm) 78 lb (35 kg) Height: 14 in (356 mm) SECTION 5 − INSTALLATION 5-1. Site Selection 3 1 1 Wire Feeder 2 Rubber Feet 3 Wire Spool/Reel 4 Gas Cylinder (Customer Supplied) 5 Welding Power Source Y Do not put feeder where welding wire hits cylinder. 4 2 3 2 Y Do not move or operate equipment when it could tip. 5 1 5 ST-801 795-A / ST-801 796-A / Ref. ST-152 468-A OM-1587 Page 11 5-2. Equipment Connection Diagram 1 1 300/400 Ampere Model CC/CV Inverter Welding Power Source . Use settings shown for both pulse MIG welding and MIG welding. 2 3 4 5 450 Ampere Model DC Inverter Welding Power Source 14-Pin Cord Positive (+) Weld Cable Negative (−) Weld Cable Be sure weld cables are sized properly for peak amperage if pulse welding (see welding power source Owner’s Manual). 6 7 8 Workpiece Voltage Sensing Lead (Optional Use) Gun Be sure gun is rated for peak amperage if pulse welding. Install according to its Owner’s Manual. 9 Wire Feeder 2 3 4 5 6 7 8 9 ST-162 129-A / Ref. ST-154 197 / ST-146 127-C / Ref. ST-163 420-A OM-1587 Page 12 5-3. Rear Panel Connections 1 2 Customer Supplied Gas Hose Shielding Gas Valve Fitting Requires fitting with 5/8-18 righthand threads. 3 4 5 6 7 7 Weld Cable Terminal Jumper Weld Cable Weld Cable 14-Pin Cord Rating Label Location 2 1 3 5 6 4 4 5 Tools Needed: 9/16, 5/8 in Ref. ST-152 567-C 5-4. Rotating The Drive Assembly Remove screws (6) from front edge of wrapper, and loosen screws on back edge of wrapper. Tools Needed: 1 2 1/4 in 3 3/16 in Front Panel Drive Assembly Rotation Adjustment Opening Drive Assembly 2 1 3 Ref. ST-153 093-A / ST-800 289 OM-1587 Page 13 5-5. 14-Pin Plug Information Pin* I J K A B L H N C M D G F E Pin Information A 24 volts ac with respect to socket G. B Contact closure to A completes 24 volts ac contactor control circuit. G Circuit common for 24 volts AC circuit. C +10 volts dc output to remote control with respect to socket D. D Remote control circuit common. E 0 to +10 volts dc input command signal from remote control with respect to socket D. H Voltage feedback; 0 to +10 volts dc, 1 volt per 10 arc volts. F Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes. M CC/CV Select (+24 V = CV) N Inductance (0-10 V) *The remaining pins are not used. 5-6. Gun Recommendation Table Process Gun GMAW − Hard or Cored Wires Roughneck C-Series Guns: 300, 400, 500, And 600 Amp. FCAW − Self-Shielding Wires FC-1260 Or FC-1150 5-7. Wire Type, Size, And Feed Speed Capability Table Motor Speed Wire Type Wire Size Feed Speed Capability Standard All .023 To 5/64 in (0.6 To 2 mm) 50 To 780 ipm (1.3 To 19.8 mpm) Standard All 3/32 To 7/64 in (2.4 To 2.8 mm) 50 To 700 ipm (1.3 To 17.8 mpm) Standard All 1/8 in (3.2 mm) 50 To 300 ipm (1.3 To 7.6 mpm) Optional High Speed All .023 To 5/64 in (0.6 To 2 mm) 92 To 1440 ipm (2.3 To 35.6 mpm) OM-1587 Page 14 5-8. Installing And Threading Welding Wire If necessary, move hub and spool support so wire runs straight from the spool through the drive rolls. Install wire spool. Adjust tension nut so wire is taut when wire feed stops. Install wire guides and anti-wear guide. Install drive rolls. Pressure Indicator Scale Pressure Adjust NONCONDUCTIVE SURFACE No Wire Slip NONCONDUCTIVE SURFACE Wire Slips . Be sure that outlet cable has proper size . For soft wire or small diameter stainless liner for the welding wire size. When installing gun, position liner extending from outlet wire guide as close as possible to drive rolls without touching. Install gun. Lay gun cable out straight. Cut off end of wire. Push wire through guides up to drive rolls; continue to hold wire. Press Jog button to feed wire out gun. steel wire, use 2 drive rolls and set drive roll pressure from 0 to a maximum of 4 on the pressure indicator scale (so that only the inner spring is compressed). This setting will generally give the best performance for these types of wires. about 2 in (51 mm) from nonconductive surface and press gun trigger to feed wire against surface. Tighten knob so wire does not slip. Do not overtighten. If contact tip is completely blocked, wire should slip at the feeder (see pressure adjustment above). Cut wire off. Close cover. To adjust drive roll pressure, hold nozzle Tools Needed: 3/16, 5/64 in 15/16, 3/8 in Ref. ST-156 929-A / Ref. SC-150 922 / Ref. ST-156 930 / S-0627-A OM-1587 Page 15 Notes OM-1587 Page 16 SECTION 6 − OPERATION 6-1. Operational Terms Note See Menu Guide for detailed programming steps. The following is a list of terms and their definitions as they apply to this wire feeder: General Terms: Adaptive Pulse Welding The wire feeder automatically regulates pulse frequency to maintain a constant arc length, regardless of change in welding wire stickout. Cold Wire Jog When weld amperage is not present, wire feeds for about three seconds at set wire feed speed. Then the welding power source contactor deenergizes and wire continues to feed at the wire jog speed. Inductance As inductance increases, arc on time increases, and the weld puddle becomes more fluid. SharpArc™ Arc cone width and arc characteristics adjustment in pulse welding. Increasing SharpArc value decreases the arc cone width. Trim Arc length adjustment in pulse welding. Increasing trim increases the actual arc length. Trim is replaced by volts in MIG programs. Synergic The operator programs pulse parameters for a specific wire feed speed. The wire feeder determines the pulse parameters between these wire feed speed increments. Side Panel Terms: Process Mode Is used to select the type of process to be used, including Pulse, Adaptive Pulse, or Mig. Sequence Mode Is used to select and program the weld sequences which include weld, crater, burnback, postflow, preflow, run-in, and start. Dual Schedule Mode Is used to select a pair of programs that can be used together. Card Mode Is used to select use of the optional data card storage and retrieval capabilities. Security Mode Only functions with an optional data card. Allows using the lock feature for restricting range of program parameter changing. 6-2. Pulse Welding Terms 1 Apk = Peak Amperage Increasing Apk increases penetration. Vpk = Peak Voltage 3 Arc voltage during peak current phase of the pulse waveform. This determines arc length during adaptive pulse welding. 2 Amps Abk = Background Amperage Maintains arc between pulses. 3 1 2 4 4 Time PPS = Pulses Per Second Increasing PPS increases travel speed. PWms = Pulse Width In Milliseconds Increasing PWms increases bead width. OM-1587 Page 17 6-3. Front Panel Controls 1 2 3 8 7 4 4 6 5 1 Display 2 Parameter Select Button Press button to move display. 3 > (the cursor) on the Display Control Turn control to change value pointed to by >. Turning control one click causes Trim (arc length) to increase/decrease by one or Volts to increase/decrease by 0.1. When IPM is selected, turning control one click causes wire feed speed (IPM) to increase/decrease by one. When MPM is selected, turning control three clicks causes wire feed speed (MPM) to increase by 0.1. When Prg # is selected, turning control one 5 click causes program number (Prg #) to increase/decrease by one. The program number cannot be changed while welding, with exception of Dual Schedule Mode (see Section 8). SharpArc™ is “Arc” on the display (see Section 13). It is used to adjust arc cone width and arc characteristics. Pulse is a default setting. To change type of process (Pulse, Adaptive Pulse, or MIG) use side panel controls. 4 Active Side Indicator Light 5 Trigger Hold Button And Indicator Light Trigger Hold can be set on a per program basis. Indicator light comes on for programs where this feature is active. To weld without holding gun trigger throughout weld cycle, press and release button to turn feature on (indicator light turns on). To start weld cycle, press and release gun trigger within three seconds after an arc has been struck. To end weld cycle, press and release gun trigger. 