Miller | LF105445 | Owner Manual | Miller D-64M WIRE FEEDER CE User manual

Miller D-64M WIRE FEEDER CE User manual
OM-1587
161 874W
January 2005
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
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 catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 7/03
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 _8/03
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.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
Y During operation, keep everybody, especially children, away.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
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 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 Keep your head out of the fumes. Do not breathe the fumes.
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 Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
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 drape cables over your body.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read 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 on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-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 a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.
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.
MAGNETIC FIELDS can affect pacemakers.
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 Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
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 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 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.
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
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, 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 Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
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.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
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.
D
OVERUSE can cause OVERHEATING
D
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
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.
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.
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
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 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 American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).
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 American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
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 and www.
sparky.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 and www. sparky.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 first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT
UTILISATION
som_fre 8/03
2-1. Signification des symboles
Signifie « Mise en garde. Faire preuve de vigilance. »
Cette procédure présente des risques identifiés par les
symboles adjacents aux directives.
Y Identifie un message de sécurité particulier.
. Signifie « NOTA » ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigilance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux
PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporter
aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.
2-2. Dangers relatifs au soudage à l’arc
Y Les symboles ci-après sont utilisés tout au long du présent
manuel pour attirer l’attention sur les dangers potentiels et les
identifier. Lorsqu’on voit un symbole, faire preuve de vigilance et
suivre les directives mentionnées afin d’éviter tout danger. Les
consignes de sécurité énoncées ci-après ne font que résumer le
contenu des normes de sécurité mentionnées à la section 2-4.
Lire et respecter toutes ces normes.
D N’utiliser que du matériel en bon état. Réparer ou remplacer sur−le−
champ les pièces endommagées. Entretenir l’appareil conformément
au présent manuel.
Y L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.
D Fixer le câble de retour de façon à obtenir un bon contact métal sur
métal avec la pièce à souder ou la table de travail, le plus près possible
de la soudure.
Y Pendant l’utilisation de l’appareil, tenir à l’écart toute personne,
en particulier les enfants.
D Porter un harnais de sécurité quand on travaille en hauteur.
D Maintenir solidement en place tous les panneaux et capots.
D
Ne pas connecter plus d’une électrode ou plus d’un câble de masse à un
même terminal de sortie.
LES DÉCHARGES ÉLECTRIQUES
peuvent être mortelles.
Un simple contact avec des pièces sous tension peut
causer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est en fonctionnement. Le circuit
d’entrée et les circuits internes de l’appareil sont également sous tension.
En soudage semi−automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en contact
avec le fil de soudage sont sous tension. Tout matériel mal installé ou mal
mis à la terre présente un danger.
D Ne jamais toucher aux pièces électriques sous tension.
D Porter des gants et des vêtements de protection secs et exempts de
trous.
D S’isoler de la pièce et de la terre au moyen de tapis ou autres dispositifs isolants suffisamment grands pour empêcher tout contact
physique avec la pièce ou la terre.
D
D
D
Ne pas se servir d’une source de courant alternatif dans les zones humides, les endroits confinés ou là où on risque de tomber.
Ne se servir d’une source de courant alternatif QUE si le procédé de soudage l’exige.
Si l’utilisation d’une source de courant alternatif s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Couper/étiqueter
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir les normes de sécurité).
D Installer et mettre à la terre correctement l’appareil conformément à
son manuel d’utilisation et aux codes nationaux, provinciaux et
municipaux.
D 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.
D Pour exécuter les branchements d’entrée, fixer d’abord le conducteur
de mise à la terre adéquat et contre−vérifier les connexions.
D Vérifier fréquemment le cordon d’alimentation et s’assurer qu’il n’est
ni endommagé ni dénudé ; le remplacer immédiatement s’il est endommagé − tout câble dénudé peut causer une électrocution.
D Mettre l’appareil hors tension quand on ne l’utilise pas.
