Miller DS-64M SWINGARC Owner’s Manual

OM-1 588
161 875N
November 1999
Miller.
Processes
(GMAW) Welding
MIG
Pulsed MIG
The Power ofBlue.
Flux Cored
(GMAW-P)
(FCAW) Welding
Description
Wire Feeder
(Use
DS-64M
with
CC/CV Power Sources)
Swingarc
y
12 and 16 Foot
p
Visit
our
website at
www.MillerWelds.com
OWNERS
MANUAL
From Miller to You
,
congratulations on choosing Miller. Now
get the job done and get it done right. We know
Thank you and
you
can
have time to do it any other way.
you dont
when Niels Miller first started
building arc
welders in 1929, he made sure his products offered
long-lasting value and superior quality. Like you, his
customers couldnt afford anything less. Miller products
had to be more than the best they could be. They had to
be the best you could buy.
Thats
why
4
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.
Today,
the
Working
Manual is
This Owners
Miller
help
products.
you
designed help you get the most out of your
Please take time to read the Safety precautions. They will
to
protect yourself against potential hazards
made installation and
1~h
the worksite. Weve
operation quick
har~i
as
you do
business.
and easy.
With Miller you can count on years of reliable
service with proper maintenance. And if for
~i IJIJI
~1
I
on
as
every power source from
Miller is backed by the most
hassle-free warranty in the
-
REGISTERED
QUALITY SYSTEM
Miller
is
the
equipment
first
the unit needs repair, theres a
Troubleshooting section that will help you
figure out what the problem is. The parts list
some reason
V
welding
manufacturer
in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
you to decide which exact part
~OU may need to fix the problem. Warranty and
service information for your particular model
will then
are
also
help
provided.
Miller offets a Technical
Manual which provides
more
detailed
se,vce
and
parts information for your
unit. To obtain a Technical
Manual, contact your local
di~tributor. Your distributor
can also supply, you with
Welding Process Manuals
.~siichasSMAW,GTAW,
GMAW, and GMAW-P.
Miller Electric manufactures
a
full line
S
of welders and
welding
For information
on
-
related
other
equipment.
quality Miller
contact your local Miller distributor
receive the latest full line catalog or
products,
to
individual
sheets. To locate your nearest
distributor call 1-800-4-A-Miller.
catalog
.verofBlue
:~,
TABLE OF CONTENTS
SECTION 1
WARNING
product, when used
for welding or cutting,
produces fumes or
-
SAFETY PRECAUTIONS
1-1.
Symbol Usage
1-2.
Arc
Welding
-
READ BEFORE USING
1
1
1
Hazards
1-3.
Additional
1-4.
Principal Safety
1-5.
EMF Information
For
Symbols
Installation, Operation,
And Maintenanc~e
3
3
Standards
4
This
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in
cases, cancer.
(California Health &
some
Safety Code Section
25249.5 et seq.)
SECTION 1
-
CONSIGNES DE SECURITE
1-1.
Signification
1-2.
Dangers relatifs
1-3.
Dangers supplØmentaires
et
a
au
Principales
normes
1-5.
Information
sur
2-1.
-
-
5
Iarc
relation
en
avec
linstallation,
les
champs ØlectromagnØtiques
9
9
INSTALLATION
Swivel Into
Pipe
Control Box And
3-3.
Installing
Boom And Reel
9
Post
Adjusting
10
Tilt
10
Support
11
Wire Guide Extension
3-5.
Installing
Equipment
3-6.
Connecting
3-7.
Control Box Connections
3-8.
14-Pin
3-9.
Motor Start Control
3-10.
Removing Safety
Connection
12
DiagrarrL
13
Weld Cables And Gas Hoses
Plug
14
14
Information
15
Collar And
Adjusting
15
Boom
16
3-11. Gun Recommendation Table
3-13.
SECTION 4
-
And
And Feed
Speed Capability
Threading Welding
Table
Wire
16
17
18
OPERATION
18
4-1.
Operational
4-2.
Pulse
4-3.
Front Panel Controls
19
4-4.
Side And Rear Panel Controls
20
SECTION 5
5-1.
-
-
Terms
Welding
Parameters In A
Dual Schedule Pair
Selecting
6-2.
Dual Schedule Switch
7-1.
-
Diagrams
USING THE OPTIONAL DATA CARD
Installing
7-3.
Card
7-4.
Entering
Security
SECTION 8
-
21
21
22
22
23
24
24
Data Card Terms
7-2.
7-5.
Program
SElliNG DUAL SCHEDULE PARAMETERS
6-1.
SECTION 7
18
Terms
SETFING SEQUENCE PARAMETERS
Sequence
SECTION 6
OM-1 588
Type, Size,
Installing
8
9
INTRODUCTION
3-2.
3-12. Wire
Ie fonctionnement
8
de sØcuritØ
Installing
Installing
3-4.
5
5
soudage a
Specifications
SECTION 3
3-1.
LIRE AVANT UTILISATION
maintenance
1-4.
SECTION 2
-
symboles
des
24
Data Card
25
Displays
26
Access Code
27
28
SYSTEM SETUP
The
Setup
8-1.
Accessing
8-2.
System Setup Display
Menu
Parameters
28
29
(Continued)
TABLE OF CONTENTS
SECTION 9- STANDARD PULSE WELDING PROGRAMS
FOR PHOENIX/INVISION 456 INVERTER WELDING POWER SOURCES
9-1.
Program
1
9-2.
Program
2
9-3.
Program
3
9-4.
Program
4
9-5.
Program
5
Program
6
Program
7
Program
8
9-6.
9-7.
9-8.
-
-
-
-
-
-
-
-
30
Steel
30
Steel
30
Steel
30
Steel
30
Stainless
31
Stainless
31
Metal Core
31
Metal Core
31
SECTION 10
STANDARD PULSE WELDING PROGRAMS
FOR XMT 304 INVERTER WELDING POWER SOURCES
-
10-1.
Program
1
10-2.
Program
2
10-3.
Program
3
10-4.
Program
4
10-5.
Program
5
10-6.
-
-
-
-
-
32
Steel
32
Steel
32
Steel
32
Stainless
33
Stainless
Program
6
10-7.
Program
7- Nickel
10-8.
Program
8
SECTION 11
11-1.
And
-
SharpArc CONTROL
Adjusting SharpArc Control
13-3.
SECTION 15
-
34
35
36
MAINTENANCE AND TROUBLESHOOTING
Displays
-
.34
35
Troubleshooting
SECTION 14
33
Teach Points
13-1. Routine Maintenance
13-2. Error
33
33
15 Points
Using
Redefining
SECTION 13
Alloy
Metal Core
TEACH POINTS
-
12-1. Teach
12-2.
-
SETTING
-
Selecting
SECTION 12
-
32
Steel
38
38
39
40
ELECTRICAL DIAGRAM
42
PARTS LIST
44
SECTION 1
SAFETY PRECAUTIONS
-
READ BEFORE USING
-
_nd4/98
sam
Symbo! Usage
:1 -1.
-
Means Warning! Watch Out! There are possible
hazards with this procedure! The possible hazards are
shown in the adjoining symbols.
A
Marks
10
Means
A
The
Note~
Arc
1-2.
symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
This group of
special safety message.
a
not
Consult symbols and related
actions to avoid the hazards.
safety related.
Welding Hazards
symbols
throughout this manual
identify possible hazards. When you
shown below are used
to call attention to and
symbol, watch out, and followthe related instructions
safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1 -4. Read and
follow all Safety Standards.
see
the
to avoid the hazard. The
A
A
instructions below for necessary
Only qualified persons
repair this unit.
should install,
operate, maintain, and
During operation, keep everybody, especially children, away.
If earth
with
grounding
kill.
required, ground
it
directly
ground,
Use
only well-maintained equipment. Repair or replace damaged
at once. Maintain unit according to manual.
parts
Wear
a
Keep
all
Clamp
safety
harness if
work cable with
worktable
as near
above floor level.
working
securely
and covers
panels
in
place.
metal-to-metal contact to
good
the weld
as
workpiece
practical.
clamp when not connected
object.
workpiece to prevent
to
contact with any metal
Do not connect
electrical parts can cause fatal
shocks or severe burns. The electrode and work
circuit is electrically live whenever the output is on.
The input power circuit and machine internal
circuits are also live when power is on. In semiautomatic or
automatic wire welding, the wire, wire reel, drive roll housing, and all
metal parts touching the welding wire are electrically live. Incorrectly
installed or improperly grounded equipment is a hazard.
live
Touching
is
Do not touch electrode if you are in contact with the work,
another electrode from a different machine.
Insulate work
can
workpiece
or
or
ELECTRIC SHOCK
of the
cable.
separate
a
single
weld
more
output
than
one
electrode
or
work cable to any
terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before
touching any parts.
Do not touch live electrical parts.
Wear
hole-free
dry,
insulating gloves
and
body protection.
yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the
work or ground.
FUMES AND GASES anbehazardOus~
Insulate
Do not
there is
a
Use AC
If AC
AC output in damp areas, if movement is confined,
danger of falling.
use
output ONLY if required for
output is required,
use
remote
the
or
if
Keep your
welding process.
output control if present
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
9~
on
unit.
If
head out of the fumes. Do not breathe the fumes.
inside, ventilate the
welding fumes
remove
Disconnect
servicing
input power or stop engine before installing or
equipment. Lockout/tagout input power according
CFR 191 0.147 (see Safety Standards).
this
to OSHA 29
If ventilation is poor,
use an
Read
Safety
Material
the
manufacturers
Properly install
cleaners, and degreasers.
Work in
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.
-
When
making input connections,
conductor first
-
attach
proper
grounding
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
Turn off all
Do not
Do not
use
equipment
worn,
drape
when not in
over
highly
your
body.
poorly spliced
cables.
to
Data
Sheets
(MSDS5)
and
the
coatings,
near
degreasing, cleaning,
on
can
or
spraying
react with vapors to
coated metals, such as galvanized, lead, or
unless the coating is removed from the
plated steel,
weld area, the
or
arc
approved air-supplied respirator.
The heat and rays of the arc
toxic and irritating gases.
Do not weld
cadmium
use.
damaged, undersized,
cables
Do not weld in locations
form
-
-
exhaust at the
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.
operations.
double-check connections.
use
instructions for metals, consumables,
Owners
and ground this equipment according to its
Manual and national, state, and local codes.
and/or
area
and gases.
area
is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
OM-1588
Page
1
ARC RAYS
I r~
bum eyes and skin
can
¶
BUILDUP OF GAS can
Shut off
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
injure
shielding gas supply when
or
not in use.
confined
ventilate
Always
spaces
approved air-supplied respirator.
a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.i
and Z87.1 listed in Safety Standards).
kill
or
use
Wear
Wear
HOT PARTS
helmet.
Do not touch hot
protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
Allow
Use
Wear
cause
can
severe
burns.
with side shields under your
approved safety glasses
parts bare handed.
cooling period before working
on
or
gun
torch.
protective clothing made from durable, flame-resistant
(leather and wool) and foot protection.
material
MAGNETIC FIELDS
WELDING can
cause
fire
or
explosion.
Pacemaker
can
wearers
affect
pacemakers.
keep away.
Wearers should consult their doctor before
containers, such as tanks,
causethem to blowup. 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
Welding
on
drums,
pipes,
yourself
or
closed
going near arc welding, gouging,
welding operations.
can
flying sparks
and others from
NOISE can
flying sparks
can
Remove all flammables within 35 ft
this is not
possible, tightly
cover
strike flammable material.
(10.7 m)
them with
Be
that
aware
can cause
fire
welding
on
Do not weld
on
unless
are
they
keep
a
fire
of the welding arc.
approved covers.
closed containers such
Connect work cable to the work
unknown
Do not
to
prevent welding
paths
as
and
as
or
equipment
can
If
Wear
approved
ear
protection
if noise level is
high.
CYLINDERS
partition
or
can
explode
if
damaged.
tanks, drums,
causing
or
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.
pipes,
(see
to AWS F4.i
close to the
current from
welding area as
traveling long, possibly
Protect
compressed gas cylinders from excessive heat,
slag, open flames, sparks, and arcs.
mechanical shocks,
electric shock and fire hazards.
welder to thaw frozen
use
processes
the hidden side.
properly prepared according
Safety Standards).
practical
some
extinguisher nearby.
ceiling, floor, bulkhead,
on a
damage hearing.
damage hearing.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Watch for fire, and
spot
and hot metal.
Noise from
Do not weld where
or
Install
pipes.
cylinders in an upright position by securing to a stationary
or cylinder rack to prevent falling or tipping.
support
Remove stick electrode from holder
contact
tip
when not in
or
cut off
welding
wire at
Keep cylinders away from any welding
use.
Wear oil-free
such
protective garments
shirt, cuffless trousers, high shoes, and
as
a
leather
Never
gloves, heavy
cap.
Remove any combustibles, such as a butane
from your person before doing any welding.
lighter
Never allow
or
matches,
Never weld
S
FLYING METAL
can
drape
injure eyes.
a
a
welding
welding
on a
torch
over a
or
gas
Wear
approved safety glasses with side
shields even under your welding helmet.
cylinder.
electrode to touch any
pressurized cylinder
-
cylinder.
explosion
will result.
shielding gas cylinders, regulators, hoses,
only
fittings designed for the specific application; maintain them
associated parts in good condition.
Use
correct
Turn face away from valve outlet when
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
other electrical circuits.
Keep protective cap in place
use or connected for use.
Read
over
and follow instructions
associated
equipment,
valve
opening cylinder
except
when
and
and
valve.
cylinder is in
compressed gas cylinders,
publication P-i listed in Safety
on
and CGA
Standards.
.
OM-1588
Page
2
1-3.
Additional
For Installation,
Symbols
Operation, And Maintenance
MOVING PARTS
FIRE OR EXPLOSION hazard.
Do not install
place
or
unit on, over,
Keep away
or near
combustible surfaces.
Do not install unit
closed and
flammables.
moving parts
panels,
securely
in
injury.
such
as
covers, and
fans.
guards
place.
building wiring be sure power supply system
properly sized, rated, and protected to handle this unit.
Do not overload
is
Keep
near
from
all doors,
can cause
-
FALLING UNIT an
cause
injury.
H.F. RADIATION
lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift and
interference.
can cause
Use
support
High-frequency (HF.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
unit.
only qualified persons familiar with
equipment perform this installation.
Have
using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
If
electronic
unit.
The
for
responsible
is
user
promptly
having
correct any interference
a
qualified
electrician
from the
problem resulting
installation.
