Miller D-64M WIRE FEEDER CE Owner’s Manual

OM1587F
February
1997
En. wlSenal Number KH339697
Miller
The Power ofBlue.
Processes
~
MIG
(GMAW) Welding
Pulsed MIG
(GMAW-P)
Flux Cored (FCAW) Welding
(Gas- and Self-Shielded)
flp~miint inn
1~~~
Wire Feeder
(Use
with CC/CV Power
!J-~ )-i
CE
OWNERS_MANUAL
Sources)
From
to You
-]
.
Thank you and congratulations on choosing Miller. Now
you can get the job done and get it done right. We know
have time to do it any other way.
you dont
Thats
why
when Neils Miller first started
building arc
sure
products offered
long-lasting value and superior quality. Like you, his
customers couldnt afford anything less. Miller products
had to be more than the best they could be. They had to
be the best you could buy.
welders in 1929, he made
Today,
his
the
people that build and sell Miller products continue the
tradition. Theyre just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owners
Miller
help
Manual is
products.
designed
to
help
you get the most out of your
Please take time to read the
yourself against potential
you protect
Safety precautions. They
hazards
made installation and
iIf~{IIiIIIII p
With Miller you
can
on
the worksite. Weve
operation quick
count
will
on
and easy.
years of reliable
service with proper maintenance. And if for
REGISTERED
QUALITY SYSTEM
some reason
the unit needs
______________
repair,
theres
a
section that will
Troubleshooting
help you
figure out what the problem is. The parts list
will then help you to decide which exact part
you may need to fix the problem. Warranty and
service information for your particular model
are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered
to the ISO 9001 Quality
System Standard.
~1~ll1ftE~ftflJ1!
Working as hard as you do
every power source from
Miller Is backed by the most
hassle-free warranty in the
business.
Miller Electric manufactures
of welders and
welding
For information
products,
to
on
contact
full line
related
other
equipment.
quality Miller
your local Miller distributor
receive the latest full line
individual
a
catalog
catalog
or
sheets. To locate your nearest
distributor call 1-800-4-A-Miller.
f//A Miller
TheThwerofBki&
r\
Front Panel Features
Description
2-line
by
16-character backlit LCD
Single push-button parameter
Single
knob
Put the benefits of technology to work on the
production line. The D-64M represents a major
advancement in wire feed technology, and
Trigger
delivers the ultimate in versatility, simplicity,
programmability and performance.
Wire
select control
parameter adjustment
hold control for
welds without
making extended
holding gun tngger
jog control feeds wire without
the contactor
The D-64M feeder includes special features for
pulsed MIG (GMAW-P) welding that requires the
use of inverter-type power sources. However the
D-64M retains the versatility that makes it
energizing
Gas purge control purges line without
energizing feeder
Side Panel Features
i+~,.1 s,. ,.nn.,~nt,nn~I ItAI(~ ~
....~
using
For
a
vanety
of Miller CV
pulsed MIG welding,
or
CC/CV machines.
the D-64M features
built-in memory with eight, factory-set synergic
pulse programs. Each program is specific for a
wire type, wire size and gas mixture. Any of these
programs
can
specific
welding application.
be modified for the
requirements of your
wires of two different sizes
in situations where
a
by
20-character backiit LCD for
parameter and mode displays
Push-button programming controls for
process, sequence, dual schedule, and data
card modes
Parameter select
push
button
Parameter increase/decrease
This dual wire model operates one gun at a time,
and provides efficiency in applications that
alternately require
types. Its also ideal
4-line
push buttons
Processes
or
MIG
standby
(GMAW) Welding
Pulsed MIG
gun is needed. This dual-wire model can be
programmed to run the identical process on both
sides, or to have one side run conventional MIG
while the other is set for pulsed MIG welding.
(GMAW-P)
Flux Cored (FCAW) Welding
(Gas- and Self-Shielded)
Table of Contents
:
Page
Section
Call
1
Precautions
1 -800-4-A-MIU.EB
1.
Safety
for your local
Miller distributor.
1.
Consignes de SØcuritØ
Soudage a Larc
Your distributor
gives
you
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
pour le
4
7
3. Introduction
9
4. Installation
9
15
5.
Operation
6.
Setting Sequence
7.
Setting
8.
Using
9.
System Setup
Parameters
Dual Schedule Parameters
18
19
Support
Need fast
answers to
the
the
Data Card
Optional
21
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
a Technical Manual
which provides more detailed
service and parts information for
your unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor can also
supply you with Welding Process
Miller offers
2. Definitions
10. Standard Pulse
23
Welding Programs
26
11. Teach Points
12. Maintenance and
13. Electrical
Troubleshooting
Diagram
14. Parts List
Options
and Accessories
Warranty
24
30
34
36
ManualssuchasSMAW, GTAW,
GMAW, and GMAW-P.
Declaration of Conformity for
European Community (CE) Products
Note ~
Manufacturers
This information is
with CE certification
Miller Electric
Name:
on
unit).
Co.
Spencer Street
Appleton, WI 54914 USA
D-64M
Declares that the product
following
Mfg.
(see rating label
1635 W.
Manufacturers Address:
conforms to the
provided for units
Directives and Standards:
Directives
Low
Voltage
Directive: 73/23/EEC
Electromagnetic Compatibility (EMC)
Machinery
Directives: 89/392/EEC,
Directive: 89/336/EEC
91/368/EEC, 93/C 133/04, 93/68/EEC
Standards
Arc
Welding Equipment Part I: Welding Power Sources:
(April 1995 Draft Revision)
Arc
Degrees
Welding Equipment:
(May 1995
of Protection Provided
Wirefeed
By
Draft
Systems:
Revision)
Enclosures
lEG 974-1
IEC 974-4
(IP Code):
IEC 529:1989
Insulation Coordination For
Part I:
Equipment With Low-Voltage Systems:
Principles, Requirements and Tests: lEG 664-1: 1992
Electromagnetic Compatibility, (EMC):
European Contact
Mr.
Luigi Vacchini, Managing Director
Europe S.P.A.
MILLER
Via Privata Iseo
20098 San Giuliano
Milanese, Italy
Telephone:
Fax:
dec_con 11/96
39(02)98290-1
39(02)98281-552
EN 50199
.
Read Before Using
1. Safety Precautions
1.1
SymbOl Usage
OM-1587F .2197,
A
Warning! Watch Out!
Means
a
hazards with this procedure! The
shown in the adjoining symbols.
Marks
a
There
hazards
are
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.
This group of
special safety message.
IE? Means ~Note; not safety related.
Arc
t2
A
The
Welding Hazards
symbols shown
below
to call attention to and
are
used
throughout this manual
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 1.3. Read and
follow all Safety Standards.
A Only qualified persons
repair this unit.
A
11/96
possible
are
possible
safety_som
should
install, operate, maintain,
and
Keep au paneis and covers Seuureiy ifi place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
SIGNIFICANT DC VOLTAGE exists after removal of
input
power
on
inverters.
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before
touching any parts.
During operation, keep everybody, especially children, away.
ARC RAYS
ELECTRIC SHOCK
can
kill
burn eyes and skin
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can bum eyes and skin. Noise from some
~\.. ~
live electrical parts can cause fatal
shocks or severe bums. 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.
can
Touching
can
damage hearing.
processes
and welds cooling throw off pieces of metal or
grinding,
Chipping,
slag.
a proper shade offilterto protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
Wear a welding helmet fitted with
Wear
approved safety glasses
with side shields.
protective screens or bamers to protect others from flash and
glare; warn others not to watch the arc.
Use
Do not touch live electrical parts.
Wear
dry, hole-free insulating gloves
and
body protection.
Wear
yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the
work or ground.
Insulate
Disconnect
servicing
to OSHA 29
Properly
Owners
input power or stop engine before installing or
equipment. Lockout/tagout input power according
CFR 191 0.147 (sec Safety Standards).
this
install and
ground
this
equipment according
making input connections, attach
conductor first
proper
grounding
double-check connections.
~ ~
fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
Welding produces
Turn off all
equipment
use worn,
when not in
use.
damaged, undersized, or poorly spliced cables.
-
cables
Do not
drape
If earth
grounding
over
of the
separate cable
-
your body.
workpiece
do not
use
is
required, ground it directly
clamp or work cable.
work
Do not touch electrode if you are in contact with the work,
or another electrode from a different machine.
If
inside, ventilate the
remove
If ventilation is poor,
Read
ground,
only well-maintained equipment. Repair or replace damaged
once. Maintain unit according to manual.
parts at
Wear
OM-1 587
a
safety
harness if
working
Material
the
above floor level.
area
and/or
use
exhaust at the
arc
to
fumes and gases.
welding
use an
Safety
approved air-supplied respirator.
Data
Sheets
(MSDSs)
instructions for metals, consumables,
and
the
coatings,
cleaners, and degreasers.
a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying
Work in
operations.
The heat and rays of the
form
toxic and
highly
arc can
react with vapors to
irritating gases.
coated metals, such as galvanized, lead, or
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
Do not weld
cadmium
Use
head out of the fumes. Do not breathe the fumes.
Keep your
manufacturers
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
a
L......
Manual and national, state, and local codes.
When
with
FUMESANDGASEScanbe hazardous
to its
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.
Do not
protective clothing made from durable, flame-resistant
(wool and leather) and foot protection.
rnaterial
on
plated steel,
containing
these elements
can
give off toxic fumes if welded.
1
CYLINDERS
explode
can
If
damaged
H.F. RADIATiON cancaUse Interference.
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
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.
from
excessive
compressed gas cylinders
slag, open flames, sparks,
Protect
mechanical shocks,
and
communications
only qualified persons familiar with
electronic equipment perform this installation.
heat,
The
arcs.
user
is
Install
cylinders in an upright position by securing to
or cylinder rack to prevent falling or tipping.
stationary
a
Keep cylinders away from any welding
Never
drape
Never allow
Never weld
a
a
welding
welding
on a
torch
over a
or
other electrical circuits.
pressurized cylinder
will result.
only correct shielding gas cylinders, regulators, hoses,
fittings designed for the specific application; maintain them
associated parts in good condition.
Use
Tum face away from valve outlet when
Keep protective cap in place
use or connected for use.
opening cylinder
valve except when
over
by
at once.
the FCC about interference,
regularly
stop using the
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.
cylinder.
explosion
If notified
equipment
Have the installation
cylinder.
gas
electrode to touch any
responsible for having a qualified electrician
problem resulting from the
correct any interference
installation.
promptly
support
equipment.
Have
and
and
FIRE OR EXPLOSION hazard.
valve.
cylinder is in
Do not install
place
or
unit on, over,
or near
combustible surfaces.
Read and follow instructions
associated
equipment,
compressed gas cylinders,
publication P-i listed in Safety
on
and CGA
Do
not
locate
unit
on,
over,
near
or
combustible surfaces.
Standards.
Do not install unit
near
flammables.
Do not overload
is
building wiring be sure power supply system
properly sized, rated, and protected to handle this unit.
WELDING can causefireorexplosion.
Welding
drums,
on
closed containers,
such
tanks,
as
pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks,
hot workpiece, and hot equipment can cause fires
and burns. Accidental contact of electrode to metal objects can
cause sparks, explosion, overheating, or fire. Check and be sure the
area is safe before doing any welding.
Protect
yourself
and others from
Do not weld where
can cause
flying sparks
flying sparks
can
possible, tightly
cover
Allow
cooling period, follow
Reduce current
starting
to weld
Do not block
or
or
If
Be
aware
that
can cause
fire
Do not weld
on
welding
on
fire
on a
extinguisher nearby.
ceiling, floor, bulkhead,
closed containers such
as
or
tanks, drums,
they are property prepared according
Safety Standards).
Connect work cable to the work
as
to
use
wearers
tip
affect pacemakers.
keep away.
Wearers should consult their doctor before
going near arc welding, gouging,
welding operations.
or
spot
or
pipes,
(see
welder to thaw frozen
when not in
HOT PARTS
can cause severe
Do not touch hot parts bare handed.
welding area as
from traveling long, possibly
Allow
cooling period before working
on
gun
or
torch.
pipes.
or
cut oft
welding
wire at
MOVING PARTS
can cause
use.
Wear oil-free
protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Remove any combustibles, such as a butane
from your person before doing any welding.
lighter or matches,
Keep away
from
moving parts
can
injure eyes
injury.
such
as
all doors, panels, covers, and
closed and securely in place.
