Miller DS-64M SWINGARC Owner's Manual

Miller.
June 1995
Form:
OM-1588B
Effective With Serial No. KF91 4926
1
OWNERS
MANUAL
~
c~~' ~F'L
DS-64M (12) And (16) Foot
Boom Mounted Wire Feeder
Boom-Mounted Microprocessor Controlled Constant
S
Multi-Power Source
Compatible
For GMAW, GMAW-P, And FCAW
For .023 To 1/8 in
(0.6
Standard Wire Feed
Programmable
For
S
Options
To 3.2
Speed Of
50 To 780
ipm (1.3 To
cover
5/94
ST-800 172
mpm)
And Accessories, See Rear Cover
~-
~
~i1~A
trained and qualified persons
or service this unit.
Call your distributor if you do not understand
the directions.
'
Give this manual to the operator.
For
install, operate,
S
19.8
Pulse Weld Parameters
Read and follow these instructions and all
blocks carefully.
only
Welding
mm) Wires
safety
Have
Speed Dual Wire Feeder
I~J
1995 MILLER Electric
or:
help,
call your distributor
MILLER Electric Mfg. Co., P.O. Box 1079,
WI 54912
414-734-9821
Appleton,
MIg. Co.
PRINTED IN USA
l
I
J
L
MILLERS
TRUE BLUETM LIMITED WARRANTY
(Equipment with
This limited warranty
Effective January 1,1995
serial number preface of KD
a
supersedes sli previous MILLER warranties and is exclusive
LIMITED WARRANTY
Subiect to the terms and conditions below, MILLER Electric
MIg. Co., Appleton, Wisconsin, warrants to its original retsil purchaser that new
6.
periods listed below, MILLER wilt repair or replace any war
components that fail due to such defects in material or workmanship.
MILLER must be notified in writing within thirty (30) days of such defect or failure, at
which time MILLER will provide instructions on the warranty claim procedures to be
ranted
parts
newer)
with no other guarantees or warranties
90
expressed
or
implied.
Parts and Labor
Days
MIG Gufls/TIG Torches
MILLER equipment sold after the effective date of this limited warranty is free of de
tects in material and workmanship at the time it is shipped by MILLER. THIS WAR
RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT
NESS.
Within the warranty
or
APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches
Remote Controls
Accessory Kits
Replacement Parts
MILLERS
True
BIueTM
Limited
or
1.
Items furnished
Warranty
by MILLER,
shall not
but manufactured
trade accessories. These items are covered
lollowed.
apply
by
to:
by others, such
as
the manulacturers
engines
or
warranty, if
any.
MILLER shall honor warranty claims on warranted equipment listed below in the
event of Such a failure within the warranty time periods. All warranty time periods
start on the date that the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American distributor or eighteen
months after the equipment is sent to an International distributor.
5 Years Parts 3
Original
3 Years
Consumable components; such as contact tips, cutting nozzles, contactors
and relays or parts that fail due to normal wear.
3.
Equipment
Years Labor
(input
and output rectifiers
or
equip
Power Sources
In the event of
Semi-Automatic and Automatic Wire Feeders
warranty claim covered by this warranty, the exclusive remedies
option: (1) repair; or (2) replacement; or, where authorized in
appropriate cases, (3) the reasonable cost of repair or replace
Stan authorized MILLER service station; or (4) payment of orcredit for the pur
a
shall be, at MILLERS
writing by MILLER in
Supplies
Inverter Power
other than MILLER.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER
CIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
Transformer/Rectifier Power Sources
Cutting
by any party
only)
Parts and Labor
Plasma Arc
that has been modified
ment 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.
main power rectifiers
Inverters
2.
2.
Intellitigs
ment
Robots
chase
price (less
reasonable
depreciation based upon actual use)
upon return of the
at customers risk and expense. MILLERS option of repair or replacement
F.O.B., Factory at Appleton. Wisconsin, or FOB, ala MILLER authorized ser
vice facility as determined by MILLER. Therefore no compensation or reimburse
goods
3.