OVERUSE
Allow
cooling period;
Reduce current
starting
Put
or
or
(ESD)
on
handling
follow rated
reduce
duty cycle.
duty cycle before
grounded
boards
or
by
at once.
the
FCC about interference, stop
regularly
using
the
checked and maintained.
panels tightly shut,
Keep high-frequency
keep spark gaps at correct setting, and use grounding and
shielding to minimize the possibility of interference.
source
filter airflow to unit.
can
If notified
equipment
Have the installation
again.
to weld
Do not block
STATIC
OVERHEATING
can cause
doors and
damage PC boards.
wrist
strap
BEFORE
parts.
ARC WELDING
static-proof bags and
store, move, or ship PC boards.
Use proper
can cause
interference.
boxes to
Electromagnetic energy can interfere with
electronic equipment such
as
computers and computer-driven equipment
sensitive
MOVING PARTS
can cause
such
injury.
as
robots.
equipment in the welding
electromagnetically compatible.
Be sure all
Keep away
from
moving parts.
Keep away
from
pinch points
such
as
To reduce
drive
possible,
rolls.
WELDING WIRE
can cause
injury.
possible interference, keep weld cables as short as
together, and down low, such as on the floor.
welding operation
equipment.
Be
sure
according
Do not press gun
trigger
until instructed to do
this
welding
100 meters from any sensitive elec
machine
is
and
installed
grounded
to this manual.
If interference still occurs, the user must take extra measures
as moving the welding machine, using shielded cables,
so.
such
Do not
other
is
close
Locate
tronic
area
point gun
people,
or
toward any part of the body,
any metal when threading
using
line filters,
or
shielding
the work
area.
welding wire.
1-4.
Principal Safety
Standards
of
Gases in
Cylinders, CGA Pamphlet
Safety in Welding and Cutting, ANSI Standard Z49. 1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten
dent of Documents, U.S. Government Printing Office, Washington,
Safe
D.C. 20402.
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1 R3.
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
Compressed
P.1, from Compressed Gas Association,
Highway, Suite 501, Arlington, VA 22202.
Code for
Safety in Welding and Cutting,
Safe Practices For
Occupation
1235 Jefferson
Davis
CSA Standard Wi 17.2, from
And Educational
Eye
And Face
Protection, ANSI Standard Z87.i, 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.
OM-i588
Page
3
EMF Information
1-5.
Considerations About Welding And The Effects Of Low
Electric And Magnetic Fields
Frequency
1.
Keep
Welding current, as it flows through welding cables, will cause electro
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: The body of evidence, in the
committees judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.
However, studies are still going forth and evidence continues to be
2.
Arrange
3.
Do not coil
examined. Until the final conclusions of the research
may wish to minimize your exposure to
welding
To
or
are
reached, you
electromagnetic
magnetic fields
procedures:
cables to
or
together by twisting
cables around your
Keep welding power
practical.
source
Connect work
to
4.
taping
side and away from the
one
drape
or
them.
operator.
.
body.
and cables as far away from opera
tor as
5.
clamp
workpiece
as
close to the weld
as
possible.
fields when
About Pacemakers:
cutting.
reduce
cables close
in the
workplace,
use
the
following
Pacemaker
then
wearers
following
consult your doctor first. If cleared by your doctor,
procedures is recommended.
the above
.
OM-1588
Page
4
SECTION 1
CONSIGNES DE SECURITE
UTI LISATION
-
LIRE AVANT
-
som
Signification
1-1
des
symboles
Signifie Mise en garde! Soyez vigilant! Cette procedure
prØsente des risques de danger! Ceux-ci sont identifies
par des symboles adjacents aux directives.
a
A Identifie
n ~ wa
Ce groupe de symboles signifie Mise en garde l Soyez vigilant II y a des
risques de danger relies aux CHOCS ELECTRIQUES, aux PIECES EN
message de sØcuritØ particulier.
un
MOUVEMENTetaux PIECES CHAUDES.
etauxdirectives ci-dessous atm
rr
Dangers relatifs
1-2
A
Łviter tout
nest pas relatif a Ia sØcuritO.
NOT/i
Signifie
soudage
au
a
symboles prØsentØs ci-aprŁs
present
A
lutilisation, lentretien
Linstallation,
vent Œtre confiØs
A
Au coursde
qu
reparations
qualifiØes.
et les
des personnes
ne
doi
lutilisation, tenirtoute personne a lØcartet plus par
Un
piŁces Łlectriques peut
electrocution ou des blessures graves.
provoquer
L?Łlectrode et le circuit de soudage sont sous tension
des que lappareil est sur ON. Le circuit dentrŁe et les
circuits internes de lappareil sont Łgalement sous
tension ace moment-l. En soudage semi-automatique ou automatique,
le fil, le dŁvidoir, le logement des galets dentraInement et les piŁces
mŁtalliques en contact avec le fil de soudage sont sous tension. Des
matŁriels mal installŁs ou mal mis a Ia terre prŁsentent un danger.
toucher les
jamais
a
piŁces Łlectriques
Porter des gants et des vŁtements de
pas de trous.
sous
protection
es
manuel.
ce
Porter
un
harnais de sŁcuritŁ
Maintenir solidement
Fixer le cable de retour de
Ia
avec
piŁce a souder ou
Isoler Ia
se
servir de
Se servir dune
procŁde
de
source
soudage
Si lutilisation dune
saire,
se
source
Łlectrique
dens les endroits confines
tion
secs ne
Łlectrique UNIQUEMENT
Ølectrique severe nŁces
rappereil en est ØquipØ.
ou
sŁcuritŁ).
Installeret mettre a laterre correctement cet appareil contormŁment
et aux codes nationaux, provinciaux et
son manuel dutilisation
municipaux.
Toujours verifier
Ia terre du cordon dalimentation
Verifier et sassu
que le fil de terre du cordon dalimentation est bien raccordŁ a Ia
borne de terre du sectionneur ou que lafiche du cordon est raccordŁe
a une prise correctement mise a Ia terre.
-
rer
En effectuant les raccordements dentrŁe fixer dabord le conducteur
appropriŁ et contre-vŁrifier les connexions.
de mise a Ia terre
pour voir sil nest pas
endommagŁoudŁnudŁ remplacerlecordon immŁdiatementsilest
endommagŁ un cable dŁnudŁ peut provoquer une electrocution.
-
-
Mettre
lappareil
hors tension
Ne pas utiliser des cables
sante ou mal ŁpissŁs.
quand
on ne
lutilise
pas.
uses, endommagŁs, de grosseur insuffi
piŁce,
Ia
quand
on
est
electrode provenant dune
en
piŁce
pour Øviter le contact
Łlectrique,
et
dŁ
selon les instructions
toucher les
piŁces.
contact avec Ia
FIJMEES
ET ifS
GAZpeuvent
Eloigner
A
IintŁrieur, ventiler Ia
veau
votre
tŒte des fumŁes. Ne pas respirer
fumŁes.
zone
etjou utiliser
un
Łchappement
au
ni
de Iarc pour lØvacuation des fumŁes et des ga.z de
soudage.
respirateur a
alimenta
Si Ia ventilation est insuffisante, utiliser
tion dair homologue.
un
Ure les spŁcificationsde sŁcuritŁ des matŁriaux (MSDS5) et les ins
tructions du tabricant concernant Ies mŁtaux, Ies consommables,
les revŁtements, les nettoyants et les dŁgraisseurs.
Travailler dans
un
espace fermŁ seulement siI est bien ventilŁ
ou
portant un respirateur a alimentation dair. Demander toujours a
se tenir a proximitØ. Des fumŁes et
soudage peuvent dŁplacer lair et abaisser Ie niveau
doxygŁne provoquant des blessures ou des accidents mortels.
Sassurer que lair de respiration ne prŁsente aucun danger.
Ne pas souder dans des endroits situŁs ~ proximite dopØrations de
dŁgraissage, de nettoyage ou de pu!vŁrisation. La chaleur et les
rayons de Iarc peuvent rŁagir en presence de vapeurs et former
des gaz hautement toxiques et irritants.
Ne pas souder des mŁtaux munis dun revŒtement, tels que lacier
galvanisŁ, plaque en p10mb ou au cadmium a moms que le revŁte
un
surveillant dOment forme de
des gaz de
ment nait
ŁtŁ enlevŁ dans Ia
ventilŁ,
et si
necessaire,
de soudure, que lendroit soit
portant un respirateur a alimenta
zone
en
tion dair. Les revŒtements et tous les mŒtaux renfermant
un
Ne pas toucher lŁlect rode
mis a Ia
Le soudage gŁnŁre des fumŁes et des gaz. Leur
inhalation peut Łtre dangereux pour votre sante.
bien
Ne pas enrouler es cables afflour du corps.
Si Ia piŁce soudŁe doitŁtre mise laterre, lefairedirectementavec
cable distinct.
terre ou une
LES
en
VerifIer frŁquemmenl le cordon dalimentation
plus prŁs possible de Ia
Œtre dangereux
si Ie
arrŒterle moteuravantde procŁder linstal
a Ientretien de lappareil. DŁverrouiller
Ialimentation selon Ia norme OSHA 29 CFR 191 0.147 (voir normes
de
Ia table de travail, Ie
charger les condensateurs dalimentation
indiquŁes dans Ia partie entretien avant de
zones
ou
lation, a Ia reparation
capots.
bon contact mŁtal-mŁtal
comportant
servir de Ia fonction de tØlŁcommande si
Couper Ialimentation
faon
un
tension.
courant Łlectrique dens las
l o on risque de tomber.
courant
hauteur.
Ølectrique.
es
Łlectrique
en
ArrŁter les convertisseurs, dØbrancher Ie courant
le demande.
source
travaille
ii y a DU COU RANT CONTINU IMPORTANT dans ies
convertisseurs aprŁs Ia suppression de lalimenta
ou
courant
Ølectrique
a obtenir
pince de masse quand ~85
objet mØtallique.
de Ia piŁce et de Ia terre au moyen de tapis ou dautres
moyens isolants suffisamment grands pour empŁcher le contact phy
sique Łventuel avec Ia piŁce ou Ia terre.
humides,
on
tous les panneaux et
tout
Sisoler
Ne pas
quand
place
en
peut tuer
une
Ne
quun materiel en bon Łtat. RŁparer ou remplacer sur-le
piŁcesendommagŁes. Entretenirlappareil conformŁment
Nutiliser
champ
avec
contact avec des
simple
danger.
soudure.
ticuliŁrement les enfants.
UN CHOC ELECTRIQUE
Reportez-vousauxsymboles
mesures a prendre pour
de connaltre Ies
Iarc
sont utilisØs tout au long du
manuel pour attirer votre attention et identifier lea
risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnØes afin dØviter tout
danger. Les conaignes de sØcuritØ prØsentØes ci-aprŁs ne font
que rØsumer linformation contenue dans les normes de sØcuritØ
ØnumØrØes a Ia section 1-4. Veuillez lire et respecter toutes ces
normes de sØcuritØ.
Les
_nd_fre 4/98
ments
peuvent dŁgager des fumŁes toxiques
en cas
de
ces
ŁlŁ
soudage.
autre machine.
OM-1588
Page
5
LES RAVONS DE LARC peuvent pro-I
voquer des brCilures dans lesyeux et
::
surla peau.
LES ACCUMULAT!ONS DE :G~ ris
quent dØ provoquer des blessures o
:mŒme Ia mort.
rayonnement de Iarc du procØdØ de soudage
gØnŁre des rayons visibles et invisibles intenses
(ultraviolets et intrarouges) susceptibles de provoquer
des brOlures dans es yeux et sur Ia peau. Des Øtincelles sont projetees
Le
pendant
le
Fermer lalimentation du gaz protecteur
non utilisation.
Veiller
toujours a
bien aØrer las espaces confines
rateur dadduction dair homologuØ.
soudage.
casque de soudage muni dun Øcran de filtre appropriØ pour
protØger votre visage et vos yeux pendant le soudage ou pour regar
der (voir ANSI Z49. 1 et Z87. 1 ØnumØrØ dans es rtormes de sØcuritØ).
Porter
protections approuvØs pour
Utiliser des Øcrans
ou
des barriŁres pour
ne
pas
Ne pas toucher des
re
Porter des vØtements de
PrØvoir
une
dutiliser
le
au
~J
m
feu
protection constituØ dans une matiŁre dura
(cuir ou lame) et une protection des pieds.
LE SOUDAGE
incendie
Le
peut provoquer
explosion.
I I
ou une
eftectuØ sur des conteneurs fermØs tels
que des reservoirs, tambours ou des conduites peut
provoquerleurØclatement. DesØtincelles peuventŒtre
projetØes de larc de soudure. La projection dØtincel
les, des piŁces chaudes et des Øquipements chauds peut provoquerdes
incendies et des brOlures. Le contact accidentel de lØlectrode avec des
objets metalliques peut provoquer des Øtincelles, une explosion, un
surchauftement ou un incendie. Avant de commencer le soudage,
verifier et sassurer que Iendroit ne prØsente pas de danger.
souda9e
Se protØger et dautres
metal chaud.
personnes de Ia
projection dØtincelles
ment passer dans dautres
des ouvertures.
LES CHAMPS
Les
zones en
traversant de
effectuØ sur un plafond, plancher,
peut dØclencher un incendie de lautre ctØ.
soudage
paroi
ou
Le bruit des processus at des
roule.
Porter des
sur Ia piŁce le plus prØs possible de Ia zone de sou
pour Øviter le transport du courant sur une longue distance par
des chemins inconnus Øventuels en provoquant des risques dØlec
trocution et dincendie.
poste de soudage pour dØgeler des conduites ge
utilisation, enlever Ia baguette dØlectrode du portecouper le fil a Ia pointe de contact.
Porter des vŒtements de protection dØpourvus dhuile tels que des
gants en cuir, une chemise en matØriau lourd, des pantalons sans re
vers, des chaussures hautes et un couvre chef.
non
ou
Avant de souder, retirer toute substance combustible de
quun allumeur au butane ou des allumettes.
vos
poches
telles
soudage, lØcaillement,
en
fil de
fer,
piŁce
meulage gØnØrent
refroidissement des soudures, elles
risquent
du laitier.
Porter des lunetles de sØcuritØ
Page
6
avec
Øcrans latØraux
les oreilles Si
trop ØlevØ.
Si des BOUTEILLES sont endomma
elles pourront exploser.
Des bouteilles de gaz protecteur contiennent du gaz
haute pression. Si une bouteille est endomma
gee, elle peutexploser. Du faitque les bouteilles de gaz
font normalement partie du procØdØ de soudage, les
ou un
sous
I
I
_____________
manipuler
avec
ProtØger
precaution.
es
des chocs
bouteilles de gaz comprimØ dune chaleur excessive,
du laitier, des flammes ouvertes, des Øtin
mØcaniques,
celles et des
arcs.
Placer les bouteilles debout en les fixant dans un support station
naire ou dans un porte-bouteilles pour les empŒcher de tomber ou
de se renverser.
Tenir les bouteilles
cuits electriques.