Keep
WELDING WIRE
FLYING METAL
burns.
to AWS F4.i
close to the
Remove stick electrode from holder
contact
can
partition
prevent welding current
unknown paths and causing electric shock and fire hazards.
Do not
before
the hidden side.
unless
practical
duty cycle.
filter airflow to unit.
MAGNETIC FiELDS
Pacemaker
a
rated
duty cycle
strike flammable material.
(10.7 m) of the welding arc.
them with approved covers.
welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
keep
reduce
again.
Be alert that
Watch for fire, and
OVERHEATING
and hot metal.
Remove all flammables within 35 ft
this is not
OVERUSE
or
Do not press gun
can cause
trigger
fans.
guards
injury
until instructed to do
so.
Chipping and grinding cause flying metal. As welds
cool, they can throw off pieces of metal or slag.
point gun toward any part of the body,
people, or any metal when threading
welding wire.
Do not
other
Wear
2
a
face shield to
protect eyes
and skin.
OM-1 587
.
NOISE
can
Noise from
FLWNG METAL or DIRT can
damage hearing
some
processes
or
equipment
Wear
can
with side shields
safety glasses
or
face
shield.
damage hearing.
Wear
injure eyes.
approved
ear
protection
if noise level is
high.
FALLING UNIT
STATIC
Put
(ESD) can damage PC
grounded wrist
handling boards or parts.
on
Use proper
store, move,
strap
Use
boards
cauŁe
can
injury.
lifting eye to lift unit only, NOT running
cylinders, or any other accessories.
gear, gas
Use
BEFORE
of
equipment
adequate capacity
to lift
unit.
static-proof bags and
or ship PC boards.
If
boxes to
using lift forks to
move
unit, be
sure
forks
are
long enough to extend beyond opposite side of
unit.
MOVING PARTS
Keep away
Keep
from
away from
can cause
BUILDUP OF GAS
injury
Shutoff
moving parts.
pinch points
such
as
injUreor. kill.
can
shielding gas supply when
not in use.
drive
rolls.
Principal Safety Standards
1 3
Safely in Welding and Cutting, ANSI Standard Z49.1, from
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
American
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten
dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances,
American Welding Society Standard AWS F4.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Handling of Compressed Gases
in
Cylinders, CGA Pamphlet
P-i, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cuffing, CSA Standard Wi 17.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1 R3.
Safe Practices For
And Face
Occupation And Educational Eye
Protection, ANSI Standard Z87.1 from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
,
Cutting And Welding Processes, NFPA Standard 51 B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
:EMF Information
1.4.
Considerations About Welding And The Effects Of Low
Electric And Magnetic Fields
Frequency
quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological
The
Safe
following
is
To
reduce
magnetic
fields in the
workplace,
use
the
following
procedures:
1.
Keep cables close together by twisting
2.
Arrange
3.
Do not coil
or
taping
them.
a
Effects of Power Frequency Electric & Magnetic Fields Background
Paper~ OTA-BP-E-53 (Washington, DC: U.S. Government Printing
there is now a very large volume of scientific
Office, May 1989):..
cables to
or
one
drape
side and away from the operator.
cables around the
body.
.
experiments at the cellular level and from studies
people which clearly establish that low frequency
magnetic fields can interact with, and produce changes in, biological
systems. While most of this work is of very high quality, the results are
complex. Current scientific understanding does not yet allow us to in
terpret the evidence in a single coherent framework. Even more
frustrating, it does not yet allow us to draw definite conclusions about
questions of possible risk or to offer clear science-based advice on
strategies to minimize or avoid potential risks.
findings
based
on
4.
with animals and
OM-1 587
Keep welding power
practical.
source
Connect work
to
and cables
as
far away from opera
tor as
5.
clamp
workpiece
as
dose to the weld
as
possible.
AbOUt Pacemakers:
The
above procedures are also recommended for
Consult your doctor for complete information.
pacemaker
wearers.
3
1. Consignes do SØcuritØ POUP 10 Soudage a larc
des
Signification
11
%\~
safety_som_cfr 2/97
2/97
oM:1 587FIcf r
&~
symboles
Signifie Mise en garde! Attention! Ce mode opØratoire peut
presenter des dangers! Les dangers possibles sont indiques par
les divers sym boles.
A Indique
~
message de sØcuritØ
un
Signifie NOTA; pas
special.
lie a Ia sØcutitØ
symboles signifie Mise en garde! Attention!, risque de CF-lOGS ELECTRIQUES,
dangers presentes par les PIECES MOBILES et les PIECES CHAUDES. Voir les symboles et es
ci-apres pour prendre les mesures nØcessaires atm de se premunir contre
Ce groupe de
,-.
r
~1~~::r:ssoc~s
Dangers du soudage a
1 2
MISE EN GARDE
A~
Les
Iarc
ci-aprŁs sont utilisØs dans tout le manuel pour attirer lattention sur les dangers
indiquer le type de danger dont ii sagit. Quand on volt le symbole, prendre garde et
directives correspondantes pour Øviter le danger. Les consignes de sØcuritØ donnØes ci-aprŁs
symboles
possibles
donnØs
et pour
suivre Ies
ne font que rØsumer Iinformation contenue dans les
respecter toutes ces normes de sØcuritØ.
Iutilisation,
Linstallation,
et les
lentretien
normes
reparations
de sØcuritØ ØnumØrØes a Ia section 1-4. Lire et
doivent Œtre confiØs
ne
des personnes
qu
qualifiØes.
Aucune personne, et
UN CHOC
Un
particuliŁrement
es
ELECTRIQUE peut
enfants,
ne
Ne
Porter des gants et des vØtements de
tant pas de trous.
3.
Sisoler de Ia piŁce et de Ia terre au moyen de tapis ou dautres
moyens isolants suffisamment grands pour empØcher le contact
physique Øventuel avec Ia piŁce ou Ia terre.
4.
5.
6.
toucher les
piŁces electriques
1.
2.
sous
tension.
protection
secs ne
compor
lalimentation
ou
Installer et mettre a Ia terre correctement cet appareil conformØ
ment a son manuel dutilisation et au codes nationaux, provin
ciaux et municipaux.
ToujoursvØnfier laterre du cordon dalimentation Verifier
surer aue
7.
et sas
le fil de terre du cordon dalimentation est bien raccordØ
RAYONNEMENT DE LARC
peut
brler les yeux et Ia peau. Le BRUIT peut
endommager louIe; les PROJECTIONS
DE LAITIER OU LES ETINCELLES
LE
8.
Utiliser
approuvØs
antibruit
poste de soudage.
frequemment le cordon dalimentation pour voir si! nest
remplacer le cordon immediate
pas endommage ou dØnudØ
ment si! est endommage
un cable dØnudØ peut provoquer une
electrocution.
9.
Mettre
lappareil
quand on ne lutilise pas.
uses, endommages, de grosseur insuf
hors tension
10. Ne pas utiliser des cables
fisante ou ma! ØpissØs.
11. Ne pas enrouler les cables autour du corps.
piŁce soudØe doit Œtre
mise a a terre, le faire directement
cable distinctne pas utiliser le connecteurde piŁce ou le
cable de retour.
avec un
1 3.Ne pas toucher lØlectrode quand on est en contact avec Ia
Ia terre ou une electrode provenant dune autre machine.
piŁce,
14. Nutiliser quun materiel en bon Øtat. Reparer ou remplacersur-le
champ !es piŁces endommagees. Entretenir lappareil conformØ
ment a ce manuel.
15. Porter
un
hamais de sØcuntØ
16.Maintenir solidement
en
metal
quand
place
17. Fixer le cable de retour de
on
travaille
en
hauteur.
tousles panneaux et
capots.
obtenir un bon contact metal
Ia table de travail, Ie plus prØs
facon a
avec Ia piŁce a souder
possible de Ia soudure.
ou
RAYONNEMENT DE LARC
2.
Porter un masque a serre-tŒte muni dun verre filtrantde nuance
pour protØger le visage et lea yeux quand on soude
ou observe Ia travail de soudage (voir les normes ANSI Z49.1 et
Z87.1 donnØes sous Ia rubrmque Principales normes de sØcu
appropnØe
rite).
3.
Porter des lunettes de sØcuritØ
approuvØes
avec
Øcrans late
raux.
4.
Utiliser des paravents ou des bamŁres de protection pour
les personnes a proximitØ contre les coups darc et
IØblouissement; avertir lea autres personnes de ne pas
protØger
regarder
bouche-oreilles ou des serre-tŒte
si !e niveau de bruit est ØlevØ.
des
du
Verifier
BRUIT
1.
proximitØ
En effectuant les raccordements dentrØe fixer dabord le conduc
appropne et contre-vØnfier les connexions.
peuvent blesser les yeux.
Larc de soudage produit des rayons visibles et invi
sibles intenses (ultraviolets et intrarouges) qui peuv
ent brUler les yeux et Ia peau. Le bruit produit par cer
tains procØdes peut endommager louie. Des projec
tions de metal ou de laitier sont produites par le
piquage, le meulage ou le refroidissement des sou
dures.
trouver a
teur de mise ala terre
12.Si Ia
arrŒter le moteur avant de proceder a
linstallation, a a reparation ou a lentretien de lappareil. DØver
rouiller lalimentation selon Ia norme OSHA 29 CFR 191 0.147
(voir normes de sØcurite).
Couper
se
a Ia borne de terre du sectionneur ou que a fiche du cordon est
raccordØe a une pnse correctement mise a Ia terre.
tuer.
simple contact avec des piŁces electriques peut pro
voquer une electrocution ou des blessures graves. LØ
lectrode et le circuit de soudage sont sous tension des
que lappareil est sur ON. Le circuit dentrØe et es cir
cuits intemes de apparel! sont Øgalement sous tension
a ce moment-l.
En soudage semi-automatique ou
automatique, le fil, le dØvidoir, le logement des galets
dentralnement et lea piŁces mØtalliques en contact
avec le fil de soudage sont sous tension. Des matØnels
ma! installØs ou ma! mis ala terre prØsentent un danger.
jamais
doit
5.
Iarc.
Porter des vŒtements de protection en tissu
(lame et cuir) et des chaussures de sØcuritØ.
ignituge
durable
___________-
4
OM-1 587
.
LES VAPEURS ET LES FUMEES peuvent
Œtre dangereuses pour Ia sante.
~
I
~
1.
Le soudage produit des vapeurs
dangereux de respirer.
~
=9~
et des fumØes
quil
5.
portant
est
ne
respiration.
pas
6.
2.
A lintØneur, ventiler le poste de travail ou utiliser un dispositif
place au niveau de larc pour Øvacuer les vapeurs et fumØes de
soudage.
3.
Si Ia ventilation est mauvaise, utiliser
adduction dair pur approuve.
7.
4.
appareil respiratoire
a
exploser
Si
Lea bouteiiies cOfli~Fiaflt des ga~ de protection SOflt a
haute prepsion. Une bouteille endommagØe peut
exploser. Etant donnØ que es bouteilles de gaz font
normalement partie du matØnel de soudage, les traiter
avec le plus grand soin.
2.
3.
Tenir les bouteilles a lØcart
circuits Ølectriques.
du
LE SOUDAGE
support fixe
basculent.
poste de soudage
ou
ou
dautres
peut causer un incendie ou
Se
protØger et proteger
lee personnes a
proximitØ
3.
Enlevertoutes les matiŁres inflammables dans un rayon de moms
m de larc. Si cola nest pas possible, bien les recouvnr en
utilisant des bches approuvØes.
de 10
4.
Prendre
garde que les Øtincelles et les projections ne pØnØtrent
dans des petites
zones adjacentes en sinfiltrant
dane des
1.3
Autres
a ctØ
2.
dune
Ne pas installer lappareil a ctØ dun objet ou dun
produit inflammable.
2.
OM-1587
le
chapeau
riots, lee bouteilles de gaz ou autres accessoires.
Pour soulever Ia source de courant, uliliser des
de
Si Ion ulilise
puissance suffisante.
ØtØvateur a fourche pour dØplacer
lappareil, sassurerque Ia fourche est suffisamment
longue et dØpasse de lautre ctØ de Iappareil.
un
bouteille.
explocerait
Ia sortie du robinet de Ia bouteille
quand
on
sur
Ia bouteille
aprŁs utilisation.
incendies et
avoir
extincteur a
5.
Prendre
6.
Se rappeler que Si Ion soude sur un plafond, un plancher,
cloison ou autre, le feu peut prendre de Iautre ctØ.