D Ne pas utiliser de câbles usés, endommagés, de calibre insuffisant ou
mal épissés.
D Ne pas s’enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce, la
terre ou une électrode d’une autre machine.
Il subsiste un COURANT CONTINU IMPORTANT
dans les convertisseurs après la suppression de
l’alimentation électrique.
D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions
énoncées à la section Entretien avant de toucher les pièces.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz dont
l’inhalation peut être dangereuse pour la santé.
D Se tenir à distance des fumées et ne pas les inhaler.
D À l’intérieur, ventiler la zone et/ou utiliser un dispositif d’aspiration au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
D Si la ventilation est insuffisante, utiliser un respirateur à adduction
d’air agréé.
D Lire les fiches techniques de santé−sécurité (FTSS) et les instructions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
D Ne travailler dans un espace clos que s’il est bien ventilé ou porter un
respirateur à adduction d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage
peuvent se substituer à l’air, abaisser la teneur en oxygène et causer
des lésions ou des accidents mortels. S’assurer que l’air est respirable.
D Ne pas souder 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 de métaux munis d’un revêtement, tels que la tôle
d’acier galvanisée, plombée ou cadmiée, à moins que le revêtement
n’ait été enlevé dans la zone de soudage, que l’endroit soit bien ventilé, et si nécessaire, porter un respirateur à adduction d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques lorsqu’on les soude.
OM-1587 Page 5
LES RAYONS DE L’ARC peuvent causer des brûlures oculaires et cutanées.
Le rayonnement de l’arc génère des rayons visibles et
invisibles intenses (ultraviolets et infrarouges) susceptibles de causer des brûlures oculaires et cutanées.
Des étincelles sont projetées pendant le soudage.
D Porter un masque de soudage muni d’un filtre de la nuance adéquate
pour se protéger le visage et les yeux pendant le soudage ou pour regarder (voir les normes de sécurité ANSI Z49.1 et Z87.1).
D Porter des lunettes de sécurité à écrans latéraux sous le masque.
D Utiliser des écrans ou des barrières pour protéger les tiers de l’éclat
éblouissant ou aveuglant de l’arc ; leur demander de ne pas regarder
l’arc.
D Porter des vêtements de protection en matière durable et ignifuge
(cuir ou laine) et des chaussures de sécurité.
LE SOUDAGE peut causer un incendie ou une explosion.
Le soudage effectué sur des récipients fermés tels que
des réservoirs, des fûts ou des conduites peut causer
leur éclatement. Des étincelles peuvent être projetées
de l’arc de soudure. La projection d’étincelles, les
pièces chaudes et les équipements chauds peuvent causer des
incendies et des brûlures. Le contact accidentel de l’électrode avec tout
objet métallique peut causer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et
s’assurer que l’endroit ne présente pas de danger.
D Se protéger et protéger les tiers de la projection d’étincelles et de métal chaud.
D Ne pas souder à un endroit où des étincelles peuvent tomber sur des
substances inflammables.
D Placer 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 agréées.
D Des étincelles et des matières en fusion peuvent facilement passer
même par des fissures et des ouvertures de petites dimensions.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
D Le soudage effectué sur un plafond, un plancher, une paroi ou une
cloison peut déclencher un incendie de l’autre côté.
D Ne pas souder des récipients fermés tels que des réservoirs, des fûts
ou des conduites, à moins qu’ils n’aient été préparés conformément à
l’AWS F4.1 (voir les normes de sécurité).
D Brancher le câble sur la pièce le plus près possible de la zone de soudage pour éviter que le courant ne circule sur une longue distance, par
des chemins inconnus, et ne cause des risques d’électrocution 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 porte−
électrode ou couper le fil au raz du tube−contact.
D Porter des vêtements de protection exempts d’huile tels que des
gants en cuir, une chemise en tissu épais, des pantalons sans revers,
des chaussures montantes et un masque.
D Avant de souder, retirer tout produit combustible de ses poches, tel
qu’un briquet au butane ou des allumettes.