Ne
jamais placer
ØloignØes des circuits de soudage ou autres cir
une
torche de
une
Une electrode de
soudage
ne
soudage sur une bouteille a gaz.
jamais entrer en contact avec
doit
bouteille.
jamais
souder
Ne pas tenir Ia tŒte
bouteille.
le passage de Ia
et le
affecter
une
bouteille
pressurisØe
-
risque dexplosion.
Utiliser seulement des bouteilles de gaz protecteur, regulateurs,
tuyaux et raccords convenables pour cette application spØcifique;
Ies maintenir ainsi que les ØlØments associes en bon Øtat.
desØtincellesetdesparticules mØtalliquesvolan
projeter
ou
gØes,
Ne
DES PARTICULES VOLANTES
peuventblesser les yeux...
a Ia brosse
Øquipements peut
protections approuves pour
le niveau sondre eat
separation
Brancher le cable
pØriode de
sapprocher
de gougeage
petites fissures et
dage
tes. Pendant Ia
a larc,
peuvent tomber
sØcuritØ).
Le
operations de soudage
soudage par points.
et de
soudage sur des conteneurs fermØs tels que des
reservoirs, tambours, ou conduites, a moms quils naient ØtØ prØpa
rØs correctement conformØment a AWS F4.1 (voir es normes de
~
restezdistance.
porteurs dun stimulateur cardiaque doivent
des
Ne pas effectuer le
Ne pas utiliser le
lees.
cardiaques.
dabord consulter leur mØdecin avant de
de
avant
MAGNETIQUES peuvent
Porteuradestimulateurcardiaque,
SurveillertoutdØclenchementdincendie ettenirun extincteurproxi
mite.
de
chaudes a mains
pØriode de refroidissement
pistolet ou Ia torche.
aftecter les stimulateurs
DØplacertoutes les substances inflammables a une distance del 0,7
m de arc de soudage. En cas dimpossibilitØ es recouvrir soigneuse
ment avec des protections homologuØs.
Des Øtincelles et des matØriaux chauds du soudage peuvent facile
cas
parties
LE BRUIT peut affecter IouIe.
Ne pas souder dans un endroit l ou des Øtincelles
sur des substances mnflammables.
electrode
pro
nues
ble, resistant
OM-i588
respi
protØger des tiers de Øclair
autres personnes de
larc.
(~ mJ
de
de
voquer des
lØblouissement; demander aux
garder
En
servir dun
PI¨CES CHAUDES peuvent
briilures graves.
DES
les oreilles si le niveau sondre est
trop ØlevØ.
Le
cas
un
Porter des
et de
ou se
en
Øcran facial.
Maintenir le
dutilisation
en
chapeau
ou
face de Ia sortie
en
ouvrant Ia soupape de Ia
de protection sur Ia soupape, sauf
de branchement de Ia bouteille.
en cas
Lire et suivre les instructions concernant les bouteilles de gaz corn
les Øquipements associØs et les publications P-i CGA Ønu
mØrØes dans les normes de sØcuritØ.
prime,
.
1-3.
Dangers supplØmentaires
en
relation
avec
Iinstallation, le fonctionnement
et Ia maintenance
Risque DINCENDIE
ORGANES MOBiLES
provoquer des blessures.
Ne pas
placer lappareil
proximitØ
au-dessus
sur.
ou
Rester a lØcart
ventilateur.
a
de surfaces infllammables.
panneaux,
-
LA CHUTE DE LAPPAREIL
blesser.
de
En utilisant des fourches de levage pour dØplacer lunitØ, sassurer
que lesfourches sont suffisamment longues pourdØpasser du ctØ
oppose de Iappareil.
LEMPLOI EXCESSIF peut
SURCHAUFFER LEQUIPEMENT.
PrØvoir
ter le
une
pØriode
de ref roidissement, respec
nominal.
de
Lerayonnementhautefrequence peutprovoquer
avec les Øquipements de ra
dio-navigationetdecommunication, lesservices
des interferences
lever lappareil, NON PAS les chariot, les bouteil
es de gaz ou tout autre accesso ire.
pour
dispositifs
et
LE :RAYONNEMENT HAUTE FRE
QUENCE (HF.) risque de provoquer
des interferences.
peut
capacitØ appropriee
place les portes,
en
recouvrements
protection.
levage uniquement pour sou
Utiliser un engin dune
soulever Iappareil.
des organes mobiles comme le
Maintenir fermØs et fixement
Ne pas installer lappareil a proximitØ de produits inflammables
Ne pas surcharger Iinstallation Ølectrique sassurer que lalimen
tation est correctement dimensionnØ et protØgØ avant de mettre
lappareil en service.
Utiliser lanneau
peuvent
DES
OU
DEXPLOSION.
de sØcuritØ et les ordinateurs.
Demander seulement a des personnes qualifiŁes familiarisØes
avec des Øquipements Ølectroniques de faire fonctionner linstalla
tion.
Lutilisateur est tenu de faire corriger rapidement par
les interferences resultant de linstallation.
un
Łlectricien
qualifiŁ
Si le FCC
reil.
signale des interferences, arrØter immØdiatement lappa
Effectuer
rŁguliØrement
le contrle
et lentretien
de linstallation.
Maintenir soigneusement fermØs les portes et les panneaux des
sources de haute frØquence, maintenir les Øclateurs a une distance
correcte et utiliser une terre et et un blindage pour rØduire es inter
fØrences Øventuelles.
cycle opØratoire
RØduire le courant ou le cycle
le soudage.
opØratoire avant de
recommancer
LE
Ne pas obstruer les passages dair du poste.
LES CHARGES
SOUDAGE
A
LARC
risque
de
provoquer des interferences.
ELECTROSTATIUES
Lenergie
ØlectromagnØtique
de
risque
provoquer des interferences pour lequipement
Ølectronique sensible tel que les ordinateurs et
lequipement commandŁ par ordinateur tel que
peuvent endommager les circuits im
primes.
les robots.
Etablir Ia connexion avec Ia barrette de terre
avant de manipuler des cartes ou des pieces.
Utiliser des
pochettes
et des boltes
pour stocker, dØplacer
circuits imprimes.
ou
antistatiques
expØdier des cartes de
Veiller ace que tout
lequipement
patible ŁlectromagnŁtiquement.
ORGANES MOBILES
provoquer des blessures.
Ne pas
sapprocher
peuvent:
des organes mobiles.
peuventpro
voquer des blessures.
Ne pas
diriger
le
Ia
gachette
pistolet
avant den
vers sd,
piŁce mØcanique
soudage.
sonnes ou toute
le fil de
sur
dautres
en
com
Pour rØduire Ia possibilitŁ dinterfØrence, maintenir les cables de
aussi courts que possible, les grouper, et les poser aussi
bas que possible
Veiller a souder a
(ex. par terre).
une
distance de 100 metres de tout
Øquipement
sensible.
Veiller a
ce que ce poste de soudage soit
conformØment a ce mode demploi.
pose
et mis
a Ia terre
lutilisation de filtres de
ligne ou
Ia pose de protecteurs dans Ia
LES CHAMPS MAGN TIQUES peuvent;
affecter les stimulateurs cardiaques.
avoir
tance.
per
dabord
engageant
zone
de travail.
Porteurs de stimulateur
Ne pas appuyer
reu linstruction.
soit
En cas dinterfØrences aprŁs avoir pris les mesures prŁcØdentes, il
incombe a lutilisateur de prendre des mesures supplØmentaires
telles que le dØplacement du poste, lutilisation de cables blindŁs,
We pas sapprocher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE
soudage
soudage
Ølectronique
PES
de Ia zone de
cardiaque,
restez a dis
Les porteurs dun stimulateur cardiaque doivent
consulter leur mŁdecin avant de sappro
cher des operations de soudage a larc, de gou
geage ou de soudage par points.
OM-1588
Page
7
Pnnctpales
1-4
normes
de securite
Safety in Welding and Cutting, norme ANSI Z49. 1, de American
ding Society, 550 NW. Lejeune Rd, Miami FL 33126
Wel
of Documents, U.S. Government
20402.
Superintendent
Printing Office, Washington, D.C.
Recommended Safe Practice for the Preparation for Welding and Cut
of Containers That Have Held Hazardous Substances, norme
,
Welding Society,
550 N.W.
Lejeune Rd,
Mia
mi FL 33126
National Electrical
Code, NFPA Standard 70, de Ia National Fire Pro
Batterymarch Park, Quincy, MA 02269.
tection Association,
Information
1-5.
sur
les
sure soudage Ølectrique et sur es effets,
champs magnØtiques basse frØquence
pour
lorganisme,
coupage et procØdØs connexes, norCSA Wi 17.2, de Association canadienne de normalisation, vente
de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W
1R3.
Safe Practices
ForOccupation And Educational EyeAnd Face Protec
ANSI Z87.1, de American National Standards Institute,
1430 Broadway, New York, NY 10018.
tion,
norme
Cutting and Welding Processes, norme NFPA 51 B, de Ia National
Protection Association, Batterymarch Park, Quincy, MA 02269.
Afin de rØduire
de travail,
soudage, pendant son passage dans es cables de sou
dage, causera des champs Ølectromagnetiques. II y a eu et il y a
encore un certain souci a propos de tels champs. Cependant, aprØs
avoir examine plus de 500 etudes qui ont ØtØ faites pendant une pØ
node de recherche de 17 ans, un comitØ special ruban bleu du
a
Cylinders, CGA Pamphlet
RŁgles de sØcuritØ en soudage,
Fire
conclu: Laccumulation
champs ØlectromagnØtiques dans
les consignes suivantes
Garder les cables ensembles en les torsadant
attachant avec du ruban adhØsif.
2
Mettre tous
3
Ne pas courber pas et
votre corps.
4
Garder le poste de
de preuves, sui
Jugement du comitØ, na pas dØmontrØ que lexposition aux
champs magnØtiques et champs electriques a haute frØquence reprØ
sente un risque a Ia sante humaine.
Toutefois, des etudes sont
es
de
Ienvironnement
respecter
1
Le courant de
National Research Council
Gases in
champs ØlectromagnØtiques
DonnØes
des
Compressed
me
ting
AWS F4.1 de IAmerican
of
Handling
P-i, de Ia Compressed Gas Association, 1235 Jefferson Davis High
way, Suite 501, Arlington, VA 22202.
OSHA 29 CFR 1910, du
Safetyand Health Sandards,
Safe
es
cables du ctØ
ne
oppose
de
es
ou en
IopØrateur.
pas entourer pas les cables autour de
soudage
et les cables le
plus
loin
possible
vous.
vant le
toujours
en cours
et es preuves continuent a Œtre examinØes. En at
tendant que es conclusions finales de Ia recherche soient Øtablies, il
vous serait souhaitable de rØduire votre exposition aux champs Ølec
tromagnØtiques pendant
OM-1588
Page
8
le
soudage
ou
le coupage.
5
Relier Ia
pince
de
masse
le
plus prØs possible
de Ia
zone
de
soudure.
Consignes
relatives
aux
stimulateurs
cardiaques
Les personnes qui portent un stimulateur cardiaque doivent avanttout
consulter leur docteur. Si vous Œtes dØclarØ apte par votre docteur, il
est alors recommandØ de respecter es consignes ci-dessus.
.
SECTION 2- INTRODUCTION
Specifications
2-1.
Type
of
Welding
Input
Source
Power
10
Speed
Range
Type
Height
With 4 ft
(1.2 m)
Max
Optional High Speed:
ipm (2.3 To
36.5 mpm)
(3.7 m)
17 ft
Post
Vertical Lift Of Boom
Horizontal to 60
Weight
Welding Circuit
Rating
100 Volts,
12 ft
Amperes,
100% Duty Cycle
207 lb
750
280 lb
16 ft
Boom
(4.9 m)
21 ft
(5.2 m)
Above Horizontal
(3.7 m):
(94 kg)
16 ft
Spool Weight:
(27 kg)
60 lb
92 To 1435
12 ft
Maximum
.023 To 1/8 in (0.6
To 3.2 mm)
ipm (1.310
Constant Voltage (CV) /
Constant Current (CC) DC
For GMAW-P
All Need 14-Pin And
Contactor Control
Amperes
50/60 Hertz
Range
Standard: 50 To 780
19.8 mpm)
Constant Voltage (CV)
DC For GMAW Or
24 Volts AC
Single-Phase
Wire Diameter
Wire Feed
Power
(4.9 m):
(127 kg)
Boom
(6.4 m)
Above Horizontal
Horizontal to 60
SECTION 3- INSTALLATION
3-1.
Installing
Swivel Into
Pipe Post
1
5
4
Swingpak
Pipe
3
Steel Bolt
Secure
mum
Base
or
CBC Cart
Post With Base
2
shown
as
using
as a
mini
1/2 in diameter SAE grade 5
steel bolts.
4
Swivel
Insert
Assembly
into
pipe post.
Lubricate
swivel.
5
2
A
Safety
Do
Collar
not
remove
until
instructed to.
3
Tools Needed:
~=:=::~
3/4 in
ST-152 382
OM-1588
Page
9
3-2.
Installing
Control Box And
Adjusting
Tilt
Weld Control
1
2
Bracket
3
Screw
Bracket and
installed
screws are
onto bottom of control at
factory.
Swivel
4
Loosen
Place control
screws.
swivel and slide forward.
on
Tighten
screws.
Tilt Bracket
5
6
Rear Pivot Screw
7
Front Screw
Loosen
front
rear
pivot
Remove
screw.
Pivot control down
screw.
ward to desired
viewing angle. Re
place and tighten front screw.
Tighten pivot screw.
3
4
Tools Needed:
ST-800 174 / ST-801 278
1
Swivel Plates
2
Yoke
Remove
plates
3
hardware
and
as
shown.
Yoke Pin
4
Install
ter
swivel
Boom
Set boom into swivel
3
from
yoke.
pin
5
pin through yoke. Install
and spread ends.
cot
Bolt
7
Install
bolt,
washers,
Tighten hardware,
4
one
half turn.
6
Locking
Install
and
nut.
and back bolt off
Knob
locking
knob
but
do
not
tighten.
7
Reel
Support
Install reel
support.
2
Tools Needed:
3/8, 3/4 in
ST-i 53 170
OM-1588
Page
10
.
3-4.
Installing
Wire Guide Extension
1
Wire Guide
2
Bolt
Fitting
3
Monocoil Liner
4
Wire Guide Extension
Tighten bolt to secure liner in wire
guide fitting. Do not overtighten
bolt and crush liner.
Repeat
procedure
for
opposite
side.
4
Tools Needed:
cI::::::1===n
3/8 in
ST-152 383
OM-1 588
Page
11
3-5.
Equipment
Connection
Diagram
1
300/400 Ampere Model
CC/CV Inverter Welding
Power Source
Use settings shown for both
pulse MIG welding and MIG
welding.