7.
Ne pas souder cur des recipients fermØs comme des reservoirs,
des tOts ou des tuyaux a moms quiIs ne soient prØparØs de faon
appropriee conformØment a Ia norme F4.1 de IAWS (voir Ia
rubrique Prlncipales normes de sØcuntØ).
8.
garde
proximite.
aux
toujours
un
une
Raccorder le cable de retour ala piŁce, le plus prØs possible de Ia
de soudage, pour empŒcher que le courant de soudage ne
suive une trajectoire longue etØventuellement inconnue etquiI ne
provoque des risques dØlectrocution et dincendie.
zone
9.
degeler des tuyaux.
porte-electrode ou couper le fil de
contact quand on ne Iutilise pas.
Ne pas utiliser le chalumeau soudeur pour
10. Enlever IØlectrode enrobØe du
soudage
au ras
du bec
protection non huileux comme des gants
Øpaisse, des pantalons sans revers, des
ii. Porter des vŒtements de
en
cuir,
une
chemise
chaussures montantes et
un
casque.
12.Ne pas porter des matiŁres combustibles cur soi
bnnupt ~ naz ou des allumettes puand on soude
comme
un
et Ientretien
LES PI¨CES CHAUDES peuvent provo
quer des brlures graves.
1.
Ne pas toucher les piŁces chaudes les mains
nues.
2.
Laisser
periode de ref roidissement
pistolet ou Ia torche.
une
toucher le
avant de
LES PI¨CES MOBILES peuvent causer
des blessures.
Se tenir a IØcart des piŁces en mouvement corn1.
me
les ventilateurs.
Sassurer
et
Nutiliser Ianneau de levage que pour soulever
lappareil; NE PAS lutiliser pour soulever lee cha
appareils
3.
Replacer
2.
graves.
pression
une
eI!e
10.Lire et suivre les consignes relatives aux bouteilles de gaz
compnme, au matØnel connexe ainsi que Ia publication P-i de Ia
CGA donnØe sous Ia rubrique Principales norrnes de sØcuritØ.
surface combustible.
EN TOMBANT, LE MATERIEL peut sen
dommager ou causer des blessures
1.
Eloigner le visage de
sous
louvre.
dangers relatifs a Iinstallation, tutilisation
UN INCENDIE OU UNE EXPLOSION peut
Œtre cause par un appareil place au
contact, au-dessus ou a ctØ de surfa
ces combustibles.
1.
Ne pas placer lappareil au contact, au-dessus, ou
soudage
toucher
Nutiliser que des bouteilles de gaz de protection, des dØtendeurs,
des tuyaux souples et des raccords appropnØs conus
pour
lapplication particuliŁre; conserver ces matØriels et leurs piŁces
en bon Øtat.
des Øtincelles
Ne pas souder dans un endroit oO les Øtincelles peuvent atteindre
des matØnaux inflammables.
coudersurune boutei!!e
bouteille de gaz.
sur une
Nejamaic
et du metal chaud.
2.
soudeur
electrode de
7.
explosion.
Ne pas souder sur des recipients fermØs comme des
reservoirs, des tOts ou des tuyaux: Is peuvent exploser.
Larc de soudage peut produire des Øtincelles. Des
Øtincelles, une piŁce chaude et un matØnel chaud
peuvent provoquer des incendies et des blessures. Le
contact accidentel de lØlectrode
sur des
objets
mØtalliques peut produire des Øtincelles, lexplosion, Ia
surchauffe ou un incendie. Sassurer que le lieu ne
prØsente pas de danger avant deffectuer le soudage.
une
6.
9.
une
1.
Ne jamais laisser
Placer les bouteilles ala verticale en les fixant a
un chariot pour Øviter quelles ne tombent ou
ne
jamais poser un chalumeau
Ne
5.
8.
un
Ne pas souder sur des mØtaux revŒtus comme lacier galvanisØ,
p10mb ou cadmiØ a moms que Ia piŁce nait ØtØ entierement
dØcapee, que le poste de travail soil bien ventilØ. SiI y a lieu,
porter un appareil respiratoire a adduction dair pur. Les
revØtements et lee mØtaux qui contiennent de tels ØlØments
peuvent degager des vapeurs toxiques lors du soudage.
4.
Proteger les bouteilles de gaz comprime contre Ia chaleur intense,
les chocs, le laitier, les flammes nues, les Øtincelles et larc.
a
Ne pas souder a proximitØ dopØrations de degraissage, de
nettoyage ou de pulvØrisation. La chaleur et es rayons de arc
peuvent rØagir avec fes vapeurs pour former des gaz hautement
toxiques et irritants.
au
Consulter les fiches signaletiques et les consignes du fabncant
relatives au mØtaux, produits dapport, revŒtements, nettoyants et
LES BOUTEILLES peuvent
elles sont endommagees.
1.
un
lair et abaisser le niveau doxygene et causer des blessures
graves voire mortelles. Sassurer que lair est propre a Ia
Garder Ia tŒte a lextØrieur des vapeurs et des fumees et
les respirer.
un
un espace confine que slIest bien ventilØ, ou en
appareil respiratoire a adduction dair pur. Demander a
un observateur ayant reu Ia bonne formation de toujours se tenir
a proximitØ. Les vapeurs etfumØes de soudage peuvent dØplacer
Ne travaillerdans
que tous lee capote, panneaux, portes
sont bien fermØs et fermement
protecteurs
maintenus.
LES ECLATS DE METAL ou
TES peuvent provoquer des
LES SALE
lesions aux
yeux.
1.
Porter des lunettes de sØcuntØ
raux ou
avec
Øcrans late
Øcran facial.
5
LES CHAMPS MAGNETIQUES PRO
DUITS PAR LES COU RANTS ELEVES
peuvent nuire au fonctionnement du sti
mulateur cardiaque
Les personnes qui portent un stimulateurcardiaque
1.
doivent se tenir eloignees du poste de soudage.
Les personnes qui portent un slimulateur
cardiaque devraient consulter leur medecin avant
de sapprocher dun
poste de soudage ou de
gougeage a Iarc ou de soudage par points.
LELECTRICITE STATIQUE peut endom
piŁces des circuits imprimØs.
mager les
1.
2.
Ies services de sØcuritØ,
Ies ordinateurs et Ie materiel de tØlØ
communications.
Ne confier cette installation qu
1.
un personnel
qualifie et connaissant bien Iequipement Ølectro
nique.
2.
Lutilisateur a Ia responsabilitØ de faire comger
rapidement par un Ølectricien qualifie les
problŁmes dintrfØrences resultant de Iinstalla
LE FIL DE SOUDAGE peut percer Ia peau.
Attendre es instructions avant dappuyer sur Ia
1.
gachette.
Ne pas pointer le pistolet sur une partie du corps,
tion.
3.
personnes, ou sur une piŁce metal
lorsquon enfile le fil de soudage.
dautres
lique
4.
1.
Laisser
RØduire le courant
de
penode
5.
recommencer
avertissement dinterfØrence
Faire verifier et entretenir
reguliŁrement linstalla
Tenir
es
portes et panneaux de Ia source de
haute
frØquence bien fermØs, maintenir les Øclateurs au
bon reglage et utiliser une mise a Ia terre et un
Øcran de protection afin de rØduire au minimum Ia
possibilitØ dinterfOrences.
de ref roidissement.
ou
dun
cas
tion.
TERIEL.
2.
Dans le
donnØ par le Conseil fØdØral des communications,
arrŁter dutiliser immØdiatement lØquipement.
UNE UTILISATION EXCESSIVE peut se
traduire par une SURCHAUFFE DU MA
une
bracelet
caries de circuits
dionavigation,
PI¨CES
sur
un
LA HAUTE FREQUENCE peut crØer des
interferences dans les systŁmes de ra
MOBILES peuvent provo
quer des blessures.
1.
Se tenir a lØcart des piŁces mobiles.
Se tenir a lØcart des points de pincement, ex.
2.
galets dentrainement.
LES
antistatique AVANT de mani
impnmØs ou les piŁces.
Utiliser des sacs et boites antistatiques adequats
pour ranger, dØplacer ou expedier es caries de
circuits imprimØs.
Mettre
pulerles
le facteur de marche avant
a souder.
Utiliser le tacteur de marche nominal.
UNE TENSION CC. IMPORTANTE est
LACCUMULATION
TECTION
DE GAZ DE PRO
prØsente sur les onduleurs aprŁs
Ion ait coupØ Ialimentation.
peut ºtre nuisible a Ia sante
voire mortel.
Quand
1.
1-J
1.
nutilise pas le gaz de
le robinet de Ia bouteille.
on
Avant de toucher les
hors
protection, fermer
mettre londuleur
tension, couper lalimentation
les condensateurs dentrØe
directives de Ia
1.4
piŁces,
que
et
decharger
conformØment
aux
~rtinn rntr~ti~n
.
:Priflcipalesnormesdesecurite
Safety in Welding and Cutting, norme ANSI Z49.1, de American
Welding Society, 550 N.W. Lejeune Ad, Miami FL 33126
Safety and Health Sandards, OSHA 29 CFR 1910, du
Superintendent of Documents, U.S. Govemment Printing Office,
Washington, D.C. 20402.
Recommended Safe Practice for the Preparation for Welding arid
Cutting of Containers That Have Held Hazardous Substances,
norme AWS F4.1 de lAmencan Welding Society, 550 N.W. Lejeune
Ad, Miami FL 33126
,
National Electrical Code, NFPA Standard 70, de Ia National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1.5
Informations
sur
les
sur
le
magnØtiques
CSA Wi 17.2, de lAssociation canadienne de norrnalisation,
normes, 178 Rexdale Boulevard, Rexdale (Ontario)
Canada M9W 1 R3.
norme
vente de
Safe Practices For Occupation And Educational Eye And Face
Protection, nornie ANSI Z87. 1, de lAmencan National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting
Welding Processes, norme NFPA SiB, de Ia National
Association, Batterymarch Park, Quincy, MA 02269.
and
Fire Protection
champs ØlectromagnØtiques
soudage et sur les effets des champs Ølectn
frØquence.
Voici une citation tirØe des conclusions gØnerales du document Biolo
gical Effects of Power Frequency Electric & Magnetic Fields Back
ground Paper (Effets biologiques des champs Ølectriques et magneti
Document de base), OTA-BP
ques aux frØquences dutilisation
-E-53 (Washington, DC: U.S Government Printing Office, mai 1989)
publiØ par lOffice of Technology Assessment (Congres des Etats
Unis): ... des experiences au niveau cellulaire et des etudes sur
Ihomme et lanimal nous ont apportØ une foule de renseignernents : II
est maintenant clair que les champs magnetiques basse frequence
peuvent influer sur les systemes biologiques et les modifier. Ces tra
vaux sont genØralement dexcellente qualite, mais les rØsultats obte
nus sont complexes. Dans IØtat actuel de nos connaissances dans le
domaine scientifique, nous ne sommes pas en mesure dinterprØter
thØone generale. Et, ce qui est
nos observations a Ia IumiŁre dune
encore plus regrettable, nous ne pouvons rien affirmer de dØfinitif au
sujet des nsques Øventuels, ni proposer des methodes scientifiques
prØcises pour rØduire ces nsques ou pour es Øviter.
NOTA DonnØes
ques et
Handling of Compressed Gases in Cylinders, CGA Pamphlet
a Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
Regles de sØcuritØ en soudage, coupage et procØdØs connexes,
Safe
P-i, de
Pour rØduire lintensitØ des
champs magneliques au poste de travail:
basse
1.
Grouper
serrant
solidement les cables
avec un
en
les
entrelaant
ou en
les
ruban adhØsif.
-
2.
Disposer
les cables
sur un
seul ctØ
et a IØcart
de
lopera
-
6
teur.
3.
4.
Eviter
les cables
Eloigner le
de
5.
denrouler
plus possible
soudage.
Ia
ou
source
Raccorder le connecteur de
prŁs possible
Stimulateurs
de les poser
piŁce
sur
lØpaule.
de courant et les cables
a Ia
piŁce a souder,
le
plus
de Ia soudure.
cardiaques:
aussi, norrnalement,
qui utilisent un stimulateur cardiaque. Pour de plus
amples renseignements, consultez votre mØdecin.
Les recommandations ci-avant sadressent
aux
personnes
OM-1 587
.
2. Definitions
Warning Label Definitions
21
A.