2 Years
Parts and Labor
Engine
Driven
4.
Generators
Welding
(NOTE: Engines
Air
will be
are
warranted
ment for
separately by the engine manufacturer.)
Compressors
1 Year
transportation
costs of
any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN
ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE
Parts and Labor
LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL
DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CON
TRACT, TORT OR ANY OTHER LEGAL THEORY,
Motor Driven Guns
Process Controllers
IHP5 Power Sources
Water Coolant
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR
RANTj, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL
Systems
HF Units
THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, IN
CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
Grids
Spot
Welders
Load Banks
FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.
SDX Transformers
Running Gear/Trailers
Plasma Cutting Torches (except APT, ZIPCUT
Tecurnseh Engines
Deutz Engines (outside North America)
Field Options
& PLAZCUT
Models)
Some states in the U.S.A. do not allow limitations of how
lasts,
or
the exclusion of incidental, indirect,
special
or
long an implied warranty
consequential damages, so
the above limitation or exclusion may not apply to you. This warranty provides spe
cific legal rights, and other rights may be available, but may vary from state to state.
(NOTE: Field options are covered under True BIueTM for the remaining
warranty period of the product they are installed in, or for a minimum of
whichever is greater.)
one year
In
Canada, legislation in
some provinces provides for certain additional warranties
remedies other than as stated herein, and to the extent that they may not be
waived, the limitations and exclusions set ouf above may not apply. This Limited
Warranty provides specific legal rights, and Other rights may be available, but may
or
6 Months Batteries
province
to
province.
1.
RECEIVING-HANDLING
unpacking equipment, check carton for any damage that may have occurred during shipment. File any claims for loss or damage
delivering carrier. Assistance for filing or settling claims may be obtained from distributor and/or equipment manufacturers
Transportation Department.
Before
with the
When
requesting
following spaces to
nameplate.
Use the
or
information about this
record Model
equipment, always provide
Model
Designation
and Serial
or
Style Number.
Designation and Serial or Style Number of your unit. The information is located on the rating label
Model
_________
Serial
or
Style No.
Date of Purchase
miller 6/95
ERRATA SHEET
September 22,
FORM: OM-1588B
1995
Use above FORM number when
L
After this manual
appearing
was
printed,
refinements in
**
Parts List
as
exceptions
to data
Replaced
No.
With
89-3.... 139 590
Added
89-
PARTS LIST
follows:
Part
89-2.... 010910
**First
occurred. This sheet lists
extra manuals.
later in this manual.
CHANGES TO SECTION 16
Change
equipment design
ordering
Description
....
010910
..
....
079 621
..
....
079 622
..
WASHER, (qtychg) (Effw/KF970957)
PULLEY, V sgl grv (Eff w/KF970957)
WASHER, shld .318 ID x .750 OD x .254thk (Eff w/KF970957)
digit represents page no digits following dash represent item no.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Quantity
6
1
....
4
ARC WELDING SAFETY PRECAUTIONS
WARNING
a
ARC WELDING
be hazardous.
can
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
Inwelding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information that will be found in the
Safety Standards listed on the next page. Read and follow all Safety Standards.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
ELECTRIC SHOCK
can
terminal in disconnect box
kill.
Touching
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.
7.
When
Do not
Do not
If earth
6.
Always verify the supply ground
power cord
~
check and be
sure
ground wire is properly connected
input
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays that
can bum eyes and skin. Noise from some processes
can damage hearing. Chipping, grinding, and welds
cooling throw off pieces of metal or slag.
NOISE
1.
Use
with
r
ear
plugs
or ear
muffs if noise level is
fumes and gases
can
17.
If inside, ventilate the
2.
area
and/or
use
exhaust at the
arc
3.
4.
CYLINDERS
can
explode
if
damaged.
1.
Protect
compressed gas cylinders from excessive heat.
slag, open flames, sparks, and arcs.
mechanical shocks,
2.
Installcylindersinanuprightpositionbysecuringtoastationary
3.