6 Side Select Button 7 Jog Button Push to momentarily feed welding wire without energizing welding circuit or shielding gas valve. Jog speed is varied using the Display Control while Jog button is pressed. Default setting is 200 IPM. 8 Purge Button Push to momentarily energize gas valve without energizing the welding circuit. Holding the Jog and Purge buttons at the same time displays pulse parameters on the side panel display and voltage on front panel display. ST-162 127 OM-1587 Page 18 6-4. Side And Rear Panel Controls 1 2 Mode Display Mode Select Button Press button to move > in display. 3 4 8 Parameter Display Parameter Select Button Press button to move > in display. 7 5 6 7 8 Parameter Increase Button Parameter Decrease Button Power Switch Circuit Breaker CB1 CB1 protects the wire feeder from overload. Rear Panel 2 1 3 5 6 4 Ref. ST-162 128 / Ref. ST-162 133-A OM-1587 Page 19 SECTION 7 − SETTING SEQUENCE PARAMETERS 7-1. Sequence Parameters In A Program . See Menu Guide for detailed programming steps. Trim is arc length. If set to zero, arc length is short. If set to 99, arc length is long. If time is set to zero in Weld sequence, welding continues until gun trigger is released. If time is set to zero in any timed sequence except Weld, the sequence is skipped. Trim 0-99 Pulse 1. Weld X Pulse X IPM 50-780 Seconds X 0-100.0 X X X X MIG 3. Burnback Inductance 0-99% X MIG 2. Crater Volts 10.0-38.0 0-5.00 X Pulse 0-0.25 X MIG 4. & 5. Postflow/ Preflow 0-9.9 6. Run-In 25-780 Pulse 6. Start X X X MIG 0.00-5.00 X X = Setting available. Weld WFS Start Time 0-100.0 sec. Crater WFS Preflow Time Run-In WFS Wire Speed Weld Time Crater Time Burnback Time Postflow Time Time Burnback Preflow Trigger Pressed OM-1587 Page 20 Run-In Arc Strike Weld Crater Trigger Released Postflow Sequence End SECTION 8 − SETTING DUAL SCHEDULE PARAMETERS 8-1. Selecting Dual Schedule Pair Dual Schedule is used with two consecutive weld programs 1 & 2, 3 & 4, 5 & 6, or 7 & 8. Any program type (MIG, Adaptive Pulse, or Pulse) can be combined in dual schedule. 1 1 Side Panel Display Use side panel to turn feature on. See Menu Guide for detailed programming steps. 2 Front Panel Display Press front panel parameter select button to select program number. P r o Seq >Du Ca r ces s uence a l S chd d >P r g On 3 4 1&2 Front Panel Display Control Dual Schedule Switch (See Section 8-2) . Switch type is set in System Setup. 5 Welding Gun Trigger Selecting dual schedule program A or B is done by using Display Control, dual schedule switch, or gun trigger (depending on system setup). When program B is active, turn Display Control one click clockwise to select another pair of dual schedule programs. . Programs can be rearranged in desired order using the data card. See Section 9. 2 1 8 . 0 V > P r g 1 2 0 0 D u a l A I PM 3 4 Display Control Or 5 > P r g 2 D u a l B Display Control > P r g 3 D u a l A OM-1587 Page 21 8-2. Optional Dual Schedule Switch Diagrams 1 1 DSS-10 1 1 DSS-9M 1 2 2 2 2 2 3 4 A 3 B 1 4 A 3 B 4 Momen 2P (Momentary-Contact 2-Pole Switch) Maint 2P (Maintained-Contact 2-Pole Switch) Maint 1P (Maintained-Contact 1-Pole Switch) Trigger Allows dual scheduling establishing a welding arc. 2 5 after Momen 1P (Momentary-Contact 1-Pole Switch) . If trigger is used for dual sched- ule switch, Trigger Hold is disabled. 3 DSS-8 TR B 4 1 2 2 2 3 3 3 Trigger 1 1 2 TR 5 1 A 4 OM-1587 Page 22 Adapter 1 4 3 . Switch type is selected in system setup (see Section 10). SECTION 9 − USING THE OPTIONAL DATA CARD 9-1. Data Card Terms CARD SCREEN TERMS WRITE Programs To Card >W r Re De Do i a l n t e d e t e e READ Programs From Card PULSE MIG TERMS PPS (Pulses Per Second) Amperage PWms (Pulse Width In Milliseconds) Apk (Peak Amperage) Time Abk (Background Amperage) SA-158 435 9-2. Installing Data Card 1 Label Apply label to data card. Write program information on label. 2 3 Data Card Card Slot For Blank Data Card: 3 Insert card into slot. To format card, turn On power. Select Card from menu. Data card formats when unit enters Card mode. 2 1 ST-156 266-B OM-1587 Page 23 9-3. Card Displays . See Menu Guide for detailed programming steps. Security mode only functions with a data card. 1 Se Du >C a Se q a r c uence l Schd d u r i t y 1 2 Moving line is under value that can be changed. 3 P r ess Be l ow 3 Read Transfers program data from card to unit. 5 Delete Deletes program data from card. >W r Re De Do 4 5 6 OM-1587 Page 24 Write Transfers program data from unit to card. The program card can hold up to 32 programs. When writing to the card, the next available program number is automatically assigned. 4 Side Panel Parameter Select Once Card Display Moving Line i a l n 6 t e d e t e e # 1 Pu l se 035 ”S t ee l A r g o n −O x y P r ess 2 Done Exits card display. 9-4. Entering Access Code 1 2 3 . Access code works only when a data card is inserted and access mode in Setup screen is turned On. Turn Unit On Press Mode Select 5 Times S eq D ua Car > S ec uence l Schd d u r i t y 1 > Pro g L oc k Tr i m R an g e With a code set, this display appears when trying to turn off a program lock. 1 On 55 10 Pressing Mode Select button will exit the access code display. . If Side Panel Parameter Select 3 2 Ent A cc C od Pre e r es s e s s > C od e N ex t C h a r . ⇒P r e s s Side Panel Parameter Select Mode Select S eq D ua Car > S ec uence l Schd d u r i t y AAA > Pro g L oc k Tr i m R an g e 1 On 55 10 P r >L o T r Ra og ck im nge 1 On 55 10 P r >L o T r Ra og ck im nge 1 On 55 10 Increase/ Decrease Security Display Program Lock Display Access Code Display any character is incorrect during code entry, pressing side panel Parameter Select button will cause the indicator to move back to beginning of character set to allow entering access code again. Press side panel Parameter Select button to enter access code. When the correct letter is entered, pressing side panel Parameter Select button moves indicator to the next character. When the final access code character is entered, press side panel Parameter Select button to automatically change display to the program lock display. Increase/ Decrease P r og >L o c k 1 Of f OM-1587 Page 25 9-5. Security The security feature allows a minimum and maximum range limit to be defined for Trim, inches per minute (IPM), and ShpArc (see Section 13). . The security feature works only when a data card is inserted. 1 Turn Unit On Press Mode Select 5 Times S eq D ua Car > S ec uence l Schd d u r i t y > Pro g L oc k When the security lock is Off, the full range of values is available for each parameter. 1 Of f When the security lock is On, the range of values available for each parameter is the defined value plus or minus the defined range. 2 3 4 P r Lo >T r Ra og c k im nge 1 2 1 On 50 0 og c k im nge P r >L o T r Ra og ck im nge 1 On 50 0 Side Panel Parameter Select Increase/ Decrease P r Lo >T r Ra Side Panel Parameter Select 1 On 55 0 P r og >L o c k Loc k T r im >R a n g e I PM On 55 0 200 Lock T r im >R a n g e I PM 55 10 225 0 On 55 10 200 Side Panel Parameter Select T r im Range >I PM Range 55 10 200 0 Increase/ Decrease Side Panel Parameter Select Increase/ Decrease 6 T r im Range I PM >R a n g e 5 1 22 10 5 0 5 0 I PM 225 Range 10 >S h p A r c 0 Range 3 Side Panel Parameter Select OM-1587 Page 26 >P r Lo T r Ra Side Panel Parameter Select Lock On/Off Toggles security feature On or Off. Definable values are displayed when Lock On is selected. Use side panel controls to change values. Increase/ Decrease T r im Range >I PM Range Card Display Moving Line Moving line is under value that can be changed. Change program number to access desired program. 