Warning! Watch Out! There
are possib!e hazards as
shown by the symbols.
injure fingers
B.
Drive rolls
C.
Welding wire and drive parts
are at welding voltage during
operation keep hands and
metal objects clear.
1
Electric shock
1.1 Wear
can
kill.
can
dry insulating gloves.
Do not touch electrode with
bare hand. Do not
or
wet
wear
damaged gloves.
yourself from
1.2 Protect
electric
shock by insulating yourself
from work and ground.
input plug
working
1.3 Disconnect
power before
machine.
2
or
on
Breathing welding fumes
can
be hazardous to your health.
2.1
Keep your head out of the
fumes.
2.2 Use forced ventilation
exhaust to
2.3 Use
remove
ventilating fan
or
local
the fumes.
to remove
fumes.
3
Welding sparks can
explosion or fire.
3.1
Keep flammables away from
welding. Dont weld near
3.2
Welding sparks
cause
flammables.
can cause
fires. Have a fire extinguisher
nearby and have a watch
person
ready
to
use
3.3 Do not weld
it.
on drums
closed containers.
4
or
any
Arc rays can bum eyes and
injure skin.
4.1 Wear hat and
Use
shirt
safety glasses.
protection and button
collar. Use welding
ear
helmet with correct shade of
filter. Wear
complete body
protection.
5
Become trained and read the
instructions before working
the machine or welding.
on
6
Do not
remove or
(cover)
the label.
OM-1 587
paint
over
7
Manufacturers
22
Rating
Label for CE Products
ST-178 794-A
f~
2.3
.
For/abe/location
see Section 4.3.
Symbols
Note ~
and Definitions
Some
symbols
are
Output
()
OjO
Off
8
on
CE products.
Current
Duty Cycle
A
p
Parameter Select
Jog
Amperes
V
Volts
Degree Of
Hz
Hertz
Protection
Line Connection
Trigger
.
Read Instructions
Increase
I
Load
1 ~\,
only
Alternating
Purge
()
found
Voltage
Trigger Hold On
IndicatorLight
Primary
Current
Trigger
Hold On
0
Trigger Hold Off
IndicatorLight
12
Rated Current
Trigger
Hold Off
PrimarY Voltage
O,/o
Percent
Single Phase
OM-1 587
3. Introduction
3 1
Specifications
Type of Input
Welding
Power
Source Type
Power
Constant Voltage (CV)
DC For GMAW Or
Constant Voltage(CV) /
24 Volts AC
Single-Phase
10 Amperes
50/60 Hertz
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
Welding
Diameter
Circuit
Range
Rating
.023 To 1/8 in
(0.6 To 3.2
mm)
100
Amperes,
Duty
Cycle
Max
Spool
60 lb
(27 kg)
Overall
Dimensions
Weight
Length: 32 in
(812 mm)
Volts,
750
100%
Weight:
IP
Rating
IP 23
Width: 18 in
78 lb
(457 mm)
(35 kg)
Height: 14 in
(356 mm)
4. Installation
Site Selection
4.1
ST-801 795 / ST-801 796 / Ref. ST-i 52468-A
1
Wire Feeder
2
Rubber Feet
3
Wire
4
Gas
5
Welding
A
Do
Spool/Reel
Cylinder (Customer
Supplied)
not
welding
A
Do
not
Power Source
put feeder where
wire hits
move
equipment when
OM-1587
cylinder.
or
operate
it could
tip.
9
42
Equipment Connection Diagram
ST-162 129/ Ref. ST-154 197/ ST-146 127-Cl Ref. ST-163 420-A
_______
1
300/400
Ampere
Model
CCICV Inverter Welding
Power Source
~ Use settings shown for both
pulse MIG welding and MIG
welding.
2
450
Ampere Model DC
Welding Power
Inverter
Source
3
14-Pin Cord
4
Positive
5
Negative ()
Be
sure
(+)
Weld Cable
Weld Cable
weld cables are sized
for peak amperage if
properly
pulse welding (see welding
source Owners
Manual).
6
Workpiece
7
Voltage Sensing
(Optional Use)
8
Gun
power
PULSED
~GJMIG
~
Lead
Be sure gun is rated for peak
amperage if pulse welding. Install
according to its Owners Manual.
9
SCRATCH
0
~
F
STICK
V-SENSE
PANEL
(C~)
START
flG
Wire Feeder
INDUCTANCE/DIG
~*~RE~TE
V/A CONTROL
.
8
$2
10
OM-1 587
Rear Panel Connections
:4~3
ri
Ref. ST-152 567-A
~
7
Tools Needed:
1
2
Gas
Customer
Hose
Supplied
Shielding
Gas Valve
~==~ 9/16,5/8
Requires fitting
in
Fitting
with 5/8-18
right-
hand threads.
3
Weld Cable Terminal
4
Jumper
5
Weld Cable
6
14-Pin Cord
7
Rating
Weld Cable
Label Location
6
5
4.4
Rotating
the Drive
Assembly
Ref. ST-153 093 I ST-800 289
Tools Needed:
Remove
of
(6) from front
wrapper, and loosen
back edge of wrapper.
screws
edge
screws on
1/4 in
3/16 in
1
Front Panel
2
Drive Assembly Rotation
Adjustment Opening
3
Drive
OM-1 587
Assembly
11
45
121
14-Pm
Plug Information
*The
remaining pins
are
.
Pin Information
pj~*
REMOTE 14
A
24 volts
B
Contact closure to A
G
Circuit
C
+10 volts dc
D
Remote control circuit
common.
E
0 to +10 volts dc
command
H
Voltage feedback;
F
Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes.
M
CC/CV Select
N
lnductance(0-1OV)
ac
with
respect
common
to socket G.
completes
24 volts
ac
contactor control circuit.
tor 24 volts AC circuit.
output
to remote control with
input
respect
signal from
remote control with respect to socket D.
0 to +10 volts dc, 1 volt per 10
(+24
V
=
to socket D.
arc
volts.
CV)
not used.
Motor Start Control
4.6
F~1
~
ST-i 62 132/ Ref. SB-146 862-D
To
change wire feed starting speed
proceed as follows:
Tum Off wire feeder and
power
welding
source.
Remove wrapper.
1
Motor Board PCi
2
Motor Start Control Poten
tiometer R70
Turn
potentiometer clockwise to in
crease
time it takes the motor to
ramp up to speed. Remove protec
tive white rubber cap before mak
ing adjustment. Adjust potentiome
using a small nonconduc
ter R70
tive screwdriver.
Reinstall wrapper.
Tools Needed:
Non-Conductive
~==-
~o
cT~I~zJ===~i
12
1/4 in
OM-1 587
47
Gun Recommendation TabJe
Gun
Process
GMAW-P
GMAW
FCAW
48
Motor
-
Hard
Hard
or
or
Cored Wires
Cored Wires
M25, M40, Or GA-50C
Wires
GA-4OGL Or GA-5OGL
Self-Shielding
Wire
Speed
Type, Size,
Wire
Type
Standard
All
Standard
All
Standard
All
Optional High
Speed
All
OM-1587
GW-500 Or GW-600
and Feed
Speed Capability
Table
Wire Size
.023 To 5/64 in
3/32 To 7/64 in
1/8 in
(0.6
Feed
To 2
(2.4 To
mm)
2.8
mm)
(3.2 mm)
.023 To 5/64 in
(0.6
To 2
mm)
Speed Capability
50 To 780 pm
50 To 700
(1.3
To 19.8
ipm (1.3 To
mpm)
17.8
mpm)
50 To 300
1pm (1.3
To 7.6
92 To 1440
1pm (2.3
To 35.6
mpm)
mpm)
13
49
Installing
and
Threading Welding
Wire
-
Ref. ST-156 929/Ref. SC-150 922 / Ref. ST-156 930/ S-0627-A
r1$ł.d *4
that outlet cable has proper size
welding wire size. When
installing gun, position linerextending fro
For soft wire
liner for the
steel wire, use 2 drive rolls and set drive
roll pressure from 0 to a maximum of 4 on
outlet wire guide as close as possible to
drive rolls without touching.
the pressure indicator scale (so that only
the inner spring is compressed). This set
ting will generally give the best perfor
mance for these types of wires.
Be
sure
m
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
Toadjustdnve roll
outgun.
or
small diameter stainless
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.
pressure, hold nozzle about
If necessary, move hub and spool sup
so wire runs straight from the
Install wire
port
anti-wear
guides
guide.
and
spool through the drive rolls. Install
spool. Adjust tension nut so wire
wire
is taut when wire feed
stops.
-4
F
Install drive rolls.
No Wire
Slip
Wire
Slips
Tools Needed:
~
~====rzz
14
~
3/16, 5/64
in
~ 15/16,3/Bin
OM-1 587
5. Operation
5.1
Operational
Note ~
The
following
is
a
Terms
1..
See Menu Guide for detailed
list of terms and their definitions
as
programming steps.
they apply
to this wire feeder:
General Terms
Pulse
Adaptive
The wire feeder
Welding
less of
Cold Wire
change
automatically regulates pulse frequency
welding wire stickout.
to maintain
a
constant
arc
length, regard
in
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
Jog
speed.
time increases, and the weld
Inductance
As inductance increases,
Trim
Arc
Synergic
The operator programs pulse parameters for a
the pulse parameters between these wire feed
arc on
length adjustment in pulse welding. Increasing
placed by volts in MIG programs.
puddle becomes
trim increases the actual
specific wire feed speed.
speed increments.
arc
more
fluid.
length.
Trim is
re
The wire feeder determines
Side Panel Terms
Is used to select the
Process Mode
Sequence
Dual Schedule Mode
Is used to select
a
Card Mode
Is used to select
use
Mode
Security
Only
functions with
rameter
Pulse
52
1
Apk
Peak
=
type of process
to be
used, including Pulse, Adaptive Pulse,
Is used to select and program the weld sequences which include
preflow, and run-in.
Mode
Welding
pair of programs
a
of the
optional
that
can
be used
data card
data card. Allows
using
or
Mig.
weld, crater, bumback, postflow,
together.
storage and retrieval capabilities.
the Jock feature for
restricting range of program pa
changing.
Terms
Amperage
Increasing Apk increases penetra
ton.
Vpk
Peak
=
Voltage
Arc
voltage during peak current
phase of the pulse waveform. This
determines arc
length during
adaptive pulse welding.
2
Abk
Maintains
3
PPS
arc
=
between
pulses.
Pulses Per Second
Increasing PPS
speed.
4
/\
Background Amperage
=
increases travel
PWms
Pulse Width In
Milliseconds
Amps
_/ ~
1\~
=
Increasing PWms increases
1
2
.114.
bead
\
width.
Time
OM-1 587
/
15
Front Panel Controls
53
ST-162 127
click
1
Display
2
Parameter Select Button
Press button to
Display
3
move > on
causes program number
crease/decrease by one.
The program number cannot be changed
while welding, with exception of Dual Sched
ule Mode (see Section 7).
display.
Pulse is
change
value
pointed
to
by>.
Turning control one click causes Trim (arc
length) to increase/decrease by one or Volt to
increase/decrease by 0.1.
When 1PM is
causes
selected, turning control one
wire feed speed (1PM) to in
crease/decrease
by
When
by
Prg
a
default
setting. To change type of
Pulse, or MIG) use
process (Pulse, Adaptive
side panel controls.
4
Active Side Indicator
5
Trigger
Light
Hold Button And Indicator
Trigger Hold
can
sis. Indicator
be set
light
Light
per program ba
on for programs
turning control
speed (MPM)
Jog Button
feature
comes
holding gun triggerthroughout
cycle, press and release button
on (indicator light turns on).
To start weld
cycle,
and release
Push to
out
momentarily feed welding wire with
energizing welding circuit or shielding gas
valve.
Jog speed is varied using the Display Control
while Jog button is pressed. Default setting is
200 1PM.
8
Purge
out
weld
one
Side Select Button
7
To weld without
three
selected, turning control
6
Push to
to in
cycle, press
trigger.
where this feature is active.
to turn
press and release gun trig
arc has been
ger within three seconds after an
Button
momentarily energize gas valve
energizing the welding circuit.
with
Holding
the Jog and Purge buttons at the
time displays pulse parameters on
the side panel display and voltage on front
same
0.1.
# is
struck. To end weld
gun
on a
one.
When MPM is selected,
clicks causes wire feed
crease
to in
Control
Turn control to
click
(Prg #)
panel display.