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical
circuits.
or
with
cable
wonc
worktable
good
as near
Wear
a
welding
metal-to-metal
the weld
helmet fitted with
Z49.1 and Z87.1 listed in
3.
4.
as
contact
to
oractical.
a
proper shade of filter to
Wear
Safety Standards).
approved safety glasses with side shields.
Use
protective screens or barriers to protect others from flash
glare; wam others not to watch the arc.
Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
and
5.
Work in
only if it is well ventilated, or while
air-supplied respirator. Always have a trained
watchperson nearby. Welding fumes and gases can displace air
and lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
wearing
to
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.
Clamp
protect your face and eyes when welding or watching (see ANSI
out of the fumes. Do not breathe the fumes.
welding fumes and gases.
If ventilation is poor, use an approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDS5) and the
manufacturers instruction for metals, consumables, coatings,
cleaners, and degreasers.
a safety hamess if working above floor level.
Keep all panels and covers securely in place.
ARC RAYS
be hazardous to your health.
remove
a
workpiece
6.
2.
your body.
over
grounding of the workpiece is required, ground it directly
separate cable do not use work clamp or work cable.
Wear
.
Keep your head
drape cables
15.
£~
1.
poorly spliced
Use only well-maintained equipment. Repair or replace
damaged parts at once. Maintain unit according to manual.
high.
FUMES AND GASES can be hazardous
to your health.
Welding produces fumes and gases. Breathing these
or
14.
5.
approved
use.
damaged, undersized,
Do not touch electrode if you are in contact with the work,
ground, or another electrode from a different machine.
ground
ARC RAYS can burn eyes and skin;
NOISE can damage hearing; FLYING
SLAG OR SPARKS can injure eyes.
worn,
13.
16.
that
to
use
cables.
11.
Manual and national, state, and local codes.
grounding
Turn off all equipment when not in
12.
Owners
attach proper
double-check connections.
9.
10.
Do not touch live electrical parts.
5.
to a
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
Wear dry, hole-free
4.
plug is connected
outlet.
8.
1.
3.
that cord
making input connections,
conductor first
2.
insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating
mats or covers big enough to prevent any physical contact with
the work or ground.
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according
to OSHA 29 CFR 1910.147 (see Safety Standards).
Properly install and ground this equipment according to its
or
properly grounded receptacle
7.
a
confined space
an
weld area, the
area
is well ventilated, and if necessary, while
wearingan air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
4.
5.
6.
7.
Never
drape
welding torch over a gas cylinder.
welding electrode to touch any cylinder.
Never weld on a pressurized cylinder
explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
Never allow
a
a
8.
Turn face away from valve outlet when
9.
Keep protective cap
in
10.
use
in
opening cylinder valve.
place over valve except when cylinder is
orconnected for
use.
Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-i listed in Safety
Standards.
5:1.1.1 2194
WELDING
can cause
fire
explosion.
or
closed containers, such as tanks, drums,
Welding
or pipes, can cause them to blow up. Sparks can fly
off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal
Be
6.
aware
that
can cause
welding
fire
ceiling, floor, bulkhead,
on a
or
partition
the hidden side.
on
on
objects can cause sparks, explosion, overheating, or
fire. Check and be sure the area is safe before doing
any welding.
1.
Protect
yourself
and others from
2.
Do not weld where
3.
Remove all flammables within 35 ft
4.
5.
flying sparks
and hot metal.
flying sparks
can
strike flammable material.
(10.7 m) of the welding arc, If
this is not possible, tightly cover them with approved covers.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Do not weld
7.
Connect work cable to the work
8.
ENGINE EXHAUST GASES
unknown
Do not
9.
Engines produce
paths
can
kill:
tanks, drums,
close to the
as
and
causing
or
welding area
as
electric shock and fire hazards.
welder to thaw frozen
use
pipes.
Remove stick electrode from holder
10.
contact
tip
cut off
or
welding
wire at
when not in use.
11.
Wearoil-free protective garments such as leather gloves,
shirt, cuffless trousers, high shoes, and a cap.