3 5 55 10 225 0 1 Of f Increase/ Decrease Side Panel Parameter Select T r im Range I PM >R a n g e For example, if the IPM value is defined as 125, and the range is defined as 50, the actual range of available IPM is 75 to 175 IPM (125 minus 50, and 125 plus 50). og ck im nge 1 On 55 10 4 5 6 Trim And Range Display IPM And Range Display ShpArc And Range Display Definable Motor): Values (Standard Trim: 0−99 Range: 0−99 IPM: 50−780 Range: 0−780 ShpArc : 0−20 Range: 0−20 In the example displays, the operator could change the value of Trim to 55 and its Range to ±10. Also, the operator could change the value of IPM to 225 and its Range to ±100 IPM from programmed values. If the range settings are left at 0, the operator cannot change values from those programmed. SECTION 10 − SYSTEM SETUP 10-1. Accessing The Setup Menu 1 1 Setup Panel 2 Power Switch Press and hold down both buttons while turning On unit. 3 Main Display Main display during setup. 4 Setup Display Follow this procedure any time access is required. Once in the setup displays, use the Mode Select button to select a particular display. Mode Select Parameter Select 2 3 S e t u p Main Display Setup Display System > Model Access Mig Type > Invisn 456 System Reset Now > System Model Access Mig Type 4 Process Capability > Pulse/Mig Press Mode Select To Change Menu Item See Section 10-2 System Setup Display Parameters OM-1587 Page 27 10-2. System Setup Display Parameters Note See Menu Guide for detailed programming steps. DISPLAY SETTING NOTES >System Select the process the welding power source is able to do. >Model For the Invision 456 and XMT 304 selections, pulse data and welding power source minimum and maximum voltage values are automatically loaded in. For the “Other” selection, welding power source minimum and maximum voltage and amperage values must be entered. Pulse data defaults to Invision 456 values. >Access♦ When on, restricts use of setup screens. >Mig Type Default is Off. Set to On only for older CV welding power source without voltage feedback at 14-socket receptacle. >Voltage Default is 14-pin receptacle. Use V. Sense when more than 50 ft (15m) of weld cable is used (including gun cable length). >Arc Start** Use Hot Start only with Inverter Model welding power source and large diameter wires. The arc starts in CV and switches to CC. >Dual Schedule See Section 8-2. >Trigger When on, trigger can be used to switch between programs that have at least 0.2 seconds of preflow time programmed. >Remote When on, an optional dual schedule switch with a “y” trigger cable adapter cord can be used to change Volts or Trim, IPM, SharpArc, or Prg depending on where the front panel display > is. >Arc Time Displays accumulated arc time and cycles. >Wire Feed Choose to display inches per minute or meters per minute and motor type, but installed motor must match selection. >Memory No Reset: allows operator to exit memory reset parameter without resetting any data. Program Reset: unit defaults to original factory setting for the last active program. Setup information does not change. If setup card is in card slot, program will be loaded from card. System Reset: unit defaults to original factory settings for all programs and setup excluding System and Arc Time. If setup card is in card slot, program will be loaded from card. Total Reset: unit defaults to original factory settings for all programs and setup including System and Arc Time. If setup card is in card slot, program will be loaded from card. >Shutdown When on, the system immediately shuts down if no arc voltage is sensed. When off, wire feeds even if no arc voltage is sensed. >Gas Flow♦♦ Setting must be Meter Off if option is not installed. >Ramps Turns start and crater ramping On or Off. When On, output power is tapered from start to weld and from weld to crater. >Software Know this when talking with service personnel. ♦ Can be used only when optional data card is inserted. * Selection does not appear on display when MIG Only is System choice. ♦♦ Must remain set to Meter Off if option is not installed to prevent system error. OM-1587 Page 28 SECTION 11 − STANDARD PULSE WELDING PROGRAMS FOR PHOENIX/INVISION 456 INVERTER WELDING POWER SOURCES Note Apk = Peak Amperage, Vpk = Peak Voltage, Abk = Background Amperage, PPS = Pulses Per Second, PWms = Pulse Width (milliseconds). The following eight pulse welding programs are in the memory of the wire feeder. Use this information if it is necessary to change a standard program, or as a basis to build your own custom program. If at any time while changing a standard program, or while building your own custom program, you want to go back to the standard program in the wire feeder, perform a system reset according to Section 10-2. 11-1. Program 1 − Steel Wire Size/Type: .035” Gas: Ar - CO2 or Ar - Oxy / 40 CFH (19 L/m) IPM / MPM Apk Vpk Abk PPS PWms 700 / 17.8 440 36.7 160 180 2.9 400 / 10.2 385 32.4 108 126 2.3 200 / 5.1 335 28.7 61 81 2.0 100 / 2.5 328 27.4 37 47 1.7 COMMENTS 11-2. Program 2 − Steel Wire Size/Type: .045” Gas: Ar - CO2 or Ar - Oxy / 40 CFH (19 L/m) IPM / MPM Apk Vpk Abk PPS PWms 700 / 17.8 518 35.0 195 205 3.6 400 / 10.2 466 31.3 147 158 2.9 200 / 5.1 412 28.5 93 106 2.4 100 / 2.5 375 26.5 50 66 2.2 COMMENTS 11-3. Program 3 − Steel Wire Size/Type: .052” Gas: Ar - CO2 or Ar - Oxy / 40 CFH (19 L/m) IPM / MPM Apk Vpk Abk PPS PWms 625 / 15.9 560 39.3 200 229 3.6 400 / 10.2 525 36.2 148 189 3.5 200 / 5.1 475 31.7 102 131 2.7 100 / 2.5 445 29.6 50 80 2.4 COMMENTS OM-1587 Page 29 11-4. Program 4 − Steel Wire Size/Type: .062” Gas: Ar - CO2 or Ar - Oxy / 40 CFH (19 L/m) IPM / MPM Apk Vpk Abk PPS PWms 400 / 10.2 550 36.8 200 195 4.1 300 / 7.6 510 36.3 145 175 3.8 200 / 5.1 480 31.6 110 155 3.2 100 / 2.5 460 28.7 69 94 2.6 COMMENTS 11-5. Program 5 − Stainless Steel Wire Size/Type: .035” Gas: Ar - He - CO2 / 40 CFH (19 L/m) IPM / MPM Apk Vpk Abk PPS PWms 700 / 17.8 403 33.9 132 191 2.8 400 / 10.2 318 31.6 87 146 2.4 200 / 5.1 295 28.5 53 94 1.9 100 / 2.5 280 26.0 32 45 1.8 COMMENTS 11-6. Program 6 − Stainless Steel Wire Size/Type: .045” Gas: Ar - He - CO2 / 40 CFH (19 L/m) IPM / MPM Apk Vpk Abk PPS PWms 700 / 17.8 480 39.0 200 227 3.2 400 / 10.2 425 32.4 155 185 2.5 200 / 5.1 360 28.0 100 115 2.0 100 / 2.5 350 26.2 40 70 2.0 COMMENTS 11-7. Program 7 − Metal Core Wire Size/Type: .045” Metal Core Gas: Ar - CO2 / 40 CFH (19 L/m) IPM / MPM Apk Vpk Abk PPS PWms 700 / 17.8 490 37.4 165 210 3.1 400 / 10.2 440 33.8 115 155 2.5 200 / 5.1 400 29.2 70 120 1.9 115 / 2.9 395 26.3 41 96 1.4 COMMENTS 11-8. Program 8 − Metal Core Wire Size/Type: .052” Metal Core Gas: Ar - CO2 / 40 CFH (19 L/m) IPM / MPM Apk Vpk Abk PPS PWms 700 / 17.8 510 38.0 230 250 3.3 400 / 10.2 460 33.3 135 200 2.5 250 / 6.4 425 31.0 100 170 2.2 175 / 4.4 410 28.6 75 155 1.9 OM-1587 Page 30 COMMENTS SECTION 12 − STANDARD PULSE WELDING PROGRAMS FOR XMT 304 INVERTER WELDING POWER SOURCES Note Apk = Peak Amperage, Vpk = Peak Voltage, Abk = Background Amperage, PPS = Pulses Per Second, PWms = Pulse Width (milliseconds). The following eight pulse welding programs are in the memory of the wire feeder. Use this information if it is necessary to change a standard program, or as a basis to build your own custom program. If at any time while changing a standard program, or while building your own custom program, you want to go back to the standard program in the wire feeder, perform a system reset according to Section 10-2. 