L1
_I~i_
2
3
8
;9>o
o-~
7
4
o~~o~o
.1
4
1
5
16
OM-1 587
54
Side and Rear Panel Controls
Ref. ST-162 128/ Ref. ST-162 133
1
Mode
2
Mode Select Button
Display
Press button to move> in
display.
Display
3
Parameter
4
Parameter Select Button
Press button to
move >
in
display.
5
Parameter Increase Button
6
Parameter Decrease Button
7
Power Switch
8
Circuit Breaker CB1
CB1
protects
the wire feeder from
overload.
OM-1587
17
6. Setting Sequence Parameters
61
Parameters
Sequence
T1
in a
Program
t$1~
~ See Menu Guide for detailed
programming steps.
Trim is
arc
length
length
is short. If set to
If
is
time
length.
If set to zero,
99,
arc
arc
long.
is
sequence,
set
to
zero
in
Weld
until
welding continues
gun trigger is released.
If time is set to zero in any timed
the
Weld,
sequence
except
sequence is skipped.
1.
Pulse
Weld
Trim
Volts
Inductance
1PM
0-99
10.0-38.0
0-99%
50-780
X
X
MIG
Pulse
Crater
2.
Bumback
X
0-25.0
X
X
X
X
MIG
3.
X
Seconds
0-2.50
X
Pulse
0-0.25
X
MIG
4. & 5. Post-
0-9.9
flow/Pref low
Pulse
Run-In
6.
X
X
MIG
X
=
Setting
X
0-2.50
X
available.
A
Weld lime
G)
0~
0 25
U)
sec.
U)
5,
IL
~
Crater
lime
U)
e
Bumback
lime
U
~
Preftow
lime
-~
Run-In
lime
I
Postf low
lime
lime
~
Burnback
Preflow
18
Run-In
Arc
Strike
Weld
Crater
Postf low
Sequence
End
Trigger
Trigger
Pressed
Released
OM-1 587
7. Setting Dual Schedule Parameters
7i
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
Side Panel
Display
Use side panel to turn feature on.
See Menu Guide for detailed
programming steps.
2
Front Panel
Display
Press front panel parameter select
button to select program number.
3
Front Panel
4
Dual Schedule Switch
Section
Display Control
(See
7.2)
~ Switch type is set in
System
Setup.
5
welding
Gun
Trigger
Selecting dual schedule program A
or B is done by using Display Con
trol, dual schedule switch,
trigger (depending
setup).
on
or
gun
system
when program B is active, turn
Display Control one click clock
wise to select another pair of dual
schedule programs.
Programs
can
be
in desired order
rearranged
using the data
card.
2
24
.
250
0 V
1PM
3
4
Display
Control
Display
Control
OM-1 587
19
DuaJ Schedule Switch
72
1
Diagrams
Momen2P
(Momentary-Contact 2-Pole
Switch Or DSS-1 0)
2
Maint 2P
1
1
>
(Maintained-Contact
DSS-9M)
2
2-Pole Switch Or
.
,
2
>
______
3
Maint 1 P
1-Pole
4
(Maintained-Contact
Switch, Or DSS-8)
Tngger
1
Allows dual
scheduling after estab
welding arc.
lishing
a
~ If
trigger
is
used
schedule switch,
is disabled.
for
dual
Trigger Hold
CBO~
A
3
B
4
p
4
1
1
Adapter
1
_
1
(~p>
~0
2
2
TR
TR
___________
I
3
________
3
3
>
A\>~Q~~>
20
4
OM-1 587
8. Using the Optional Data Card
81
Data Card Terms
SA-1 58 435
CARD SCREEN TERMS
WRITE
Programs To
Card
~
READ
Programs
From Card
PULSE MIG TERMS
Amperage
-r
Apk (Peak
Amperage)
17
Abk
Time
(Background
Amperage)
82
Installing Data Card
ST-156 266-B
Label
Apply label
to data card. Write pro
gram information
2
Data Card
3
Card Slot
on
label.
For Blank Data Card:
lnsertcard into slot. To format card,
3
turn On power. Select Card from
menu. Data card formats when unit
enters Card mode.
For Power Source Data Card:
Insert card into slot. Turn On pow
Push Parameter Select button
er.
1
within 3 seconds and the 8 pro
grams and setup information are
read into the wire feeder memory.
Unit is ready to use when Please
Wait message disappears from
front panel display.
OM-1 587
21
83
Card
Displays
lJ~ See Menu Guide for detailed
programming steps. Security
mode only functions with a
.
data card.
1
Card
2
Moving
Display
Line
Sequ
Moving line is
be changed.
3
under value that
can
en ce
Dual Schd
>Card
Write
Secu
Press
rity
Bel
ow
Transfers program data from unit
to card. The program card can hold
up to 32 programs. When writing to
the card, the next available pro
gram number is
automatically
Side Panel
as
signed.
4
rJ
Read
Parameter
Select Once
Transfers program data from card
to unit.
-
5
Delete
4
Deletes program data from card.
6
Done
Exits card
display.
5
6
.
22
OM-1587
0. System Setup
/
9 1
System Setup Display
Note ~
See Menu Guide for detailed
DISPLAY SETIING
>System
>Range
Parameters
programming steps.
NOTES
*
Select the process the
*
welding power
source
is able to do.
Welding power source minimum and maximum voltage values are always
for pulse welding. Set values to match welding power source ranges.
>Access.
When on, restricts
>Mig Type
Default is Off. Set to On
>Voltage
Default is
use
of
setup
only for
14-pin receptacle.
needed.
Amperage
values
are
required
screens.
older CV
welding
Use V. Sense when
power
more
source
than 50 ft
without
(15m)
voltage feedback
at 14-socket
of weld cable is used
(including
receptacle.
gun cable
length).
>Arc Start**
Use Hot Start only with 450
in CV and switches to CC.
>Dual Schedule
See Section 7.2.
>Tngger
When on,
trigger can
Ampere Inverter Model welding
power
source
and
large
diameter wires. The
be used to switch between programs that have at least 0.2 seconds of
preflow
arc
starts
time pro
grammed.
>Remote
When on,
is.
>Arc Time
Displays
>Wire Feed
Choose to
>Model**
Pulse programs differ between bench and boom models.
>Memory
Program Reset: unit defaults to original factory setting for the last active program. Setup information
change. If setup card is in card slot, program will be loaded from card.
a
DSS-1 0
can
accumulated
display
be used to
arc
time and
change
Volts
or
mm, 1PM,
or
Prg depending
on
or
meters per minute and motor
type,
but installed motor must match selection.
Reset: unit defaults to original factory settings for all programs and setup
Model. If setup card is in card slot, program will be loaded from card.
System
When on, the system
age is sensed.
>Teach
Default is 15
>Gas Flow..
Setting
>Software
Know this when
Automatically
.
Can be used
points,
immediately
but
can
must be Meter Oft if
talking
shuts down if
be set to 4
option
no arc
voltage
is sensed. When
does not
excluding System, Arc Time,
off, wire feeds
even
if
no arc
and
volt
points.
is not installed.
with service
personnel.
set if power source data card is 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
OM-1 587
panel display>
cycles.
inches per minute
>Shutdown
where the front
error.
23
10. Standard Pulse Welding Programs
Note@~
Apk
=
PPS
=
Peak
Amperage, Vpk
Pulses Per
factory set programs.
interpolations from the
10.1
Wire
Program
SizelType:
1
=
Peak
Second, PWms
Voltage,
Abk
If selection is set for
4
Background Amperage,
(milliseconds). Four teach points were used for
fifteen teach points, the remaining points are
=
Pulse Width
=
taught points.
Steel
Gas: Ar
.035
-
CO2
or
Ar
Oxy
-
/40 CFH
(19 Urn)
IPM/MPM
Apk
Vpk
Abk
PPS
PWms
700/17.8
440
367
160
180
2.9
400/10.2
385
324
108
126
2.3
200/5.1
335
287
61
81
2.0
100/2.5
328
274
37
47
1.7
102
Wire
Program
Size/Type:
2
Steel
Gas: Ar
.045
-
CO2
or
Ar
-
Oxy/40
CFH
(19 Urn)
IPM/MPM
Apk
Vpk
Abk
PPS
PWrns
700/17.8
518
376
195
205
3.6
400/10.2
476
361
157
168
3.0
200/5.1
412
303
93
106
2.4
100/2.5
375
277
50
66
2.2
110.3.
Wire
~rog~aiit3~Stee!_.
Size/Type:
Gas: Ar
Apk
625 /15.9
-
CO2
or
Ar
-
Oxy /40
CFH
(19 Urn)
Vpk
Abk
PPS
PWrns
560
393
200
229
3.6
400 /10.2
525
362
148
189
3.5
200/5.1
475
317
102
131
2.7
100/2.5
445
296
50
80
2.4
10.4
Wire
Program
Size/Type:
4
COMMENTS
Steel
.062
Gas: Ar
-
CO2
or
Ar
-
Oxy/40
CFH
(19 Urn)
1PM! MPM
Apk
Vpk
Abk
PPS
PWms
400/10.2
580
366
200
200
4.3
300/7.6
539
348
160
200
4.2
20015.1
499
315
121
170
3.6
100/2.5
460
283
69
118
2.6
24
COMMENTS
~1:
I!11~
.052
1PM! MPM
COMMENTS
COMMENTS
OM-1587
105
Wire
Program
5
Stainless
Sizeuiype: .035
Gas: Ar- He-
C02140
CFH
(19 Urn)
1PM! MPM
Apk
Vpk
Abk
PPS
PWms
700/17.8
403
339
132
191
2.8
400/10.2
318
316
87
146
2.4
200 /5.1
295
285
53
94
1.9
100 /2.5
280
260
32
45
1.8
10.6
Wire
Program .6
Size/Type:
Stainless
.045
:
Gas: Ar
-
He
-
CO2 /40
CFH
(19 Urn)
1PM! MPM
Apk
Vpk
Abk
PPS
PWms
700/17.8
480
390
200
227
3.2
400/10.2
425
324
155
185
2.5
200/5.1
360
280
100
115
2.0
100/2.5
350
262
40
70
2.0
10.7
Wire
Program
Size/Type:
7
Nickel
.035
Nickel
Gas: Ar
Alloy
-
He!40 CFH
(19 Urn)
Apk
Vpk
Abk
PPS
PWrns
700/17.8
350
345
130
144
3.7
400/10.2
310
300
80
105
3.3
200 / 5.1
280
275
48
55
2.9
100 / 2.5
260
251
28
36
2.5
Wire
Program
Size/Type:
.035
8
COMMENTS
Alloy
IPM!MPM
108
COMMENTS
COMMENTS
Sthcon Bronze
SiBr
Gas:
Argon /40 CFH (19 Urn)
Apk
Vpk
Abk
PPS
PWrns
510/13.0
340
307
100
125
3.7
400/10.2
310
298
83
97
3.4
200 / 5.1
277
266
48
55
3.0
242
252
31
31
3.0
COMMENTS
-
1PM! MPM
120/3.1
OM-1 587
25
11. Teach Points
111
Teach
Using
15 PoEnts
The teach mode allows the user to create custorn pulse programs. The teach mode seleclion 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
thepulsewaveformoftheweldoutput.Thesix
parameters are: 1PM (MPM), Apk, Vpk, Abk,
.
Under some conditions, the wire feeder limits
wire feed speed to maintain all pulse parame
Apk, Vpk, Abk, PPS, and PWms acting
togetherprovide the energy necessary to burn
oft 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).
ters within the
capability
of the system.
PPS, and PWms.
~
Apk
=
Peak
Amperage
A
Vpk
=
Peak
Voltage
~
Abk
=
Background Amperage
0
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 1PM With
400/10.2
All Teach Points Set At 50
1PM
350/8.9
(1.3 MPM)
Increments
300/7.6
250/6.4
200/5.1
150 / 3.8
100/2.5
50 /1.3
Apk
100
180
210
240
270
300
330
360
370
420
450
480
510
540
565
Apk
Abk
10
20
30
40
50
60
70
80
90
100
110
120
130
140
200
Abk
PPS
20
55
80
105
130
160
185
210
235
260
290
315
340
365
400
PPS
PWms
26
1
2
3
4
5
PWms
OM-1587
.
11 2
Teach
Using
4 Points
The teach mode allows the userto create custorn pulse programs. The teach mode selection for 4 teach
points gives the whole welding
quickly. At each teach point, the user
adjust five parameters to shape the pulse
range
can
waveform of the weld output. The six parameters are: 1PM (MPM), Apk, Vpk, Abk, PPS, and
PWms.
