Miller DS-64M SWINGARC Owner’s Manual

Processes
Pulsed MIG
Miller
~
The Power ofBlue.
(GMAW-P)
MIG(GMAW)
Flux Cored (FCAW)
and Self-Shielded)
(Gas-
Description
Wire Feeder
(Use
r-~iI
with CC/CV Power
TM
I
OM-1 5880
February
1997
Effective with
Serial Number
KH339697
OWNERS
Sources)
MANUAL
From
to You
Thank you and congratulations on choosing Miller. Now
you can get the job done and get it done right. We know
have time to do it any other way.
you dont
Thats
why
when Neils Miller first started
building arc
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.
people that build and sell Miller products continue the
tradition. Theyre just as conmiitted to providing equipment and service
that meets the high standards of quality and value established in 1929.
Today,
the
This Owners
Manual is
designed
to
help
you get the most out of your
Miller
products; Please take time to read the Safety precautions. They will
help you protect yourself against potential hazards on the worksite. Weve
made installation and operation quick and easy.
With Miller you
lIk(IIllhIiI p
can
count
on
.
years of reliable
service with proper maintenance. And if for
REGISTERED
QUALITY SYSTEM
reason the unit needs
some
______________
repair,
theres
a
Troubleshooting section that will help you
figure out what the problem is. The parts list
will then help you to decide which exact part
you may need to fix the problem. Warranty and
service information for your particular model
are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered
to ihe ISO 9001 Quality
System Standard.
~1~Jftft31Wfl~fi
~
Working as hard as you do
every power source from
Miller Is backed by the most
hassle-free warranty in the
business.
Miller Electric manufactures
of welders and
welding
For information
products,
on
a
full line
related
other
equipment.
quality Miller
contact your local Miller distributor
to receive the latest full line
individual
catalog
catalog
or
sheets. To locate your nearest
distributor call 1-800-4-A-Miller.
f//A Miller
The Power ofBb~e.
TM
LI. E;4j~jJ ~ ~A
n
Front Panel Features
Description
2-line
by
16-character backlit LCD
Single push-button parameter
Put the benefits of
technology
to work
on
the
production line. The DS-64M represents a major
advancement in wire feed technology, and
delivers the ultimate in versatility, simplicity,
programmability and performance.
special features for
pulsed MIG (GMAW-P) welding that requires the
use of inverter-type power sources. However the
DS-64M retains the versatility that makes it
perfectly suited to conventional MIG processes
using a variety of Miller CV or CC/CV machines.
The DS-64M feeder includes
select control
Single knob parameter adjustment
Trigger
Wire
making extended
holding gun trigger
hold control for
welds without
jog
control feeds wire without
energizing
the contactor
Gas purge control purges line without
feeder
energizing
Side Panel Features
4-line
by
20-character backlit LCD for
parameter and mode displays
For pulsed MIG welding, the DS-64M features
built-in memory with eight, factory-set synergic
pulse programs. Each program is specific for a
wire type, wire size and gas mixture. Any of these
programs can be modified for the specific
programming controls for
process, sequence, dual schedule, and data
card modes
requirements of your welding application.
Parameter increase/decrease
This dual wire model
operates
gun at a
efficiency in applications that
and
one
time,
Push-button
Parameter select push button
Pulsed MIG (GMAW-P)
gun is needed. This dual-wire model can be
programmed to run the identical process on both
sides, orto have one side run conventional MIG
MIG
pulsed
MIG
buttons
Processes
provides
alternately require wires of two different sizes or
types. Its also ideal in situations where a standby
while the other is set for
push
(GMAW)
Flux Cored (FCAW)
(Gas- and Self-Shielded)
welding.
Table of Contents
Call
1 -800-4-A-MILLER
for your local
Miller distributor.
Section
Page
1
Precautions
1.
Safety
1.
Consignes
Soudage a
de SØcuritØ pour le
Larc
4
Miller offers
Your distributor
gives
2. Introduction
3. Installation
7
5.
Setting Sequence
6.
Setting
7.
Using
Contact your distributor.
expertise of the
8.
System Setup
distributor and Miller is
there to help you, every
9. Standard Pulse
step of
10. Teach Points
be in your
hands in 24 hours.
parts
can
Parameters
Dual Schedule Parameters
19
20
Support
Need fast
answers
to the
the
Data Card
Optional
21
tough welding questions?
23
The
the way.
Welding Programs
11. Maintenance and
12. Electrical
26
Troubleshooting
Diagram
13. Parts List
Options
and Accessories
Warranty
24
30
34
36
more
contact your local
distributor. Your distributor can also
supply you with Welding Process
Manuals such as SMAW, GTAW,
GMAW, and GMAW-P
Manual,
Operation
detailed
service and parts information for
your unit. To obtain a Technical
16
4.
Technical Manual
which
you
Service
You always get the fast,
reliable response you
need. Most replacement
a
provides
7
.
1. Safety Precautions
Read Before Using
Symbol Usage
I ~1
OM-1588D
Warning! Watch Out! There are possible
hazards with this procedure! The possible hazards are
shown in the adjoining symbols.
Marks
a
Arc
1.2
The
safety related.
Hazards
Welding
are used throughout this manual
identify possible hazards. When you
below
symbols shown
to call attention to and
see
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary
actions to avoid the hazards.
special safety message.
~ Means ~Note; not
A
2/97, safety_som 11/96
Means
4A
A
-
the symbol, watch out, and follow the related instructions
safety information given below is
and
Keep all panels
Clamp
or
covers
work cable with
worktable
as near
good
securely
in
place.
metal-to-metal contact to
the weld
as
workpiece
practical.
to avoid the hazard. The
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1.3. Read and
follow all Safety Standards.
A Only qualified persons should install, operate, maintain,
repair this unit.
A
and
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before
touching any parts.
During operation, keep everybody, especially children, away.
ARC RAYS
ELECTRIC SHOCK
can
kill.
live electrical parts can cause fatal
shocks or severe bums. The electrode and work
circuit is electrically live whenever the output is on.
The input power circuit and machine internal
circuits are also live when power is on. In semiautomatic or
automatic wire welding, the wire, wire reel, drive roll housing, and all
metal parts touching the welding wire are electrically live. Incorrectly
installed or improperly grounded equipment is a hazard.
grinding,
burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can bum eyes and skin. Noise from some
,t.. /
Touching
can
can
damage hearing.
processes
and welds cooling throw off pieces of metal or
Chipping,
slag.
a propershade of filterto protect
welding or watching (see ANSI Z49.1
Standards).
Weara welding helmetfitted with
your face and eyes when
and Z87.1 listed in Safety
Wear
approved safety glasses
with side shields.
protective screens or bamers to protect others from flash and
glare; warn others not to watch the arc.
Use
Do not touch live electrical parts.
Wear
dry, hole-free insulating gloves
and
body protection.
Wear
yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the
work or ground.
Insulate
input power or stop engine before installing or
equipment. Lockout/tagout input power according
servicing
to OSHA 29 CFR 191 0.147 (see Safety Standards).
Disconnect
this
Properly
Owners
ground
install and
this
equipment according
to
making input connections,
conductor first
attach
proper
grounding
double-check connections.
Turn off all
equipment
Do not
use
worn,
Do not
drape
If earth
grounding
a
when not in
over
of the
separate cable
your
or
required, ground it directly
clamp or work cable.
workpiece
is
work
a
poorly spliced cables.
body.
do not
another electrode from
fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
Welding produces
use
are
in contact with the
work, ground,
different machine.
only well-maintained equipment. Repairor replace damaged
at once. Maintain unit according to manual.
parts
Wear
OM-1 588
a
safety
harness if
working
above floor level.
out of the fumes. Do not breathe the fumes.
Keep your head
If inside, ventilate the area and/or
remove welding fumes and gases.
If ventilation is poor,
use an
Material
Safety
Read
the
use
exhaust at the
arc
to
approved air-supplied respirator.
Data
instructions for
Sheets
(MSDSs)
and
the
metals, consumables, coatings,
cleaners, and degreasers.
a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
Work in
Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
Do not weld
cadmium
Use
be hazardous.
.......:.~
manufacturers
use.
damaged, undersized,
cables
Do not touch electrode if you
or
FUMES AND GASES cm
I ~,,
its
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
with
flame-resistant
Manual and national, state, and local codes.
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
protective clothing made from durable,
(wool and leather) and foot protection.
material
on
coated metals, such as galvanized, lead, or
the coating is removed from the
plated steel, unless
weld area, the
area
is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
1
CYLINDERS
can
explode If damaged
H.F.RADIATION
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the welding
process, be sure to treat them carefully.
compressed gas cylinders from excessive heat,
slag, open flames, sparks, and arcs.
Protect
mechanical shocks,
communications
Install
cylinders in an upright position by securing to a stationary
or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding
The
user
Never
drape
Never allow
Never weld
welding torch
a
a
welding
gas
over a
at once.
cylinder.
Have the installation
will result.
Read and follow instructions
except when
checked and maintained.
regularly
and
and
valve.
FIRE OR EXPLOSION hazard.
cylinder is in
Do not install
place
or
unit on, over,
or near
combustible surfaces.
compressed gas cylinders,
publication P-i listed in Safety
on
and CGA
equipment,
opening cylinder
stop using the
Keep high-frequency source doors and panels tightly shut,
keep spark gaps at correct setting, and use grounding and
shielding to minimize the possibility of interference.
cylinder.
only correct shielding gas cylinders, regulators, hoses,
fittings designed for the specific application; maintain them
associated parts in good condition.
associated
the FCC about interference,
by
Use
Keep protective cap in place overvalve
use or connected for use.
installation.
If notified
explosion
Turn face away from valve outlet when
responsible for having a qualified electrician
problem resulting from the
equipment
electrode to touch any
pressurized cylinder
on a
is
correct any interference
other electrical circuits.
or
equipment.
only qualified persons familiar with
electronic equipment perform this installation.
Have
promptly
support
interference
can caajse
Do
unit
locate
not
on,
or
over,
near
combustible surfaces.
Standards.
Do not install unit
near
flammables.
building wiring be sure power supply system
is properly sized, rated, and protected to handle this unit.
Do not overload
WELDING can
Welding
fire orexplosion.
cause
closed containers,
on
such
tanks,
as
pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks,
hot workpiece, and hot equipment can cause fires
and burns. Accidental contact of electrode to metal objects can
cause sparks, explosion, overheating, or fire. Check and be sure the
area is safe before doing any welding.
drums,
Protect
yourself
and others from
Do not weld where
OVERUSE
can cause
flying sparks
flying sparks
Allow
cooling period,
Reduce current
starting
to weld
Do not block
Be
that
aware
fire
Do not weld
on
welding
on
a
fire
on a
extinguisher nearby.
ceiling, floor, bulkhead,
closed containers such
as
Connect work cable to the work
Do not
prevent welding current
paths and causing electric
tip
welder to thaw frozen
when not in
Wear oil-free
wearers
affect pacemakers.
keep away.
Wearers should consult their doctor before
going near arc welding, gouging,
welding operations.
or
spot
or
pipes,
(see
HOT PARTS
can
caUse severe burns.
to AWS F4.1
Do not touch hot
welding area as
from traveling long, possibly
Allow
parts bare handed.
cooling period
before
working
or
such
shirt, cuffless trousers, high shoes, and
cut oft
as
a
welding
wire at
leather
gloves, heavy
cap.
Remove any combustibles, such as a butane
from your person before doing any welding.
MOVING PARTS
lighter or matches,
Keep away
can cause
or
from
moving parts
can
Injure eyes
injury.
such
as
Keep all doors, panels, covers, and
closed and securely in place.
WELDING WIRE
FLYING METAL
gun
shock and fire hazards.
use.
protective garments
on
torch.
pipes.
Remove stick electrode from holder
contact
can
partition
close to the
as
to
use
or
tanks, drums,
they are properly prepared according
Safety Standards).
unknown
filter airflow to unit.
the hidden side.
unless
practical
duty cycle.
duty cycle before
again.
MAGNETIC FIELDS
Pacemaker
welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
fire, and keep
follow rated
reduce
strike flammable material.
can
Be alert that
Watch for
or
or
and hot metal.
Remove all flammables within 35 ft (10.7 rn) of the welding arc. If
this is not possible, tightly cover them with approved covers.
can cause
OVERHEATING
or
Do not press gun
can cause
trigger
fans.
guards
injury.
until instructed to do
so.
Chipping and grinding cause flying metal. As welds
cool, they can throw off pieces of metal or slag.
point gun toward any part of the body,
people, or any metal when threading
welding wire.
Do not
other
Wear
2
a
face shield to protect eyes and skin.
OM-1 588
NOISE
Noise from
FLYING METALorDiRlcaninjureeyes
damage hearing
can
some
processes
or
equipment
Wear
approved
safety glasses with
Wear
can
side shields
or
face
shield.
damage hearing.
protection
ear
if noise level is
high.