LES PARTICULES PROJETÉES peuvent blesser les yeux.
D Le soudage, le burinage, le passage de la pièce à
la brosse métallique et le meulage provoquent
l’émission d’étincelles et de particules métalliques. Pendant leur refroidissement, les soudures risquent de projeter du
laitier.
D
Porter des lunettes de sécurité à écrans latéraux agréés, même sous le
masque de soudage.
OM-1587 Page 6
LES ACCUMULATIONS DE GAZ peuvent causer des blessures ou même
la mort.
D
D
Couper l’alimentation en gaz protecteur en cas de
non utilisation.
Veiller toujours à bien ventiler les espaces confinés ou porter un respirateur à adduction d’air agréé.
LES PIÈCES CHAUDES peuvent causer des brûlures graves.
D Ne pas toucher les pièces chaudes à main nue.
D Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
LES CHAMPS MAGNÉTIQUES peuvent
perturber le fonctionnement des stimulateurs cardiaques.
D
D
Les personnes qui portent un stimulateur cardiaque
doivent se tenir à distance.
Ils doivent consulter leur médecin avant de s’approcher d’un lieu où on exécute des opérations de soudage à l’arc, de gougeage ou de soudage par points.
LE BRUIT peut affecter l’ouïe.
Le bruit de certains processus et équipements peut
affecter l’ouïe.
D
Porter des protecteurs d’oreille agréés si le niveau
sonore est trop élevé.
Les BOUTEILLES
peuvent exploser.
endommagées
Les bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Toute bouteille endommagée
peut exploser. Comme les bouteilles de gaz font
normalement partie du procédé de soudage, les
manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé de la chaleur excessive, des
chocs mécaniques, du laitier, des flammes nues, 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 poser une torche de soudage sur une bouteille de gaz.
D Ne jamais mettre une électrode de soudage en contact avec une bouteille de gaz.
D Ne jamais souder une bouteille contenant du gaz sous pression − elle
risquerait d’exploser.
D N’utiliser que les bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords adéquats pour l’application envisagée ; les maintenir en bon
état, ainsi que les pièces connexes.
D Détourner la tête lorsqu’on ouvre la soupape d’une bouteille.
D Laisser le capuchon protecteur sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille
D Lire et suivre les instructions concernant les bouteilles de gaz comprimé, les équipements associés et les publications P−1 de la CGA,
mentionnées dans les normes de sécurité.
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de
l’appareil.
Risque D’INCENDIE OU D’EXPLOSION
LES ORGANES MOBILES peuvent
causer des blessures.
D Ne pas placer l’appareil sur une surface inflammable, ni au−dessus ou à proximité d’elle.
D Se tenir à l’écart des organes mobiles comme les
ventilateurs.
D Maintenir fermés et bien fixés les portes,
panneaux, recouvrements et dispositifs de
protection.
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.
LA CHUTE DE L’APPAREIL peut
blesser.
D N’utiliser que l’anneau de levage pour lever l’appareil. NE PAS utiliser le chariot, les bouteilles de
gaz ou tout autre accessoire.
D Utiliser un engin de capacité adéquate pour lever
l’appareil.
D Si on utilise un chariot élévateur pour déplacer l’unité, s’assurer que
les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.
L’EMPLOI EXCESSIF peut FAIRE
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le cycle opératoire avant de
reprendre le soudage.
D Ne pas obstruer les orifices ou filtrer l’alimentation en air du poste.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Mettre un bracelet antistatique AVANT de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimés.
LES PIÈCES MOBILES peuvent causer des blessures.
D Se tenir à l’écart des pièces mobiles.
D Se tenir à l’écart des points de coincement tels
que les dévidoirs.
LES FILS DE SOUDAGE peuvent causer des blessures.
D Ne pas appuyer sur la gâchette avant d’en avoir
reçu l’instruction.