Apk, Vpk, Abk, PPS, and PWms acting
together provide the energy necessary to bum
off welding wire at a set wire feed speed. The
graphbelowshowsthataswirefeedspeedin
creases, energy increases (Apk, Vpk, Abk,
PPS, and PWrns acting synergically).
Under some conditions, the wire feeder limits
wire feed speed to maintain all pulse parame
ters within the capability of the system.
i~
Apk
=
Peak
Amperage
A
Vpk
=
Peak
Voltage
EJ
Abk
=
Background Amperage
o
PPS
IPM/MPM
780 / 19.8
Pulses Per Second
=
PWrns
=
Pulse Width
(Milliseconds)
750/19.1
700 /17.8
650/16.5
600 / 15.2
550/14.0
500/12.7
450/11.4
Example
400/10.2
Setting
Of A
Synergic
For 425 1PM With
Teach Points Set At
350/8.9
(2.5),
(10.2), And
(17.8 MPM)
Intervals Of 100
200
400
700
(5.1),
1PM
300/7.6
Increments
250/6.4
200/5.1
150/3.8
100/2.5
50/1.3
Apk
Vpk
100
180
210
240
270
300
330
360
370
420
450
480
510
540
565
100
180
210
240
270
300
330
360
370
420
450
480
510
540
565
Apk
Vpk
Abk
10
20
30
40
50
60
70
80
90
100
110
120
130
140
200
Abk
PPS
20
55
80
105
130
160
185
210
235
260
290
315
340
365
400
PPS
PWms
OM-1 587
1
2
3
4
5
PWms
27
11.3
Redefining
Teach Points
Ret. S-0259 / Ref. ST-i 54 109
1
1PM
1PM determines the weld metal de-
position
f~
Redefining
1PM Teach Point
rate.
Redefining 1PM is not normally
required unless special wire or
unusual
joint
design is
Use front panel parameter select
button to move> to select 1PM. Use
Display Control to select teach
point value.
Press and hold
Purge
/
button while
Purge
2
Apk
Peak
3
Abk
Background Amperage
~
Trim
50
Prg
1PM
>450
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.
Peak and
Trim
50
needed.
>460
1PM
1
Pulse
Ar~d
Prg
1
Pulse
Amperage
background amperage
depend on the range of the welding
power
4
source.
Pulses Per Second Of
PPS
20-400
5
Redefining
Pulse Parameters
PWms
Pulse Width Of
1.0-5.0 Milliseconds
Use side
pulse
panel controls
parameters.
Guide for detailed
to
change
See
Menu
programming
steps.
After values are set, strike and
maintain an arcforfive seconds.
Do this for each teach point.
End weld
by releasing gun trigger,
by pulling gun out of weld. Re
peat for each custom teach point.
2
not
The taught arc length represents
Trim (arc length) setting of 50.
a
Once the teach points are set, the
wire feeder adjusts parameters be
tween teach points synergically.
5
___r3
I
I
400
1PM
340
Apk
340
Apk
340
Apk
70
Abk
70
Abk
Abk
>160
PPS
1.4
1>70
160
PPS
160
PPS
PWms
>1.9
PWms
.
28
OM-1 587
Date__________________ Program Number
Wire
Size/Type..
G~s
.CFH(Umin)
Equipment
Used
Power Source__ Serial Number
Wire Feeder______
Serial Number
_________--
Gun Model
Weld Cable
______________________
Wire Manufacturer
IPM/MPM
Positive
Negative
Mfg. Date
Apk
Abk
PPS
PWms
Vpk
COMMENTS
Pref low Seconds:_________
Run-In TrimNolts:________ 1PM I MPM:___________________________________ Seconds:___________________________
Crater Volts:____________________ 1PM! MPM:____________________________ Seconds:___________________________
Postf low Seconds:________
Date________________ Program Number____________________ Wire Size/Type
Gas______________________________________________________ Flowrate
Equipment Used
OM-1 587
Power So urce.
CFH(Lfmin)
Serial Number__________________________
29
12. Maintenance And Troubleshooting
Routine Maintenance
12.1
ri~$v~
A
Disconnect power before
maintaining.
3 Months
Repair
replace
Replace
unreadable
labels.
cracked
weld
cable.
Re lace
Check
cracked
14-pin
parts.
cord.
Blow out
inside.
Check
gas
hose and
fittings.
6 Months
or vacuum
During heavy
service, clean
or
Check
gun
cable.
-
Clean
drive
rolls.
monthly.
.
30
OM-1587
122
Error
Displays
Ref. ST-i 55222
Release
Trigger
I
2
00
No
Volt
Sensed
1Error
3
1
Memo
r
Prg
y
CRC
Error
4
Memo
r
Prg
y
Er
Range
ror
Release
Error
Trigger
2
No Volt Sensed Error
The
arc
Display
voltage sense circuit is not
receiving feedback. Check voltage
connections.
Check
sensing
connections at 14-position plugs/
receptacles at the unit and welding
power
source.
Turn unit off and back
5
Display
This appears if the trigger is closed
when the unit power is turned on, or
if the trigger is stuck or defective.
after
on
correcting problem.
Tach
No
Sensed
1Error
6
\
If this
when
continues to
it may
pulse welding,
occur
help
to
3
Memory
CRC Error
Display
saved.
Start
Er
Perform
ror
4
7
Arc
Stop
8
Mi
Ga
9
Ma
n
s
x
C F H
F
I
x
o w
C F H
GasF
x
x
x
low
10
\~
Gas
of
11
I
Out
Range
Coo
Ian
Flow
N
Unlock
OM-1 587
t
1Error ~
1Error
1E~or
1E~or
1Error
1Error ~
a
7
Arc
Stop
panel
Parameter
error.
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
front
Press
Select to clear
8
cause
panel
this
error.
Parameter
error.
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.
select Hot Start.
The data in the program indicated
is not the same data that was
Arc
12
error
Press
front
Select to clear
system
Error
9
panel
Parameter
error.
Maximum Gas Flow Error
This appears when gas flow is
above the maximum CFH set (xx in
reset.
Memory Range
front
Press
Select to clear
Display
The data in the program indicated
is out of usable range.
Go
through pulse parameters to
sure they do not exceed
settings of the Range display or
perform a system reset.
example). Adjust gas flow
to
bring
it below set value.
Press
front
Select to clear
10
panel
Parameter
error.
Gas Out Of
Range
Error
make
5
No Tach Sensed Error
the internal sensor, the unit shuts
down until the gas flow can be
Display
adjusted
The motor tach feedback is not
reaching the control. Check
connections.
Press
front
Select to clear
6
This appears when gas flow is
greater than 100 CFH. To protect
panel
Parameter
error.
Arc Start Error
be
started.
correct program
below 100 CFH.
Coolant Flow Error
This appears only when coolant
flow switch option is installed.
Check
coolant
recirculating
system.
Display
12
This appears when pulse welding
and current is detected but the arc
cannot
11
Check
and
pulse parameters
settings. Check
and
voltage
voltage sensing connections.
Unlock 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.
31
12.3
Troubleshooting
r1~+wdH
A
Disconnect power before
Trouble
Remedy
Wire feeds, shielding gas flows, but
electrode wire is not energized.
Check
Wire feeder is on, meter(s) do not light
up, motor does not run, gas valve and
Check and reset CB1
welding
pull in.
power
source
interconnecting cord
4.3).
or
feeds
trigger
Check gun
trigger.
Change
Clean
or
Replace
to correct size drive roll
replace dirty
tip
Wire does notfeed until
trigger is pulled,
but continues to feed after trigger is released, and trigger hold is not on.
Check for
drive roll.
guides.
foreign
Manual.
matter from around nozzle
opening.
check drive motor
or
motor control board PCi.
input voltage.
a
short between
welding gun trigger
a
short between
welding gun trigger leads
Unit does
Install, reconnect,
of Run-In
(see Section 14.6).
leads and weld cable.
Repair
short
or
replace welding
Repair short
or
replace welding
gun.
Check for
out
(see Section 4.9).
liner. See gun Owners
or
Manual.
Manual.
Factory Authorized Service Agency
Gas valve in feeder is rattling loudly
erratic or slow wire
along with possible
feed speed.
wire
or
spatter
Check for correct
slowly.
or worn
or worn
contact
Remove weld
Have
See gun Owners
hub tension and drive roll pressure
Incorrect size
not switch
continuity and repair or replace (see
(see Section 5.4).
connection. See gun Owners
Check gun
Readjust
runs
connections. If secure, check cord for
Sections 4.2 and
contactor do not
Electrode wire feeding stops
erratically during welding.
Motor
troubleshooting
and weld cable.
gun.
or
replace voltage sensing
lead.
Speed.
Wire feeder power is on, displays
up, but unit is inoperative.
light
Check
welding gun trigger
leads for
continuity,
and
repair
leads
or
replace gun.
S
32
OM-1587
Notes
cu-iw
33
13. Electrical Diagram
13.1
Circuit
Diagram
I-
I
I~
--
~TO4
~4M ~krr
(~E
M~ ~I
~ff0~Y J
~1i
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I
P~4T
~
I91~M-I~
~4Tflllllllifl J
___
___
I
00
I
~AI
00
FBA2
~
0
00
__
________
AUE
~
_______
____
~fflfflffl
0
00
0
~0TTJ4
L~
~
~rr
T~
0
-a-
00
0
>)
~~1
~4T
WT
I~
I
J
IflD
~
I
0
P~
F~I
lifT
tT~JA
I
4>
4
I
#0.2
10.2
LED
LED
~I:~>2uT1
>1
L~1I
~
LED
~:
1~
I~T0Aw~I
23451
I9~D
~
~uj~z:*_~!~ I I ~
~9-8
~
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ii
I
;~Tj~rtI
~ Aim
F1IED
1
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fflw~j
a~I
VVVVVV
ii
ii
I
L–
>>~
#00.#2IT
1V
-r
V
TJJ~TJHRED
~i_L~JhLk_
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AAAAA1L
1~E
T~XR
______
>
tEll
In
H~Gn
I
I
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R~
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J
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=~
____
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~t7iTLGI7
~II-e>>
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.
~
1
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VVV
V
~-J<
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~Ts-~ >>_
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#7
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I
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RR~
c..az
(~PTo~J)
Th
34
0~0
____________
DATA C~
I
W
I,
A
________
I
2 ~t3~
c~aE
t~~I
~
j L4
______
___
~
V.VV
FC4D
~4V~I.G4I
0
V
0
I
Ill
V
I
C
I
scc o~
f~S8
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FOD
~3
7
Y~
I
I
_
__
~
~
LI
2>2
>>t~~j
L~1i
I
LLL~
~ ~
E-~--<12 4E-~-< ~-~32 >~<
RJn7M~
~
I~
I
I
I0~I
~(2E
2
2
7
I
1
ELI
WifH ~7GN~
~ ~T#0IC4T ~TDI
I
7*~
<~<~3>-~(I
<Il
I
__I
~
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~
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~-~-<D
~~*~>~zi
~4__!_<
4-~*I >_!_<
a
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F
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PU2I7,tL#2I7~~~*-~<~i4~*2~
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~ ~~_<I7
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2
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~-<3*2<3(-~+3>-~-<I
I
I
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aa-
<
~
_____
~4*-J~<4~1~4(
I
I
.
34
OM-1 587
/
V..-,..
~
.v,
:.v,,:
,.,::....,...:.,.,...
--V
SD-164 796-A
I
flt OSI~ W4CD01 FDA I~AQDE
~AM WA
(~ FUD IflCTOA)
I
______
___
Act
wse
cfl
__________
DC
B
_________________________
___________________________
Act-2
FLTrnmS
I
I
A
~iIlIl
liii
~lII~
III~
C
~
iii
p
IwTob~~~o
I
I
I I
I
Act-C
XCIC-3
_____
I
I
I I
I I
I
arooooooo~1
L21 .L LJ~
J~ I
FCflw~
~w-2>
t/0
,cwa:,: I
PS-B
FLTrn~Am
~
rcw~s).I
v~v~v~v_v_v_v~v~v~v~v
I
~
LT~d~UA1~E:r~
S
flA ~
_________
a
~tv (.24v-CII)
IB~-2
~
~
a
~-cv
M
%fttM~ F~
~
Ienc;iu
I H~ p
>
L~si~iq~~t, J
1~1
(wM)
I C I
fl~bWnWrnæat]
I rn raa~en DATh I
_____________
M~AfI
n
a
a~4T ta
S
D~T ta
_____________
n
~
C~
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)~~40 kM.~B I l>-~~-
~
~
W1
j~LLtL~L~,
-
OM-1587
~a
35
14. Parts List
141
Main
Assembly
ST-800 084-D
1~)
~ Hardware is common and
not available unless listed.