FALLING UNIT
STATIC
Put
(ESD) can damage PC
grounded
on
handling
boards
or
wrist
strap
can cause
injury
boards
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
BEFORE
Use
equipment of adequate capacity
to lift
unit.
parts.
static-proof bags and boxes
store, move, or ship PC boards.
Use proper
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
to
unit.
MOVING PARTS
Keep away
Keep
from
can cause
BUILDUP OF GAS
injury
Shut oft
moving parts.
away from
pinch points
such
as
can
kill
injure or
shielding gas supply when
not in
use.
drive
rolls.
1 3
Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from Amencan
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards,
OSHA 29 CFR 1910, from
dent of Documents, U.S. Government
D.C. 20402.
Superinten
Printing Office, Washington,
NFPA Standard 70, from National Fire
Association, Batteryrnarch Park, Quincy, MA 02269.
National Electrical Code,
1.4
Handling
of
Compressed Gases
in
Cylinders,
CGA
Pamphlet
Wi 17.2, from
Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1 R3.
Code for
Safety in Welding and Cutting, CSA Standard
Canadian Standards
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
Protection
Safe
P-i, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51 B, from National
Batterymarch Park, Quincy, MA 02269.
Fire Protection Association,
EMF Information
Considerations About
Electric And
Welding
Magnetic Fields
And The Effects Of Low
Frequency
following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields Background
Paper, OTA-BP-E-53 (Washington, DC: U.S. Government Printing
there is now a very large volume of scientific
Office, May 1989):..
findings based on experiments at the cellular level and from studies
with animals and people which clearly establish that low frequency
magnetic fields can interact with, and produce changes in, biological
systems. While most of this work is of very high quality, the results are
complex. Current scientific understanding does not yet allow us to in
terpret the evidence in a single coherent framework. Even more
frustrating, it does not yet allow us to draw definite conclusions about
questions of possible risk or to offer clear science-based advice on
strategies to minimize or avoid potential risks.~
To
reduce
magnetic
fields in the
workplace,
use
the
following
procedures:
1.
Keep cables
2.
Arrange
3.
Do not coil
close
together by twisting
or
taping
them.
The
cables to
or
one
side and away from the operator.
drape cables
around the
body.
.
OM-1588
4.
Keep welding power
practical.
source
Connect work
to
and cables
as
far away from opera
tor as
5.
clamp
workpiece
as
close to the weld
as
possible.
AbOUt Pacemakers:
The
procedures are also recommended for
Consult your doctor for complete information.
above
wearers.
pacemaker
3
1. Consignes de SecuritØ pour le Soudage a larc
11
OM-1 588D/cfr
4A
~
des
Signification
symboles
safety_som_cfr 2/97
2/97
Signifie Mise en garde! Attention! Ce mode opØratoire peut
prØsenterdes dangers! Les dangers possibles sont indiquØs par
!es divers symboles.
A Indique
f~
special.
message de sØcuritØ
un
Signifie NOTA; pas
lie a Ia sØcuritØ
Ce groupe de symboles signifie Mise en garde! Attention!, risque de CHOCS ELECTR!QUES
dangers presentes par !es PI¨CES MOBILES et !es P!ECES CHAUDES. Voir les symbo!es et les
consignes associØes ci-aprŁs pour prendre les mesures nØcessaires afin de se premunir contre
!es dangers.
Dangers du soudage a
1 2
Iarc
MISE EN GARDE
a
Les symboles donnØs ci-aprŁs sont utilisØs dans tout le manuel pour attirer Iattention sur les dangers
possibles et pour indiquer le type de danger dont ii sagit. Quand on voit le symbole, prendre garde et
suivre les directives correspondantes pour Øviter le danger. Les consignes de sØcuritØ donnØes ci-aprŁs
ne
font que rØsumer Iinformation contenue dans les
toutes ces normes de sØcuritØ.
de sØcuritØ ØnumØrØes a Ia section 1-4. Lire et
normes
respecter
Linstallation,
Iutilisation,
reparations
et les
lentretien
doivent Œtre conflØs
ne
qu
des personnes
qualifiØes.
Aucune personne, et
UN CHOC
les enfants,
particuliŁrement
ELECTRIQUE peut
ne
doit
a
tuer.
trouver a
se
bome de terre du sectionneur
a
raccordØe a
Un
simple contact avec des piŁces Ølectriques peut pro
voquer une electrocution ou des blessures graves. LØ
!ectrode et le circuit de soudage sont sous tension des
que lappareil est sur ON. Le circuit dentrØe et !es cir
cuits intemes de lappareil sont egalement sous tension
En soudage semi-automatique ou
a ce moment-l.
automatique, le fil, !e dØvidoir, !e logement des galets
dentralnement et !es piŁces meta!!iques en contact
avec !e fil de soudage sont sous tension. Des matØne!s
mat installØs ou ma! mis a Ia terre prØsentent un danger.
piŁces e!ectriques
1.
Ne
2.
Porter des gants et des vŒtements de
tant pas de trous.
toucher !es
jamais
sous
tension.
protection
secs ne
compor
Siso!er de !a piŁce et de Ia terre au moyen de tapis ou dautres
moyens iso!ants suffisamment grands pour empØcher !e contact
physique Øventuel avec Ia piŁce ou !a terre.
4.
Couper
5.
arrŒter !e moteur avant de procØder a
linsta!!ation, a !a reparation ou a !entretien de lapparei!. DØver
roui!ler Ialimentation selon Ia norme OSHA 29 CFR 1910.147
(voir normes de sØcuntØ).
Installer et mettre a !a terre correctement cot appareil conformØ
ment a son manue! duti!isation et au codes nationaux, provin
ciaux et
6.
ou
municipaux.
En effectuant
VØrifieretsas
!e fi! de terre du cordon dalimentation est bien raccordØ
RAVONNEMENT DE LARC
peut
brler les yeux et Ia peau. Le BRUIT peut
endommager IouIe; les PROJECTIONS
DE LAITIER OU LES ETINCELLES
LE
8.
Larc de soudage produit des rayons visibles et invi
sibles intenses (ultravio!ets et infrarouges) qui peuv
ent brUler les yeux et Ia peau. Le bruit produit par cer
tains procØdes peut endommager Iouie. Des projec
tions de metal ou de laitier sont produites par le
piquage, le meulage ou le refroidissement des sou
dures.
UtHiser
des
4
bouche-oreilles
ou
des
si le niveau de bruit est ØlevØ.
serre-tŒte
antibruit
que Ia fiche du cordon est
correctement mise a Ia terre.
raccordements dentrØe fixer dabord
appropne
le conduc
et contre-vØnfier !es connexions.
frØquemment !e cordon dalimentation pour voir siI nest
endommage ou dØnudØ remplacer le cordon immediate
ment siI est endommage
un cb!e dØnudØ peut provoquer une
pas
Ø!ectrocution.
9.
Mettre
!appareil
hors tension
10. Ne pas utiliser des cables
fisante ou ma! ØpissØs.
quand
on ne
lutilise pas.
uses, endommages, de grosseur insuf
11. Ne pas enrouler les cables autour du corps..
doit Œtre mise a !a terre, !e faire directement
cable distinct ne pas uti!iser le connecteurde piŁce ou !e
cable de retour.
piŁce soudØe
avec un
1 3.Ne pas toucher lØlectrode quand on est en contact avec Ia
!a terre ou une electrode provenant dune autre machine.
1
piŁce,
4.Nutiliserquun matØnel en bon Øtat. Reparer ou remplacersur-!e
champ !es piŁces endommagees. Entretenir lapparei! conformØ
ment a ce manuel.
15.Porter
un
hamais de sØcuntØ
16.Maintenir solidement
metal
avec
possible
en
Ia
quand
place
facon
piŁce a souder
on
travaille
en
hauteur.
tousles panneaux et
ou
capots.
a obtenir un bon contact metal
Ia table de travail, le plus prŁs
de !a soudure.
RAYONNEMENT DE LARC
2.
Porter un masque a serre-tŒte muni dun verre filtrant de nuance
pour protØger le visage et les yeux quand on soude
ou observe Ia travail de soudage (voir es normes ANSI Z49. 1 et
Z87.1 donnØes sous Ia rubnque Principales normes de sØcu
appropnØe
ntØ).
3.
Porter des lunettes de sØcuritØ
approuvØes
avec
Øcrans late
raux.
4.
paravents ou des barnØres de protection pour
les personnes a proximite centre les coups darc et
Ieblouissement; avertir les autres personnes de ne pas
regarder arc.
Utiliser des
protØger
BRUIT
approuvØs
ou
soudage
VØnfier
peuvent blesser les yeux.
1.
es
prise
17. Fixer !e cable de retour de
ToujoursvØnfierla terre du cordon dalimentation
surer que
une
teur demise a !a terre
12.Si !a
3.
Ia!imentation
7.
du poste de
proximitØ
5.
Porter des vŁtements de protection en tissu
(lame et cuir) et des chaussures de sØcuritØ.
ignifuge durable
OM-1588
I
LES VAPEURS ET LES FUMEES peuvent
Œtre dangereuses pour Ia sante.
Le soudage produit des vapeurs
dangereux de respirer.
et des fumØes
quit
5.
est
un espace confine que sil est bien ventilØ, ou en
portant un appareil respiratoire a adduction dair pur. Demander a
un observateur ayant recu Ia bonne formation de toujours se tenir
a proximite. Les vapeurs et fumØes de soudage peuvent dØplacer
Ne travaillerdans
doxygŁne
lair et abaisser le niveau
graves voire mortelles. Sassurer
1.
2.
Garder Ia tŒte a lextØneur
des vapeurs et des fumØes et
ne
6.
Si Ia ventilation est mauvaise, utiliser
adduction dair pur approuvØ.
4.
Consulter les fiches
un
appareil respiratoire
a
exploser Si
Les bouteilles contenant des gaz de protection sont a
haute prepsion. Une bouteille endommagØe peut
exploser. Etant donnØ que es bouteilles de gaz font
normalement partie du matØnel de soudage, les traiter
avec le plus grand soin.
les chocs, le laitier,
2.
3.
chaleur intense,
flammes flues, les Øtincelles et larc.
Proteger les bouteilles de gaz comprime contre
es
Tenir
bouteilles a lØcart
es
circuits
du
dØcapØe, que le poste de travail soit bien venlilØ. Sil y a lieu,
porter un appareil respiratoire a adduction dair pur. Les
revŒtements et les mØtaux qui contiennent de tels ØlØments
peuvent degager des vapeurs toxiques lors du soudage.
4.
Ne
support fixe
ne
basculent.
poste de soudage
ou
ou
dautres
3.
4.
bouteille de gaz.
sur une
soudage
toucher une bouteille.
Ne jamais laisser
Nejamais soudersur une bouteille sous pression
7.
Nutiliser que des bouteilles de gaz de protection, des dØtendeurs,
des tuyaux souples et des raccords appropnØs concus pour
lapplication particuliŁre; conserver ces matØriels et leurs piŁces
8.
une
:
elle
exploserait.
ban Øtat.
Eloigner le visage de
Ia sortie du robinet de Ia bouteille
quand
on
louvre.
9.
Replacer
le
chapeau
sur
Ia bouteille
utilisation.
aprŁs
10.Lire et suivre les consignes relatives aux bouteilles de gaz
compnmØ, au matØnel connexe ainsi que Ia publication P-i de Ia
CGA donnØe sous Ia rubrique Principales normes de sØcuritØ.
garde
proximitØ.
incendies et
toujours
avoir
extincteur a
Prendre
Ne pas souder sur des recipients fermØs comme des
reservoirs, des Wits ou des tuyaux: ils peuvent exploser.
Larc de soudage peut produire des Øtincelles. Des
Øtincelles, une piŁce chaude et un materiel chaud
peuvent provoquer des incendies et des blessures. Le
des objets
sur
contact accidentel de lØlectrode
metalliques peut produire des Øtincelles, lexplosion, Ia
surchauffe ou un incendie. Sassurer que le lieu ne
presente pas de danger avant deffectuer le soudage.
6.
Se rappeler que si Ion soude sur un plafond, un plancher,
cloison ou autre, le feu peut prendre de lautre cotØ.
7.
Ne pas souder sur des recipients fermØs comme des reservoirs,
des fts ou des tuyaux a mains quils ne soient prØparØs de faon
appropriØe conformØment a Ia norrne F4.1 de lAWS (voir Ia
causer un
les personnes a
proximitØ
ou
les Øtincelles
peuvent atteindre
rubrique Pnncipales
garde que les Øtincelles et les projections ne penetrent
dans des petites
zones adjacentes en sinfiltrant
dangers
relatifs a Iinstallation,
UN INCENDIE OU UNE EXPLOSION peut
Œtre cause par un appareil place au
contact, au-dessus ou a ctØ de surfa
ces combustibles.
Ne pas placer Iappareil au contact, au-dessus, ou
1.
a ctØ
2.
Ne pas installer Iappareil a ctØ dun
produit inflammable.
Ne pas utiliser le chalumeau soudeur pour
soudage
au ras
en
cuir,
objet ou
dun
Pour soulever Ia
appareils
3.