450
Ampere Model CV
Welding Power
Inverter
Source
3
14-Pin Cord
4
Positive
5
(+) Weld Cable
Negative (-) Weld Cable
Be
sure
cables
weld
are
sized
properly for peak amperage it
pulse welding (see welding power
source Owners
Manual).
Workpiece
Voltage Sensing Lead
(Optional Use)
PANEL
8
0
9
REMOTE
INI~UCTANCE/DIG
Gun
gun is rated for peak am
perage if pulse welding. Install ac
cording to its Owners Manual.
Be
V/A CONTROL
sure
Wire Feeder
For connections
see
Gas
Section 3-7.
Supply
10
Shielding
11
Supplied
12
Gas Hose From Boom
Y
Adapter
.
ST-801 806/Ref. ST-175 086 / Ref. ST-180 311-B
OM-1 588
Page
12
3-6.
Connecting Weld Cables
And Gas Hoses
OM-1 588
Page
13
3-7.
Control Box Connections
Optional
Reed
Relay
Connection
2
Wire Feed Motor And Gas
3
Wire Feed Motor And Gas
Valve Control Plug From
Valve Control
Receptacle
Boom
4
14-Pin Cord
5
Volt Sense Lead
(Optional
Use)
6
Gun
Trigger Plug
From Boom
0
p
2
ST-Boo 177-A/ Ref. ST-BOO 175
3-8.
14-Pin
Plug Information
Pin Information
24 volts
ac
with
respect
Contact closure to A
Circuit
common
+10 volts dc
to socket G.
completes
24 volts
ac
contactor control circuit.
for 24 volts AC circuit.
output
to remote control with
Remote control circuit
common.
0 to +10 volts dc
command
input
Voltage feedback;
signal
respect
to socket D.
from remote control with respect to socket D.
0 to +10 volts dc, 1 volt per 10
arc
volts.
Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes.
CC/CV Select (+24
Inductance
*The
remaining pins
are not
V
=
CV)
(0-10 V)
used.
.
OM-1588
Page
14
Motor Start Control
3-9.
To
change wire feed starting speed
proceed
as
follows:
Turn Off wire feeder and
power
welding
source.
Remove wrapper.
1
Motor Board PCi
2
Motor Start Control Poten
tiometer R70
Turn
potentiometer clockwiseto
in
time it takes the motor to
ramp up to speed. Remove protec
tive white rubber cap before mak
crease
ing adjustment. Adjust potentiome
using a small nonconduc
ter R70
tive screwdriver.
Reinstall wrapper.
Tools Needed:
Non-Conductive
~==-
~==~
cI:I:::::::J=::=ln
1/4 in
ST-162 132/Ref. SA-183 121-B
3-10.
Removing Safety Collar And Adjusting
Boom
1
Locking
Tighten
Knob
knob
to
boom
prevent
movement. Loosen knob to allow
movement. Change knob
position to limit upward movement.
boom
Pull boom down
move
safety
balance in any
zontal to 60
slightly
position
degrees
zontal. If necessary,
as follows:
re
2
Threaded Rod
3
Jam Nut
from hori
above hori
adjust
boom
Loosen jam nut and turn threaded
rod until boom balances. Tighten
jam nut. Be sure several full
2
threads are through
vent boom falling.
3
4
E
and
collar. Boom should
yoke
to pre
Yoke
safety collar for use in
assembling or moving boom.
Retain
0
dis
Rod
Tools Needed:
~
1-1/8 in
Increasing Spring
Decreasing Spring
Pressure For A
Pressure For A
Heavy Gun
Ughter Gun
ST-142 599-B
OM-1588
Page
15
3-11. Gun Recommendation Table
Process
GMAW-P
GMAW
FCAW
3-12. Wire
Motor
-
-
-
Hard
Hard
or
or
Gun
Cored Wires
Cored Wires
Self-Shielding
Wires
GW-500 Or GW-600
M25, M40, Or GA-500
GA-4OGL Or GA-5OGL
Type, Size, And Feed Speed Capability Table
Speed
Wire
Type
Wire Size
.023 To 5/64 in
Feed
Standard
All
Standard
All
3/32 To 7/64 in (2.4 To 2.8 mm)
Standard
All
1/8 in (3.2 mm)
Optional High
OM-1588
Page
16
All
.023 To 5/64 in
(0.6
(0.6
To
2mm)
To 2
50 To 780
ipm (1.3
50 To 700 pm
50 To 300
mm)
Speed Capability
(1.3
1pm (1.3
92 To 1440 pm
(2.3
To 19.8
mpm)
To 17.8
mpm)
To 7.6
mpm)
To 35.6
mpm)
Tools Needed:
~ 15/16,3/8 in
3/16,5/64 in
Install
E
wire
Adjust tension
wire
is
wire feed
taut
spool.
nut
so
when
stops.
4,
Install wire
guide.
4-
S
-.
Install drive rolls.
~7
Be
that outlet cable has proper
size liner for the welding wire size.
sure
installing gun, position liner
extending from outlet wire guide as
close as possible to drive rolls without
touching.
Install gun. Lay gun cable out straight. Cut
oft end of wire. Push wire through guides up
fl7 Forsoft wire orsmall diameterstainless
steel wire, use 2 drive rolls and set drive
roll pressure from 0 to a maximum of 4
on the pressure indicator scale (so that
When
to drive
Jog
rolls; continue
only
the inner
spring
is
compressed).
setung will generally give the best
performance for these types of wires.
This
To
adjust
drive roll pressure, hold nozzle
about 2 in (51 mm) from nonconductive
surface and press gun trigger to feed wire
against surface. Tighten knob so wire does
not slip. Do not overtighten. If contact tip is
completely blocked, wire should slip at the
feeder
(see pressure adjustment above).
Cut wire off. Close
Repeat
cover.
for other side.
to hold wire. Press
button to feed wire out gun.
5T-152 564-B! Ref. ST-156 929 I Ref. Sc.150 922 / Ref. ST-156 gaO I S.0627-A
OM-1588
Page
17
SECTION 4- OPERATION
4-1.
Operational
Note ~
The
following
is
a
Terms
See Menu Guide for detailed
list of terms and their definitions
as
I
programming steps.
they apply
to this wire feeder:
General Terms:
Adaptive
Pulse
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.
Inductance
As inductance
Trim
Arc
increases,
arc on
time increases, and the weld
length adjustment in pulse welding. Increasing
placed by volts in MIG programs.
Synergic
The
the
puddle
becomes
trim increases the actual
operator programs pulse parameters for a specific wire feed speed.
pulse parameters between these wire feed speed increments.
more
fluid.
length.
arc
Trim is
re
The wire feeder determines
Side Panel Terms:
Process Mode
Sequence
Is used to select the
type of process
to be
used, including Pulse, Adaptive Pulse,
or
Mig.
Is used to select and program the weld sequences which include weld, crater, burnback,
and run-in.
Mode
postflow,
preflow,
Dual Schedule Mode
Is used to select
a
Card Mode
Is used to select
use
Security
Only functions with
rameter changing.
4-2.
Mode
Pulse
Welding
pair
a
of programs that
of the
optional
can
be used
data card
data card. Allows
using
together.
storage and retrieval capabilities.
restricting range of program
the lock feature for
pa
Terms
1
Apk
Peak
=
Increasing Apk
Amperage
increases penetra
tion.
Vpk
Peak
=
Voltage
voltage during peak current
phase of the pulse waveform. This
determines
arc
length during
adaptive pulse welding.
Arc
3
/
2
\
I
\
I
/
Amps
\
I
/
/
/
/
\
3
\
2
PPS
4
Page
18
between
/
pulses.
Pulses Per Second
increases travel
Pulse Width In
Milliseconds
PWms
width.
OM-1 588
arc
=
Increasing
4
Time
Background Amperage
=
increasing PPS
L..
1
Abk
Maintains
=
PWms increases bead
4-3.
Front Panel Controls
~:
I
3
8
~
7
4
4
1
ST-162 127
1
ule Mode
2
Parameter Select Button
setting. To change type of
process (Pulse, Adaptive Pulse, or MIG) use
side panel controls (see Section 4-4).
Pulse is
Press button to
3
Display
exception of Dual Sched
(see Section 6).
while welding, with
Display
move > on
display.
Control
Turn control to
change value pointed to by>.
Turning control one click causes Trim (arc
length) to increase/decrease by one or Volt
to increase/decrease by 0.1.
When 1PM is selected,
click causes wire feed
crease/decrease by
turning control one
speed (1PM) to in
When MPM is selected, turning control three
clicks causes wire feed speed (MPM) to in
crease by 0.1.
When Prg # is selected, turning control one
click causes program number (Prg #) to in
crease/decrease by
one.
The program number cannot be
Active Side Indicator
5
Trigger
changed
Light
Hold Button And Indicator
Trigger Hold
can
sis. Indicator
be set
light
on a
Light
per program ba
for programs
comes on
To weld without
holding gun trigger through
cycle, press and release button to
feature on (indicator light turns on).
out weld
To start weld
and release gun
within three seconds after an arc has
cycle, press
been struck. To end weld
release gun
6
7
cycle, press
and
trigger.
Side Select Button
The feeder remembers the last used pro
gram for each side and returns to that pro
gram when the active side is changed.
Button
Jog
momentarily feed welding wire with
energizing welding circuit or shielding
Push to
out
where this feature is active.
trigger
active side of the feeder.
default
4
turn
one.
a
11? The gun trigger may be used to change
gas valve.
Jog speed is varied using the Display Con
Jog button is pressed. Default set
ting is 200 1PM.
trol while
8
Purge
Button
momentarily energize gas valve
energizing the welding circuit.
Push to
without
ltT Jog and Purge only work
on
the active
side of the feeder.
Holding the Jog and Purge buttons at the
time displays pulse parameters on
the side panel display and voltage on
front panel display.
same
OM-1 588
Page
19
4-4.
Side And Rear Panel Controls
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.
3
~
Ret ST-162 128/Ref. ST-162 133
OM-1 588
Page
20
SECTION 5- SETTING SEQUENCE PARAMETERS
5-1.
Sequence
Parameters In A
Program
ItT See Menu Guide for detailed
programming steps.
Trim is
length
length
arc
length.
is short.
is
If time
If set to zero,
If set to 99,
arc
arc
long.
is
set
to
zero
in
Weld
sequence, welding continues until
gun trigger is released.
If time is set to zero in any timed
the
Weld,
except
sequence
sequence is skipped.
X
=
Setting
available.
0
Run-In
-
25
sec.
Arc
Strike
Trigger
Released
OM-1588
Page
21
SECTION 6- SETTING DUAL SCHEDULE PARAMETERS
6-1.
Selecting
Dual Schedule Pair
i~H
Dual Schedule is used with two
consecutive weld programs 1 & 2,
3 & 4, 5 & 6, or 7 & 8. Any program
__________________
type (MIG, Adaptive Pulse, or
Pulse) can be combined in dual
schedule.
1
1
Side Panel
Display
Use side panel to turn feature on.
See Menu Guide for detailed
programming steps.
2
Front Panel
Press front
Display
panel parameter select
button to select program number.
3
Front Panel
4
Dual Schedule Switch
Section
Display Control
(See
6-2)
lET 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
setup).
(depending
on
or
gun
system
When program B is active, turn
Display Control one click clock
wise to select another
pair
of dual
schedule programs.
lET Programs
can
be
in desired order
rearranged
using the data
card. See Section 7.
18.OV
200
I
PM
I
>Prg
1
I
Dual
A
Or
~D~ay
V
OM-1 588
Page
22
>Prg
2
Dual
B
>Prg
3
Dual
A
6-2.
Dual Schedule Switch
Diagrams
1
Momen 2P
(Momentary-Contact
Switch)
2
1
1
>
>
>
2
2
Maint 2P
2-Pole
>
(Maintained-Contact
Switch)
______
3
>
Maint 1 P
1-Pole
2
2
>
>
1
1
______
2-Pole
>
4
(Maintained-Contact
Switch)
Trigger
scheduling after estab
welding arc.
Allows dual
lishing
3
A
2
1
>
O~
A
3
t~ If trigger
>
B
a
B
4
is
used
schedule switch,
is disabled.
for
dual
Trigger
Hold
4
4
3
I
___________________________
1
(~
p
Adapter
1
>~i>
2
.TR
1
2
2
~
3
I
1
~p
I
2
TR
>~
IBO
I
3
>>
OM-1588
Page
23
SECTION 7- USING THE OPTIONAL DATA CARD
7-1.
Data Card Terms
CARD SCREEN TERMS
WRITE
READ
Programs
To Card
Programs From Card
PULSE MIG TERMS
PPS
Amperage
(Pulses
Per
Second)
1~
Apk (Peak
Amperage)
Abk
Time
(Background
Amperage)
SA-158 435
7-2.
Installing
Data Card
1
Label
Apply
label to data card. Write pro
on label.
gram information
2
Data Card
3
Card Slot
For Blank Data Card:
Insert card into slot. Toformat card,
3.
turn On power. Select Card from
menu. Data card formats when unit
enters Card mode.
2
For Power Source Data Card:
Insert card into slot. Turn On pow
Push Parameter Select button
er.
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.
ST-156 266-B
OM-1 588
Page
24
7-3.
Card
Displays
See Menu Guide for detailed
programming steps. Security
mode only functions with a
data card.
1
Card
2
Moving
Display
Line
Moving line is
be changed.
Seq
under value that
can
u en c e
3
Write
Dual Schd
Pr
>Card
Secu
r
i
ty
Transfers program data from unit
ess
to card. The program card can hold
up to 32 programs. When writing to
Be low
the card, the next available pro
gram number is automatically as
signed.
4
Parameter
Transfers program data from card
to unit.
Select Once
5
3
Read
Side Panel
Delete
Deletes program data from card.
6
Done
4
Exits card
display.
5
6
OM-1568
Page
25
7-4.
Entering Access Code
lI~ Access code works only when
access
mode in
Setup
screen
1
a
data card is inserted and
is turned On.
Security Display
2
Program Lock Display
3
Access Code
With
a
code
appears when
program lock.
Display
this
set,
Pressing Mode
display
to turn off
trying
a
Select button will
exit the access code
display.
lE~ If any character is incorrect
during code entty pressing
side panel Parameter Select
button will cause the indicator
to move back to beginning of
character set to allow
access
Press side
code
panel
button to enter
entering
again.
Parameter Select
access
code. When
the correct letter is entered, press
ing side panel Parameter Select
button
moves indicator to the next
character. When the final access
code character is entered, press
side
panel Parameter Select
button to automatically change
display to the program lock display.
Mode
Select
Seq
Prog
>Prog
1
Dua lSc hd
Lock
On
Card
Trim
55
Range
10
uen ce
>Secur i
ty
1
J>Lock
Qfl
Trim
55
Range
10
~
Increase!