CD
U,
CU
.
cJ
0,
CU
CU
C.,
\
a)
Li.
CD
E
CO
LL
CO
-a
C.)
C
.
cJj
c\j
LL.
36
OM-1 587
Item
No.
Part
No.
1
108008
2
168103
3
+168104
166 594
124 900
143 160
058 427
180 573
010 233
057 971
10
010 191
11
058 628
Description
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 .l25thkstl
WASHER, flat .656 ID x 1.500 OD x .l25thk fbr
WASHER, brakesti
Quantity
1
1
1
1
1
1
1
1
1
2
2
2
601 872
HUG, spool
TUBING, stl .875 OD x l2ga wall x 2.375
NUT, .625-11 .94hex .77 high stl elastic stop
SCREW, .375-16 x .750hexhd
SUPPORT, spool
FOOT, rubber 1 .25Odia x 1 .375high
BRACKET, mtg spool RH
WASHER, lock .380 ID x .683 OD x .ll5thk stl split
NUT, .375-16 .S6hex .34 high stl
139 226
BASE
...25
159 647
...26
139 752
...27
167 768
WEATHERSTRIPPING, adh .125x 1.500 (order by ft)
INSULATOR, screw machine
CLAMP, motor base
INSULATOR, motor clamp
SPACER, stl .500 OD x l2ga wall x 3.750
DRIVE ASSEMBLY, wire RH (Fig 14.3)
DRIVE ASSEMBLY, wire RH (high speed) (Fig 14.3)
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 14.3)
DRIVE ASSEMBLY, wire LH (high speed) (Fig 14.3)
1ff
8
...24
083 639
159 360
159 646
CONTROL BOX
CABLE, weld cop strd No. 4/0
1
3ff
058 428
071 730
135 205
601 964
141 411
134 306
142 838
602 213
...22
27
167770
...28
156243
...29
145639
30
125473
167762
167764
Fig
32
14.2
600324
1
1
1
2
1
4
1
2
2
1
(order by ft)
2
2
1
1
1
2
2
2
1
1
OPTIONAL
+When
a precautionary label, the label should also be ordered.
of your equipment, use only Manufacturers
performance
factory original
Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
ordering
a
component originally displaying
To maintain the
OM-1 587
37
142
Control Box
(Fig 14
1 Item
32)
ST-800 111-C
Hardware is
common
and
not available unless listed.
C
U,
C
a)
A
/\
/
/
\
/
\
/
\
/
\
\
\
/
/
/
K
C~J)
LL
\
)
a)
(\1
F.
.
0
a)
LI~
38
OM-1 587
Item
No.
Part
No.
Dia.
Mkgs.
1
161707..
2
GS1,2.... 125785..
134201..
PCi
PLG1
PLG2
PLG3
PLG4
PLG6
183120..
....
115092
....
115093
....
115094
....
115091
....
136810
184824..
6
CB1
083432..
111997..
8
Si
PC8O
....
182403
...
115093
...
158720
PLG81
PLG82
PLG89
PLG9O
...
131 054
...
153501
073756..
151187..
....
600399..
138044..
CR101
25
SRi
...26
...28
29...
PLG12,50
..
097132..
PC5O
PLG51
PLG52
PLG53
PLG54
PLG55
32
....
163917
...
158720
...
...
...
...
.33
PC1O
34
PLG11
PLG15
PLG17
PLG18
35...
36...
PLG1O,24
PLG16,41
...
...
...
..
..
1
1
1
1
1
1
1
1
4
x
1.500
BLANK, snap-in nyl .875mtg hole
605227.. NUT, .750-14 knurled 1.68dia .41 high nyl
072817
RELAY,encI24VACDPDT
035704.. RECTIFIER, integ 40A 800V
030170.. BUSHING, snap-in nyl .750 ID x 1 .000mtg hole
Figi4.4.. PANEL, front w/components
155629
CABLE, ribbon l4posn (RC12) (RC5O)
154938.. STRIP, mtg PC card
000527..
...24
1
lg
1
CONNECTOR w/SOCKETS
603106..
RC7O
1
048 282
601222..
22
1
1
107983..
141 162
079739
...23
STAND-OFF, 6-32 x .625 Ig
LATCH, slide flush mtg hole 1.000 wide
1
1
163520..
PLG9
1
CONNECTOR & SOCKETS (RC1)
CONNECTOR & SOCKETS (RC2)
CONNECTOR & SOCKETS (RC3)
CONNECTOR & SOCKETS (RC4)
CONNECTOR & SOCKETS (RC6)
CASE SECTION, bottom/rear
CIRCUIT BREAKER, man reset 1P 10A250V
SWITCH, rocker SPST 1 OA 25OVAC
CIRCUIT CARD, HF filter dual
CONNECTOR & SOCKETS (RC81)
CONNECTOR & SOCKETS (RC82)
CONNECTOR & SOCKETS (RC89)
CONNECTOR & SOCKETS (RC9O)
1
178936..
16
10
BUSHING, strain relief 1.030 ID
LABEL, warning general precautionary
LABEL, warning general precautionary CE
CABLE, port No. 18/14 1 1/c (order by ft)
CONNECTOR & PINS, (consisting of)
CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2
CLAMP, univ 50A
HOSE, nprn brd No. 1 x .250 ID (order by ft)
WIRE, strd i4ga blk 600V 105c (order by ft)
BUSHING, strain relief .120/.150 ID x .500mtg hole
BLANK, snap-in nyl .500mtg hole
010290
134464..
15
1
2
WRAPPER
+161710..
12
Quantity
Description
PANEL, side lower
VALVE, 24VAC 2 way custom port 1/8 oil
STAND-OFF SUPPORT, PC card .3121.375
CIRCUIT CARD, motor control
164059
1
1 2ft
1
1
1
ift
35ft
1
1
1
1
2
1
1
3
1
1
1
STAND-OFF, 6-32 x .375 Ig
CIRCUIT CARD, interface
4
CONNECTOR
CONNECTOR
CONNECTOR
CONNECTOR
CONNECTOR
1
& SOCKETS
& SOCKETS
(RC51)
(RC52)
131 204
& SOCKETS (RC53)
& SOCKETS (RC54)
148439
& SOCKETS (RC55)
115092
126689.. STAND-OFF, 6-32 x 1.500 Ig
CIRCUIT CARD, processor w/proms
184775
CONNECTOR & SOCKETS (RC11)
115092
CONNECTOR & SOCKETS (RC15)
153501
CONNECTOR & SOCKETS (RC17)
115093
CONNECTOR & SOCKETS (RC18)
162382
170980
CABLE, nbbon 34posn (RC1O) (RC24)
155023
CABLE, nbbon 24posn (RC16) (RC41)
Figi4.5.. PANEL, side w/components
010146.. CLAMP, nyl .625 clamp dia
158719
1
HOSE ASSEMBLY, gas
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
a precautionary label, the label should also be ordered.
factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
+When
ordering
a
component originally displaying
To maintain the
OM-1 587
39
143
Drive
Assembly,
Wire
(Fig
141 Item 27 &
31)
ST-152 711-G
~ Hardware is common and
not available unless listed.
See Section 14.6 For
Drive Roll & Wire Guide Kits
15
18
14
13
23
6
S
40
OM-1587
Item
No.
Part
No.
Dia.
Mkgs.
1
010 668...
4
2
172 075
4
6
SCREW, cap stl sch .250-20 x 1.500
CARRIER, drive roll w/components 24 pitch
149 962
SPACER, carrier drive roll
149 486... PIN, rotation arm rocker
132750... ARM, pressure
150 520... SPACER, rotation pin
7
133493...
3
5
8
9
9
...
4
...
4
RING, retaining
ext .250 shaft
x
.O25thk
MOTOR, gear 1/8hp 24VDC 272RPM (consisting of)
MOTOR, gear 1/8hp 24VDC 500RPM (consisting of)
KIT, brush replacement (consisting of)
156354...
...
156
353...
CAP, brush
BRUSH, carbon
KIT, cover motor gearbox (consisting of)
COVER, motor gearbox (consisting of)
GASKET, cover
SCREW, cover
SPACER, locating
RING, rtngext.25oshaftgrvx.O25thk
153 493
155 098
153 550
155 099
155 100
154 031
133493
PLG11,17
...
PLG51 ,57
...
RC7,8
1
2
2
1
1
1
5
2
1
1
1
CONNECTOR & PINS
1
...
14
137248... SPRING, indicator
129 351
SCREW, hexwhd-slt stl
15
602 200
13
1
131 203... CONNECTOR & PINS
182414... WASHER, flat
182415... PIN, cotterhair
12
2
115092... CONNECTOR&SOCKETS
135 409
11
2
2
....
153492
10
2
1
133350...PIN,hinge
M1,2
M1,2
153 491
...
1
1
1
slffmg
8-32
x
.500
1
1
17
WASHER, lock stl split No. 8
604772
WASHER,flatstlSAENo.8
182156... SPRING, cprsn .57300x.O88wirex 1.0621g
18
182155... SPRING
1
19
132746...
2
20
SHAFT, spring
132747... CARRIER,shaft
133739... WASHER, flat .375 lOx .625ODx .062
183 330
KNOB, extension
153 631
CIRCUIT CARD, digital tach (consisting of)
16
182 522
23
24..
...
1
...
...22
BUSHING,spring
2
1
...
1
1
1
...
TK1 ,2/PC51
PLG57
..
....
131 204....
CONNECTOR & SOCKETS
604 311
GROMMET, rbr .250 ID
....
132 611
...
26
149 959
...
27
179 625
..
27
179 624
..
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
Optional High Speed
1
...
25
...
Quantity
Description
...
...
...
...
...
...
...
x
1
.375mtg
hole
OPTICAL ENCODER DISC
FITTING, brs barbed M
3/l6tbg
1
1
x
.312-24
ADAPTER, gun/feeder LH
ADAPTER, gun/feeder RH
SCREW, cap stl hexwhd .250-20 x .750
WASHER, flat stl SAE .312
KNOB, plstcT 1.125 Ig x .312-18 x 1.500 bar
SCREW, hexwhd-slt stl slftmg 10-32 x .500
COVER, drive roll
NUT, sti 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 .O25thk
LABEL, warning electric shock
1
1
1
4
1
1
2
2
1
1
1
1
2
1
1
1
Motor
To maintain the factory original performance of your equipment, use only Manufacturers
Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1587
41
167700
Panel, Front w/Components (Fig 142 item 28)
144
ST-800 111-C
4
II3~ Hardware is common and
not available unless listed.
a
9
11
Item
No.
Dia.
Mkgs.
10
Part
No.
167697
147139
171 814
165484
CONNECTOR & SOCKETS
See
159264
167633
179201
.
2
PLG25
PLG24
.
1
PANEL, front
TAPE, adh acrylic double sided .010
PC2O,30
144844
....
NAMEPLATE, (order by model and serial number)
METER LENS, w/gasket
STAND-OFF, 6-32 x .875 Ig
CIRCUIT CARD, schd front
164842
6
Quantity
Description
11
153169
12
010291
13.
Figure
14.2 Item 35
1
x
.500
(RC25)
(RC24)
RING, ext .625 shaft grv x .O45thk E style
WASHER, shldr .612 ID
LENS, LED 4345 green panel mtg
ACTUATOR, switch
WASHER, flat .625 ID nylafil
KNOB, pointer
x
3.000
1
9
1
1
1
1
4
6
1
1
factory original performance of your equipment, use only Manufacturers Suggested
Parts. Model and serial number required when ordering parts from your local distributor.
To maintain the
Replacement
.
42
OM-1 587
145
Panel, Side w/Components (Fig 142 Item 37)
ST-800 113-B
Hardware is
common
and
not available unless listed.
3
8
Item
No.
Dia.
Part
No.
Mkgs.
147139..
155024
154933
PC6O
PLG6O
PLG41
PC4O
....