Si Ion
de
Iappareil,
tuyaux.
accessoires.
de courant, utiliser des
suffisante.
source
puissance
un
de
protection non huileux comme des gants
Øpaisse, des pantalons sans revers, des
chaussures montantes et
un
casque.
Iutilisation
comme
un
et Ientretien
LES
PI¨CES
CHAUDES peuvent provo
graves.
toucher les piŁces chaudes les mains
quer des brlures
1.
Ne pas
flues.
2.
Laisser
LES
periode de
pistolet ou Ia
une
toucher Ie
PI¨CES
ref roidissement avant de
torche.
MOBILES peuvent
causer
des blessures.
ØlØvateur a fourthe pour dØplacer
sassurer que Ia fourche est suffisamment
et dØpasse de Iautre ctØ de Iappareil.
utilise
des
12.Ne pas porter des matiŁres combustibles sur soi
bnauet a aaz ou des allumettes quand on soude
1.
Se tenir a IØcart des
me les ventilateurs.
piŁces
en
mouvement
cam-
Sassurer que tous Ies capots, panneaux, portes
protecteurs sont bien fermØs et fermement
et
de
ou autres
du bec
chemise
une
levage que pour soulever
NE PAS lutiliser pour soulever les cha
Ianneau
riots, les bouteilles de gaz
2.
degeler
porte-electrode ou couper le fil
contact quand on ne lutilise pas.
11. Porter des vŒtements de
2.
Iappareil;
sØcuntØ).
9.
graves.
Nutiliser
de
une
Raccorder le cable de retour ala piŁce, le plus prØs possible de Ia
zone de soudage, pour empŒcher que le courant de soudage ne
suive une trajectoire longue et Øventuellement inconnue et quit ne
provoque des risques dØlectrocution et dincendie.
dune surface combustible.
EN TOMBANT, LE MATERIEL peut sen
dommager ou causer des blessures
1.
normes
un
10. Enlever lØlectrode enrobØe du
dans des
Autres
aux
8.
des Øtincelles
Enlevertoutes les matiŁres inflammables dans un rayon de mains
de 10 m de larc. Si cela nest pas possible, bien les recouvnr en
utilisant des bches approuvees.
OM-1 588
electrode de
5.
Ne pas souder dans un endroit
des matØnaux inflammables.
1.3
chalumeau soudeur
5.
explosion.
proteger et protØger
Prendre
un
6.
et du metal chaud.
2.
jamais poser
incendieou
une
Se
un
~ues
LE SOUDAGE peut
1.
a
Placer les bouteilles ala verticale en les fixant a
a un chariot pour Øviter quelles ne tombent ou
de
degraissage,
Ne pas souder sur des mØtaux revŒtus comme lacier galvanise,
p10mb ou cadmiØ a moms que Ia piŁce nait ØtØ entiŁrement
en
1.
de
proximitØ dopØrations
Ne pas souder a
au
signaletiques et les consignes du fabncant
relatives au mØtaux, produits dapport, revŒtements, nettoyants et
LES BOUTEILLES peuvent
elles sont endornmagØes.
propre a Ia
est
nettoyage ou de pulvensation. La chaleur et les rayons de larc
peuvent reagir avec les vapeurs pour former des gaz hautement
toxiques et irritants.
7.
3.
lair
respiration.
pas
es respirer.
A lintØrieur, ventiler le paste de travail ou utiliser un dispositif
place au niveau de larc pour Øvacuer es vapeurs et fumØes de
soudage.
et causer des blessures
que
maintenus.
LES ECLATS DE METAL ou
TES peuvent provoquer des
LES SALE
lØs ions aux
yeux.
1.
Porter des lunettes de sØcuntØ
raux ou
avec
Øcrans late
Øcran facial.
5
CHAMPS MAGNETIQUES PRO
DUITS PAR LES COU RANTS ELEVES
peuvent nuire au fonctionnement du sti
LELECTRICITE STATIQUE peutendom
mager les piŁces des circuits imprimØs.
1.
Mettre un bracelet antistatique AVANT de mani
puler les cartes de circuits impnmØs ou les piŁces.
2.
Utiliser des sacs et boites antistatiques adequats
pour ranger, dØplacer ou expedier les cartes de
circuits imprimes.
LES
mulateur cardiaque
1.
Lespersonnesqui portentunslimulateurcardiaque
doivent se tenir eloignØes du poste de soudage.
2.
Les
personnes qui portent un stimulateur
cardiaque devraient consulter leur mØdecin avant
de sapprocher dun poste de soudage ou de
gougeage a larc ou de soudage par points.
FREQUENCE peut crØer des
interferences dans les systŁmes de ra
dionavigation, les services de sØcuritØ,
les ordinateurs et le materiel de tØlØ
communications.
Ne confier cette installation qu
1.
un personnel
qualifiØ et connaissant bien lequipement Ølectro
nique.
Lutilisateur a Ia responsabilitØ de faire corriger
2.
rapidement par un Ølectncien qualifie les
problŁmes dintrfØrences resultant de linstalla
LA HAUTE
LES PI¨CES MOBILES peuvent provo
quer des blessures.
Se tenir a IØcart des piŁces mobiles.
1.
Se tenir a lØcart des points de pincement, ex.
2.
alets dentrainement.
LE AL DE SOUDAGE peut percer Ia peau.
1.
Attendre les instructions avant dappuyer sur Ia
gachette.
Ne pas pointer le pistolet sur une partie du corps,
2.
sur dautres
personnes, ou sur une piŁce metal
lique lorsquon enfile le fil de soudage.
..Q=HF))
)J
tion.
3.
4.
UNE UTILISATION EXCESSIVE
traduire par
TERIEL.
Laisser
RØduire le courant
3.
U
I
pØnode
1.
de
recommencer
se
5.
avertissement dinterfØrence
Faire vØnfier et entretenir
regulierement
installa
Tenir
es
portes et panneaux de Ia source de haute
frequence bien fermØs, maintenir les Øclateurs au
bon reglage et utiliser une mise a Ia terre et un
Øcran de protection afin de rØduire au minimum Ia
possibilitØ dinterfØrences.
de refroidissement.
ou
dun
cas
tion.
SURCHAUFFE DU MA
une
2.
une
peut
Dans le
donnØ par le Conseil fØdØral des communications,
arrŒter dutiliser immØdiatement Iequipement.
le facteur de marche avant
a souder.
Utiliser le facteur de marche nominal.
UNE TENSION C.C. IMPORTANTE est
prØsente sur les onduleurs aprŁs que
Ion ait coupØ Ialimentation.
DE GAZ DE PRO
LACCUMULATION
TECTION peut Œtre nuisibte a Ia sante
voire mortel.
1.
Quand on nutilise pas le gaz de protection, fermer
1.
piŁces,
Avant de toucher les
mettre Ionduleur
hors tension, couper lalimentation et dØcharger
les condensateurs dentrØe conformØment aux
le robinet de Ia bouteille.
directives de Ia section Entretien.
IA
Principalesnormesde!securite
-
Safely in Welding and Cutting, norrne ANSI Z49.1, de American
Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safely and Health Sandards, OSHA 29 CFR 1910, du
Superintendent of Documents, U.S. Govemment Printing Office,
Washington, D.C. 20402.
Recommended Safe Practice for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances,
norme AWS F4. 1, de American Welding Society, 550 N.W. Lejeune
Rd, Miami FL 33126
National Electrical Code, NFPA Standard 70, de Ia National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1.5
Informatins
sur
le
magnØtiques
Handling of Compressed Gases
in
CGA
Cylinders,
Pamphlet
P-i, de Ia Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
de sØcuritØ en soudage, coupage et procedØs connexes,
CSA Wi 17.2, de lAssociation canadienne de normalisation,
vente de normes, 178 Rexdale Boulevard, Rexdale (Ontario)
Canada M9W 1 R3.
Regles
norme
Safe Practices For
And Educational
Occupation
Eye
And Face
Protection, norme ANSI Z87.1, de IAmencan National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting
Welding Processes, norme NFPA 51 B, de
Association, Batterymarch Park, Quincy,
and
Fire Protection
Ia National
MA 02269.
1:1:
surlescharnpseiectromagnetiques
soudage et sur les effets des champs Ølectnfrequence.
Voici une dtation tiree des conclusions generales du document Biolo
gical Effects of Power Frequency Electric & Magnetic Fields Back
ground Paper (Effets biologiques des champs electriques et magnØtiDocument de base), OTABP
ques aux frequences dutilisation
-E-53 (Washington, DC: U.S Govemment Printing Office, mai 1989)
publiØ par IOffice of Technology Assessment (Congres des EtatsUnis): ... des experiences au niveau cellulaire et des etudes sur
Ihomme et lanimal nous ont apportØ une foule de renseignements : 1
est maintenant clair que les champs magnetiques basse frØquence
peuvent infiuer sur les systŁmes biologiques et les modifier. Ces tra
vaux sont gØneralement dexcellente qualite, mais les rØsultats obtenus sont complexes. Dans IØtat actuel de nos connaissances dans le
domaine scientifique, nous ne sommes pas en mesure dinterpreter
nos observations a Ia lumiŁre dune thØone gØnerale. Et, Ce qui est
encore plus regrettable, nous ne pouvons nen affirmer de dØfinitif au
sujet des nsques Øventuels, ni proposer des mØthodes scientifiques
precises pour rØduire ces nsques ou pour les Øviter.~
NOTA DonnØes
ques et
Safe
Pour reduire lintensitØ des
champs magneliques
au
poste de travail:
basse
1.
Grouper
serrant
solidement les cables
avec un
en
les
entrelaant
ou en
les
ruban adhØsif.
-
2.
Disposer
les cables
sur un
seul ctØ
et a IØcart
de
Iopera
-
6
teur.
3.
4.
Eviter denrouler les cables
ou
Eloigner
source
de
5.
le plus possible
soudage.
Ia
Raccorder le connecteur de
prŁs possible
Stimulateurs
de les poser
piŁce
sur
Iepaule.
de courant et les cables
a Ia
piŁce a souder,
plus
cardiaques:
Les recommandations ci-avant sadressent
aussi, normalement,
qui utilisent un stimulateur cardiaque.
amples renseignements, consultez votre mØdecin.
aux
le
de Ia soudure.
personnes
Pour de
plus
OM-1 588
.
2. Introduction
21
Type
Specifications
of
Welding
Input
Wire Feed
Power
Power
Source
24 Volts AC
Constant Voltage (CV)
DC For GMAW Or
Constant Voltage (CV) /
Constant Current (CC) DC
Single-Phase
10 Amperes
50/60 Hertz
Type
Wire Diameter
Speed
Range
Range
Standard: 50 To 780
pm (1.3 To 19.8 mpm)
To 3.2
.023 To 1/8 in
Welding
Rating
(0.6
100 Volts,
750 Amperes,
mm)
100%
Optional High Speed:
92 To 1435 ipm (2.3 To
36.5 mpm)
For GMAW-P
All Need 14-Pin And
Circuit
Weight
12 ft
(3.7 m):
(94 kg)
207 lb
Duty Cycle
(4.9 m):
(127 kg)
Max
16 ft
60
280 lb
Spool Weight:
lb (27 kg)
Contactor Control
Maximum
Height
With 4 ft
(1.2 m)
Post
12 ft
(3.7 m)
17 ft
(5.2 m)
Horizontal to 60
Vertical Lift Of Boom
16 ft (4.9 m) Boom
Boom
21 ft
Above Horizontal
(6.4 m)
Honzontal to 60
Above Horizontal
3. Installation
Installing
3.1
Swivel into
Pipe Post
5
.
ST-152 382
4
1
Swingpak
2
Pipe
3
Steel Bolt
Base
or
CBC Cart
Post With Base
Secure as shown using as a mini
mum 1/2 in diameter SAE grade 5
steel bolts.
4
Swivel
Insert
into
Assembly
pipe post.
2
Lubricate
swivel.
3
Collar
5
Safety
A
not
Do
remove
instructed to.
until
Tools Needed:
~
OM-1 588
3/4in
7
Installing Control
32
1
Weld Control
2
Bracket
3
Screw
Bracket and
Box and
Adjusting
Tilt
ST-BOO 174 I ST-801 278
screws are
onto bottom of control at
installed
factory.
Swivel
4
Loosen
Place control
screws.
on
swivel and slide forward. Tighten
screws.
5
Tilt Bracket
6
Rear Pivot Screw
7
Front Screw
pivot
Loosen rear
front
2,
screw.
.6
Remove
Pivot control down
screw.
ward to desired
viewing angle. Re
place and tighten front screw.
Tighten pivot screw.
3~
Tools Needed:
3~3
Installing
Boom and Reel
Support
ST-153 170
1
Swivel Plates
2
Yoke
3
Remove
plates
hardware
and
from
swivel
yoke.
7
Boom
3
Set boom into swivel
4
as
shown.
Yoke Pin
Install
ter
pin through yoke. Install
pin and spread ends.
5
cot
4
Bolt
Install
bolt,
washers,
and
nut.