Decrease
Prog
1
>Lock
QIl
.
OM-1588
Page
26
7-5.
Security
security feature
The
allows
mini
a
and maximum range limit to
be defined for trim, inches per min
mum
I~ The security feature works only when
a
data card is inserted.
ute
(1PM),
tion
11).
and
ShpArc (see Sec
security lock is Off, the
full range of values is available for
each parameter.
When the
Press
Mode
Select
~~~5~mes
c e
>Prog
1
Dual Schd
Lock
Off
Seq
u e n
Car d
Sec
u
r
i
t y
When the security lock is On, the
range of values available for each
parameter is the defined value plus
or
minus the defined range.
___
For
example,
fined
fined
if the 1PM value is de
125, and the range is de
50, the actual range of
as
as
available IPM is 75to 175 1PM
minus 50, and 125
Prog
1
1
Card
2
Moving
(125
plus 50).
Display
Line
Moving line is under value that can
be changed. Change program
>
number to
access
desired
pro-
gram.
Lock On/Off
3
Increase/
Decrease
Side Panel
Increase!
Parameter
Select
Decrease
Toggles security feature
On
or
Off.
Definable values are displayed
when Lock On is selected. Use
side
panel controls
to
change
val
ues.
4
Trim And
Range Display
5
1PM And
Range Display
6
ShpArc
And
Range Display
Definable Values:
Trim: 0-99
Range:
IPM: 70-875
ShpArc
:
0-20
0-99
Range:
0-875
Range:
0-20
example displays, the
operator could change the value of
Trim to 55 and its Range to –10%.
Also, the operator could change
In
the
the value of 1PM to 225 and its
Range to –100 ipm from
programmed values. If the range
settings are left at 0, the operator
cannot change values from those
programmed.
~>Prog
Trim
55
Range
1Oj=~~.J
IPM
>Range
1
Lock
On
225
Trim
55
1Q~
Range
10
Side Panel
Parameter
Select
OM-1 588
Page
27
SECTION 8
8-1.
SYSTEM SETUP
Accessing The Setup Menu
1
Setup
2
Power Switch
Panel
Press and hold down both buttons
while turning On unit.
3
Main
Main
4
Display
display during setup.
Setup Display
Follow this
procedure any
time
required. Once in the
setup displays, use the Mode
Select button to select a particular
display.
access
is
2
4
Setup Dispay
System
>
>
lnvisn 456
>
Model
/
System
Process
Model
Capability
Pulse/Mig
Access
System
Access
Mig Type
Reset Now
Mig Type
>
Press
Mode Select
To Change Menu Item
.
OM-1588
Page
26
8-2.
System Setup Display
Note f~~
DISPLAY SETTING
>System
Parameters
See Menu Guide for detailed
NOTES
Select the process the
*
programming steps.
welding power
source
is able to do.
For the Invision 456 and XMT 304 selections, pulse data and
are automatically loaded in. For the Other
selection,
>Model*
values
welding power source
welding power source
minimum and maximum
minimum and maximum
voltage
voltage
and amperage values must be entered. Pulse data defaults to XMT 304 values.
of
>Access
When on, restricts
>Mig Type
Default is Off. Set to On
Default is
>Voltage
use
setup
only for
14-pin receptacle.
screens.
older CV
welding power
Use V. Sense when
source
without
than 50 ft
more
(1 5m)
voltage
feedback at 14-socket
of weld cable is used
receptacle.
(including gun
cable
length).
Use Hot Start
>Arc Start~
only
with Inverter Model
welding power
source
and
large
diameter wires. The
arc
starts in CV and
switches to CC.
>Dual Schedule
See Section 6-2.
>Trigger
When on,
trigger
can
be used to switch between programs that have at least 0.2 seconds of
preflow
time pro
grammed.
>Remote
When on,
a
dual schedule switch
panel display
>
can
be used to
change
Volts
or
Trim, 1PM,
or
Prg depending
>Arc Time
Displays accumulated
>Wire Feed
Choose to
>Memory
No Reset: allows
display
arc
time and
where the front
cycles.
inches per minute
operator
or
meters per minute and motor
to exit memory reset
type, but installed
motor must match selection.
parameter without resethng any data.
Program Reset: unit defaults to original factory setting for the last active program. Setup
change. If setup card is in card slot, program will be loaded from card.
System
on
is.
Reset: unit defaults to
original factory settings
for all programs and
information does not
setup excluding System and
Arc Time. If
setup card is in card slot, program will be loaded from card.
Total Reset: unit defaults to
original factory settings
for all programs and
setup including System and
Arc Time. If
setup card is in card slot, program will be loaded from card.
>Shutdown
When on, the system
age is sensed.
>Gas Flow
Setting
>Ramps
Turns start and crater
immediately
must be Meter Off if
option
ramping On
shuts down if
no arc
voltage
is sensed. When
off, wire feeds
even
if
no arc
volt
is not installed.
or
Off. When On,
output power
is
tapered
from start to weld and from weld to
crater.
>Software
*
Automatically
Can be used
**
Know this when
talking
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
error.
OM-1 588
Page
29
SECTION 9- STANDARD PULSE WELDING PROGRAMS
FOR PHOENIX/INVISION 456 INVERTER
WELDING POWER SOURCES
Note ~
Apk
Peak
=
Amperage, Vpk
=
Peak
Voltage,
Abk
=
Background Amperage,
Pulses Per Second, PWms Pulse Width (milliseconds). Four teach points were use d for
factory set programs. If selection is set for fifteen teach points, the remaining points are
PPS
=
=
interpolations from the
9-1.
Wire
Program
Size/Type:
1
-
4
taught points.
Steel
Gas: Ar
.035
-
CO2
or
Ar
-
Oxy /40
CFH
(19 Urn)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
700) 17.8
440
36.7
160
180
2.9
400/10.2
385
32.4
108
126
2.3
200/5.1
335
28.7
61
81
2.0
100/2.5
328
27.4
37
47
1.7
9-2.
Wire
Program
Size/Type:
2
-
COMMENTS
Steel
.045
Gas: Ar
-
CO2
or
Ar
-
Oxy/40
CFH
(19 Urn)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
700/17.8
518
35.0
195
205
3.6
COMMENTS
_________________
400/10.2
466
31.3
147
158
2.9
200/5.1
412
28.5
93
106
2.4
100/2.5
375
26.5
50
66
2.2
9-3.
Wire
Program
Size/Type:
3
-
Steel
.052
Gas: Ar
-
CO2
or
Ar
-
Oxy /40
CFH
(19 L/m)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
625/15.9
560
39.3
200
229
3.6
400/10.2
525
36.2
148
189
3.5
200/5.1
475
31.7
102
131
2.7
100/2.5
445
29.6
50
80
2.4
9-4.
Wire
Program
Size/Type:
4
-
Steel
.062
Gas: Ar
-
CO2
or
Ar
-
Oxy /
40 CFH
(19 U/rn)
1PM / MPM
Apk
Vpk
Abk
PPS
PWrns
400/10.2
550
36.8
200
195
4.1
300/7.6
510
36.3
145
175
3.8
200/5.1
480
31.6
110
155
3.2
100/2.5
460
28.7
69
94
2.6
OM-1588
Page
30
COMMENTS
COMMENTS
.
9-5.
Wire
Program
Size/Type:
5
-
Stainless
Gas: Ar
.035
-
He
-
C02/40 CFH (19 L/m)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
700/ 17.8
403
33.9
132
191
2.8
400/10.2
318
31.6
87
146
2.4
200/5.1
295
28.5
53
94
1.9
100/2.5
280
26.0
32
45
1.8
9-6.
Program
Size/Type:
Wire
6
-
Stainless
Gas: Ar
.045
-
He
-
CO2 /
40 CFH
(19 L/m)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
700 / 17.8
480
39.0
200
227
3.2
400/10.2
425
32.4
155
185
2.5
200/5.1
360
28.0
100
115
2.0
100/2.5
350
26.2
40
70
2.0
9-7.
Wire
Program
Size/Type:
7
-
Gas: Ar
-
CO2 /
40 CFH
(19 L/m)
PWms
IPM/MPM
Apk
Vpk
Abk
PPS
700 / 17.8
490
37.4
165
210
3.1
400/10.2
440
33.8
115
155
2.5
200/5.1
400
29.2
70
120
1.9
115/2.9
395
26.3
41
96
1.4
9-8.
Wire
Program
Size/Type:
.052
8
-
COMMENTS
Metal Core
Metal Core
.045
COMMENTS
COMMENTS
Metal Core
Gas: Ar
Metal Core
-
CO2 /40
CFH
(19 L/m)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
700/17.8
510
38.0
240
250
3.3
400/10.2
460
33.3
135
200
2.5
250/6.4
425
31.0
100
170
2.2
175/4.4
410
28.6
75
155
1.9
COMMENTS
OM-1588
Page
31
SECTION 10- STANDARD PULSE WELDING PROGRAMS
FOR XMT 304 INVERTER WELDING POWER SOURCES
Note ~
Apk
Peak
=
PPS
=
Amperage, Vpk
factory set programs.
interpolations from the
10-1.
Wire
Program
Size/Type:
1
-
=
Peak
Pulses Per Second, PWms
=
Voltage,
Abk
If selection is set for
4
Background Amperage,
(milliseconds). Four teach points were use d for
fifteen teach points, the remaining points are
Pulse Width
taught points.
Steel
Gas: Ar
.035
-
CO2
or
Ar
-
Oxy /
40 CFH
(19 L/m)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
700/17.8
400
36.7
127
137
1.8
400 / 10.2
340
32.4
84
98
1.6
200/5.1
305
28.7
52
60
1.4
100/2.5
285
27.4
30
30
1.4
10-2.
Wire
Program
2
-
Steel
Size/Type: .045
Gas: Ar
-
CO2
or
Ar-
Oxy /40 CFH (19 L/m)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
700/17.8
400
37.6
170
188
2.3
400/10.2
400
36.1
95
113
2.0
200 / 5.1
370
30.3
53
70
1.8
100/2.5
350
27.7
32
36
1.7
10-3.
Wire
Program
Size/Type:
3
-
.052
Gas: Ar
-
CO2
or
Ar.
Oxy /40
CFH
Vpk
Abk
PPS
PWms
625 / 15.9
400
39.3
200
200
3.7
400 / 10.2
395
36.2
165
165
3.4
200/5.1
375
31.7
97
97
2.7
100/2.5
366
29.6
54
54
2.4
Wire
Size/Type:
4
-
Gas: Ar
CO2
or
Ar
-
Oxy /
40 CFH
(19 1/rn)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
400 / 10.2
315
36.6
70
94
1.7
300/7.6
290
34.8
60
72
1.6
200/5.1
280
31.5
45
46
1.5
25
1.4
OM-1588
Page
32
COMMENTS
Steel
.062
265
.
(19 L/m)
Apk
Program
COMMENTS
Steel
1PM / MPM
10-4.
COMMENTS
COMMENTS
10-5.
Wire
5
Program
Size/Type:
-
Stainless
Gas: Ar
.035
-
He
-
C02/40 CFH (19 L/m)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
700 / 17.8
400
33.9
95
200
2.0
400/10.2
370
31.6
50
145
1.8
200/5.1
315
28.5
38
80
1.6
100/2.5
300
26.0
30
36
1.4
10-6.
Wire
Program
Size/Type:
6
-
Stainless
Gas: Ar. He
.045
-
CO2 /40
CFH
(19 L/m)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
700 / 17.8
400
39.0
180
312
2.5
400/10.2
395
32.4
112
185
2.1
/5.1
370
28.0
72
100
2.0
100/2.5
337
26.2
40
60
1.9
200
10-7.
Wire
Program
Size/Type:
.035
7
-
Nickel
Nickel
Gas: Ar
Alloy
He / 40 CFH
-
(19 L/m)
Apk
Vpk
Abk
PPS
PWms
700/17.8
400
34.5
150
167
1.8
400/10.2
380
30.0
95
105
1.5
200/5.1
330
27.5
47
60
1.3
100/2.5
315
25.1
21
30
1.2
Wire
Program
Size/Type:
.045
8
-
Gas:
Ar
-
CO2 /
40 CFH
(19 L/m)
Vpk
Abk
PPS
PWms
400
34.0
200
220
2.8
500/12.7
400
34.0
155
190
2.6
300/7.6
370
31.3
105
140
2.4
Apk
625 / 15.9
COMMENTS
Metal Core
Metal Core
1PM / MPM
COMMENTS
Alloy
1PM / MPM
10-8.
COMMENTS
COMMENTS
108
OM-1 588
Page
33
SECTION
11-1.
Selecting
And
11
-
SETTING
SharpArcTM CONTROL
Adjusting SharpArcM Control
r~ *4
1
Arc
SharpArc~
is Arc
It is used to
and
arc
on
adjust
the
display.
width
arc cone
characteristics.
Use front
panel parameter
button to
move>
Display
setting.
Control
select
to select Arc. Use
to
adjust
Arc
SharpArc~ setting range is from 0
factory default is set at
zero
(0). When Arc value is
to 20. The
50
Trim
I
200
PM
>Prg
1
increased toward 20, the arc cone
and the weld puddle
S t
0 3 5
narrows
becomes less fluid.
/
Parameter
Select
5 0
200
5 0
200
Tr
im
Prg
1
1PM
>Arc
0
Tr
im
1PM
lU
Prg
>
A
r
c
2
0
Rel. 5-0259
OM-1588
Page
34
SECTION 12- TEACH POINTS
12-1. Teach
Using
15 Points
rri~ *4
Apk
=
Peak
Amperage
A
Vpk
=
Peak
Voltage
o
Abk
=
Background Amperage
o
PPS
1PM / MPM
Pulses Per Second
=
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
100
180
210
240
270
300
330
360
370
420
10
18
21
24
27
30
33
36
37
42
Abk
10
20
30
40
50
60
70
80
90
100
110
120
130
PPS
20
55
80
105
130
160
185
210
235
260
290
315
340
Apk
Vpl<
PWms
2
The teach mode allows the user to create
custom pulse programs. The teach mode
selection for 15 teach points gives a more
defined curve for a specific range. At each
point, the user can adjust five paramshape the pulse waveform of the
weld output. The six parameters are: 1PM
(MPM), Apk, Vpk, Abk, PPS, and PWms.
teach
eters to
56
Apk
Vpk
140
200
Abk
365
400
PPS
450
480
510
540
45
48
51
54
3
Apk, Vpk, Abk, PPS, and PWms acting
together provide the energy necessary to
burn off welding wire at a set wire feed
speed. The graph below shows that as wire
feed speed increases, energy increases
(Apk, Vpk, Abk, PPS, and PWms acting
synergically).