12-1. Program 1 − Steel Wire Size/Type: .030” Gas: Ar - CO2 or Ar - Oxy / 40 CFH (19 L/m) IPM / MPM Apk Vpk Abk PPS PWms 700 / 17.8 400 37.2 127 137 1.8 400 / 10.2 340 33.3 94 98 1.6 200 / 5.1 305 29.6 58 63 1.4 100 / 2.5 285 27.7 32 36 1.4 COMMENTS 12-2. Program 2 − Steel Wire Size/Type: .035” Gas: Ar - CO2 or Ar - Oxy / 40 CFH (19 L/m) IPM / MPM Apk Vpk Abk PPS PWms 700 / 17.8 400 34.9 170 188 2.2 400 / 10.2 400 32.5 95 113 1.9 200 / 5.1 370 29.9 53 70 1.7 100 / 2.5 350 29.7 26 40 1.7 COMMENTS 12-3. Program 3 − Steel Wire Size/Type: .045” Gas: Ar - CO2 or Ar - Oxy / 40 CFH (19 L/m) IPM / MPM Apk Vpk Abk PPS PWms 500 / 12.7 400 32.0 200 200 3.5 400 / 10.2 400 31.0 165 165 3.0 200 / 5.1 375 29.0 97 97 2.5 100 / 2.5 366 27.4 54 50 2.1 COMMENTS OM-1587 Page 31 12-4. Program 4 − Stainless Steel Wire Size/Type: .030” Gas: Ar - He - CO2 / 40 CFH (19 L/m) IPM / MPM Apk Vpk Abk PPS PWms 700 / 17.8 350 34.1 102 130 1.8 400 / 10.2 315 31.7 70 94 1.7 200 / 5.1 280 30.1 50 46 1.5 100 / 2.5 265 29.9 26 25 1.4 COMMENTS 12-5. Program 5 − Stainless Steel Wire Size/Type: .035” Gas: Ar - He - CO2 / 40 CFH (19 L/m) IPM / MPM Apk Vpk Abk PPS PWms 700 / 17.8 385 35.8 106 163 2.3 400 / 10.2 370 32.9 57 137 2.0 200 / 5.1 316 29.7 39 95 1.5 100 / 2.5 311 29.1 30 41 1.4 COMMENTS 12-6. Program 6 − Stainless Steel Wire Size/Type: .045” Gas: Ar - He - CO2 / 40 CFH (19 L/m) IPM / MPM Apk Vpk Abk PPS PWms 700 / 17.8 400 34.2 200 275 2.8 400 / 10.2 395 33.1 123 158 2.6 200 / 5.1 370 30.9 75 104 2.1 100 / 2.5 337 28.2 40 70 1.9 COMMENTS 12-7. Program 7 − Nickel Alloy Wire Size/Type: .035” Nickel Alloy Gas: Ar - He / 40 CFH (19 L/m) IPM / MPM Apk Vpk Abk PPS PWms 625 / 15.9 400 32.5 128 145 3.5 400 / 10.2 370 30.1 94 92 3.3 200 / 5.1 299 27.8 56 65 2.9 125 / 3.2 256 25.6 40 40 2.8 COMMENTS 12-8. Program 8 − Metal Core Wire Size/Type: .045” Metal Core Gas: Ar - CO2 / 40 CFH (19 L/m) IPM / MPM Apk Vpk Abk PPS PWms 625 / 15.9 400 34.0 200 220 2.8 500 / 12.7 400 34.0 155 190 2.6 300 / 7.6 370 31.3 105 140 2.4 150 / 3.8 352 27.7 60 108 1.7 OM-1587 Page 32 COMMENTS SECTION 13 − SETTING SharpArcE CONTROL 13-1. Selecting And Adjusting SharpArcE Control 1 Arc SharpArc™ is “Arc” on the display. It is used to adjust arc cone width and arc characteristics. Use front panel parameter select button to move > to select Arc. Use Display Control to adjust Arc setting. 5 0 T r i m 2 0 0 I PM > P r g 1 0 3 5 “ S t 1 Parameter Select 5 0 2 0 0 5 0 2 0 0 SharpArc™ setting range is from 0 to 20. The factory default is set at zero (0). When Arc value is increased toward 20, the arc cone narrows and the weld puddle becomes less fluid. T r i m P r g 1 I PM > A r c 0 T r i m P r g 1 I PM > A r c 2 0 Ref. S-0259 OM-1587 Page 33 SECTION 14 − TEACH POINTS 14-1. Teach Using 15 Points Apk = Peak Amperage Vpk = Peak Voltage Abk = Background Amperage PPS = Pulses Per Second IPM / MPM PWms = Pulse Width (Milliseconds) 780 / 19.8 750 / 19.1 700 / 17.8 650 / 16.5 600 / 15.2 550 / 14.0 500 / 12.7 450 / 11.4 Example Of A Synergic Setting For 425 IPM With All Teach Points Set At 50 IPM (1.3 MPM) Increments 400 / 10.2 350 / 8.9 300 / 7.6 250 / 6.4 200 / 5.1 150 / 3.8 100 / 2.5 50 / 1.3 Apk Vpk Abk PPS PWms 100 10 10 20 1 180 18 20 55 210 21 30 80 240 24 40 105 2 270 27 50 130 The teach mode allows the user to create custom pulse programs. The teach mode selection for 15 teach points gives a more defined curve for a specific range. At each teach point, the user can adjust five parameters to shape the pulse waveform of the weld output. The six parameters are: IPM (MPM), Apk, Vpk, Abk, PPS, and PWms. OM-1587 Page 34 300 30 60 160 330 33 70 185 360 36 80 210 3 370 37 90 235 420 42 100 260 450 45 110 290 Apk, Vpk, Abk, PPS, and PWms acting together provide the energy necessary to burn off welding wire at a set wire feed speed. The graph below shows that as wire feed speed increases, energy increases (Apk, Vpk, Abk, PPS, and PWms acting synergically). 4 480 48 120 315 510 51 130 340 540 54 140 365 565 56 200 400 5 Apk Vpk Abk PPS PWms Under some conditions, the wire feeder limits wire feed speed to maintain all pulse parameters within the capability of the system. 14-2. Redefining Teach Points 1 IPM IPM determines the weld metal deposition rate. . Redefining IPM is not normally required unless special wire or unusual joint design is needed. Redefining IPM Teach Point 5 0 T r i m >4 5 0 1 P r g I PM T r i m >4 6 0 P u l s e Press and hold Purge button while turning Display Control to redefine the ipm teach point. For example: there are teach points at 150, 200, and 250 ipm; the teach point at 200 can be adjusted to a wire feed speed of 151 to 249 ipm. And Purge 5 0 Use front panel parameter select button to move > to select IPM. Use Display Control to select teach point value. 1 I PM P r g 1 2 Vpk − Peak Voltage Arc voltage during peak current phase of the pulse waveform. This determines arc length during adaptive pulse welding. P u l s e 3 4 Apk − Peak Amperage Abk − Background Amperage Peak and background amperage depend on the range of the welding power source. Redefining Pulse Parameters 5 6 PPS − Pulses Per Second Of 20-400 PWms − Pulse Width Of 1.0-5.0 Milliseconds Use side panel controls to change pulse parameters. See Menu Guide for detailed programming steps. T 4 >3 3 P r oces s e 0 2 8 After values are set, strike and maintain an arc for five seconds. Do this for each teach point. 2 a c h On 0 I PM . 4 Vpk 5 Apk End weld by releasing gun trigger, not by pulling gun out of weld. Repeat for each custom teach point. The taught arc length represents a Trim (arc length) setting of 50. Once the teach points are set, the wire feeder adjusts parameters between teach points synergically. 3 4 3 >3 1 0 2 8 0 0 . 4 5 8 I PM Vpk Apk Abk 4 3 3 >1 1 2 8 0 2 . 4 5 8 6 Vpk Apk Abk PPS 5 3 1 >1 2 8 0 2 . 5 8 6 3 Apk Abk PPS P Wm s 6 3 1 1 >2 8 0 2 . 5 8 6 3 Apk Abk PPS P Wm s Ref. S-0259 / Ref. ST-154 109 OM-1587 Page 35 Date Program Number Wire Size/Type Wire Manufacturer Mfg. Date Gas Flowrate CFH(L/min) Equipment Used − Power Source Serial Number Wire Feeder Serial Number Gun Model IPM / MPM Weld Cable − Negative Vpk Apk Abk PPS Positive PWms COMMENTS Preflow Seconds: Run In IPM: Start Trim/Volts: IPM / MPM: Seconds: Crater Trim/Volts: IPM / MPM: Seconds: Burnback Volts/Seconds: SharpArc: OM-1587 Page 36 Ramps/Start: Crater: Postflow Seconds: Arc Start: Trim: SECTION 15 − MAINTENANCE AND TROUBLESHOOTING 15-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Clean and tighten weld terminals. Replace unreadable labels. Replace cracked parts. Repair or replace cracked weld cable. Check 14-pin cord. Check gas hose and fittings. Check gun cable. 6 Months Blow out or vacuum inside. During heavy service, clean monthly. Clean drive rolls. Or 15-2. Motor Start Control To change wire feed starting speed proceed as follows: Turn Off wire feeder and welding power source. Remove wrapper. Right Side 1 Motor Board PC1 2 Motor Start Control Potentiometer R70 Turn potentiometer clockwise to increase time it takes the motor to ramp up to speed. Remove protective white rubber cap before making adjustment. Adjust potentiometer R70 using a small nonconductive screwdriver. Reinstall wrapper. Tools Needed: 1 2 Non-Conductive 1/4 in ST-162 132-A / Ref. SA-183 121-B OM-1587 Page 37 15-3. Error Displays 1 R e l e a s e T r i g g e r 2 N o V o l t S e n s e d E r r o r 3 1 1 Memo r y P r g CRC E r r o r 2 Memo r y P r g R a n g e E r r o r The arc voltage sense circuit is not receiving feedback. Check voltage sensing connections. Check connections at 14-position plugs/ receptacles at the unit and welding power source. 4 5 T a c h S e n s e d E r r o r 6 S t a r t S t o p E r r o r E r r o r 8 Perform a system reset. 