Tighten hardware, and back bolt off
one
half turn.
6
Locking
Install
2
Knob
locking
knob
but do
not
tighten.
7
Reel
Support
Install reel
support.
Tools Needed:
~
3/8,314in
.
8
OM-1 588
34
tnstallung Wire Guide Extension
1
Wire Guide
2
Bolt
ST-152 383
Fitting
3
Monocoil Liner
4
Wire Guide Extension
4
Tighten bolt to secure liner in wire
guide fitting. Do not overtighten
bolt and crush liner.
Repeat procedure for opposite
side.
Tools Needed:
c-~:I:~::::~=~iJ
OM-1 588
3/8 in
9
3.5
Equipment
Connection
Diagram
ST-801 806/Ref. ST-175 086/Ref. ST-i 80 311-B
1
1
300/400 Ampere Model
CCICV Inverter Welding
Power Source
U7 Use settings shown for both
pulse MIG welding and MIG
welding.
2
Ampere Model CV
Welding Power
450
Inverter
Source
3
14-Pin Cord
4
Positive
5
Negative ()
Be
sure
Weld Cable
(+)
Weld Cable
weld
cables
are
sized
properly for peak amperage if
pulse welding (see welding power
source Owners
Manual).
6
Workpiece
7
Voltage Sensing
(Optional Use)
8
PANEL
0
Lead
Gun
REMOTE
gun is rated for peak am
perage if pulse welding. Install ac
Be
sure
cording
9
to its Owners
Manual.
Wire Feeder
For connections
10
V/A CONTROL
INDUCTANCE/DIG
Shielding
see
Gas
V
Section 3.7.
Supply
11
Supplied
12
Gas Hose From Boom
Adapter
9
.
12
10
OM-1 588
Connecting Weld CabLes And Gas Hoses
36
Ref. ST-801 806 / Ref. ST-i 52 800-A
The weld cables and shielding gas
hoses extend 10 ft (3 m) from the
boom.
Route
from
cables
weld
through reed relays,
if
boom
applicable.
If the welding power source or gas
supply are further from the boom,
extend cables
or
1
Weld Cable
2
Insulated
hoses
as
follows:
Sleeving
together weld cables from
welding power source and boom.
Bolt
Use electrical tape and insulated
to cover connection.
sleeving
3
Shielding Gas
Hose
Connect hose to gas supply or ex
tension hose. The hose from the
5/8-18
boom
has
right-hand
threads.
Tools Needed:
~ 518in
OM-1 588
11
Control Box Connections
37
ST-800 1 77-A / Ref. ST-800 175
~~
rn
1
Optional Reed Relay
2
Wire Feed Motor And Gas
Valve Control Receptacle
3
Wire Feed Motor And Gas
Valve Control Plug From
Connection
6
Boom
4
14-Pin Cord
5
Volt Sense Lead
(Optional
5
Use)
6
Gun
Trigger Plug
From Boom
4
3~8
14-Pin
Plug
Information
pin.
Pin Information
A
24 volts
B
Contact closure to A
G
Circuit
C
+10 volts dc
D
Remote control circuit
common.
E
0 to +10 volts dc
command
H
Voltage feedback;
F
Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes.
M
CC/CV Select
N
Inductance
REMOTE 14
*The
12
remaining pins
are
ac
with
common
respect
to socket G.
completes
24 volts
ac
contactor control circuit.
for 24 volts AC circuit.
to remote control with
output
input
respect
signal from
remote control with
0 to +10 volts dc, 1 volt per 10
(+24
V
=
to socket D.
arc
respect
to socket 0.
volts.
CV)
(0-10 V)
not used.
OM-1 588
MotorStart Control
3.9
ST-162 132/Ret. 55-146862-0
,~~
To change wire feed
proceed
as
starting speed
follows:
Turn Off wire feeder and
power
welding
source.
Remove wrapper.
1
2
Motor Board PCi
Motor Start Control Poten
tiometer R70
Turn
potentiometerclockwiseto in
time it takes the motor to
crease
ramp up to speed. Remove protec
tive white rubber cap before mak
ing adjustment. Adjust potentiome
using a small nonconduc
ter R70
tive screwdriver.
Reinstall wrapper.
Tools Needed:
Non-Conductive
~====-
~w===~
1III~I~j~1J
Removing Safety Collar
3.10
and
Adjusting
1/4 in
Boom
ST-142 599-B
Tools Needed:
~
1
Locking
1-lI8in
Knob
knob
Tighten
~
to
prevent boom
movement. Loosen knob to allow
boom
Change knob
upward movement.
movement.
position
to limit
Pull boom down slightly and re
safety collar. Boom should
move
balance in any position from hori
zontal to 60 degrees above hori
zontal. If necessary, adjust boom
as follows:
2
Threaded Rod
3
Jam Nut
2
Loosen jam nut and turn threaded
rod until boom balances. Tighten
jam nut. Be sure several full
threads are through yoke to pre
vent boom falling.
4
1
3
H:
Yoke
Retain safety collar for use in
assembling or moving boom.
dis
Rod
.-~
j,
~~2
Rod
OM-1 588
Increasing Spring
Decreasing Spring
Pressure For A
Pressure For A
Heavy Gun
Lighter Gun
13
Gun Recommendation Table
3.11
Gun
Process
GMAW- P
GMAW
Hard
Hard
or
or
FCAW
Self-Shielding
3.12
Wire
Motor
Speed
GW-500 Or GW-600
Cored Wires
Cored Wires
M25, M40, Or GA-50C
GA-40GL Or GA-5OGL
Wires
Type, Size, and Feed Speed Capability Table
Wire
Type
Wire Size
Feed
Standard
All
.023 To 5/64 in
(0.6
Standard
All
3/32 To 7/64 in
(2.4 To
Standard
All
1/8 in
Optional High
Speed
All
.023 To 5/64 in
14
To 2
mm)
2.8
mm)
Speed Capability
50 To 780
ipm (1.3
To 19.8
mpm)
50 To 700
ipm (1.3
To 17.8
mpm)
50 To 300 pm
(3.2 mm)
(0.6
To 2
mm)
92 To 1440
(1.3
To 7.6
ipm (2.3
mpm)
To 35.6
mpm)
OM-1 588
313
Installing
and
Threading Welding
Wire
riV~d 4
that outlet cable has proper size
welding wire size. When
installing gun, position liner extending fro
~ Be
fJ
sure
moutlet wire guide as close as possible to
touching.
Install gun. Lay gun cable out straight. Cut off
end of wire. Push wire through guides up to
drive rolls; continue to hold wire. Press Jog
button to feed wire out gun.
Install
or
small diameter stainless
To adjust drive roll pressure, hold nozzle about
wire
Adjust tension
wire
For soft wire
steel wire, use 2 drive rolls and set drive
roll pressure from 0 to a maximum of 4 on
the pressure indicator scale (so that only
the inner spring is compressed). This set
ting will generally give the best perfor
mance for these types of wires.
liner for the
drive rolls without
ST-i 52 564-5 I Ref. ST-i 56 929 I Ref. SC-i 50 922 / Ref. ST-i 56 930 / S-0627-A
is
wire feed
taut
(51 mm) from nonconductive surface and
press gun tnggerto 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
2 in
pressure
adjustment above).
Cut wire off Close
Repeat
cover.
for other side.
spool.
nut so
when
stops.
Install wire
guide.
4-
Tools Needed:
3/16,5/64
OM-1 588
in
~
~ 15/16,3/8 in
15
4. Operation
Operational
41
Note 1iLI~
The
following
is
a
Terms
See Menu Guide for detailed
list of terms and their definitions
as
programming steps.
they apply
to this wire feeder:
General Terms
Pulse
Adaptive
The wire feeder
Welding
less of
Cold Wire
change
automatically regulates pulse frequency
welding wire stickout.
to maintain a constant arc
length, regard
in
When weld amperage is not present, wire feeds for about three seconds at set wire feed speed.
Then the welding power source contactor deenergizes and wire continues to feed at the wire jog
Jog
speed.
Inductance
As inductance increases,
Trim
Arc
Synergic
The
arc on
time increases, and the weld
in
length adjustment pulse welding. Increasing
placed by volts in MIG programs.
the
operator programs pulse parameters for
pulse parameters
a
between these wire feed
puddle becomes
trim increases the actual
specific wire feed speed.
speed increments.
more
arc
fluid.
length.
Trim is
re
The wire feeder determines
Side Panel Terms
Process Mode
Is used to select the
Sequence
Is used to select and program the weld sequences which include weld, crater, bumback,
preflow, and run-in.
Mode
Dual Schedule Mode
Is used to select
Card Mode
Is used to select
Security Mode
Only
1
Pulse
Apk
Peak
=
Increasing Apk
Welding
a
of the
including Pulse, Adaptive Pulse,
process to be used,
pair of programs
use
functions with
rameter
4.2
a
type of
optional
that
can
be used
data card
data card. Allows
using
or
Mig.
postflow,
together.
storage
and retrieval
the lock feature for
capabilities.
restricting range of program
pa
changing.
Terms
Amperage
increases
penetra
tion.
Vpk
=
Peak
Voltage
Arc
voltage during peak current
phase of the pulse waveform. This
determines arc
length during
adaptive pulse welding.
2
Abk
3
PPS
Background Amperage
=
Maintains
arc
=
Increasing
speed.
4
3
PWms
between
pulses.
Pulses Per Second
PPS increases travel
p
/
Amps
I\
/
________________
=
Pulse Width In
________________
k
Milliseconds
Increasing
width.
16
PWms increases bead
Time
/
OM-1 588
Front Panel Controls
4.3
5T-162 127
Display
2
Parameter Select Button
Press button to
Display
3
move > on
display.
Control
Turn control to
change
value
pointed
to
by>.
control one click causes Trim (arc
length) to increase/decrease by one or Volt to
increase/decrease by 0.1.
Turning
When 1PM is selected,
click causes wire feed
crease/decrease
by
When
by
Prg
turning control one
speed (1PM) to in
one.
When MPM is selected,
clicks causes wire feed
crease
turning control
speed (MPM)
three
to in
0.1.
# is
selected, turning control
program number
crease/decrease by one.
click
exception of Dual Sched
ule Mode (see Section 6).
Pulse is a default setting. To change type of
process (Pulse, Adaptive Pulse, or MIG) use
side panel controls (see Section 4.4).
Active Side Indicator Light
4
5
Trigger Hold Button And Indicator Light
Trigger Hold can be set on a per program ba
sis. Indicator light comes on for programs
while
1
causes
The program
(Prg #)
number cannot be
one
to in
changed
welding,
with
where this feature is active.
cycle, press and release gun trig
ger within three seconds after an arc has been
struck. To end weld cycle, press and release
gun
trigger.
6
Side Select Button
Jog Button
momentarily feed welding wire with
energizing welding circuit or shielding gas
Push to
out
valve.
~Jog speed is varied using the Display Control
while Jog button is pressed. Default setting is
8
Purge
changed.
Button
momentarily energize gas valve
energizing the welding circuit.
Push to
out
g7 Jog and Purge only work
side of the feeder.
on
with
the active
Jog and Purge buttons at the
displays pulse parameters on
the side panel display and voltage on front
panel display.
Holding
The feeder remembers the last used program
for each side and returns to that program
when the active side is
7
change
200 1PM.
To weld without holding gun tnggerthroughout
weld cycle, press and release button to turn
feature on (indicator light turns on).
To start weld
~ The gun tngger may be used to
active side of the feeder.
same
the
time
2
3
8
7
4
4
5
OM-1 588
6
5
17
44
Side and Rear Panel Controls
1
Mode
2
Mode Select Button
Ref. ST-i 62 128/ Ref. ST-162 133
Display
Press button to
move >
in
display.
3
Parameter
4
Parameter Select Button
Display
1
Press button to move> in
5
3
display.
Parameter Increase Button
6
Parameter Decrease Button
7
Power Switch
8
Circuit Breaker CB1
CB1 protects the wire feeder from
overload.
~
4
18
OM-1 588
5. Setting Sequence Parameters
51
Setting Sequence
Parameters
in a
Program
~ See Menu Guide for detailed
programming steps.
If set to zero,
Trim is
arc
length
length
is short. If set to 99,
is long.
length.
If time is set to
zero
arc
arc
in Weld se
welding continues
gun trigger is released.
quence,
until
If time is set to zero in any timed se
the
Weld,
except
quence
sequence is skipped.
.
1.
Volts
10.0-38.0
Burnback
X
0-0.25
X
4.&5. Postflow/Preflow
0-9.9
X
Pulse
Run-In
=
Setting
X
X
MIG
X
0-2.50
X
Pulse
MIG
6.
0-25.0
X
X
MIG
3.
X
X
Pulse
Crater
Seconds
50-780
X
X
MIG
2.
1PM
Inductance
0-99%
X
Pulse
Weld
Trim
0-99
0-2.50
X
available.
A
Weld Time
a,
a,
025
0.
C)
sec.
U)
U
0
~
Ci)
U
~.