12.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
ENGINES
harmful exhaust gases.
as
practical to prevent welding current from traveling long, possibly
WARNING
a
closed containers such
on
pipes, unless they are properly prepared according toAWS F4.1
(see Safety Standards).
1.
Use
2.
If used in
equipment
can
heavy
be hazardous.
outside in open, well-ventilated
a closed area, vent
engine
areas.
exhaust outside and
away from any building air intakes.
ENGINE
FUEL
cause
can
fire
or
explosion.
Engine
fuel is
1.
Stop engine and
2.
Do not add fuel while
open flames.
3.
Do not overfill tank
4.
Do not
engine.
highly flammable.
let it cool off before
smoking
or
MOVING PARTS
checking
if unit is
allow room for fuel to expand.
spill fuel. If fuel is spilled, clean up before starting
or
near
adding
fuel.
any sparks
or
Injury.
can cause
3.
Have
4.
troubleshooting as necessary.
To prevent accidental starting during servicing,
negative () battery cable from battery.
only qualified people
guards
remove
or covers
for
maintenance and
Moving parts, such as fans, rotors, and belts can
fingers and hands and catch loose clothing.
cut
1.
Keep all doors, panels,
securely in place.
2.
Stop
eng
ne
before
covers, and
installing
or
Batteries contain acid and generate explosive
iases.
STEAM
AND
COOLANT
can
PRESSURIZED HOT
burn face, eyes, and
6.
Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
1.
Always wear
Stop engine
2.
It is best to check coolant level when
to avoid scalding.
engine
is cold
a
clothing,
face shield when
before
working
disconnecting
or
on a
battery.
connecting battery
cables.
3.
Do not allow tools to
4.
Do not
5.
Observe correct polarity (+ and )
1.
If the
use
cause
welder to
engine
is
warm
sparks when working on a battery.
charge
and
batteries
checking
on
or
jump
start vehicles.
batteries.
is needed, follow steps 2
and 3.
2.
skIn.
moving
Keep hands, hair,
parts.
connecting unit.
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin,
and tools away from
5.
guards closed and
loose
disconnect
3.
safety glasses and gloves and put a rag over cap.
slightly and let pressure escape slowly before
completely removing cap.
Wear
Turn cap
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49. 1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten
dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, Ameri
can Welding Society Standard AWS F4. 1, from American Welding So
Safe Handling of
Compressed
Gases in
Cylinders. CGA Pamphlet
P-1,from Compressed Gas Association, 1235 Jefferson Davis High
way, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, GSA Standard Wi 17.2. from
Canadian Standards Association. Standards Sales. 178 Rexdale Bou
levard. Rexdale. Ontario, Canada M9W 1 R3.
ciety, 550 N.W. LeJeune Ad, Miami, FL 33126
Safe Practices For Occupation And Educational Eye And Face Protec
tion, ANSI Standard Z87. 1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
National Electrical Code, NFPA Standard 70, from National Fire Pro
tection Association, Batterymarch Park, Quincy, MA 02269.
Fire Protection Association,
srl.1.1 V94
Cutting And Welding Processes, NFPA Standard 51 B, from National
Batterymarch Park, Quincy, MA 02269.
CONSIGNES DE
SECURITE
MISE EN GARDE
a
A LARC
POUR LE SOUDAGE
A LARC
LE SOUDAGE
pout Œtre dangereux.
SE PROTEGER ET PROTEGER LES AUTRES CONTRE LES BLESSURES GRAVES VOIRE MORTELLES. TENIR LES ENFANTS A LECART. LES
PERSONNES QUI PORTENT UN STIMULATEUR CARDIAQUE NE DOIVENT PAS NON PLUS SAPPROCIIER DU POSTEDE SOUDAGE A MOINS
DAVOIR CONSULTE UN MEDECIN.
Le
soudage, comme Ia plupart des travaux, prØsente certains dangers. Par contre, to soudage peut Øtre ettectuØ en toute sØcuntØ quand on prend los
qui simposent. Los consignes de sØcuntØ donnŁes ci-aprŁs ne font quo rØsumor linformation contonue dans los normes do sØcuntØ OnumOrØes
mesures
a Ia page suivante. Lire et respecter toutes ces normes do sØcuntO.