4
565
5
PWms
Under some conditions, the wirefeeder lim
its wire feed speed to maintain all pulse pa-
rameterswithinthecapabilityofthesystem.
OM-1588 Page 35
12-2.
Redefining Teach Points
~~
1PM
1
1PM determines the weld metal de
position
rate.
.
U~ Redefining 1PM is not normally
Redefining
required unless special wire or
unusual
is
joint
design
1PM Teach Point
needed.
Trim
50
I
>450
Prg
PM
1/
Use front panel parameter select
button to move >to select 1PM. Use
Display Control to select teach
point value.
1
Pulse
And
Purge
Control to redefine
the pm teach point. For example:
there are teach points at 150, 200,
and 250 ipm; the teach point at 200
Purge
3
be
can
Trim
50
Prg
speed
1
2
>460
Redefining
1PM
button while
Press and hold
turning Display
Pu
I
se
adjusted
to
of 151 to 249
Vpk
-
Peak
a
wire feed
ipm.
Voltage
voltage during peak current
phase of the pulse waveform. This
determines
arc
length during
adaptive pulse welding.
Arc
3
Apk
4
Abk
-
-
Peak
Peak and
Pulse Parameters
depend on
power
5
Amperage
Background Amperage
background amperage
welding
the range of the
source.
PPS
Pulses Per Second Of
-
20-400
6
PWms
-
Pulse Width Of
1.0-5.0 Milliseconds
Use side
pulse
panel controls to change
parameters. See Menu
Guide for detailed
2
programming
steps.
After values are set, strike and
maintain an arcforfive seconds.
Do this for each teach
point.
by releasing gun trigger,
by pulling gun out of weld. Re
peat for each custom teach point.
End weld
not
The
Trim
taught arc length represents
(arc length) setting of 50.
a
Once the teach
points are set, the
adjusts parameters be
teach points synergically.
wire feeder
tween
4
400
1PM
32.4
__~7~5
Apk
385
Vpk
Apk
385
108
Abk
>385
Vpk
Apk
>108
Abk
>126
PPS
108
Abk
126
PPS
2.3
PWms
385
Apk
108
Abk
32.4
126
PPS
>2.3
PWms
Ref. S-0259/Ref. ST-154 109
OM-1588
Page
36
.
Date
Program
Number
Wire
Gas
Sizefrype
Flowrate______
.CFH(L/min)
____
Equipment Used
-
Power Source
Serial Number___________________________
Serial Number
Wire Feeder
Gun Model_______________________ Weld Cable
Wire Manufacturer
1PM / MPM
Mfg.
Vpk
Apk
-
Negative____________________
PositivA
-
Date
Abk
PPS
PWms
COMMENTS
Preflow Seconds:_________
Run-In
Trim/Volts:________ 1PM / MPM:___________________________________ Seconds:___________________________
Crater Volts:_____________________ 1PM I MPM:_____________________________ Seconds:_____________________________
Postflow Seconds:_______
OM-1 588
Page
37
SECTION 13- MAINTENANCE AND TROUBLESHOOTING
13-1. Routine Maintenance
A
Disconnect power before
maintaining.
3 Months
Repair
or
replace
cracked
weld
cable.
Replace
cracked
parts.
I
Check
14-pin
cord.~
Months
Blow out
inside.
or vacuum
During heavy
service, clean
monthly.
OM-1588
Page
38
Or
Check gas
hose and
fittings.
Check gun
cable.
13-2. Error
Displays
Release
Trigger
~TIII1
I
I
2
00
\
No
LS
e
Volt
n
s
e
d
1Error ~
1
3
Prg
Memory
Er
CRC
Release
1
2
ror
No Volt Sensed Error
4
Prg
Range
Er
Display
voltage sense circuit is not
receiving feedback. Check voltage
Check
connections.
sensing
connections at 14-position plugs/
receptacles at the unit and welding
The
Memory
Display
Error
Trigger
This appears if the trigger is closed
when the unit power is turned on, or
if the trigger is stuck or defective.
1
arc
source.
power
ror
Turn
5
unit off and
back
after
on
correcting problem.
N
Tach
o
S ensed
6
Arc
Start
7
Arc
Stop
8
9
Mi
nCFH
Ga
s
Ma
x
F
xx
o w
C F H
GasF
x
x
low
10
Gas
fRange
o
11
Coo
12
Out
I
ant
Flow
Unlocked
P
r
o
g
r
am
~Error
1Error
~Error
1Error
1Error
1Error
1Error
1Error
~
~
~
~
If this
when
error
continues
to
it may
pulse welding,
occur
help
to
front
Select to clear
Press
7
Arc
Error
Display
This appears when pulse welding
and the motor does not stop at the
end of the weld. If there is high
used in the area,
A motor brake circuit
frequency being
turn it off.
problem
can
also
front
Press
Select to clear
8
cause
this
error.
Parameter
panel
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.
front
Press
3
Memory CRC
Display
Error
The data in the program indicated
is not the same data that was
saved.
Perform
4
a
system
reset.
Error
Memory Range
Display
The data in the program indicated
is out of usable range.
Go
through pulse parameters to
make sure they do not exceed
settings of the Range display or
perform
a
system
9
reset.
No Tach Sensed Error
it below set value.
front
Press
Select to clear
10
Display
Gas Out Of
until the gas flow
below 100 CFH.
Select to clear
Parameter
error.
Arc Start Error
be
Coolant Flow Error
Display
coolant
recirculating
system.
12
6
can
This appears only when coolant
flow switch option is installed.
Check
panel
Error
Range
This appears when gas flow is
greater than 100 CFH. To protect
the internal sensor, the unit shuts
11
front
Parameter
panel
error.
adjusted
The motor tach feedback is not
reaching the control. Check
Press
error.
Maximum Gas Flow Error
down
5
Parameter
panel
Select to clear
This appears when gas flow is
above the maximum CFH set (xx in
example). Adjust gas flow to bring
connections.
~
~
Stop
Parameter
panel
error.
Unlocked
Program
Error
Display
This appears when pulse welding
and current is detected but the arc
This appears when attempting to
run an unlocked program while
and
other programs are locked. Either
lock the unlocked program or
cannot
be
started.
correct program
and
voltage
voltage sensing
Check
pulse parameters
settings. Check
connections.
select
a
different program that is
locked.
Ret. ST~t55 222
OM-1 588
Page
39
13-3.
Troubleshooting
~:t~
Disconnect power before
A
troubleshooting
S
Remedy
Trouble
Wire
feeds, shielding gas flows, but
electrode wire is not
energized.
Wire feeder is on, meter(s) do not light
up, motor does not run, gas valve and
welding power
pull
source
Check interconnecting cord connections. If secure, check cord for continuity and
Sections 3-5 and 3-7).
Check and reset CB1
repair or replace (see
(see Section 4-4).
contactor do not
in.
Electrode wire feeding stops
erratically during welding.
or
feeds
Check gun
trigger
Check gun
trigger. See gun
Clean
or
to correct size drive roll
replace dirty
Incorrect size
Replace
Motor
runs
Wire does not feed until
is
trigger pulled,
trigger is re-
but continues to feed after
leased, and trigger hold is
Gas valve in feeder is
along with possible
speed.
or worn
contact
tip
wire
guides.
Have
Authorized Service
Check for
3-13).
15-1).
liner. See gun Owners
or
Section
drive roll.
spatter
Factory
Table
(see
foreign
Manual.
matter from around nozzle
Agency
opening.
check drive motor
or
motor control board PCi.
input voltage.
a
short between
welding gun trigger
leads and weld cable.
Repair
short
or
replace welding
a
short between
welding gun trigger
leads and weld cable.
Repair
short
or
replace welding
gun.
S
not on.
rattling loudly
erratic
or
or worn
Manual.
Manual.
(see
Remove weld
Check for correct
slowly.
Owners
hub tension and drive roll pressure
Readjust
Change
connection. See gun Owners
or
slow wire
Check for
gun.
feed
Unit does
not
switch
out
of
Run-In
Install, reconnect,
or
replace voltage sensing
lead.
Speed.
Wire feeder power is on, displays
up, but unit is inoperative.
OM-1 588
Page
40
light
Check
welding gun trigger
leads for
continuity,
and
repair leads
or
replace gun.
Notes
OM-1588
Page
41
I
SECTION 14
-
ELECTRICAL DIAGRAM
~1
I
I
PC7D
Flcl)SO
1FIflWIIEIW
N17
-_______________________________
FLOW 561104
RCl/PLD7I
fl
FE
I
accilofi GS
FLOW IIETW
L~..
2~j
______I
I
DSPL1
FRONT DISPLAY
I
I
I
I
H
SIDEDISPLAY
~
______
_______
___
L~...._i
H ~1 ~IH H
1*
?uhh1~~it1
0i
I~
__________________
I~
I
I
I
CWIECDDN FED FESDIE
I~
~j
RPS8
OPTION
(2~fiI
1~
I
II
r
i~
_____
IDA0~
I
J
pcifi
*
~
_________
___
ar
c;~__m~H!..~.1!.~J
______
I
41
2
v
v_v_v_v_v_v_v_v
I
________I
II
PESO
-a-
0
.,
.1~IR
~
~j__Lr~_..
I
0
pB~
L1~
~
r~mcAnnnn!cAvcAcA
I:
0
ca_c
REV
W62X~
11
ca_c
0
P621
0
II
0
P622
L~
~
woo
woo
6211
PESo
REID
~
~
0
~
P624
P623
1100
LW
HOlD
RcIOftLolO
6211/Roll
62I2/Pl012
fiiS/Piois
6216/Role
s
~
~~~2
cctl~tcTuR
-a
RcDS>>~~
Dcl
7/R017
6216/111016
I6~~
4>
4
i
I 1~2>2~
L
L~JI
LW
nra
LED
LED
~
~
~
jJ J~
p
I
~rIo~
Eli
I
4>
4
3>3
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2~2>
2
PC2D
RE2,/R024
6223/NOV
LP1~
J
-
RE26~7>>h
IL(E~
r ~ccc~r ~~1
ED DETOOIWOIT EDOfil
HII~
PtW7/PlDDl~i
- 24~~-C~
IsIcIoJ
C
I~l~I~
I
>
~
2
4-~< 2~-~*2
~
24~
+iw s*~a..<3 ~
H
In
I______
L~i
44_t<..~_e4.4>_2<I
o
....
I
I
S
0
~-
____
E(J2-<~2 <-~< 24a>2 >~<I
a< ,a~7
+1SV
~
4.~<
~
>-~<
3~>~<I
Sc
~Q1T
<I~ .e_a.zi,<Si!*io._.LL.c1
<I +.2~< ~
SO-
ic
6
0
I44_LCO.E_a~..>~z<I4C
GS2~JIi
Figure
OM-1 588
Pa9e
42
6211-6)--
?flt?1
nra
14-1. Circuit
Diagram
Sc
6211-3>>~-
Foil_It
PCI1O
I
mom
I
RCIIO/P1.G1I0
LenD
I A
I I
I
~-c< Bciio3
<<RElICI
~-<<RC1lO--5
POIOBBIT
I\/~1~~
bpnc.
1~Z<RC11O-2
~B
(im P10.0 BISIBEflB)
SUECT
PUfl ~lBE
1
BETIOB
OC
9
BA
liii
~iii
Li
I
!
!
~
I
I
I
I
~IIIIi
I I
I I
I I
I
I I
I I
h
i
i
i ~
ii! 1
L
0
2
2BE10
2- .L05
2~2
2
0
0
00
~22 ~
0
00
oIl
2-
L
I
RC1002>
BES-~R I/O
Fum BEBBE
RCIBB3)
BEIBE/OtCIOB
RCIOI/PtOlOa
ii
I
~-~-
~
r
I
I
I
RumB>
ii
RC100O>
j I
I
I
I
I
I
I
I
I
I1BE BEI1OBI lOBE 05CC
BY
IIS0J~,
OR RI PLACE
P13CC BBBOR.
I
I
I
I
L
~2
14
COBRI.ICIOB
04811
RC543>>
RCSA1)>
17
S
PIN
COBBOR
F~
(1Y/1RBQ
<<~B
(O-I0l~
INTERFACE BOARD
~
Ru/BE F~I 110/CC)
RCNA_BX,_a~COmoIT
RESBMSB
REST/POST
RE52
OROR
wa
<<FORE-C
<<REB23
ok
~-i
RE00/PL050
~
ii DI
CCTRO4BCNT OPTICAl
~ Ii~ ~
-
<C W-B
RC53-2)*~~-
IRaTE
~
~ i~
RCBo_1>,-_4Bi>.~L*Bi I)-<&E~fl>_*BI>_ n&!~C~n
SINE
REM/PESO
I
rmr
~mss~
REB2/PLBB2
BCBO/PLGBC
ii
~J
PCBO
P13CC
~
RCOA-B>
I
om22
CE/CA (+24W.OA
II
<C ~-R
Rr~BR~S>
hfl
~j I~OA4~fl>_81~S3_.
-
ClOVE OW
-IflUT)
TEND
SD-184 792-B
OM-1588
Page
43
SECTION 15- PARTS LIST
Hardware is
~
common
and
not available unless listed.
L()
(0
c~)
N
cc
cc
0)
.
c~)
If)
(N
0)
U-
//?
It)
(N
cc
(N
It)
It)
0)
If)
U-
U)
0)
U-
Figure
OM-1 588
Page
44
15-1. Main
Assembly
ST-BOO 272-B
Quantity
Dia.
Item
No.
Model
Part
No.
Mkgs.
Figure
149 251
149 252
PLG21,23
079 878
12
Description
15-1. Main
CABLE, trigger (consisting of)
CABLE, trigger (consisting of)
2
2
CONNECTOR&PINS
1
CONNECTOR, circ clamp str rlf sz 11 Amp 206358-2
605 156
CABLE, port No. 184/c (order by ft)
080 328
CONNECTORw/SOCKETS
SeeNote:. CONTROL BOX, (Fig 15-4)
164 475
CABLE, interconnecting (consisting of)
164 474
CABLE, interconnecting (consisting of)
.3
.3
PLG27,28,37,38 047 636
079 739
163 519
159 297
139 600
.5
139 599
.6
600 324
602 243
602 213
...8
601 872
10
10
080 947
151 626
11
132 053
Fig
.12
15-2
.13
149
838
.13
149
839
078
079
264
216
075
078
079
217
.15
Fig
605 227
.16
17....
RC27,37
047 637
048 144
PLG11,17
19 PLG33,34
115 092
18...
135 409
139 813
.20
.21
15-8
GS1,2....
...22
125 785
...23
139 816
159 647
...24
156 243
...25
159 360
...26
159 646
.27
145 639
.28
134 834
167 774
...29
.29
167
776
157 295
.30
604 612
.32
082 050
164 969
167 780
167782
NOTE: When
ordering
16
Assembly
2
079 531
PLG28,29
I
17ft
1
1
1
2
....