~
Pref low
Time
Crater
Time
Bumback
Time
1
/
Run-In
Time
/
0
/
Time
Time
Bumbacl<
Pref low
OM-1588
Run-In
Arc
Strike
Weld
Crater
Postflow
Seqpence
hnd
Trigger
Trigger
Pressed
Released
19
G. Setting Dual Schedule Parameters
Dual Schedule Pair
Selecting
61
Dual Schedule is used with two
consecutive weld programs 1 & 2,
3 & 4, 5 & 6, or 7 & 8. Any program
type (MIG, Adaptive Pulse, or
Pulse) can be combined in dual
schedule.
1
Side Panel
Use side
panel
Display
to turn feature on.
See Menu Guide for detailed pro
gramming steps.
2
Front Panel
Display
Press front
panel parameter select
button to select program number.
3
Front Panel
4
Dual Schedule Switch
Section 6.2)
Display
Control
(See
~ Switch type is set in System
Setup. See Section 8.
5
Welding
Gun
Trigger
2
Selecting dual schedule program A
or B is done by using Display Con
trol, dual schedule switch, or gun
trigger (depending
up).
on
system
set
When program B is active, turn
Display Control one click clockwise to select another pair of dual
4
Dis Ia
Control
schedule programs.
~
Programs
can
be
rearranged
in desired order using the data
card. See Section 7.
Display
Control
20
CM-i 588
Dual Schedule Switch
6.2
1
Diagrams
Momen2P
(Momentary-Contact 2-Pole
DSS-1O)
2
3
1
Switch Or
>___,
Maint 2P (Maintained-Contact
2-Pole Switch Or DSS-9M)
2
Maint 1 P
1
>
2
>
2
2
>
(Maintained-Contact
DSS-8)
>
1-Pole Switch, Or
4
Trigger
A
Allows dual
scheduling after estabwelding arc.
lishing
a
~ If
trigger
is
used
schedule switch,
is disabled.
for
3
1
2
0
A
3
>
0
dual
Trigger Hold
4
4
B
p
3
4
2
TR
___________
3
ii
Adapter
1
>
>
2
>
3
>
2
TR
3
>
>
4
7. Using the Optional Data Card
7.1
Data Card Terms
SA-158 435
CARD SCREEN TERMS
WRITE
READ
Programs
Programs
To Card
From Card
PULSE MIG TERMS
PPS
Amperage
(Pulses Per
Second)
-r
Apk (Peak
Amperage)
Abk
Time
(Background
Amperage)
OM-1 588
21
7.2
:;lflStItiflg
Data Card
Label
1
ST-156 266-B
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. To format card,
turn On power. Select Card from
menu. Data card formats when unit
enters Card mode.
1
For Power Source Data Card:
Insert card into slot. Tum 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
Wait
ready
to
use
front
when Please
disappears from
message
panel display.
7.3
Card
Displays
~ See Menu Guide for detailed
programming steps. Security
mode only functions ~i4th a
data card.
1
Card
2
Moving
Display
Line
Moving line is
be changed.
3
Sequence
under value that
can
Dual Schd
>C
Write
a
r
d
Security
Press
Be I
ow
Transfers program data from unit
to card. The program card can hold
up to 32 programs. When writing to
the card, the next available pro
gram number is
automatically
Side Panel
as
Parameter
signed.
4
Select Once
Read
3
Transfers program data from card
to unit.
5
Delete
4
Deletes program data from card.
6
Done
Exits card
22
display.
5
OM-1 588
8. System Setup
Si
Display Settings
Note 1EI~
DISPLAY SETrING
>System
>Range
*
*
See Menu Guide for detailed
programming steps.
NOTES
Select the process the
welding
Welding
minimum and maximum
for
source
power
pulse welding. Set
power
values to match
>Access,
When on, restricts
>Mig Type
Default is Off. Set to On
>Voltage
Default is
use
of
setup
is able to do.
voltage values are always
welding power source ranges.
needed.
Amperage
values
are
required
screens.
for older CV
only
14-pin receptacle.
source
welding power source wfthout voltage feedback
Use V. Sense when
than 50 ft
more
(15m)
at 14-socket
of weld cable is used
receptacle.
(including gun
cable
length).
>Arc Start**
Use Hot Start
only
with 450
Inverter Model
Ampere
welding
power
source
and
large
diameter wires. The
arc
starts
in CV and switches to CC.
>Dual Schedule
>Tngger
See Section 6.2.
When on,
trigger can
be used to switch between programs that have at least 0.2 seconds of
preflow
time pro
grammed.
When on,
is.
>Arc Time
Displays accumulated
>Wire Feed
Choose to
>Model**
Pulse programs differ between bench and boom models.
>Memory
Program Reset: unit defaults to onginat factory setting for the last active program. Setup information
change. If setup card is in card slot, program will be loaded from card.
a
DSS-10
can
be used to
Prg depending
>Remote
change Volts
or
Trim, 1PM,
or
on
where the front
panel display>
-
System Reset:
unit defaults to
Model. If
card is in card
setup
When on, the system
age is sensed.
>Teach
Default is 15
>Gas Flow,
Setting
>Software
Know this when
Can be used
**
,
time and
cycles.
display inches per minute
>Shutdown
Automatically
arc
points,
can
must be Meter Off if
talking
meters per minute and motor
original factory settings
shuts down if
for all programs and
be set to 4
option
no arc
motor must match selection.
does not
setup excluding System, Arc Time, and
voltage
is sensed. When
off, wire feeds
even
if
no arc
volt
points.
is not installed.
with service
personnel.
set if power source data card is used.
only when optional data card is inserted.
Selection does not appear on display when MIG Only is System choice.
Must remain set to Meter Off if option is not installed to prevent system
OM-1 588
type, but installed
slot, program will be loaded from card.
immediately
but
or
error.
23
0. Standard Pulse Welding Programs
Note~
Apk
=
PPS
Peak
Amperage, Vpk
=
Peak
Voltage,
Abk
=
Background Amperage,
Pulse Width (milliseconds). Four teach points were used for
Pulses Per Second, PWms
factory set programs. If selection is set for fifteen teach points, the remaining points are
=
=
interpolations
taught points.
Program 1Steel
91
Wire
from the 4
Size/Type:
Gas: Ar
.035
-
CO2
or
Ar
-
Oxy /40 CFH (19 Urn)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
700/17.8
440
367
160
180
2.9
400/10.2
385
324
108
126
2.3
200 /5.1
335
287
61
81
2.0
100/2.5
328
274
37
47
1.7
92
Wire
Program
Size/Type:
2
Steel
Gas: Ar-
.045
CO2
or
Ar
-
Oxy /40
CFH
(19 Urn)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
700/17.8
518
376
195
205
3.6
400/10.2
476
361
157
168
3.0
200/5.1
412
303
93
106
2.4
100/2.5
375
277
50
66
2.2
93
Wire
Program
Size/Type:
3
Steel
Gas: Ar
.052
-
CO2
or
Ar
-
Oxy / 40 CFH (19 Urn)
Apk
Vpk
Abk
PPS
PWrns
625/15.9
560
393
200
229
3.6
400/10.2
525
362
148
189
3.5
200/5.1
475
317
102
131
2.7
100/2.5
445
296
50
80
2.4
Wire
Program
Size/Type:
4
COMMENTS
Steel
Gas: Ar
.062
-
CO2
or
Ar
-
Oxy / 40
CFH
(19 Urn)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
400/10.2
580
366
200
200
4.3
300/7.6
539
348
160
200
4.2
200/5.1
499
315
121
170
3.6
100/2.5
460
283
69
118
2.6
24
COMMENTS
.
1PM / MPM
94
COMMENTS
COMMENTS
OM-1 588
Program
95
Wire
5
Stainless
Gas: Ar
.035
Size/Type:
-
He
-
CO2 / 40
CFH
(19 Urn)
1PM! MPM
Apk
Vpk
Abk
PPS
PWms
700/17.8
403
339
132
191
2.8
400/10.2
318
316
87
146
2.4
200/5.1
295
285
53
94
1.9
100 /2.5
280
260
32
45
1.8
96
Wire
Program
Size/Type:
6
Stainless
Gas: Ar
.045
-
He
-
CO2
/40 CFH
(19 Urn)
1PM /MPM
Apk
Vpk
Abk
PPS
PWms
700/17.8
480
390
200
227
3.2
400/10.2
425
324
155
185
2.5
200/5.1
360
280
100
115
2.0
100/2.5
350
262
40
70
2.0
9.7
Wire
Program
Size/Type:
.035
7
Nickel
Nickel
Alloy
Gas: Ar
-
He /40 CFH
(19 Urn)
Apk
Vpk
Abk
PPS
PWms
700/17.8
350
345
130
144
3.7
400/10.2
310
300
80
105
3.3
200/5.1
280
275
48
55
2.9
100/2.5
260
251
28
36
2.5
Wire
Program
Size/Type:
.035
8
COMMENTS
Silicon Bronze
SiBr
Gas:
Argon /40
CFH
(19 Urn)
IPM/MPM
Apk
Vpk
Abk
510/13.0
340
307
100
125
3.7
400/10.2
310
298
83
97
3.4
200 / 5.1
277
266
48
55
3.0
120/3.1
242
252
31
31
3.0
OM-1 588
COMMENTS
Alloy
IPM/MPM
.9.8
COMMENTS
PPS
PWms
COMMENTS
25
10. Teach Points
10.1
Teach
Using 15 Points
The teach mode allows the userto create custorn pulse programs. The teach mode selection for 15 teach
points gives a more defined
specific range. At each teach point,
the user can adjust five parameters to shape
thepulsewaveformof theweld output. Thesix
parameters are: 1PM (MPM), Apk, Vpk, Abk,
curve
for a
Apk, Vpk, Abk, PPS, and PWms acting
Under some conditions, the wire feeder limits
speed to maintain all pulse parame
togetherprovide the energy necessary to bum
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).
wire feed
ters within the
capability
of the
system.
PPS, and PWms.
L~
Apk
=
Peak
Amperage
A
Vpk
=
Peak
Voltage
~
Abk
=
Background Amperage
0
PPS
S
PWms
=
Pulses Per Second
IPM/MPM
=
Pulse Width
(Milliseconds)
780/19.8
750/19.1
700/17.8
650 /16.5
600/15.2
550/14.0
500/12.7
450 / 11.4
Example Of A Synergic
Setting For 425 1PM With
400/10.2
All Teach Points Set At 50
1PM
350/8.9
(1.3 MPM) Increments
300/7.6
250/6.4
200/5.1
150/3.8
100/2.5
50/1.3
Apk
100
180
210
240
270
300
330
360
370
420
450
480
510
540
565
Apk
Abk
10
20
30
40
50
60
70
80
90
100
110
120
130
140
200
Abk
PPS
20
55
80
105
130
160
185
210
235
260
290
315
340
365
400
PPS
PWms
26
1
2
3
4
5
PWms
CM-i 588
102
Teach
Using
4 Points
The teach mode allows the user to create custom pulse programs. The teach mode selection for 4 teach points gives the whole welding
range quickly. At each teach point, the user
can adjust five parameters to shape the pulse
waveform of the weld output. The six parameters are: 1PM
Apk, Vpk, Abk, PPS, and PWms acting
togetherprovide the energy necessary to bum
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).
Under
some
conditions, the wire feeder limits
wire feed
ters
speed to maintain all pulse parame
within the capability of the system.
(MPM), Apk, Vpk, Abk, PPS, and
PWms.
i~
Apk
A
=
Peak
Amperage
Vpk
=
Peak
Voltage
U
Abk
=
Background Amperage
o
PPS
IPM/MPM
780/19.8
=
PWms
Pulses Per Second
=
Pulse Width
(Milliseconds)
750/19.1
700/17.8
650/16.5
600/15.2
550/14.0
500/12.7
450/11.4
Example Of A Synergic
Setting For 425 1PM With
400/10.2
Teach Points Set At
350/8.9
Intervals Of 100
200
400
700
(5.1),
1PM
(2.5),
(10.2), And
(17.8 MPM)
Increments
300 /7.6
250 /6.4
200/5.1
150 /3.8
100/2.5
50/1.3
Apk
Vpk
100
180
210
240
270
300
330
360
370
420
450
480
510
540
565
100
180
210
240
270
300
330
360
370
420
450
480
510
540
565
Apk
Vpk
Abk
10
20
30
40
50
60
70
80
90
100
110
120
130
140
200
Abk
PPS
20
55
80
105
130
160
185
210
235
260
290
315
340
365
400
PPS
PWms
OM-1 588
1
2
3
4
5
PWms
27
1O~3
Redefining
Teach Points
Ref. S-0259/ Ref. ST-154 109
Redefining
1PM Teach Point
1PM determines the weld metal de
position
rate.
Trim
50
~
Redefining 1PM is not normally
required unless special wire or
unusual
is
joint design
Use front
buttonto
Purge
Display
point value.
button while
are
teach
points
at
Trim
50
turning Display Control to redefine
the ipm teach point. For example:
there
Pulse
And
1
>toselect 1PM. Use
Control to select teach
Purge
1
/
panel parameter select
move
Press and hold
1PM
>450
needed.