4 Memory Range Error Display G a s o f R a n g e No Tach Sensed Error Display Press front panel Parameter Select to clear error. O u t E r r o r Press front panel Parameter Select to clear error. 8 Minimum Gas Flow Error This appears when gas flow falls below the minimum CFH set (xx in example). Adjust gas flow to bring it above set value. Press front panel Parameter Select to clear error. 9 Maximum Gas Flow Error This appears when gas flow is above the maximum CFH set (xx in example). Adjust gas flow to bring it below set value. 10 Gas Out Of Range Error Ga s F l o w E r r o r Arc Stop Error Display This appears when pulse welding and the motor does not stop at the end of the weld. If there is high frequency being used in the area, turn it off. A motor brake circuit problem can also cause this error. Go through pulse parameters to make sure they do not exceed settings of the Range display or perform a system reset. The motor tach feedback is not reaching the control. Check connections. G a s F l o w 7 Press front panel Parameter Select to clear error. 5 E r r o r Press front panel Parameter Select to clear error. The data in the program indicated is out of usable range. Mi n C F H x x Ma x C F H x x 11 Memory CRC Error Display The data in the program indicated is not the same data that was saved. A r c 10 If this error continues to occur when pulse welding, it may help to select Hot Start. 3 A r c 9 1 No Volt Sensed Error Display Turn unit off and back on after correcting problem. N o 7 Release Trigger Error Display This appears if the trigger is closed when the unit power is turned on, or if the trigger is stuck or defective. 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 voltage settings. Check voltage sensing connections. This appears when gas flow is greater than 100 CFH. To protect the internal sensor, the unit shuts down until the gas flow can be adjusted below 100 CFH. 11 Coolant Flow Error This appears only when coolant flow switch option is installed. Check coolant recirculating system. 12 Unlocked Program Error Display This appears when attempting to run an unlocked program while other programs are locked. Either lock the unlocked program or select a different program that is locked. C o o l a n t 12 F l o w E r r o r U n l o c k e d P r o g r am E r r o r Ref. ST-155 222 OM-1587 Page 38 15-4. Troubleshooting Y Disconnect power before troubleshooting Trouble Remedy Wire feeds, shielding gas flows, but elec- Check interconnecting cord connections. If secure, check cord for continuity and repair or replace (see trode wire is not energized. Sections 5-2 and 5-3). Wire feeder is on, meter(s) do not light Check and reset CB1 (see Section 6-4). up, motor does not run, gas valve and welding power source contactor do not pull in. Electrode wire feeding stops or feeds er- Check gun trigger connection. See gun Owner’s Manual. ratically during welding. Check gun trigger. See gun Owner’s Manual. Readjust hub tension and drive roll pressure (see Section 5-8). Change to correct size drive roll (see Table 17-1). Clean or replace dirty or worn drive roll. Incorrect size or worn wire guides. Replace contact tip or liner. See gun Owner’s Manual. Remove weld spatter or foreign matter from around nozzle opening. Have Factory Authorized Service Agency check drive motor or motor control board PC1. Motor runs slowly. Check for correct input voltage. Wire does not feed until trigger is pulled, Check for a short between welding gun trigger leads and weld cable. Repair short or replace welding gun. but continues to feed after trigger is released, and trigger hold is not on. Gas valve in feeder is rattling loudly Check for a short between welding gun trigger leads and weld cable. Repair short or replace welding gun. along with possible erratic or slow wire feed speed. Unit does not switch out of Run-In Install, reconnect, or replace voltage sensing lead. Speed. Wire feeder power is on, displays light Check welding gun trigger leads for continuity, and repair leads or replace gun. up, but unit is inoperative. OM-1587 Page 39 SECTION 16 − ELECTRICAL DIAGRAM Figure 16-1. Circuit Diagram OM-1587 Page 40 SD-184 796-B OM-1587 Page 41 15 SECTION 17 − PARTS LIST . Hardware is common and 16 Figure 17-1. Main Assembly OM-1587 Page 42 17 27 *Includes Item 6 Fig 17-3 Fig 17-2 32 31 30 Fig 17-3 28 29 26 6 25 24 23 22 2 3 1 21 4 7 20 19 8 9 18 10 11 12 5* 11 10 9 13 14 not available unless listed. ST-800 084-E Item No. Part No. Description Quantity Figure 17-1. Main Assembly . . . 1 . . . . . . . . . . . . . . ♦108 008 . . . 2 . . . . . . . . . . . . . . . . 168 103 . . . 3 . . . . . . . . . . . . . . . +168 104 . . . . . . . . . . . . . . . . . . . . . . 166 594 . . . 4 . . . . . . . . . . . . . . . . 124 900 . . . 5 . . . . . . . . . . . . . . . . 143 160 . . . 6 . . . . . . . . . . . . . . . . 058 427 . . . 7 . . . . . . . . . . . . . . . . 180 573 . . . 8 . . . . . . . . . . . . . . . . 010 233 . . . 9 . . . . . . . . . . . . . . . . 057 971 . . . 10 . . . . . . . . . . . . . . . . 010 191 . . . 11 . . . . . . . . . . . . . . . . 058 628 . . . 12 . . . . . . . . . . . . . . . . 058 428 . . . 13 . . . . . . . . . . . . . . . . 071 730 . . . 14 . . . . . . . . . . . . . . . . 135 205 . . . 15 . . . . . . . . . . . . . . . . 601 964 . . . 16 . . . . . . . . . . . . . . . . 141 411 . . . 17 . . . . . . . . . . . . . . . . 134 306 . . . 18 . . . . . . . . . . . . . . . . 142 838 . . . 19 . . . . . . . . . . . . . . . . 602 213 . . . 20 . . . . . . . . . . . . . . . . 601 872 . . . 21 . . . . . . . . . . . . . . . . 139 226 . . . 22 . . . . . . . . . . . . . . . . 083 639 . . . 23 . . . . . . . . . . . . . . . . 159 360 . . . 24 . . . . . . . . . . . . . . . . 159 646 . . . 25 . . . . . . . . . . . . . . . . 159 647 . . . 26 . . . . . . . . . . . . . . . . 139 752 . . . 27 . . . . . . . . . . . . . . . . 167 768 . . . 27 . . . . . . . . . . . . . . ♦167 770 . . . 28 . . . . . . . . . . . . . . . . 156 243 . . . 29 . . . . . . . . . . . . . . . . 145 639 . . . 30 . . . . . . . . . . . . . . . . 125 473 . . . 31 . . . . . . . . . . . . . . . . 167 762 . . . 31 . . . . . . . . . . . . . . ♦167 764 . . . 32 . . . . . . . . . . . . . . . . Fig 17-2 . . . . . . . . . . . . . . . . . . . . . . 600 324 . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHAFT, support spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPRING, cprsn .970 OD x .120 wire x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . WASHER, flat .632 ID x 1.500 OD x .125thk stl . . . . . . . . . . . . . . . . . . . . . WASHER, flat .656 ID x 1.500 OD x .125thk fbr . . . . . . . . . . . . . . . . . . . . . WASHER, brake stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HUG, spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TUBING, stl .875 OD x 12ga wall x 2.375 . . . . . . . . . . . . . . . . . . . . . . . . . . NUT, .625-11 .94hex .77 high stl elastic stop . . . . . . . . . . . . . . . . . . . . . . SCREW, .375-16 x .750hexhd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SUPPORT, spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FOOT, rubber 1.250dia x 1.375high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, mtg spool RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WASHER, lock .380 ID x .683 OD x .115thk stl split . . . . . . . . . . . . . . . . . NUT, .375-16 .56hex .34 high stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WEATHERSTRIPPING, adh .125 x 1.500 (order by ft) . . . . . . . . . . . . . . . INSULATOR, screw machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLAMP, motor base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSULATOR, motor clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPACER, stl .500 OD x 12ga wall x 3.750 . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE ASSEMBLY, wire RH (Fig 17-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE ASSEMBLY, wire RH (high speed) (Fig 17-3) . . . . . . . . . . . . . . . . CLAMP, motor top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STRIP, buna N compressed sheet .062 x 4.000 x 4.000 . . . . . . . . . . . . . . HOSE, SAE .187 ID x .410 OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE ASSEMBLY, wire LH (Fig 17-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE ASSEMBLY, wire LH (high speed) (Fig 17-3) . . . . . . . . . . . . . . . . . CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CABLE, weld cop strd No. 4/0 (order by ft) . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 1 1 1 1 1 1 2 2 2 1 1 1 2 1 4 1 2 2 1 1ft 8 2 2 1 1 1 2 2 2 1 1 1 3ft ♦OPTIONAL +When ordering a component originally displaying a precautionary label, the label should also be ordered. To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-1587 Page 43 OM-1587 Page 44 Figure 17-2. Control Box 31 32 33 34 35 30 Fig 17-5 36 37 29 PC50 PC10 29 Fig 17-4 28 2 1 3 PC1 27 5 4 6 26 7 8 PC80 11 10 23 25 12 9 24 38 21 19 22 20 14 13 2 18 17 16 15 . Hardware is common and not available unless listed. 800 111-E Item No. Dia. Mkgs. Part No. Description Quantity Figure 17-2. Control Box (Figure 17-1 Item 32) . . . 1 . . . . . . . . . . . . . . . . 161 707 . . PANEL, side lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 2 . . . . . GS1,2 . . . . 228 036 . . VALVE, 24VAC 1way .750−14 thd 2mm orf 100PSI . . . . . . . . . . . . . . . . 2 . . . 3 . . . . . . . . . . . . . . . . 134 201 . . STAND-OFF SUPPORT, PC card .312/.375 . . . . . . . . . . . . . . . . . . . . . . 10 . . . 4 . . . . . . PC1 . . . . . 198 037 . . CIRCUIT CARD, motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . PLG1 . . . . 115 092 . . CONNECTOR & SOCKETS (RC1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . PLG2 . . . . 115 093 . . CONNECTOR & SOCKETS (RC2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . PLG3 . . . . 115 094 . . CONNECTOR & SOCKETS (RC3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . PLG4 . . . . 115 091 . . CONNECTOR & SOCKETS (RC4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . PLG6 . . . . 136 810 . . CONNECTOR & SOCKETS (RC6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 5 . . . . . . . . . . . . . . . . 184 824 . . CASE SECTION, bottom/rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 6 . . . . . . CB1 . . . . . 083 432 . . CIRCUIT BREAKER, man reset 1P 10A 250V . . . . . . . . . . . . . . . . . . . . 1 . . . 7 . . . . . . . S1 . . . . . 111 997 . . SWITCH, rocker SPST 10A 250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 8 . . . . . PC80 . . . . 182 403 . . CIRCUIT CARD, HF filter dual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . PLG81 . . . . 115 093 . . CONNECTOR & SOCKETS (RC81) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . PLG82 . . . . 158 720 . . CONNECTOR & SOCKETS (RC82) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . PLG89 . . . . 131 054 . . CONNECTOR & SOCKETS (RC89) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . PLG90 . . . . 153 501 . . CONNECTOR & SOCKETS (RC90) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 9 . . . . . . . . . . . . . . . . 073 756 . . STAND-OFF, 6-32 x .625 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 10 . . . . . . . . . . . . . . . . 151 187 . . LATCH, slide flush mtg hole 1.000 wide x 1.500 lg . . . . . . . . . . . . . . . . . 1 . . . 11 . . . . . . . . . . . . . . . +161 710 . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 12 . . . . . . . . . . . . . . . . 010 290 . . BUSHING, strain relief 1.030 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 13 . . . . . . . . . . . . . . . . 134 464 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 13 . . . . . . . . . . . . . . . . 178 936 . . LABEL, warning general precautionary CE . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 14 . . . . . . . . . . . . . . . . 163 520 . . CABLE, port No. 18/14 11/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . 12ft . . . 15 . . . . . PLG9 . . . . 141 162 . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 16 . . . . . . . . . . . . . . . . 079 739 . . . . CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2 . . . . . . . . . 1 . . . 17 . . . . . . . . . . . . . . . . 601 222 . . CLAMP, univ 50A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 18 . . . . . . . . . . . . . . . . 603 106 . . HOSE, nprn brd No. 1 x .250 ID (order by ft) . . . . . . . . . . . . . . . . . . . . . 1ft . . . 19 . . . . . . . . . . . . . . . . 600 399 . . WIRE, strd 14ga blk 600V 105c (order by ft) . . . . . . . . . . . . . . . . . . . . . 35ft . . . 20 . . . . . . . . . . . . . . . . 138 044 . . BUSHING, strain relief .120/.150 ID x .500mtg hole . . . . . . . . . . . . . . . 1 . . . 21 . . . . . . . . . . . . . . . . 107 983 . . BLANK, snap-in nyl .500mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 22 . . . . . RC70 . . . . 048 282 . . CONNECTOR w/SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 23 . . . . . . . . . . . . . . . . 000 527 . . BLANK, snap-in nyl .875mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 24 . . . . . . . . . . . . . . . . 605 227 . . NUT, .750-14 knurled 1.68dia .41 high nyl . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 25 . . . . . CR101 . . . . 072 817 . . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 26 . . . . . . SR1 . . . . . 035 704 . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 27 . . . . . . . . . . . . . . . . 030 170 . . BUSHING, snap-in nyl .750 ID x 1.000mtg hole . . . . . . . . . . . . . . . . . . . 3 . . . 28 . . . . . . . . . . . . . . . . Fig 17-4 . . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 29 . . . PLG12,50 . . 155 629 . . CABLE, ribbon 14posn (RC12) (RC50) . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 30 . . . . . . . . . . . . . . . . 154 938 . . STRIP, mtg PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 31 . . . . . . . . . . . . . . . . 097 132 . . STAND-OFF, 6-32 x .375 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 32 . . . . . PC50 . . . . 189 124 . . CIRCUIT CARD, interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . PLG51 . . . . 158 720 . . CONNECTOR & SOCKETS (RC51) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . PLG52 . . . . 158 719 . . CONNECTOR & SOCKETS (RC52) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . PLG53 . . . . 131 204 . . CONNECTOR & SOCKETS (RC53) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . PLG54 . . . . 148 439 . . CONNECTOR & SOCKETS (RC54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . PLG55 . . . . 115 092 . . CONNECTOR & SOCKETS (RC55) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 33 . . . . . . . . . . . . . . . . 126 689 . . STAND-OFF, 6-32 x 1.500 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . 34 . . . . . PC10 . . . . 191 996 . . CIRCUIT CARD, processor w/proms (16 M) . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . PLG11 . . . . 115 092 . . CONNECTOR & SOCKETS (RC11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . PLG15 . . . . 153 501 . . CONNECTOR & SOCKETS (RC15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . PLG17 . . . . 115 093 . . CONNECTOR & SOCKETS (RC17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . PLG18 . . . . 162 382 . . CONNECTOR & SOCKETS (RC18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 35 . . . PLG10,24 . . 170 980 . . CABLE, ribbon 34posn (RC10) (RC24) . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 36 . . . PLG16,41 . . 155 023 . . CABLE, ribbon 24posn (RC16) (RC41) . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 37 . . . . . . . . . . . . . . . . Fig 17-5 . . PANEL, side w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . . 010 146 . . CLAMP, nyl .625 clamp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . . . . 164 059 . . HOSE ASSEMBLY, gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 38 . . . . . . . . . . . . . . . . 211 989 . . FITTING, w/screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 +When ordering a component originally displaying a precautionary label, the label should also be ordered. To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-1587 Page 45 . Hardware is common and not available unless listed. See Table 17-1 For Drive Roll & Wire Guide Kits 15 16 17 18 19 14 20 21 13 22 12 11 6 5 7 4 9 8 3 23 2 10 1 24 3 2 36 37 1 25 38 39 34 35 33 26 32 3 27 31 30 29 2 28 1 3 4 5 6 2 1 ST-152 711-G Figure 17-3. Drive Assembly, Wire OM-1587 Page 46 Item No. Dia. Mkgs. Part No. Description Quantity Figure 17-3. Drive Assembly, Wire (Figure 17-1 Items 27 & 31) . . . 1 . . . . . . . . . . . . . . . . 010 668 . . . 2 . . . . . . . . . . . . . . . . 172 075 . . . 3 . . . . . . . . . . . . . . . . 149 962 . . . 4 . . . . . . . . . . . . . . . . 149 486 . . . 5 . . . . . . . . . . . . . . . . 132 750 . . . 6 . . . . . . . . . . . . . . . . 150 520 . . . 7 . . . . . . . . . . . . . . . . 133 493 . . . 8 . . . . . . . . . . . . . . . . 133 350 . . . 9 . . . . . . M1,2 . . . . 156 354 . . . 9 . . . . . . M1,2 . . . ♦156 353 . . . . . . . . . . . . . . . . . . . . . . 153 491 . . . . . . . . . . . . . . . . . . . . . . 153 492 . . . . . . . . . . . . . . . . . . . . . . 153 493 . . . . . . . . . . . . . . . . . . . . . . 184 136 . . . 10 . . . . . . . . . . . . . . . . 155 098 . . . . . . . . . . . . . . . . . . . . . . 153 550 . . . . . . . . . . . . . . . . . . . . . . 155 099 . . . . . . . . . . . . . . . . . . . . . . 155 100 . . . . . . . . . . . . . . . . . . . . . . 154 031 . . . . . . . . . . . . . . . . . . . . . . 133 493 . . . . . . . . . PLG11,17 . . 115 092 . . . . . . . . . PLG51,57 . . 131 203 . . . . . . . . . . . RC7,8 . . . . 135 409 . . . 11 . . . . . . . . . . . . . . . . 182 414 . . . 12 . . . . . . . . . . . . . . . . 182 415 . . . 13 . . . . . . . . . . . . . . . . 137 248 . . . 14 . . . . . . . . . . . . . . . . 129 351 . . . 15 . . . . . . . . . . . . . . . . 602 200 . . . 16 . . . . . . . . . . . . . . . . 604 772 . . . 17 . . . . . . . . . . . . . . . . 182 156 . . . 18 . . . . . . . . . . . . . . . . 182 155 . . . 19 . . . . . . . . . . . . . . . . 132 746 . . . 20 . . . . . . . . . . . . . . . . 182 522 . . . 21 . . . . . . . . . . . . . . . . 132 747 . . . 22 . . . . . . . . . . . . . . . . 133 739 . . . 23 . . . . . . . . . . . . . . . . 183 330 . . . 24 . . TK1,2/PC51 . 198 004 . . . . . . . . . . . PLG57 . . . . 131 204 . . . . . . . . . . . . . . . . . . . . . . 604 311 . . . 25 . . . . . . . . . . . . . . . . 132 611 . . . 26 . . . . . . . . . . . . . . . . 149 959 . . . 27 . . . . . . . . . . . . . . . . 179 265 . . . 27 . . . . . . . . . . . . . . . . 179 264 . . . 28 . . . . . . . . . . . . . . . . 108 940 . . . 29 . . . . . . . . . . . . . . . . 604 538 . . . 30 . . . . . . . . . . . . . . . . 151 437 . . . 31 . . . . . . . . . . . . . . . . 128 237 . . . 32 . . . . . . . . . . . . . . . . 179 263 . . . 33 . . . . . . . . . . . . . . . . 601 872 . . . 34 . . . . . . . . . . . . . . . . 602 213 . . . 35 . . . . . . . . . . . . . . . . 602 243 . . . 36 . . . . . . . . . . . . . . . . 601 966 . . . 37 . . . . . . . . . . . . . . . . 167 387 . . . 38 . . . . . . . . . . . . . . . . 168 825 . . . 39 . . . . . . . . . . . . . . . . 133 308 . . . . . . . . . . . . . . . . . . . . . . 178 937 . . SCREW, cap stl sch .250-20 x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARRIER, drive roll w/components 24 pitch . . . . . . . . . . . . . . . . . . . . . . . . SPACER, carrier drive roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PIN, rotation arm rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ARM, pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPACER, rotation pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RING, retaining ext .250 shaft x .025thk . . . . . . . . . . . . . . . . . . . . . . . . . . . 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, brush holder repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KIT, cover motor gearbox (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COVER, motor gearbox (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKET, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCREW, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPACER, locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RING, rtng ext .250 shaft grv x .025thk . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WASHER, flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PIN, cotter hair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPRING, indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCREW, hexwhd-slt stl slffmg 8-32 x .500 . . . . . . . . . . . . . . . . . . . . . . . . . WASHER, lock stl split No. 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WASHER, flat stl SAE No. 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPRING, cprsn .573 OD x .088 wire x 1.062 lg . . . . . . . . . . . . . . . . . . . . . SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUSHING, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHAFT, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARRIER, shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WASHER, flat .375 ID x .625 OD x .062 . . . . . . . . . . . . . . . . . . . . . . . . . . . KNOB, extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD, digital tach (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GROMMET, rbr .250 ID x .375mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . OPTICAL ENCODER DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FITTING, brs barbed M 3/16tbg 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, plstc T 1.125 lg x .312-18 x 1.500 bar . . . . . . . . . . . . . . . . . . . . . . SCREW, hexwhd-slt stl slffmg 10-32 x .500 . . . . . . . . . . . . . . . . . . . . . . . . COVER, drive roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUT, stl hex full .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WASHER, lock stl split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WASHER, flat stl .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCREW, cap stl hexhd .375-16 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPACER, locating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE, pinion 40T 24P .376 bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RING, retaining ext .375 shaft x .025thk . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4 4 2 2 2 2 1 1 1 1 2 2 1 1 1 1 5 2 1 1 1 1 1 1 1 1 1 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 4 1 1 2 2 1 1 1 1 2 1 1 1 ♦Optional High Speed Motor To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-1587 Page 47 Item No. Dia. Mkgs. Part No. Description Quantity Figure 17-4. Panel, Front w/Components (Figure 17-2 Item 28) ... 1 ............................ . . . 2 . . . . . . . . . . . . . . . . . 167 697 . . . . . 3 . . . . . . . . . . . . . . . . . 147 139 . . . . . 4 . . . . . . . . . . . . . . . . . 164 842 . . . . . 5 . . . . . . . . . . . . . . . . . 144 844 . . . . . 6 . . . . PC20,30 . . . . 221 780 . . . . . . . . . . . . . PLG25 . . . . . 165 484 . . . . . 