LINSTALLATION, LUTILISATION, LENTRETIEN El LES REPARATIONS NE DOIVENT
UN CHOC
ELEcTRIQUE pout
simple
1.
Ne
Porter des gants et dos vØtements do protection
Jamais toucher los piŁces etectnques
sous
7.
En offectuant los raccordemonts dontrØe fixer dabord 10 conducteur
do mise a Ia terre appropnØ 01 contro-vŁnfier les connexions.
8.
Verifier frØquomment to cordon datimentation pour voir sit nest pas
endommage ou dØnudØ romplacer le cordon immØdiatoment sit
cable dOnudØ pout provoquer uno
est endommagØ
un
electrocution.
9.
Mettre
secs no
comportant
Iatimentation ou arrŒtor le moteur avant do procØdor a
do tapparoil.
linstatlation, a Ia reparation ou a lentretien
DØverrouiller latimontation selon Ia norme OSHA 29 CFR 1910.147
(voir normes do sØcuntØ).
5.
6.
Ne pas enrouler les cables autour du corps.
Si Ia piŁce soudØe doit Œtre miso ala terre, le faire directement avec
no pas utiliser to connecteur do piŁce ou 10 cØble
un cable distinct
do retour.
13.
Ne pas toucher lØlectrodo quand on est en contact avec Ia
terre ou une electrode provenant dune autre machine.
14.
Nutiliser
15.
municipaux.
Toujours vØnfior
17.
.
~
.
-
16.
Ia terre du cordon datimentation
Verifier et
Quo 10 fit do terre du cordon dalimontation est bien
LE RAYONNEMENT DE LARC pout brler les
yeux et Ia peau. Le BRUIT pout endommager
IouIe; les PROJECTIONS DE LAITIER OU LES
ETINCELLES peuvent blesser les yeux.
Larc do soudage produit des rayons visibles et invisiblos
intenses (ultraviolots et infrarougos) qui pouvent brlor
los yeux et Ia peau. Le bruit produit par certains procŁdŁs
pout endommagor IouIe. Des projections de metal ou de
laitier sont produites par le piquago, le meulage ou le
refroidissemont dos soudures.
Utiliser des boucho-oroittes ou des serre-tOto antibruit
to niveau de bruit est ØlovØ.
I
~Q
V
approuvØs
vapeurs et des fumOes
2.
quit
2.
no
pas les
ventiler le posto de travail ou utiliser un dispositif place
niveau do Iarc pour Øvacuer los vapeurs et fumŁes de soudage.
masque a serre-tØte muni dun vorre filtrant do nuance
pour proteger Ia visage et los yeux quand on soudo ou
observe Ia travail do soudago (voir los normes ANSI Z49. 1 01 Z87. I
donnØes sous Ia rubrique Principales norrnes de sØcurite).
Porter
un
3.
Porter des lunettes do sØcuntŁ
4.
Utitiser des paravents ou des barriŁres do protection pour proteger
los personnes a proximitØ contre les coups darc et lØblouissement;
avertir los autres personnes do ne pas regarder larc.
5.
5.
4.
Consulter los fichos signafetiques et les consignes du fabncant
relatives au mØtaux, produits dapport. revŒtements. nettoyants et
un
6.
approuvØos
Porter dos vŒtomenls do protection en tissu
et des chaussures do sOcuntØ.
avoc
Øcrans latOraux.
ignifugo durable (tame ot
Ne travailler dans un espace confine que sit est bien ventilØ, ou en
portant un appareit respiratoire a adduction dairpur. Demander a un
observateur ayant recu Ia bonne formation do toujours so lenir a
proximitØ. Los vapeurs et fumØes de soudage peuvent doplacer lair
7.
pas souder a
proximitO dopOrations
de
dOgraissage,
de
Ne pas souder
sur
des mØtaux revŒtus comme lacier
galvanisŁ,
au
p10mb ou cadmiØ a moms quota piŁce nait ØtØ ontiŁrement dØcapOe.
quote posto do travail soit bion vontilØ. Sit y a lieu, porter un appareil
respiratoire a adduction dair pur. Les revØtements et los mŁtaux qui
contiennont do tels ŁlŁments pouvont dogager des vapeurs toxiquos
lors du soudage.
degraissants.