Prg
>460
150, 200,
1PM
Prg
1
Pulse
and 250
ipm; the teach point at 200
can be adjusted to a wire feed
speed of 151 to 249 ipm.
2
Apk
Peak
3
Abk
Background Amperage
Amperage
Peak and background amperage
depend on the range of the welding
power
4
Redefining Pulse
Parameters
source.
PPS
Pulses Per Second Of
20-400
5
PWms
Pulse Width Of
1.0-5.0 Milliseconds
Use side
pulse
panel
controls to
change
See
Menu
parameters.
Guide for detailed
programming
steps.
After values are set, strike and
maintain an arc for five seconds.
Do this for each teach point.
2
End weld
by releasing gun trigger,
by pulling gun out of weld. Re
peat for each custom teach point.
not
The
Tnm
taught arc length represents
(arc length) setting of 50.
a
Once the teach points are set, the
wire feeder adjusts parameters be
tween teach points synergically.
3
400
1PM
340
Apk
340
Apk
340
Apk
70
Abk
70
Abk
Abk
>160
PPS
160
PPS
PWms
>1.9
PWms
>70
160
28
75
___y4
1.4
OM-1 588
Wire
Date________________ Program Number
G~s
Equipment
Flowrate
Used
Power Source
CFH(Llmin)
Serial Number__________
Wire Feeder
Serial Number_
Gun Model_____________________ Weld Cable
Wire Manufacturer________________
1PM! MPM
Size/Type
Apk
Abk
Negative
Positive_______
Mfg. Date______________
PPS
PWms
Vpk
COMMENTS
Pref low Seconds:_________
Run-In TrimiVolts:________ 1PM / MPM:________
Crater Volts:_____________________ 1PM I MPM:
Seconds:
Postf low Seconds:________
OM-1588
29
11. Maintenance and Troubleshooting
Routine Maintenance:
11.1
A
Disconnect power before
maintaining.
3 Months
Replace
Repair Or
Replace
Unreadable
Labels
Weld
Cracked
Cable
14-Pin
Replace
Cracked
Parts
~
00
6 Months
Blow Out Or Vacuum
Inside.
During Heavy
Service, Clean
Co~
Gas
Hose And
Gun
Cable
Fittings
-
A~
Clean
Drive
Rolls
Monthly
30
OM-1588
Error
11.2
Displays
Ref. ST-155 222
Release
T
r
I
gge
r
I
2
~No
Volt
~_Sensed
1Error
1
3
Memory
c
Prg
R C
Er
ror
4
~Memo
r
Prg
y
Er
Range
ror
Release
2
No Volt Sensed Error
The
arc
Display
Display
voltage sense circuit is not
receiving feedback. Check voltage
Check
connections.
sensing
connections at 14-position plugs/
receptacles at the unit and welding
power
source.
Turn unit oft and
5
Error
Trigger
This appears if the trigger is closed
when the unit power is turned on, or
if the trigger is stuck or defective.
back
on
after
correcting problem.
N
S
Tach
o
ens
e
d
1Error
If this
when
error
continues
to
it may
pulse welding,
occur
help
to
3
Memory CRC Error Display
The data in the program indicated
is not the same data that was
Arc
Start
7
Arc
Stop
8
~
Mi
n
C F H
Ga
s
F
Ma
x
I
Gas
of
11
o
C F H
GasF
x
x
x
low
Out
Range
N
Cool
ant
Flow
12
N
Unlock
OM-1588
1Error
1Error
1Error
1Error
1Error
1Error
1Error
saved.
Perform
4
a
system
reset.
Error
Display
Go through pulse parameters to
make sure they do not exceed
settings of the Range display or
a
system
reset.
No Tach Sensed Error
The motor tach feedback is not
the
control.
panel
Parameter
error.
Arc Start Error
Display
started.
correct program
and
problem
can
also
front
Select to clear
Press
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
Press
front
Select to clear
9
Parameter
panel
error.
Maximum Gas Flow Error
to
bring
it below set value.
front
Select to clear
Press
10
Parameter
panel
error.
Gas Out Of
Range
Error
This appears when gas flow is
greater than 100 CFH. To protect
the internal sensor, the unit shuts
11
can
be
Coolant Flow Error
coolant
Check
recirculating
system.
12
This appears when pulse welding
and current is detected but the arc
be
used in the area,
turn it oft. A motor brake circuit
frequency being
This appears only when coolant
flow switch option is installed.
front
Press
Select to clear
cannot
Display
Check
connections.
6
Error
down until the gas flow
adjusted below 100 CFH.
Display
reaching
Stop
This appears when pulse welding
and the motor does not stop at the
end of the weld. If there is high
example). Adjust gas flow
Memory Range
perform
Arc
error.
This appears when gas flow is
above the maximum CFH set (xx in
The data in the program indicated
is out of usable range.
5
7
Parameter
panel
Select to clear
it above set value.
select Hot Start.
6
front
Press
Check
and
pulse parameters
voltage settings. Check
voltage sensing connections.
Unlock Error
Display
This appears when attempting to
run an unlocked program while
other programs are locked. Either
lock
the
select
a
unlocked program or
different program that is
locked.
31
Troubleshooting
11.3
A
Trouble
Wire
feeds, shielding gas flows, but
energized.
Wire feeder is on, meter(s) do not light
up, motor does not run, gas valve and
welding power
not pull in.
source
.
Check interconnecting cord connections. If secure, check cord for
(see Sections 3.5 and 3.7).
Check and reset CB1
(see
Section
continuity
and
repair
or
replace
4.4).
contactor do
Electrode wire feeding stops
erratically during welding.
or
feeds
connection. See gun Owners
Check gun
trigger
Check gun
trigger.
Change
Clean
or
to correct size drive roll
replace dirty
Incorrect size
Replace
See gun Owners
contact
tip
Wire does not feed until trigger is
but continues to feed after
Check for
trig
(see Section 3.13).
(see Section 13.6).
drive roll.
guides.
Manual.
liner. See gun Owners
or
or
foreign
matter from around nozzle
Authorized Service
Check for correct
slowly.
pulled,
Factory
wire
or worn
Remove weld spatter
Have
or wom
Manual.
Manual.
hub tension and drive roll pressure
Readjust
runs
troubleshooting
Remedy
electrode wire is not
Motor
Disconnect power before
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 weld
a
short between
welding gun trigger
leads and weld cable.
Repair short
or
replace
ing gun.
ger is released, and trigger hold is not
on.
Gas valve in feeder is rattling loudly
along with possible erratic or slow wire
feed speed.
Check for
Unit does not switch out of Run-In
Install, reconnect,
weld
ing gun.
or
replace voltage sensing
lead.
Speed.
Wire feeder power is on, displays
up, but unit is inoperative.
32
light
Check
welding gun trigger
leads for
continuity,
and
repair leads
or
replace gun.
OM-1 588
.
Notes
OM-1MB
33
12. Electrical Diagram
12.1
CIrcuit
Diagram
WCTE
~I
~)
(~o~)
LT
____j
3S
AAAA
______
pcv
WW~V
~1I-4>>
~I8
>
.
-.9
.9V
~
<< ~
_
~-,
J
~-~
~6
I
~
~
~<2+~<I2
~~~-<I~
*~+~+~I
-~-~<I
~~
WI
<I, .~2_.(3~
~
<II ~_i_<(~3~
~j4 ~
I
I
h
~
~~
~IT
a,
34
OM-1 588
.
A
SD-184 792-A
I
anTh~c
9w~~~
~1ifli
~~III~
I II
I
~
rn ma
l~
W2~~9~99~
wio~~~I!,o
~roooocoooc
II
J
mw-i>
~cw
mw-n>
bib
~s-s
I
I
I
nan ma
I
~fflffl~___
_____
mw-n>
-J
-X-M-
-
VVV
I
4 mT 44
I ~ ~ ~pga
__________
TiM ni iOm ow
NY III!, m on-ga
~
n-cc
SI
.
______
17 PH
IctC~J<~2
Mm7
>
51
ft/a)
QIT
InrT~a
~-w)
~cno
w4-g XII
s~
a
alni Ima
(
cmama
Mm>>S__<4I
<<MmQ
~1
I
<
L~Ef~IP~_ _J
~
<<Mm-I
I
~,
_________________
1k_E~_~F
~
riri r~-j~ 5ijjg~1
I
in i
~
~-
--
>>2-~V~-I
lbs
wgowsr
roil
I~j~fflI~
j~$)WfflIL
Mm
>
gai-4 ~>
&~#tV (ibPtCV)
0
ma cap
flK
Mw-i
Mmn:
Mm
OM-1 588
35
13. Parts List
13.1
Main
Assembly
ST-800 272-B
~ Hardware is
common
and
not available unless listed.
ce).
.
N-
0)
U-
c~J
cJ
U,
D0
L
N
cJ
c,J
=
U,
C.,
0)
UC.)
0)
U-
36
OM-1 588
Quantity
Item
No.
Mkgs.
1
149251
1
149252
PLG21,23
.
.
.079878
079531
605156
PLG28,29
.
.
.
080 328
2
SeeNote
3
164475
3
164474
PLG27,28,37,38
047 636
079 739
163519
4
159297
5
139600
5
139599
6
600324
7
602243
8
602213
9
601872
10
080947
151626
132053
12
Fig
13.2
149838
13
149839
078264
079216
075078
14
079217
15
Figl3.8
16
605227
17....
RC27,37
.
.
.
.
047 637
048144
18...
19...
PLG11,17
PLG33,34
.20
..21
...
115092
...
135409
139813
GS1,2
125785
22
139816
23
159647
24
156243
25
159360
26
159646
27
145639
28
134834
29
167774
29
167776
30
157295
604612
...32
082050
164969
33
167780
33
NOTE: When
Model
Part
No.
Dia.
167782
ordering Control
12
Description
CABLE, trigger (consisting of)
CABLE, trigger (consisting of)
16
2
2
CONNECTOR& PINS
1
CONNECTOR, circ clamp str rlf sz 11 Amp 206358-2
CABLE, port No. 184/c (order by if)
2
17ff
....
....
..
CONNECTOR w/SOCKETS
CONTROL BOX, (Fig 13.4)
1
....
1
....
CABLE, interconnecting (consisting of)
CABLE, interconnecting (consisting of)
2
CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2
CABLE, port No. 18/14 8/c (order by if)
HOSE ASSEMBLY, gas
HOSE, gas
HOSE, gas
CABLE, weld cop strd No. 4/0 (order by if)
WASHER, flat stl std .375
WASHER, lock stl 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
...PIPEPOST,4ftw/baseor
PIPE POST, 6ff w/base
...PIPEPOST,4ftw/baseor
PIPE POST, 6ff w/base
PIPE POST, 4ff w/o base
PIPE POST, 6ftw/o base
Amp
200821 -1
COVER, protector
VALVE, 24VAC 2 way custom port 1/8 oil
PANEL, end cover
INSULATOR, motor clamp
CLAMP, motor top
INSULATOR, screw machine
CLAMP, motor base
STRIP, buna N compressed sheet .062 x 4.000sq
motor
HOSE,SAE.187IDx.4100D(orderbyft)
DRIVE ASSEMBLY, wire RH (Fig 13.5)
DRIVE ASSEMBLY, wire RH (high speed) (Fig 13.5)
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 13.5)
DRIVE ASSEMBLY, wire LH (high speed) (Fig 13.5)
Box contact
Factory
Service
Department
21ff
1
1
2
CONNECTOR&PINS
BOOM ASSEMBLY
NUT, nyl hex jam .75ONPST
CONNECTOR& SOCKETS
CONNECTOR, circ pin plug keying
CONNECTOR& SOCKETS
CONNECTOR & PINS
1
2
..
2
....
2
....
17ff
1
..
....
2
2
21ff
1
2
2
26ff
..
30ff
8
8
4
4
4
4
1
1
4
4
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
1
1
2
2
1
1
2
2
2
2
8
8
2
2
2
2
3ff 3ff
1
1
1
1
2
4
4
2
1
1
1
1
1
1
for proper number.
OPTIONAL
To maintain the
Replacement
OM-1 588
factory original performance of your equipment, use only Manufacturers Suggested
required when ordering parts from your local distributor.
Parts. Model and serial number
37
Support, Hub & Reel (Fig
132
131 Item
12)
ST-081 760-C
.
10
J~ Hardware is
common
and
not available unless listed.
ttem
No.
Part
No.
1
058427
RING, retaining spool
2
136684
hex reg .625-11 w/nyl insert
WASHER, flat stl .640 ID x 1.000 OD x l4ga thk
SPRING, cprsn .970 OD x .120 wire x 1.250
2
....
2
....
3
....
605941
4
....
010233
....
057971
6....
010191
7
....
058628
8
....
058428
9
....
080393
5
10... ,108008
11
....
124900
12... +168 104
166594
13....