D Ne pas diriger le pistolet vers soi, vers d’autres
personnes ou vers toute pièce mécanique en engageant le fil de soudage.
LE RAYONNEMENT HAUTE FRÉQUENCE (H. F.) risque de causer des
interférences.
D Le rayonnement haute fréquence peut causer
des interférences avec les équipements de radionavigation et de communication, les services de
sécurité et les ordinateurs.
D Ne demander qu’à des personnes qualifiées familiarisées avec les
équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences causées par l’installation.
D Si la Federal Communications Commission signale des interférences, arrêter immédiatement l’appareil.
D Faire régulièrement contrôler et entretenir l’installation.
D Maintenir soigneusement fermés les panneaux et les portes des sources de haute fréquence, maintenir le jeu d’éclatement au réglage
adéquat et utiliser une terre et un blindage pour réduire les interférences éventuelles.
LE SOUDAGE À L’ARC peut causer
des interférences.
D L’énergie électromagnétique peut causer des
interférences avec l’équipement électronique
sensible tel que les ordinateurs et l’équipement
commandé par ordinateur tel que les robots.
D Veiller à ce que tout l’équipement de la zone de soudage soit compatible au point de vue électromagnétique.
D Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas
que possible (par ex. : à terre).
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
D Veiller à ce que le poste de soudage soit posé et mis à la terre conformément au présent manuel.
D En cas d’interférences après exécution des directives précédentes, il
incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de
travail.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, restez 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.
OM-1587 Page 7
2-4. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1,
de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(téléphone : (305) 443−9353, site Web : www.aws.org).
Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800)
463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, norme American Welding Society AWS
F4.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126 (téléphone : (305) 443−9353, site Web : www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
norme ANSI Z87.1, de l’American National Standards Institute, 11 West
42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900,
site Web : www.ansi.org).
National Electrical Code, norme NFPA 70, de la National Fire Protection
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (téléphone : (617) 770−3000, sites Web : www.nfpa.org et
www.sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, norme NFPA 51B, de la National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617) 770−3000, site Web : www.nfpa.org et www.sparky.org).
Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1,
de la Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900,
site Web : www.cganet.com).
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Canadian Standards Association, Standards Sales, 178 boulevard
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 l’U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a
10 bureaux régionaux − Téléphone pour la Région 5, Chicago : (312)
353−2220, site Web : www.osha.gov).
2-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et les effets des champs magnétiques basse fréquence sur l’organisme
En parcourant les câbles de soudage, le courant crée des champs électromagnétiques. Les effets potentiels de tels champs restent
préoccupants. Cependant, après avoir examiné plus de 500 études qui
ont été faites pendant une période de recherche de 17 ans, un comité
de spécialistes du National Research Council a conclu : « L’accumulation de preuves n’a pas démontré que l’exposition aux champs
magnétiques et aux champs électriques à haute fréquence constitue un
risque pour la santé humaine ». Toutefois, les études et l’examen des
preuves se poursuivent. En attendant les conclusions finales de la recherche, il serait souhaitable de réduire l’exposition aux champs
électromagnétiques pendant le soudage ou le coupage.
OM-1587 Page 8
Afin de réduire les champs électromagnétiques en milieu de travail, respecter les consignes suivantes :
1. Garder les câbles ensemble en les torsadant ou en les fixant avec du
ruban adhésif.
2. Mettre tous les câbles du côté opposé à l’opérateur.
3. Ne pas s’enrouler les câbles autour du corps.
4. Garder le poste de soudage et les câbles le plus loin possible de soi.
5. Placer la pince de masse le plus près possible de la zone de soudage.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur médecin. Si ce dernier les déclare aptes, il leur est recommandé de respecter les consignes ci-dessus.
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
300/400 Ampere Model
CC/CV Inverter Welding
Power Source
. Use
1
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
4
5
6
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
Front Panel
Drive Assembly Rotation
Adjustment Opening
Drive Assembly
3/16 in
2
1
3
Ref. ST-153 093-A / ST-800 289
OM-1587 Page 13
5-5. 14-Pin Plug Information
Pin*
J
I
K
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)
A
B
L
H
N
C
M D
G
F E
*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
7
Parameter Display
Parameter Select Button
Press button to move > in display.