156623
Description
TAPE, adh acrylic double sided .010
LENS, clear anti-glare
PANEL, inner control
CIRCUIT CARD, data card
Quantity
x
.500
x
3.000
2
1
1
1
1
CONNECTOR & SOCKETS (RC6O)
See Figure 14.2, Item 36 (RC41)
158160
1
CIRCUIT CARD, side display
144844
4
STAND-OFF, 6-32 x .875 Ig
154109.. PLATE, ident inner control
1
153169.. ACTUATOR, switch
4
To maintain the factory original performance of your equipment, use only Manufacturers
Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1587
...
153501
....
43
146
Drive Roll and Wire Guide Kits
a)
a)
U
Wire Size
U-GROOVE
VK-GROOVE
E~
4 Roll
Drive
4 Roll
Drive
4 RoIl
Drive
4 Roll
Drive
Kit
Roll
Kit
Roll
Kit
Roll
Kit
Roll
149518
151024
087130
150993
149518
151025
053695
0.9mm
150993
149518
151 026
053700
151 036
072000
Thi O~2
1S2958
.O4Oin.
1.0mm
150993
149518
161 189
053696
.045 in.
.1/1.2mri
150994
149519
151 027
053697
151 037
053701
151 053
132957
151 070
083489
.052 in.
1.3/1.4mrT
150994
149519
151 028
053698
151 038
053702
151 054
132956
151 071
083490
1.6mm
150995
149520
151029
053699
151039
053706
151055
132955
151072
053708
1.8
mm
150995
149520
151 056
132959
(.079 in.)
2.0
mm
150995
149520
151040
053704
151 057
132960
151 073
053710
(.094in.)
2.4mm
150996
149521
151041
053703
151058
132961
151074
053709
2.8mm
150996
149521
151042
053705
151059
132962
151075
053711
3.2
150997
149 522
151 043
053 707
151 060
132963
151 076
053 712
C
Fraction
Metric
.023-.025in
0.6mm
150993
.030in.
0.8mm
.035w.
.068-072 in
5/64 in.
1/8 in.
(.125 in.)
mm
S-0549-D
Each Kit Contains An Inlet Guide, Intermediate
With 4 Drive Rolls.
2 Kits Required For Dual Models.
Guide,
And 045 233 Antiwear Guide With 604612 Setscrew 8-32
x
.125, Along
.
44
OM-1 587
Options and Accessories
9196
Skill Level Index
The box to the
A
nght of the stock
options contains
a
number of field-installed
letter and number. The letter indicates
the skill level required to install the option. The number
indicates the approximate time required for installation
(see legend).
Weld Current Sensor
Required
when
using
#160 963
A
:05
B
Easy. No previous experience needed.
Average. Requires removal of seivice panels,
Mechanical ability is helpful.
DTechnical.
May require the use of an ohmmeter and/or
splicing of electrical wires. Repair or replacement of
component parts is more difficult
Example:
CDifficult.
sources
I
B
I
:30
sizes
I
the 60M feeder with
Miller conventional MIG power
not have 17-pin receptacle.
May require the use of an ohmmeter and
ability to read a circuit diagram. Repair or
replacement of component parts is complex.
the
Skill Level: B, Time: 30 minutes
larger than
Same
that do
I
speed
5/64 in
(2.0 mm).
motor must be used on each
side of the dual wire models.
Factory-written
Pulse MIG programs will not
with
operate
high-speed motor.
synergic
Power Source Data Card for XMT 304 CCCV
#043 390
Simply insert the Data Card in the 60M control
and with the push of a button the eight
synergic pulse programs for the XMT 304
are loaded in memory and ready to use.
eight XMT programs are for:
.030 in steel wire with Argon/CO2
.035 in steel wire with Argon/CO2
.045 in steel wire with Argon/CO2
The
Water Hose Kit
_____
Control Detachment Kit
#13493410ft(3m) IBI:551
#134 935 25ft (7.6 m) B 1:55 I
For 60M bench models only. Field-installed
only. Separates the feeder control module~
from the wire drive assembly and base. Ideal
when using Automation Upgrade Module.
.035 in SS wire with Pulse Ui-mix
Automation
.045 in SS wire with Pulse Ui-mix
This module consists of
.035 in SiB wire with
software
.035 in Nickel
wire
with Ar/He
coolant
Miller
systems and water-cooled welding
guns. Can be used with or without
water flow safety switch.
If water kit is to be used
dual wire feeder,
a
on
optional
both sides of a
kit must be ordered for
each side of the feeder.
.030 in SS wire with Pulse Ui-mix
Argon
lOft(3m) IAI:10I
For bench-style feeders. Use with
#096746
Upgrade
Module
an
#172 886
I/O board and
upgrade that enables the 60M
control to better communicate with other
peripheral equipment and improves
performance in an automatic welding
cell.
Features: two
remote
programmable outputs,
remote program elect, arc voltage
arc error monitor and wire stuck checic
start/stop,
monitor,
Water Flow Shutdown Switch
#180390 IAI:15l
For
use
with the water hose kits. Protects
water-cooled gun from overheating by
down system if water does not flow.
If
required
on
both sides of
a
shutting
dual model, two
water flow shutdown switches must be ordered.
Dual Schedule Switches
For
use
with Dual Schedule Control in 60M
feeder.
6oMDataCard
#155910
Blank Card. Stores up to 32 complete weld
programs. Ideal for saving custom programs
and
transfening programs to other 60M feeders.
Wire
Straightener
For . in
#141 580
( mm) wire
Al :051
For 1/161/8 in
(1.63.2 mm) wire
#141581 IAI:051
DSS-8
#079693 IAI:051
Requires adapter cord #157 364. Two-position
trigger switch that easily attaches to the
welding gun. Use in place of the standard
trigger for dual scheduling.
Reduces cast in wire. Improves wire feeding
performance and increases life of gun liner
and contact tip.
Remote Program Selectors
#160977 Field
RPS-8
RPS-8 Mini
(10 m) cord.
OM-1 587
IBI:201
#173 047 Field I B 1:20 I
rotary switch used to
Eight-position
remotely select weld
33 ft
____
programs. Includes
High-Speed Motor
For right side. #132129 Factory only
For left side. #132130 Factory only
speed range of 90-1400 1PM
(2.335.6 rnmiin). Not recommended for wire
Provides wire
DSS-9M
#0417931A1:05I
Two-position
slide switch that attaches to the
Options
and Accessories Continued
Spool Covers
Fits a 12 in (304 mm)
spool of wire.
welding gun. Selects welding condition when
utilizing the dual schedule feature. Gun trigger
operates as standard trigger.
#057607
.
IAI:05I
For left side of D-60M dual
wire model.
#090389 IAI:051
For
right side of D-60M
Turntable
dual wire model.
work
DSS-1 0 Remote Increase/Decrease Switch
Carrying
,.
.i...
position. Reduces strain
and
bending
of
I
#056301 I Al :301
Two-position, momentary contact switch that
~
as
.
9U1
#042749 IAI:051
~L(~UI~ LU UI~
cart
B 1:20 I
operator changes
#146236 I
Assembly
Allows feeder to rotate
.....I..j;......
~....
YV~IUuuI~ ~UII.
Carries wire feeder and
Extension Cords
I I.~.. ...e4., +4.,,.~
.J~
miscellaneous
~
Remote Parameter Increase/Decrease feature
welding
sup
plies. Height: 34 in (863 mm).
Lower tray height: 9 in (228
mm). Shipped disassembled.
parameters at the welding gun
welding. Gun trigger operates as
standard trigger.
to fine tune
while
For
optimum performance, do not extend
(18 m) from power
60M
feeder more than 60 ft
source.
14-Pin Extension Cord
#043 690 25 ft
#043691
(7.6 m)
50ft(15m)
Water Coolant
Systems
Systems literature,
Refer to Water Coolant
Index No. AY/7.2.
FeederCart
Wire
#108008
ReelAssembly
Accommodates 60 lb
(27 kg)
coil of wire.
#142382
Al :201
Low-profile, creeper cart Shipped
disassembled.
Reel Covers
Accommodates 60 lb (27
kg)
coil of wire.
#058 256
For left side of D-60M dual wire model.
#091 668
For
right side of D-60M
Protects
wire
I
dual wire model.
from contaminants.
Hanging Bail #058435 IA 1:15 I
Electrically isolated. Suspends feeder over
work
area.
OM-1587
(Equipment with
This limited warranty
Effective January 1, 1997
serial number preface of KW
a
supersedes
all
guarantees
or
newer)
previous
or
Miller warranties and is exclusive with
warranties expressed or implied.
LIMITED WARRANTY
Subject to the terms and conditions
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 tree 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
INCLUDING
WARRANTIES
OF
THE
IMPLIED,
MERCHANTABILITY AND FITNESS.
Millers
True Bluefi Limited
Warranty
no
other
shall not
apply
to:
below,
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
within
thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
claim
procedures to be followed.
warranty
writing
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within fhe warranty
time periods. All warranty time periods start on the date that
the
by Miller, but manufactured by others,
engines or trade accessories. These items are
covered by the manufacturers warranty, if any.
Items furnished
such
2.
3.
as
Consumable components; such as contact tips, cutting
nozzles, contactors, brushes, slip rings, relays or parts
that fail due to normal wear.
Equipment
that has been modified
by any party other
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.
than Miller,
or
equipment
was delivered to the original retail purchaser,
year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to
or one
an
1.
International distributor.
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.
1.
2.
5 Years Parts 3
*
Original
*
Inverters
3 Years
*
Warranty
Questions?
Call
1 -800-4-A-MILLER
for your local
Miller distributor.
Years Labor
main power rectifiers
(input and output
rectifiers
only)
Parts and Labor
Transformer/Rectifier Power Sources
*
Plasma Arc
*
Semi-Automatic and Automatic Wire Feeders
*
Inverter Power
*
Intellitig
*
Cutting
Power Sources
Supplies
Robots (1 year labor)
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
3.
1 Year
Parts and Labor
*
Motor Driven Guns
*
Process Controllers
*
IHPS Power Sources
*
Water Coolant
*
HF Units
*
Grids
*
Spot
*
Load Banks
Systems
SDX Transformers
*
Miller
*
installed in, or for
whichever is greater.)
are
6 Months
5.
90
Days
a
minimum of
one
year
Batteries
Parts and Labor
MIG Guns/TIG Torches
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
Miller
The Thwer ofB&
*
Remote Controls
*
Accessory Kits
Replacement Parts (No labor)
*
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
LEGAL THEORY WHICH, BUT FOR THIS
ARISE
MIGHT
BY
PROVISION,
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.
OTHER
Cyclomatic Equipment
Running Gear/Trailers
Plasma Cutting Torches (except APT, ZIPCUT &
PLAZCUT Models)
Deutz Engines (outside North America)
Field Options
(NOTE: Field options are covered under True Bluefi
for the remaining warranty period of the product they
4.
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
Welders
*
*
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Millers option: (1) repair; or
(2) replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost 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 customers risk and expense. Millers option of
repair or replacement will be FOB., Factory at Appleton,
Wisconsin, or FOB. at a Miller authorized service facility as
determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be
allowed.
Some states in the U.S.A. do not allow limitations of how long
an impfied warranty lasts, or the exclusion of incidentaf,
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.
miter_warr
1/97
Owners Record
Please complete and retain with your personal records.
Serial/Style Number
Model Name
Purchase Date
(Date
when
equipment
was
delivered to
original customer.)
DIstrIbutor
Address
CIty
Zip
State
Resources Available
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies
Options
To locate the distributor nearest you, call
1-800-4-A-Miller.
and Consumables
and Accessories
Personal
Safety Equipment
Service and
Miller Electiic
Repair
Mfg. Co.
An Illinois Tool Wortcs
Replacement
Parts
1635 West
Appleton,
Training (Schools, Videos, Books)
Owners
(Servicing
Information and
USA & Canada FAX:414-735-4134
lntemationaJ FAX: 414-735-4125
European Ileadquaeters
United Kingdom
Circuit
Welding
a
(0)1625-525556
44(0) 1625-537553
Phone: 44
Diagrams
FAX:
File
Headquarters~-USA
Phone: 414-734-9821
Parts)
Contact the Delivering Cariier to:
WI 54914 USA
International
Manuals
Technical Manuals
Company
Spencer Street
Process Handbooks
claim for loss
or
damage during shipment.
settling claims,
equipment
manufacturers Transportation Department.
For assistance in
filing
or
contact your distributor and/or
r//~A Millet
PRINTED IN USA
'
The Thwer ~Bb4e.
1997 Miller Electdc
Mtg.
co.