Quantity
Description
168103
NU1 stl
slflkg
2
2
2
WASHER, flat stl keyed 1 .500dia x .l25thk
WASHER, fbr .656 ID x 1.500 OD x .l25thk
WASHER, brake stl
HUB, spool
SUPPORT reel
REEL, wire 60 lb
4
4
2
1
2
(consisting of)
SUPPORT, reel spool
RETAINER, spool support (consisting of)
LABEL, caution falling wire reel can cause damage
NUT, spanner retaining
1
1
1
1
OPTIONAL
+When
ordenng
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.
38
OM-1 588
.
Panel, Front wlComponents (FIg 134 Item 28)
133
ST-Boo 112-C
~ Hardware is common and
not available unless listed.
13
12
11
Item
No.
10
Part
No.
Dia.
Mkgs.
171 814
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
165484
CONNECTOR & SOCKETS
2
167697
3
147139
4
164842
5
144844
6
....
PC2O,30
PLG25
See
PLG24
8
159264
9
167633
10
089032
12
010291
153169
13
....
Quantity
Description
167700
Figure
13.4 Item 35
(RC5)
(RC24)
RING, ext .625 shaft grv x .O45thk E style
WASHER, shldr .612 ID
LENS, LED 4341 red panel mtg
ACTUATOR, switch
WASHER, flat .625 ID nylafil
KNOB, pointer
1
1
2
1
9
1
1
1
1
4
6
1
1
factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
To maintain the
OM-1 588
39
134
Control Box
(Fig
13.1 Item
2)
ST-BOO 273-B
Hardware is
common
and
.
not available unless listed.
c~J
cJ
.
/
/
/
K
C)
\
U-
0)
cJ
I-.
C.,
0)
U-
40
0
C.)
CM-i 588
item
No.
2
Dia.
Mkgs.
RC3O,40
....
Part
No.
162 253
PANEL, side lower
1
047 637
CONNECTOR&SOCKETS
2
048 144
CONNECTOR, circ pin plug keying in sockets Amp 200821-1
STAND-OFF SUPPORT, PC card .3121.375
CIRCUIT CARD, motor control
134 201
....
PCi
183 120
PLG1
115 092
PLG2
115 093
PLG4
115 091
PLG6
136 810
184 824
...6
...8
CB1
083 432
Si
111 997
PC8O
182 403
PLG81
115 093
PLG82
158 720
PLG89
131 054
PLG9O
153 501
073 756
151 187
STAND-OFF, 6-32 x .625 Ig
LATCH, slide flush mtg hole
600 399
138 044
...24
CR101
072 817
...25
SRi
035 704
...26
030 170
...27
145 948
...28
Fig
13.3
155 629
154 938
097 132
PC5O
184 775
PLG51
158 720
PLG52
158 719
PLG53
131 204
PLG54
148 439
PLG55
115 092
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
126 689
STAND-OFF,
PC1O
161 781
PLG11
115 092
PLG15
153 501
PLG17
115 093
PLG18
162 382
PLG1O,24
PLG16,41
170 980
155 023
Fig
13.7
010 146
ordering
a
1
(RC81)
(RC82)
(RC89)
(RC9O)
1
1
1
4
1.000 wide
x
1 .500
Ig
1
1
19
+When
SOCKETS
SOCKETS
SOCKETS
SOCKETS
BLANK, snap-in nyl .875mtg hole
RELAY,encI24VACDPDT
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
CIRCUITCARD,intertace
176 089
36...
1
HF filter dual
000 527
18
35...
1
1
601 222
...32
1
CONNECTOR w/SOCKETS
17
PLG12,50
1
048 282
079 739
...29
1
1
107 983
141 162
16
...23
CIRCUIT CARD,
CONNECTOR &
CONNECTOR &
CONNECTOR &
CONNECTOR &
1
1
163 520
RC7O
1
1
134 464
...22
1
CONNECTOR & SOCKETS (RC1)
CONNECTOR & SOCKETS (RC2)
CONNECTOR & SOCKETS (RC4)
CONNECTOR & SOCKETS (RC6)
CASE SECTION, bottom/rear
CIRCUIT BREAKER, man reset 1 P 1OA 250V
SWITCH, rocker SPST 1OA 25OVAC
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 l4ga blk 600V 105c (order by ft)
BUSHING, strain relief .120/.150 ID x .500mtg hole
BLANK, snap-in nyl .500mtg hole
010 290
PLG9
4
10
WRAPPER
+162 364
11
Quantity
Description
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
6-32
(RC51)
(RC52)
(RC53)
(RC54)
(RC55)
1.500
lg
CIRCUIT CARD, processor w/proms
CONNECTOR & SOCKETS (RC11)
CONNECTOR & SOCKETS (RC15)
CONNECTOR & SOCKETS (RC17)
CONNECTOR & SOCKETS (RC1 8)
CABLE, ribbon 34posn (RC1O) (RC24)
CABLE, ribbon 24posn (RC16) (RC41)
PANEL, side w/components
CLAMP, nyl .625dia
component originally displaying
a
x
precautionary label,
1
i7ft
1
1
1
1
35ft
1
1
1
1
3
1
1
1
1
4
1
1
1
1
1
1
4
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
41
135
Drive
Assembly,
Wire
(Fig
131 Items 29 &
33)
ST-801 456-A
Hardware is
common
and
not available unless listed.
See Section 13.6 For
Drive Roll & Wire Guide Kits
18
19
20
22
23
24
16
25
7
8
10
12
11
26
.
1
28
33
42
32
OM-1588
Item
No.
Part
No.
Dia.
Mkgs.
Quantity
Description
_______
010 668
172 075
...
...
4
149 962
149 486
5
6
163282
163 281
6
7
165 798
...
165 799
...
3
8
9
10
11
12
12
M1,2
M1,2
...
...
...
...
...
SCREW, cap stl sch .250-20 x 1.500
CARRIER, drive roll w/components
SPACER, carrier drive roIl
PIN, rotation arm rocker
NUT, .250-28st1
SPRING, pressure arm retaining LH
SPRING, pressure arm retaining RH
WASHER, flat .257 ID stl
4
4
4
2
2
2
painted
....
....
PLG29,39
PLG51,57
RC7,8
...
...
CONNECTOR & SOCKETS
115 092
131 203... CONNECTOR & PINS
16
17
18
...
1
1
1
1
2
2
1
1
1
5
2
1
1
1
1
1
1
x
.500
...
19
2
2
1
1
182414...WASHER,flat
182415... PIN,cotterhair
137248... SPRING, indicator
129 351
SCREW, hexwhd-slt stl slffmg 8-32
602 200
WASHER, lock stl split No. 8
604772
WASHER,flatstlSAENo.8
15
2
2
2
...
135409... CONNECTOR & PINS
14
1
1
1
...
21
...22
182156...
SPRING,cprsn
182 155
132746...
181 522
SPRING, cprsn
...
23
...24
25
26
27
(shown)
132750...ARM, pressure
150 520... SPACER, rotation pin
133493... RING, retaining ext .250 shaft x .O25thk
133350... PIN, hinge
156354... MOTOR, gear 1/8hp 24VDC 272RPM (consisting of)
156 353... MOTOR, gear 1/8hp 24VDC 500RPM (consisting of)
153 491
KIT, brush replacement (consisting of)
153 492
CAP, brush
*153 493
BRUSH, carbon
155 098
KIT, cover motor gearbox (consisting of)
153 550
COVER, motor gearbox (consisting of)
155 099
GASKET, cover
155 100
SCREW, cover
154 031
SPACER, locating
133493.... RING, rtng ext .250 shaft grv x .O25thk
184 136
KIT, brush holder
....
13
end
BUSHING,spring
SHAFT, spring
132747...CARRIER,shaft
133 739
WASHER, flat .375 ID x .625 OD x .062
183 330
KNOB, extension
CIRCUIT CARD, digital tach (consisting of)
153 631
2
2
2
1
...
1
1
...
1
...
TK1 ,2/PC51
PLG57
..
....
1
...
CONNECTOR & SOCKETS
GROMMET, rbr .250 ID x .375mtg hole
OPTICAL ENCODER DISC
132 611
149 959
FITTING, brs barbed M 3/l6tbg x .312-24
149 746
ADAPTER, gun/feeder LH
149 745
ADAPTER, gun/feeder RH
108940... SCREW, cap stl hexwhd .250-20 x .750
604 538
WASHER, flat stl SAE .312
151 437... KNOB, plstcT 1.125 Ig x .312-18 x 1.500 bar
128 237... SCREW, hexwhd-slt stl slffmg 10-32 x .500
149 527... COVER, drive roll
601 872
NUT, stl hex full .375-16
602 213
WASHER, lock stl split .375
602 243
WASHER, flat stl .375
149 964... PIN, groove .2SOdia x .500 Ig
601 966
SCREW, cap stl hexhd .375-16 x 1.250
131 204....
604 311
1
1
....
28
29
30
30
...31.
.32.
...33.
...34.
...35.
...36.
...37.
...38.
...39.
...40.
41
42
43
1
...
1
...
1
...
1
...
4
1
...
...
...
1
2
1
1
1
1
...
...
167 387
168 825
133 308
...
...
...
SPACER, locating
DRIVE, pinion
RING, retaining ext .375 shaft
x
.O2Sthk
2
1
2
1
1
Optional High Speed Motor
Spare Parts.
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.
*Recommended
OM-1 588
43
136
Drive Roll And Wire Guide Kits
S-0549-C
a
a
Wire Size
a
V-GROOVE
U-GROOVE
VK-GROOVE
UC-GROOVE
E~
-C,
4 Roll
Drive
4 Roll
Drive
4 Roll
Drive
4 Roll
Drive
Kit
Roll
Kit
Roll
Kit
Roll
Kit
Roll
149518
151024
087130
150993
149518
151025
053695
0.9mm
150993
149518
151026
053700
151036
072000
151052
132958
.045in.
1.1mm
150994
149519
151027
053697
151037
053701
151053
132957
151070
083489
.052in.
1.3mm
150994
149519
151028
053698
151038
053702
151054
132956
151071
083490
1.6mm
150995
149520
151029
053699
151039
053706
151055
132955
151072
053708
1.8mm
150995
149520
151 056
132959
(.079in.)
2.0mm
150995
149520
151040
053704
151057
132960
151073
053710
(.O94irl.)
2.4mm
150996
149521
151041
053703
151058
132961
151074
053709
2.8mm
150996
149521
151 042
053705
151 059
132962
151 075
053711
3.2mm
150997
149522
151043
053707
151060
132963
151076
053712
C
Fraction
Metric
.023-.025in
0.6mm
150993
.030in.
0.8mm
.035in.
.068-.0721n
5/64 in.
(ibm:)
1/8 in.
(.125 in.)
Each Kit Contains An Inlet
Guide, Intermediate Guide, And 045 233 Antiwear Guide With 604612 Setscrew 8-32
x
.125, Along
With 4 Drive Rolls.
2 Kits
44
Required
For Dual Models.
OM-1 588
137
Panel, Side wlComponents (Fig 134 Item 37)
ST-800 113-B
5
U? Hardware is common and
not available unless listed.
6
2
7
8
9
Dia.
item
No.
Mkgs.
Part
No
PC6O
156 623
TAPE, adh acrylic double sided .010
LENS, clear anti-glare
PANEL, inner control
CIRCUIT CARD, data card
PLG6O
153 501
CONNECTOR & SOCKETS
147 139
155 024
154 933
PLG41
...6
PC4O
158 160
144 844
154 109
153 169
To maintain the
Replacement
OM-1 588
Quantity
Description
x
.500
x
3.000
2
1
1
1
1
(RC6O)
See Fig 13.3, Item 40 (RC41)
CIRCUIT CARD, side display
STAND-OFF, 6-32 x .875 Ig
4
PLATE, ident inner control
ACTUATOR, switch
4
1
1
factory original performance of your equipment, use only Manufacturers Suggested
required when ordering parts from your local distributor.
Parts. Model and serial number
45
138
Boom
131 Rem
Assembly (Fig
15)
ST-i 42 306-G
g7 Hardware is common and
not available unless listed.
V
\
.
\
\~_
C~)
c\J
tO
~
CD
\
\
\
\
\
//%
\
\
~
0)
.
(0
to
CD
(~1
ce).
(~.J
0)
c%j
-
46
OM-1 588
Quantity
1
Model
Part
No.
Item
No.
010313
.
2
010910
3
079622
4
079621
5
079667
5
080812
6
079632
7
079665
7
080811
8
079664
9
139633
10
159999
Description
12
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
4
6
16
....
4
....