7 . . . . . PLG24 . . . . . . . . . . . . . . . . . . . 8 . . . . . . . . . . . . . . . . . 159 264 . . . . . 9 . . . . . . . . . . . . . . . . . 167 633 . . . . . 10 . . . . . . . . . . . . . . . . . 179 201 . . . . . 11 . . . . . . . . . . . . . . . . . 153 169 . . . . . 12 . . . . . . . . . . . . . . . . . 010 291 . . . . . 13 . . . . . . . . . . . . . . . . . 167 700 . . 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 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD, schd front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS (RC25) . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Figure 17-2 Item 35 (RC24) RING, ext .625 shaft grv x .045thk E style . . . . . . . . . . . . . . . . . . . . . . . WASHER, shldr .612 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LENS, LED 4345 green panel mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACTUATOR, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WASHER, flat .625 ID nylafil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KNOB, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . Hardware is common and 1 1 2 1 9 1 1 1 1 4 6 1 1 4 not available unless listed. 2 1 5 6 PC20, 30 8 7 9 13 12 11 10 ST-800 112-C Figure 17-4. Panel, Front w/Components To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-1587 Page 48 Item No. Dia. Mkgs. Part No. Description Quantity Figure 17-5. Panel, Side w/Components (Figure 17-2 Item 37) . . . 1 . . . . . . . . . . . . . . . . 147 139 . . . . . 2 . . . . . . . . . . . . . . . . 155 024 . . . . . 3 . . . . . . . . . . . . . . . . 154 933 . . . . . 4 . . . . . PC60 . . . . 156 623 . . . . . . . . . . . . . PLG60 . . . . 153 501 . . . . . 5 . . . . . PLG41 . . . . . . . . . . . . . . . . . . 6 . . . . . PC40 . . . . 158 160 . . . . . 7 . . . . . . . . . . . . . . . . 144 844 . . . . . 8 . . . . . . . . . . . . . . . . 154 109 . . . . . 9 . . . . . . . . . . . . . . . . 153 169 . . TAPE, adh acrylic double sided .010 x .500 x 3.000 . . . . . . . . . . . . . . . LENS, clear anti-glare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, inner control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD, data card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR & SOCKETS (RC60) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Figure 17-2, Item 36 (RC41) CIRCUIT CARD, side display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STAND-OFF, 6-32 x .875 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLATE, ident inner control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACTUATOR, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 1 1 1 1 4 1 4 . Hardware is common and not available unless listed. 5 4 6 3 1 PC60 2 PC40 7 9 8 ST-800 113-B Figure 17-5. Panel, Side w/Components To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-1587 Page 49 Fraction Intermediate Guide Wire Size Inlet Guide Table 17-1. Drive Roll and Wire Guide Kits 150 993 149 518 151 024 087 130 Metric .023-.025 in. 0.6 mm V-GROOVE 4 Roll Kit Drive Roll U-GROOVE VK-GROOVE 4 Roll Kit Drive Roll 4 Roll Kit Drive Roll 151 036 072 000 151 052 132 958 UC-GROOVE 4 Roll Kit Drive Roll .030 in. 0.8 mm 150 993 149 518 151 025 053 695 .035 in. 0.9 mm 150 993 149 518 151 026 053 700 .040 in. 1.0 mm 150 993 149 518 161 189 053 696 .045 in. 1.1/1.2 mm 150 994 149 519 151 027 053 697 151 037 053 701 151 053 132 957 151 070 083 489 .052 in. 1.3/1.4 mm 150 994 149 519 151 028 053 698 151 038 053 702 151 054 132 956 151 071 083 490 151 029 053 699 151 039 053 706 151 055 132 955 151 072 053 708 151 056 132 959 1/16 in. (.062 in.) 1.6 mm 150 995 149 520 .068-.072 in. 1.8 mm 150 995 149 520 5/64 in. (.079 in.) 2.0 mm 150 995 149 520 151 040 053 704 151 057 132 960 151 073 053 710 3/32 in. (.094 in.) 2.4 mm 150 996 149 521 151 041 053 703 151 058 132 961 151 074 053 709 7/64 in. (.110 in.) 2.8 mm 150 996 149 521 151 042 053 705 151 059 132 962 151 075 053 711 1/8 in. (.125 in.) 3.2 mm 150 997 149 522 151 043 053 707 151 060 132 963 151 076 053 712 Each Kit Contains An Inlet Guide, Intermediate Guide, And 045 233 Antiwear Guide With 604 612 Setscrew 8-32 x .125, Along With 4 Drive Rolls. 2 Kits Required For Dual Models. OM-1587 Page 50 S-0549-D Notes Notes Effective January 1, 2006 (Equipment with a serial number preface of “LG” or newer) Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way. This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions * Induction Heating Coils and Blankets, Cables, and below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to Non-Electronic Controls its original retail purchaser that new Miller equipment sold after * APT & SAF Model Plasma Cutting Torches the effective date of this limited warranty is free of defects in * Remote Controls material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER * Accessory (Kits) WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE * Replacement Parts (No labor) WARRANTIES OF MERCHANTABILITY AND FITNESS. * Spoolmate Spoolguns Within the warranty periods listed below, Miller will repair or * Canvas Covers replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed. Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor. 1. 5 Years Parts — 3 Years Labor 2. 3 Years — Parts and Labor * * * * * * * * * 3. Original main power rectifiers Transformer/Rectifier Power Sources Plasma Arc Cutting Power Sources Process Controllers Semi-Automatic and Automatic Wire Feeders Inverter Power Sources (Unless Otherwise Stated) Water Coolant Systems (Integrated) Intellitig Engine Driven Welding Generators (NOTE: Engines are warranted separately by the engine manufacturer.) 1 Year — Parts and Labor Unless Specified * * * * * * * * * * * * * * * * * * * Motor Driven Guns (w/exception of Spoolmate Spoolguns) Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources, Coolers, and Electronic Controls/Recorders Water Coolant Systems (Non-Integrated) Flowgauge and Flowmeter Regulators (No Labor) HF Units Grids Spot Welders Load Banks Arc Stud Power Sources & Arc Stud Guns Racks Running Gear/Trailers Plasma Cutting Torches (except APT & SAF Models) Field Options (NOTE: Field options are covered under True Blue® for the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.) Bernard-Branded Mig Guns (No Labor) Weldcraft-Branded TIG Torches (No Labor) Subarc Wire Drive Assemblies 4. 6 Months — Batteries 5. 90 Days — Parts * MIG Guns/TIG Torches and Subarc (SAW) Guns Miller’s True Blue® Limited Warranty shall not apply to: 1. Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear. (Exception: brushes, slip rings, and relays are covered on Bobcat, Trailblazer, and Legend models.) 2. Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any. 3. Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment. MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT. In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed. TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER. Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state. In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province. miller_warr 2006−01 Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Miller Electric Mfg. Co. Replacement Parts Training (Schools, Videos, Books) Technical Manuals (Servicing Information and Parts) Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www.millerwelds.com or call 1-800-4-A-Miller Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. PRINTED IN USA © 2006 Miller Electric Mfg. Co. 2006−01 An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 European Headquarters − United Kingdom Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066 www.MillerWelds.com
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