21ft
..
1
....
....
1
2
2
CONNECTOR & PINS
CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2
CABLE, port No. 18/14 8/c (order by ft)
HOSE ASSEMBLY, gas
HOSE, gas
HOSE, gas
CABLE, weld cop strd No. 4/0 (order by ft)
WASHER, flat stl std .375
WASHER, lock sti split .375
NUT, stl hex full .375-16
BRACKET, spring retaining
BRACKET, spring retaining
SCREW, cap stl hexhd .375-16 x 1.500 Ig
SUPPORT, hub & reel
PIPE POST, 4ft w/base or..
PIPE POST, 6ft w/base.
PIPE POST, 4ft w/base or
PIPE POST, 6ft w/base
PIPE POST, 4ftw/o base
PIPE POST, 6ft w/o base
....
2
..
2
17ft
1
2
....
2
....
21ft
..
1
....
2
2
26ft
30ft
..
8
8
4
4
4
4
1
1
4
4
1
1
1
1
1....
1
1....
1
BOOM ASSEMBLY
NUT, nyl hex jam .75ONPST
CONNECTOR&SOCKETS
1
1
2
2
2
2
CONNECTOR, circ pin plug keying Amp 200821-1
2
2
CONNECTOR&SOCKETS
CONNECTOR&PINS
2
2
2
2
COVER, protector
VALVE, 24VAC 2 way custom port 1/8 on
PANEL, end cover
INSULATOR, motorclamp
CLAMP, motor top
INSULATOR, screw machine
CLAMP, motor base
STRIP, buna N compressed sheet .062 x 4.000sq
HOSE, SAE .187 ID x .410 OD (order by ft)
DRIVE ASSEMBLY, wire RH (Fig 15-5)
DRIVE ASSEMBLY, wire RH (high speed) (Fig 15-5)
GUIDE, monocoil
SCREW, set stl sch 8-32 x .125 cup point
LINER, monocoil inlet wire
BUS BAR, connecting weld current
DRIVE ASSEMBLY, wire LH (Fig 15-5)
DRIVE ASSEMBLY, wire LH (high speed) (Fig 15-5)
1
1
2
2
Control Box contact
motor
Factory
Service
1
1
2
2
2....
2
8....
8
.2....
2
.2....
2
...3ft.... 3ft
1
2
4
2
1....
1
1
1
....
....
1
Department for proper number.
OPTIONAL
To maintain the
Replacement
factory original performance of your equipment, use only Manufacturers Suggested
required when ordering parts from your local distributor.
Parts. Model and serial number
OM-1588
Page
45
Part
No.
Item
No.
Description
Figure
1
136684
....
....
605941
....
010233
....
057971
6....
010191
7
....
8
....
058628
058428
9
....
080393
3
4
5
10... 108008
11
124900
....
12...
+168104
166594
13....
Support, Hub
& Reel
(Fig
15-1 Item
12)
RING, retaining spool
NUT, stl slflkg hex reg .625-11 wlnyl insert
WASHER, flat stl .640 ID x 1.000 OD x l4ga thk
SPRING, cprsn .970 OD x .120 wire x 1.250
WASHER, flat stl keyed 1.S0Odiax .l2Sthk
WASHER, fbr .656 ID x 1.500 OD x .l25thk
WASHER, brake sti
HUB, spool
SUPPORT, reel
REEL, wire 60 lb (consisting of)
SUPPORT, reel spool
RETAINER, spool support (consisting of)
LABEL, caution falling wire reel can cause damage
NUT, spanner retaining
058427
....
2
15-2.
Quantity
168103
2
2
2
2
2
4
4
2
1
2
1
1
1
1
Hardware is
common
and
not available unless listed.
.3
4
5
.
8
7
10
ST-081 760-C
Figure
15-2.
Support,
Hub & Reel
OPTIONAL
+When
ordering
a
component originally displaying
a
precautionary label,
the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1588
Page
46
Part
No.
Dia.
Item
No.
Mkgs.
Figure
1
2
167 697
3
147 139
..
4
164 842
..
5
144 844
..
PC2O,30
171 814
..
PLG25
165 484
..
6
7
....
..
PLG24
8
159 264
..
9
167 633
..
10
089 032
..
..
11
153 169
12
010 291
13
167 700
Quantity
Description
..
..
15-3.
Panel, Front w/Components (Fig
15-4 Item
28)
NAMEPLATE, (order by model and serial number)
PANEL, front
TAPE, adh acrylic double sided .010 x .500 x 3.000
METER LENS, w/gasket
STAND-OFF, 6-32 x .875 Ig
CIRCUIT CARD, schd front
CONNECTOR & SOCKETS (RC5)
See Figure 13.4 Item 35 (RC24)
RING, ext .625 shaft grv x .O45thk E
1
1
2
1
9
1
1
1
style
1
WASHER, shldr .612 ID
LENS, LED 4341 red panel mtg
ACTUATOR, switch
WASHER, flat .625 ID nylafil
KNOB, pointer
4
6
1
1
U7 Hardware is common and
not available unless listed.
£0
9
13
12
ST-800 112-C
11
Figure
To maintain the
Replacement
15-3.
Panel, Front w/Components
factory original performance of your equipment, use only Manufacturers Suggested
required when ordering parts from your local distributor.
Parts. Model and serial number
OM-1588
Page
47
U~ Hardware is
common
and
not available unless listed.
C
0)
N
CJ
.
0)
/
/
(
C
\
)
0)
C)
C)
U-
0)
C
N
C,)
C)
LL
0
C)
~.
C)
C)
C)
CM
C)
C)
ST-BOO 273-B
Figure
OM-1 588
Page
48
15-4. Control Box
010146
Item
No.
Dia.
Mkgs.
Part
No.
Figure
....
RC3O,40
CONNECTOR, circ pin plug keying in sockets Amp 200821-1
4
STAND-OFF SUPPORT, PC card .312/.375
CIRCUIT CARD, motor control
CONNECTOR & SOCKETS (RC1)
CONNECTOR & SOCKETS (RC2)
CONNECTOR & SOCKETS (RC4)
CONNECTOR & SOCKETS (RC6)
10
198037
115092
PLG2
115093
PLG4
115091
PLG6
136810
1
2
PC8O
182403
SWITCH, rocker SPST 1OA 25OVAC
CIRCUIT CARD, HF filter dual
PLG81
PLG82
115093
CONNECTOR & SOCKETS
158720
PLG89
131 054
PLG9O
153501
151 187
LATCH, slide flush mtg hole 1.000 wide
ii
+162 364
i2
010290
.13
134464
.14
163520
1
1
4
x
1.500
1
Ig
WRAPPER
1
1
158720
CONNECTOR & SOCKETS
1
PLG52.
158719
1
PLG53.
PLG54.
131 204
PLG55.
115092
CONNECTOR
CONNECTOR
CONNECTOR
CONNECTOR
17
601 222
18
176089
600399
.20
138044
...2i
107983
RC7O
...23
048 282
000527
CR101
SRi
...26
072817
.035704
030170
...27
145948
Fig
28
PLG12,50
15-3
155629
30
154938
31
097132
33
148439
126689
PC1O
191 996
PLG11
115092
PLG15....
PLG17....
PLG18....
153501
115093
162382
PLG1O,24
36... PLG16,41
170980
37
Fig
35...
+When
1
189124
141 162
079 739
34
1
PC5O
PLG51
PLG9
32
1
BUSHING, strain relief 1.030 ID
LABEL, warning general precautionary
CABLE, port No. 18/14 11/c (order by ft)
CONNECTOR & PINS, (consisting of)
CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2
CLAMP, univ 50A
TUBING, plstc PVC .250 ID x .375 OD x 9.000
WIRE, strd i4ga blk 600V 105c (order by ft)
BUSHING, strain relief .120/.150 ID x .500mtg hole
BLANK, snap-in nyl .500mtg hole
CONNECTOR w/SOCKETS
BLANK, snap-in nyl .875mtg hole
RELAY, end 24VAC DPDT
RECTIFIER, integ 40A 800V
BUSHING, snap-in nyl .750 ID x 1 .000mtg hole
BRACKET, mtg control box
PANEL, front w/components
CABLE, ribbon l4posn (RC12) (RC5O)
STRIP, mtg PC card
STAND-OFF, 6-32 x .375 Ig
CIRCUIT CARD, interface
16
29
1
1
111 997
073 756
...25
1
1
1
Si
10
...24
1
1
083 432
(RC81)
CONNECTOR & SOCKETS (RC82)
CONNECTOR & SOCKETS (RC89)
CONNECTOR & SOCKETS (RC9O)
STAND-OFF, 6-32 x .625 Ig
...22
1
CASE SECTION, bottom/rear
CIRCUIT BREAKER, man resetiP 10A250V
CB1
...6
2)
134201
184824
...8
15-1 Item
048144
PCi
.5
(Fig
PANEL, side lower
CONNECTOR & SOCKETS
PLG1
.4
15-4. Control Box
047637
162253
2
Quantity
Description
ordering
a
155023
15-7
1
l7ft
1
1
1
1
35ft
1
1
1
1
1
1
3
1
1
1
1
4
1
(RC51)
(RC52)
(RC53)
& SOCKETS (RC54)
& SOCKETS (RC55)
STAND-OFF, 6-32 x 1.500 Ig
CIRCUIT CARD, processor w/proms (16 M)
CONNECTOR & SOCKETS (RC11)
CONNECTOR & SOCKETS (RC15)
CONNECTOR & SOCKETS (RC17)
CONNECTOR & SOCKETS (RC18)
CABLE, ribbon 34posn (RC1O) (RC24)..
CABLE, ribbon 24posn (RC16) (RC41)..
PANEL, side w/components
CLAMP, nyl .625dia
component originally displaying
a
& SOCKETS
& SOCKETS
precautionary label,
1
1
1
4
1
1
1
1
1
1
1
1
I
the label should also be ordered.
factory original performance of your equipment,
Parts. Model and serial number required when ordering
only Manufacturers
Suggested
To maintain the
use
Replacement
parts from your local distributor.
OM-1 588
Page
49
ttT Hardware is
common
and
not available unless listed.
See Table 15-1 For
Drive Roll & Wire Guide Kits
18
19
20
22
16
7
8
10
12
11
26
28
38
36~~
29
30
32
31
ST-8O1 456-A
Figure
OM-1588
Page
50
1 5-5. Drive
Assembly,
Wire
Item
No.
Dia.
Part
No.
Mkgs.
Figure
132750
ARM, pressure
SPACER, rotation pin
RING, retaining ext .250 shaft x .O25thk
PIN, hinge
MOTOR, gear 1/8hp 24VDC 272RPM (consisting of)
MOTOR, gear 1/8hp 24VDC 500RPM (consisting of)
KIT, brush replacement (consisting of)
CAP, brush
BRUSH, carbon
KIT, cover motor gearbox (consisting of)
COVER, motor gearbox (consisting of)
GASKET, cover
SCREW, cover : : : : :
SPACER, locating
RING, rtng ext .250 shaft grv x .O2Sthk
KIT, brush holder
WASHER, flat
PIN, cotter hair
SPRING, indicator
SCREW, hexwhd-slt stl slffmg 8-32 x .500
WASHER, lock stl split No. 8
WASHER, flat stl SAE No. 8
SPRING, cprsn
SPRING, cprsn
BUSHING, spring
SHAFT, spring
CARRIER, shaft
WASHER, fIat .375 ID x .625 OD x .062
KNOB, extension
CIRCUIT CARD, digital tach (consisting of)
.2
150520
10...
133493
11
133350
156354
M1,2
M1,2.... 156353
153491
153492
*153 493
155098
153550
155099
155100
154031
133493
184136
14
182414
15
182415
16
137248
17
129351
602 200
604 772
182156
182155
132746
181 522
132747
133739
183330
198004
131 204
604311
131 203
23
24
25
26
27
PC51
PLG57....
....
PLG58....
28
132611
29
149959
30
179265
31
108940
32
604538
33
151 437
34
128237
35
+179 263
178937
36
601 872
37
38
602213
39
41
601 966
167387
168825
42
133308
602 243
40
Part
of 132 129
33)
.2
149486
22
15-1 Items 29 &
SPRING, pressure arm retaining
WASHER, flat .257 ID stl
4
19
(Fig
165798
165799
149962
20
21
Wire
163282
3
18
Assembly,
.4
172075
12...
15-5. Drive
SCREW, cap stl sch .250-20 x 1.500
CARRIER, drive roll w/components 24 pitch
SPACER, carrier drive roll
PIN, rotation arm rocker
NUT, .250-28 stl
010 668
2
12...
Quantity
Description
.4
.4
.2
.2
.2
.2
.2
.1
.1
.1
1
.
.1
.2
.1
.2
.1
.1
.1
.1
.1
CONNECTOR & SOCKETS
.1
GROMMET, rbr .250 ID
.1
x
.375mtg hole
CONNECTOR&PINS
OPTICAL ENCODER DISC
FITTING, brs barbed M 3/l6tbg x .312-24
ADAPTER, gun/feeder LH
SCREW, cap stl hexwhd .250-20 x .750
.1
WASHER,fIatstISAE.312
KNOB, plstc 11.125 Ig x .312-18 x 1.500 bar
SCREW, hexwhd-slt stl slffmg 10-32 x .500
COVER, drive roll (consisting of)
LABEL, warning electric shock and pinch
NUT, stl hex full .375-16
WASHER, lock stl split .375
WASHER, flat stl .375
SCREW, cap stl hexhd .375-16 x 1.250
SPACER, locating
DRIVE, pinion 40T 24P .376 bore
RING, retaining ext .375 shaft x .O25thk
.1
.1
.1
.1
.4
.1
2
1
1
1
1
1
1
2
1
1
Optional High Speed
Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers
Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Motor
*Recommended
OM-1 588
Page
51
Table 15-1. Drive Roll and Wire Guide Kits
oi
.~
Wire Size
E~
(,
~
V-GROOVE
U-GROOVE
VK-GROOVE
UC-GROOVE
E~
~
.
4 RoIl
Drive
4 RoIl
Drive
4 RoIl
Drive
4 Roll
Drive
Kit
Roll
Kit
Roll
Kit
Roll
Kit
Roll
149518
151 024
087130
150 993
149 518
151 025
053 695
mm
150993
149518
151 026
053700
151 036
072000
151 052
132958
mm
150993
149518
161 189
053696
~
Fraction
Metric
.023-025 in
0.6mm
150993
.030 in.
0.8
mm
.035 in.
0.9
.040 in.
1.0
.045in.
1.1/1.2mn
150994
149519
151 027
053697
151 037
053701
151 053
132957
151 070
083489
.052 in.