6
2....2
2....2
2
2
8....10
2
2
2....2
2....2
1
10
160513
11
073742
PIN,clevis.7500Dx2.156lg
1
12
073741
1
1
13
079029
2
2
14
075462
15
602250
16
079020
17
155335
18
149858
18
151625
19
150258
20
024605
21
075101
22
079030
23
+174754
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
SPRING, cprsn 3.750 OD x .640 wire x 36.000
RETAINER, spring
BEARING, ball thr sgl row .750 x 1.625 x .625
NUT, stl hex special .750-16 x 1.250
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 stl std .500
BUSHING, snap-in nyl .625 ID x .875mtg hole
GUARD, motor protector
080157
24
174688
142804
134327
25
073666
26
047224
27
602246
28
010493
29
139818
+When
ordering
a
component originally displaying
a
precautionary label, the label should
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
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
47
Notes
I
S
S
Options and Accessories
DS-60M
9196
A
Skill Level Index
of the stock number of field-installed
B
options contains a letter and number. The letter indicates
required to install the option. The number
indicates the approximate time required for installation
(see legend).
C
The box to the
nght
the skill level
#160 963 I Al
Weld Current Sensor
when
Required
using
:05
I
the 6DM feeder with
Miller conventional MIG power
not have 1 7-pin receptacle.
sources
that do
Power Source Data Card for XMT 304 CC~CV
#043 390
Simply insert the
Data Card in the 6DM control
D-Technical.
May require the use of an ohmmeter and
ability to read a circuit diagram. Repair or
replacement of component parts is complex.
Easy. No previous experience needed.
Average. Requires removal of service panels.
Mechanical
Difficult.
ability
is
the
helpful.
May require
the use of
an
ohmmeter and/or
splicing of electrical wires. Repair or replacement of
component parts is more difficult.
software
upgrade that enables the 60M
I
:30
I
Skill Level: B, Time: 30 minutes
standard
Features: two programmable outputs, remote
start/stop, remote program select,
arc voltage monitor, arc error monitor and wire
stuck check.
push of a button the eight
synergic pulse programs for the XMT 304
are loaded in memory and ready to use.
DSS-9M
#041793 IAI:051
Two-position slide switch that attaches to the
welding gun. Selects welding condition when
utilizing the dual schedule feature. Gun trigger
operates as standard trigger.
eight XMT programs are for:
.030 in steel wire with Argon/CO2
The
.045 in steel wire with
B
cell.
and with the
.035 in steel wire with
I
welding gun. Use in place of the
trigger for dual scheduling.
control to better communicate with other
peripheral equipment and improves
performance in an automatic welding
Example:
Argon/CO2
Argon/C02
.030 in SS wire with Pulse tn-mix
.035 in SS wire with Pulse tn-mix
Straightener
.045 in SS wire with Pulse tn-mix
Wire
.035 in SiB wire with
For . in
Argon
#141580
.035 in Nickel wire with Ar/He
(0.91.1 mm) wire
IAI:051
DSS-10 Remote Increas&Decrease Switch
For 1/161/8 in
#042749 IAI:051
IAI:051
#141581
Reduces cast in wire.
~:\,
wire
(1.63.2mm
performance and
and contact tip.
Improves wire feeding
increases life of gun liner
Two-position, momentary contact switch that
attaches to the welding gun. Use with the
Remote Parameter Increase/Decrease feature
parameters at the welding gun
welding. Gun trigger operates as
standard trigger.
to fine tune
while
High-Speed Motor
For single and right side
#132129 Factory only
60MDataCard
#155910
Adjustable Spool Carrier #096 075 I A I :20 I
For use only with Swingarc models with 6 ft
(1.8 m) pipe post mounted on Swingpak base.
For left side of dual wire models.
Blank Card. Stores up to 32 complete weld
programs. Ideal for saving custom programs
and
of dual models.
transferring programs to other 6DM
feeders.
#132130
Factory only
Provides wire
speed range of 901400
1PM
(2.335.6 m/min). Not recommended for wire
larger than 5/64 in (2.0 mm).
Replaces standard spool assembly. Positions
welding wire lower for easier loading and
unloading.
sizes
i.~1
Same
speed
motor must be used on each
side of the dual wire models.
synergic
Factory-written
Pulse MIG programs will not
operate with high-speed
motor.
Extension Cords
For
optimum performance, do not extend
m) from power
6DM
feeder more than 60 ft (18
source.
14-Pin Extension Cord
Dual Schedule Switches
For use with Dual Schedule Control ~ 6DM
feeder.
-
Remote
#043690
#043691
25ft(7.6m)
50ft(15m)
Water Coolant
__
Program Selectors
Systems
Systems literature,
Refer to Water Coolant
_____
161:201
RPS-8 Mini #173047 Field I B 1:20 I
Eight-position rotary switch used to
RPS-8
#160977Field
remotely select weld programs.
33ft(lOm)cord.
Automation
Upgrade
Module
This module consists of
OM-1 588
an
Index No. AYI7.2.
Includes
#079693 IAI:051
Requires adapter cord #157364. Two-position
trigger switch that easily attaches to the
DSS-8
#172 886
I/O board and
Options
One of the
and Accessories Continued
is
following
required for mounting
Swingarc~ booms:
the SS-60M and DS-60M
Swingpak Base pipe post with base plate
CBC Cart (for use with 12 ft 3.7 m] model
only) the 6 ft (1.8 m) pipe post without
base plate (ordered separately)
Pipe Post
The
Swingpak~ Bases
Swingpak-1 2 base to mount a 12 ft
Swingpak-16 base is for
use with a 16 ft (4.9 m) boom.
Order
a
(3.7 m)
boom. The
Each base accommodates
a
power source,
Swingarc feeder system, water coolant
system, and gas cylinder. The base plate is
solid to help better organize components and
cables. Base includes a three-compartment
storage locker. The entire unit
with
a
can
be moved
forklift truck.
CBC Carts
For
use
Specifications and Ordering
with 12 ft
(3.7 m)
CBC Cart accommodates
boom
only.
power source, 12 ft
Swingarc feeder, and two gas cylinders.
The CBC is the standard model with 10 in
diameter
by
ft(1.2 m) pipe post
recommended for
use
is not
with the CBC Carl. The 16 ft
(4.9 m) Swingarc feeder
Stock No.
Length
Width
Net Weight
Ship Weight
#085 276
65 in
(1.7 m)
50‰ in (1.3 m)
412 lb
(187 kg)
418 lb
(190 kg)
Swingpak-16
#085 934
79 in
(2.0 m)
66‰ in (1.7 in)
504 lb
(229 kg)
510 lb
(231 kg)
CBC Cart
#152638
68 in
(1.7m)
34 in
(864 mm)
295 lb
(134 kg)
CBC-HD Cart
#152 637
70 in
(1.8 m)
34 in
(864 mm)
328 lb
(149 kg)
510 lb
(231 kg)
2 in
(51 mm) wide
wheels. The CBC-HD heavy-duty model is
designed for use on rough or uneven surfaces
and features 12 in (305 mm) diameter by 3 in
(76 mm) wide wheels.
Note: The4
Model
Swingpak-12
a
(3.7 m)
Designed to provide mobility and a neat,
orderly arrangement of welding equipment.
(254 mm)
Information
The
Pipe Pest Model
(3.7 m)
(18 in (457 mm) Base Plate)
(24
4ft(1.2m)nobase
#075078
#075078
4ft(1.2m)withbase
#149838
#078264
6ft(1.8m)nobase
#079217
#079217
6ft(1.8m)withbasc
#149839
#079216
For 12 ft Boom
~
ForlB ft (4.9 m) Boom
in (610 mm) Base Plate)
cannot be used.
CBC Cart Features
2000 lb
(907 kg) load capacity
Multi-position boom
Swing-out outriggers
CBC Carl with 12 ft
Maxtron 450 power
Swingarc SS-60M,
and gas cylinder.
source
L
Wide front-wheel stance and automotive-
type steering
Mounting
power
facilities for most Miller CV
sources
Compartment in base of cart to add ballast
weight when using lightweight power
sources. Minimum ballast weight of 300 lb
(136 kg) required
Fold-up gas bottle loading ramp
Order 6 ft (1.8 m) Pipe
Poet #079 217 only
U
I
OM-1588
(Equipment with
This limited warranty
a
Effective January 1, 1997
serial number prelace of RH
supersedes
all
guarantees
previous
or
Miller
warrants
to
Subject to the terms and conditions
Mtg. Co., Appleton, Wisconsin,
original retail purchaser that new Miller
expressed
Millers
its
1.
the effective date of this limited warranty
is tree of defects in material and workmanship at the time it is
IS EXPRESSLY IN
OTHER WARRANTIES, EXPRESS OR
INCLUDING
THE
WARRANTIES
OF
IMPLIED,
MERCHANTABILITY AND FITNESS.
writing
was delivered to, the original retail purchaser,
year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to
an International distributor.
Call
1 -800-4-A-MILLER
for your local
Miller distributor.
5 Years Parts 3
*
Original
*
Inverters
3 Years
Items furnished
by Miller, but manufactured by others,
engines or trade accessories. These items are
covered by the manufacturers warranty, if any.
as
by any party other
equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
Equipment
than Miller,
that has been modified
or
(input
and output rectifiers
In the event of
Parts and Labor
*
Plasma Arc
Semi-Automatic and Automatic Wire Feeders
Cutting
*
Inverter Power
*
Intellitig
*
Robots
Supplies
allowed.
the
and Labor
Motor Driven Guns
Process Controllers
IHPS Power Sources
Systems
HF Units
ANY
IMPLIED WARRANTY,
GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
BY
MIGHT
ARISE
IMPLICATION,
PROVISION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED
AND DISCLAIMED BY MILLER.
AND
Welders
Load Banks
SDX Transformers
Cyclomatic Equipment
Running GearlTrailers
Plasma Cuffing Torches (except APT, ZIPCUT &
PLAZCUT Models)
Deutz Engines (outside North America)
Field Options
(NOTE: Field options are covered under True Bluefi
for the remaining warranty period of the product they
Miller
*
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE
FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
Grids
Spot
installed in, or for
whichever is greater.)
are
a
minimum of
one
year
Some states in the U.S.A. do not allow limitations of how long
implied warranty lasts, or the exclusion of incidental,
an
consequential damages, so the above
apply to you. This warranty
provides specific legal rights, and other rights may be
indirect, special
limitation
4.
6 Months
5.
90
warranty claim covered by this warranty, the
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit .for the purchase price (less reasonable
depreciation based upon actual use) upon return of the
goods at customers risk and expense. Millers option of
repair or replacement will be FOB., Factory at Appleton,
Wisconsin, or FOB. at a Miller authorized service facility as
determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be
Power Sources
(1 year labor)
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
engine manufacturer.)
Water Coolant
a
exclusive remedies shall be, at Millers option: (1) repair; or
(2) replacement; or, where authorized in writing by Miller in
only)
Transformer/Rectifier Power Sources
1 YearParts
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
Years Labor
main power rectifiers
*
*
3.
Batteries
or
or
exclusion may not
available, but may vary from
Days
MIG Guns/TIG Torches
*
APT, ZIPCUT & PLAZCUT Model Plasma Cuffing
~
The Power ofBb~e.
*
Remote Controls
*
Accessory Kits
Replacement Parts (No labor)
*
state to state.
Parts and Labor
*
Torches
f//A Miller.
to:
equipment
*
Warranty Questions?
apply
3.
within
or one
2.
shall not
Consumable components; such as contact tips, cuffing
nozzles, contactors, brushes, slip rings, relays or parts
that fail due to normal wear.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
1.
Warranty
2.
thirty (30) days of such detect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
the
other
ALL
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in
no
implied.
True Bluefi Limited
such
shipped by Miller. THIS WARRANTY
OF
or
Electric
equipment sold after
LIEU
newer)
Miller warranties and is exclusive with
warranties
LIMITED WARRANTY
below,
or
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated
herein, and to the extent that they may not be waived, the
limitations and exclusions set Out above may not apply. This
Limited Warranty provides specific legal rights, and other
rights may be available, but may vary from province to
province.
rnillerwarr 1/97
Owners Record
Please complete and retain with your personal records.
Serial/Style Number
Model Name
Purchase Date
(Date
when
equipment
was
delivered to
original customer.)
Distributor
Address
City
State
Zip
Resources Available
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies
Options
To locate the distributor nearest you, call
1-800-4-A-Miller.
and Consumables
and Accessories
Personal
Safety Equipment
Service and
Miller Etectiic
Repair
Mfg. Co.
An Illinois Tool Works
Replacement
Parts
1635 West
Ap~feton,
Training (Schools, Videos, Books)
Owners
(Servicing
Information and
Contact the Delivering Carrier to:
For assistance in
filing
File
a
International FAX: 414-735-4125
European Headquarters
United Kingdom
Phone: 44 (0) 1625-525556
FAX: 44(0) 1625-537553
Diagrams
Welding
Headquarters~-USA
Phone: 414-734-9821
USA & Canada FAX: 414-735-4134
Parts)
Circuit
WI 54914 USA
intemadonal
Manuals
Technical Manuals
Company
Spencer Street
Process Handbooks
claim for loss
or
damage during shipment.
settling claims,
equipment
manufacturers Transportation Department.
or
contact your distributor and/or
___
w
PRINTED IN USA
'
1997 Miller Etectiic
Mtg.
Co.
The Power ~fBkse~