5
6
7
8
Parameter Increase Button
Parameter Decrease Button
Power Switch
Circuit Breaker CB1
CB1 protects the wire feeder from
overload.
Rear Panel
1
3
2
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
Allows dual scheduling
establishing a welding arc.
2
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
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
4
1
2
2
2
3
3
3
Trigger
1
. Switch type is selected in system setup
1
2
TR
5
B
1
A
4
OM-1587 Page 22
Adapter
1
4
3
(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
1
2
Moving line is under value that can
be changed.
uence
l Schd
d
u r i t y
3
P r ess
Be l ow
3
Write
Transfers program data from unit to
card. The program card can hold up
to 32 programs. When writing to the
card, the next available program
number is automatically assigned.
4
Side Panel
Parameter
Select Once
Read
Transfers program data from card
to unit.
5
Delete
Deletes program data from card.
6
>W r
Re
De
Do
4
5
6
OM-1587 Page 24
Card Display
Moving Line
i
a
l
n
t e
d
e t e
e
# 1 Pu l se
035 ”S t ee l
A r g o n −O x y
P r ess
2
Done
Exits card display.
9-4. Entering Access Code
. 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
2
3
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
When the security lock is Off, the
full range of values is available for
each parameter.
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
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
Side Panel
Parameter
Select
3
4
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).
1
2
P r
Lo
>T r
Ra
og
ck
im
nge
1
On
50
0
og
ck
im
nge
og
ck
im
nge
1
On
50
0
Side Panel
Parameter
Select
Increase/
Decrease
P r
Lo
>T r
Ra
P r
>L o
T r
Ra
1
On
55
0
P r og
>L o c k
1
Of f
On
55
0
200
Lock
T r im
>R a n g e
I PM
On
55
10
200
Side Panel
Parameter
Select
5
T r im
Range
I PM
>R a n g e
T r im
Range
>I PM
Range
55
10
225
0
55
10
225
0
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
Side Panel
Parameter
Select
Moving line is under value that can
be changed. Change program
number to access desired program.
3
Increase/
Decrease
Loc k
T r im
>R a n g e
I PM
Card Display
Moving Line
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
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.
1
0 3 5 “ S t
1
Parameter
Select
5 0
2 0 0
5 0
2 0 0
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
270
27
50
130
2
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).
480
48
120
315
4
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
2
1
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
Memory CRC Error Display
The data in the program indicated is
not the same data that was saved.
S t a r t
E r r o r
7
Perform a system reset.
4
A r c
S t o p
E r r o r
8
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
If this error continues to occur when
pulse welding, it may help to select
Hot Start.
3
A r c
10
1
No Volt Sensed Error Display
Turn unit off and back on after
correcting problem.
N o
9
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 . . . . 216 126 . . VALVE, gas w/fittings 24VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
9
4
8
3
23
2
10
1
24
3
2
36
37
1
25
38
39
35
34
33
26
32
3
27
31
30
29
2
28
6
5
4
1
3
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. Hardware is common and
3
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
PC60
1
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, 2005
(Equipment with a serial number preface of “LF” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
*
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Induction Heating Coils and Blankets
*
APT & SAF Model Plasma Cutting Torches
*
Remote Controls
*
Accessory Kits
*
Replacement Parts (No labor)
*
Spoolmate Spoolguns
*
Canvas Covers
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Miller’s True Blue Limited Warranty shall not apply to:
1.
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.
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.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
*
Water Coolant Systems (Integrated)
*
*
*
Intellitig
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources and Coolers
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
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.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
MIG Guns/TIG Torches
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 1/05
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.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
www.MillerWelds.com
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
 2005 Miller Electric Mfg. Co.
1/05
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