1.3/1.4
150 994
149519
151 028
053 698
151 038
053 702
151 054
132956
151 071
083 490
151 029
053699
151 039
053706
151 055
132955
151 072
053708
151 056
132959
mn
1.6
mm
150995
149520
1.8
mm
150995
149520
(.079 in.)
2.0mm
150 995
149 520
151 040
053 704
151 057
132 960
151 073
053 710
(094 in.)
2.4mm
150 996
149 521
151 041
053 703
151 058
132 961
151 074
053 709
2.8
mm
150996
149521
151 042
053705
151 059
132962
151 075
053711
3.2mm
150 997
149 522
151 043
053 707
151 060
132 963
151 076
053 712
.068-072 in
5/64 in.
(1~5in)
Each Kit Contains An Inlet
Guide,
Intermediate
Guide,
And 045 233 Antiwear Guide With 604 612 Setscrew 8-32
x
.125, Along
With 4 Drive Rolls.
2 Kits
OM-1 588
Required
Page
52
For Dual Models.
s-os~-o
Item
No.
Dia.
Part
No.
Mkgs.
Description
Figure
155024
154933
PLG6O
PLG41
PC4O...
Panel, Side w/Components (Fig
TAPE, adh acrylic double sided .010
LENS, clear anti-glare
PANEL, inner control
CIRCUIT CARD, data card
147139
PC6O...
15-6.
156623
153501
CONNECTOR & SOCKETS (RC6O)
See Fig 15-3, Item 40 (RC41)
158160
CIRCUIT CARD, side
144844
STAND-OFF, 6-32 x .875 Ig
PLATE, ident inner control
ACTUATOR, switch
154109
153169
Quantity
x
.500
x
15-4 Item
37)
3.000
1
display
4
1
4
5
11T Hardware is
common
and
not available unless listed.
6
2
7
8
9
ST-BOO 113-B
Figure
15-6.
Panel, Side w/Components
To maintain the
factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1 588
Page
53
Hardware is
common
and
not available unless listed.
T1727Z
V
\
\
0
c\1
c~)
~
U)
~D
\
\
\
\
.
I)
c~J
C)
C
ST-142 306-G
Figure
OM-1 588
Page
54
15-7. Boom
Assembly
Quantity
Item
No.
Model
Part
No.
Description
Figure
1
010313
.
.
2
010 910
.
.
.
.
.
.
.
.
.
.
.
.
3
079 622
4
079 621
5
079 667
5
080 812
6
079 632
7
079 665
.
.
7
080811
.
.
8
079 664
.
.
9
139 633
.
.
10
159 999
.
.
10
160 513
.
.
11
073 742
.
.
12
073 741
.
.
079029
.
.
13
Assembly (Fig
15-1 Item
PIN, cotterhair.072x1.437
WASHER, flat stl SAE .375
WASHER, shld .381 ID x .750 OD
PULLEY, V sgl grv 7.75Odia x 8.000P x .625 bore
PIPE, plstc .500 x 133.750
PIPE, plstc .500 x 181 .750
BOLT, U stl .250-20 x .875 wide x 1.375 deep
GUIDE, wire
GUIDE,wire
GUIDE, wire inlet
LINER, monocoil 3/32-1/8 wire x 15.687
BOOM, dual
BOOM, dual
PIN, clevis .750 OD x 2.156 Ig
CLEVIS, .812 yoke 6.062 Ig .750-l6thd
NUT, stl hex full fnsh .750-16
SHAFT, boom counterbalance
WASHER, flat stl SAE .750
NUT, stl hex elastic stop .750-16
PIPE, blk 3.000 x .875
SPRING, cprsn 3.750 OD x .625 wire x 36.000
4
6
2
2
2
1
2
.
16
079 020
.
.
17
155 335
.
.
18
149 858
.
.
18
151625.
.
19
150 258
.
20
024 605
.
.
21
075 101
.
.
079 030
.
.
.
.
.
...
1
174 688
25
..
26
..
27
28
..
29
..
ordering
SPRING,cprsn3.7500Dx.64Owirex36.000
RETAINER, spring
BEARING, ball thr sgl row .750 x 1.625 x .625
NUT, stl hex special .750-16 x 1.250
1
1
1
1
1
1
.
.
.
047 224
.
.
.
.
.
.
.
.
139 818
component originally displaying
a
precautionary label,
2
....
....
2
....
....
1
1
2
....
....
....
1
2
1
....
1
1
...
.
10
1
.
134 327
....
1
.
010 493
a
1
.
602 246
..
1
2
142 804
073 666
2
....
1
1
.
24
2
1
.
080 157
6
....
2
2
.
+174 754
4
2
602 250
23
....
2
8
075 462
WASHER, lock stl ext tooth .750
BASE, swivel boom (consisting of)
FITTING, grease 1/8NPT
BRACKET, mtg control tilt
LABEL, Swingarc caution heavy spring
LABEL, warning general precautionary
BOLT, mach stl hexhd .750-16 x 2.750
KNOB, T-bar .500-l3thd
WASHER, flat sti std .500
BUSHING, snap-in nyl .625 ID x .875mtg hole
GUARD, motor protector
....
2
15
.
16
15)
14
22
+When
15-7. Boom
12
1
..
..
..
..
..
1
1
1
1
1
....
....
....
....
....
....
....
....
....
....
....
....
....
1
1
1
1
1
1
1
1
1
1
1
1
1
1
....
the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1 588
Page
55
Notes
S
OM-1586
Page
56
Notes
OM-1588
Page
57
Notes
.
OM-1 588
Page
58
Miller
SERVICE VIDEOS
SERVICE TRAINING
FROM MILLER ELECTRIC
-
These Service Videos will
help you learn about main
tenance, troubleshooting, and servicing specific Miller
equipment.
Also, if you
can
included test will
points
Miller Certified Service Technician,
are a
these videos
help you recertify. Passing the
five points towards the forty
earn
needed.
You will find each of these
professionally produced
videos to be very informative and
your Service Video Library.
11
L1
U
U
(#197 007)
U
$3.00
324-1031
$86.00
(#197 009)
$86.00
324-1018
$3.00
324-1032
$86.00
Additional Deltaweld Test Sheet
(#197 011)
324-1019
Information
Payment
Check
or
Money
Send check
Order
or
money order payable to:
Neenah
AUn:
Printing
Literature Distribution Center
P.O. Box 506
Neenah, WI 54957-0506
Lii
Purchase Order
LII
Mastercard
Visa
_________________
Name of Card holder
__________________________________________________
Account #
____________________________________
CardhoIder~s
Exp.
Date
__________
signature
To Order call 920-751-2120
or
Fax 920-751-2121
Distributor Name
60M)
324-1014
$3.00
324-1017
S-62& S-54 &
$126.00
Additional S-MM Test Sheet
(#197 017)
-
324-1009
Deltaweld 452 Video Kit
(#197 010)
U
videos
Additional Bobcat 225 NT Test Sheet
U
324-1016
(2
Bobcat 225 NT Video Kit
$86.00
324-1030
S-MM Video Kit
(#197 015)
l~
U
Additional S-62 & S-64 Test Sheet
(#197 014)
Package
(#197 006)
$3.00
324-1008
S-62 & S-64 Series Video Kit
(#197 012)
Feeder Series
$86.00
324-1035
Additional XMT 304 Test Sheet
(#197 019)
U
valuable part of
XMT 304 Video Kit
(#197 018)
U
a
Customer #
$3.00
..
WELDiNG EQUiPMENT
SER VICE ENGINEERING
SELF-PACED
TRAINING COURSE
FROM MILLER ELECTRIC
-
Learn the basics of
welding equipment troubleshooting
servicing with this three module course designed
for home study, industrial and educational use. This
course will provide the basic knowledge to begin a
career in
servicing welding equipment, act as a
refresher, or provide a welding salesman or technician
service and troubleshooting techniques.
and
A certificate of
completion is awarded by the Miller
upon successful completion of the
Training Department
course.
N
MODULE 1
MODULE 2
Visual
Inspection
High Frequency
Safety
MODULE 3
Volt-ohm Meter
Load Bank
Electronic
Operation
Operation
Symbols
Component Identification
Troubleshooting
V....
~
~
~~ ~
___
U Welding Equipment
Service
(Includes text, videotape,
registered
U
(#145 870)
$60.00
Course
Engineering Training
Additional Text
(Includes
text and
registered
(#145 871)
answer
card.)
exams, and
card.)
answer
Payment Information
El
Check
or
Money
Order
Send check
or
money order payable to:
Neenah
Attn:
Printing
Literature Distribution Center
P0. Box 506
Neenah, WI 54957-0506
El
El
Purchase Order
Mastercard
LI
Visa
_________________
Name of Card holder
Account #__________
Cardholder~s
Exp. Date
signature
To Order call 920-751-2120
or
Fax 920-751-2121
Distributor Name
Customer #
$35.00
j
4
Effective
with
(Equipment
Warranty Questions?
This limited
Call:
H.
....
1-8OO-4~A-MILLER
for your local
Miller distributor~.
LIMITED WARRANTY
-
a
serial
January 1, 1999
number preface of
retail
original
Subject
*
to the terms end conditions
purchaser that
new
Miller
equipment
gives
H
Service
You always get the fast,
reliable response you~
need. Most replacement
parts can be in your
hands in 24 hours,
Need fast
answers
to
the
tough welding questions?
Contact your .distributo~.
The expertise of the
distributor and Mi(ler is
thereto
help
other
APT, ZIPCUT & PLAZCUT Model Plasma Cuffing
*
Remote Controls
*
Accessory
warranty periods listed below, Miller will repair or
replace any warranted parts or components that tail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such detect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Kits
*
Replacement
*
Spoolmate
Parts
(No labor)
lBS
Within the
claims
warranted
on
Miller shall honor warranty
equipment
listed below in the event of such a failure within the warranty
time
start
the
date that
All
on
periods
periods.
warranty
the equipment was delivered to the original retail purchaser, or
Millers
one
equipment is sent to a North American
eighteen months after the equipment is sent to an
year after the
distributor
or
such
you, every
5 Years Parts
Original
*
Inverters
step of the way.
2.
3 Years
*
-
and
Power Sources
Plasma Arc
*
Semi-Automatic and Automatic Wire Feeders
*
Inverter Power
Supplies
Parts and Labor
Motor Driven Guns
1
(w/exception
of
Spoolmate
B5)
*
Process Controllers
*
Positioners and Controllers
*
Automatic Motion Devices
*
Robots
tips, cuHing
or
parts
wear.
that has been modified by any party other
Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
than
has
been
specifications
operation
equipment.
used for
for the
outside
ot the
AND MAINTENANCE OF WELDING EOUIPMENT.
Intellitig
1 Year
*
as contact
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
Parts and Labor
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
3.
to:
Equipment
3.
which
*
*
apply
by Miller, but manufactured by others,
engines or trade accessories. These items are
by the manufacturers warranty, if any.
that fail due to normal
output rectifiers only)
Transformer/Rectifier Power Sources
Cutting
shall not
nozzles, contactors, brushes, slip rings, relays
3 Years Labor
(input
Warranty
Consumable components: such
2.
main power rectifiers
*
as
covered
International distributor.
t.
True Bluefi Limited
Items turnished
1.
time
Support
no
sold
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Your dishibUtar also
newer)
Torches
aher the effective date of this limited warranty is tree of defects
in material and workmanship at the time it is shipped by Miller.
V
or
warranty supersedes all previous Miller warranties and is exclusive with
guarantees or warranties expressed or implied.
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrents
to its
KK
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
risk and expense. Millers option of repair or
at customers
replacement will be FOB., Factory at Appleton, Wisconsin, or
FOB. at a Miller authorized service tacility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
OR
INCIDENTAL
SPECIAL,
INDIRECT,
DIRECT,
RFCS Foot Controls
DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
CONSEQUENTIAL
3:
IHPS Power Sources
ANY OTHER LEGAL THEORY.
*
Water Coolant
ANY
*
HF Units
AND
*
Grids
*
Maxstar 140
*
Spot
*
Load Banks
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
BY
MIGHT
ARISE
IMPLICATION,
PROVISION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
*
SDX Transformers
Systems
EXPRESS WARRANTY NOT PROVIDED HEREIN
OR
GUARANTY
IMPLIED
ANY
WARRANTY,
REPRESENTATION AS TO PERFORMANCE, AND ANY
.
3:.
1.
~
.
.
Welders
OR FITNESS FOR PARTICULAR
TO
ALL
ANY
AND
RESPECT
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.
.
MERCHANTABILITY
.
*
*
*
PURPOSE,
Cyclomatic Equipment
Running GearfTrailers
Miller
Plasma
Cuffing Torches (except APT,
Models)
ZIPCUT &
PLAZCUT
*
Options
(NOTE: Field options are covered under True
Bluefi for the remaining warranty period of the
product they are installed in, or for a minimum of
whichever is greater.)
one year
Field
4.
6 Months
5.
90
*
Days
Batteries
Parts
MIG Guns/TIG Torches
WITH
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion ot incidental,
indirect, special or consequential damages, so the above
limitation
or
exclusion may not
provides specific
legal rights,
apply
and
available, but may vary from state
to you. This
other
be
to state.
In Canada, legislation in some provinces provides tor certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.
miller
31
warranty
rights may
warr
wee
Owners
Please
complete
Record
and retain with your
Model Name
(Date
which
equipment
was
Pr
records.
Number
Serial/Style
Purchase Date
personal
delivered to
original customer.)
Distributor
Address
City
State
Zip
I
L~
I,
Resources Available
Always provide
Model Name and
Serial/Style
Contact your Distributor for:
Welding Supplies
To locate
Options
a distributor or service agency
you, call 1-800-4-A-Miller or visit our
website at www.MillerWelds.com
Number.
and Consumables
and Accessories
near
Personal
Safety Equipment
Service and
Repair
Replacement
Miller Elecinc
International
and
(Servicing
Information
Auto-Attended
USA & Canada FAX 920 735-4134
International FAX 920 735-4125
Diagrams
Welding
Headquarters-USA
~USA PlionØ:920-735-4505
Parts)
Circuit
Co
Company
:;1635 West:SpencerStI-Øet
Appleton WI 54914 USA
Training (Schools, Videos, Books)
Technical Manuals
Mfg
An Illinois Tool V~rks
Parts
European Headquarters
Kingdom
PItone: 44 (0) 1204-593493;
-
United
Process Handbooks
FAX44(O)1204-598066
www.MillerWelds.com
Contact the
Delivering
Carrier for:
File
a
claim for loss
or
damage during
shipment.
For assistance in
filing
or
settling claims,
equipment
Department.
contact your distributor and/or
manufacturers Transportation
~//A Millet
w
PRINTED IN USA
'
1999 Miller Electric
Mfg.
Co.
9/99
The I~i~fBhte.
:~
(~.