LES BOUTEILLES peuvent exploser sI elles
No
nettoyage ou de pulvØnsation. La chateur et los rayons do larc
peuvent reagir avec los vapours pour former des gaz hautement
toxiques et irritants.
appareil respiratoire a
Si Ia ventilation ost mauvaiso, utiliser
adduction dair pur approuvØ.
jamais
jamais
jamais
poser un chatumeau soudeur sur une bouteille do gaz.
laisser une electrode do soudago toucher une bouteille.
4.
Ne
5.
Ne
Los bouteillos contenant des gaz do protection sont a
Une bouteillo endommagee pout
haute pression.
exploser. Etant donnØ que los bouloilles do gaz font
norrnalement partie du materiel de soudage. les traitor
avec le plus grand soin.
6.
No
7.
Nutilisor quo dos boutoilles do gaz de protection, des dØtendeurs,
des tuyaux souplos ot dos raccords appropriŁs concus pour
application particuliŁre; consorvor ces matØriels at leurs piŁces en
los bouteillos do gaz comprimØ contre Ia chaleur intense,
les chocs, te tail ier, les flammes nues. les Øtincetles el larc.
8.
~
sont
.z~.
endommagØes.
ProtØgor
Placer los bouteiltes a Ia vorticale
un
3.
en
appropnee
est
3.
2.
un
Maintenir solidement
do~gene et causer dos blessures graves voire
mortelles. Sassurer que lair est propre a Ia respiration.
respirer.
A linlØnour,
1.
hamais de sŁcuntØ
quand on travaille en hauteur.
place tous los panneaux at capots.
Fixer le cable do retour do faon ~ obtonir un bon contact mØtal-mØtal
avec Ia piŁce a souderou Ia table do travail, le plus pres possible de Ia
Porter
et abaisser le niveau
Garder Ia tŒte a lextrieur des vapeurs et des fumŁos et
~
remplacer
lappareil
cuir)
LES VAPEURS ET LES FUMEES peuvent ºtre
pour Ia sante.
Le soudage produit des
dangereux do respirer.
Ia
RAVONNEMENT DE LARC
dangereuses
1.
au
si
piŁce.
soudure.
BRUIT
1.
RØparer ou
quun materiel en bon Øtat.
Entretenir
les piŁces endommagØes.
conformØment a ce manuel.
sur-le-champ
Installer et mettre a Ia terre correctoment cet appareit confomiØment
a son manuel dulilisation et au codes nationaux, provinciaux et
sassurer
quand on ne lutilise pas.
uses, endommagØs. do grosseur
11.
Couper
4.
hors tension
No pas utiliser des cables
insuffisante ou mal ØpissOs.
12.
Sisoler do Ia piŁce et de Ia terre au moyen de tapis ou dautros
moyens isolants suffisamment grands pour empecher le contact
physique Øventuel avec Ia piŁce ou Ia terre.
lappareil
10.
tension.
pas de trous.
3.
OUALIFIEES
est raccordŁe a uno pnso correctoment mise a Ia terre.
contact avec des
2.
DES PERSONNES
raccordO a Ia borne do terre du sectionnour ou quo Ia fiche du cordon
tuer.
piŁces Ølectnques pout
provoquer une Olectrocution ou des blessures graves.
LØlectrode et to circuit de soudago sont sous tension des
que Iapparoil est surON. Le circuit dentrØe et les circuits
intemos de Iappareit sont egalement sous tension a ce
moment-l.
En
soudage semi-automatique ou
automatique, le fit, le dØvidoir. to logement dos galets
dentrainemont ot los piŁces mØtalliques en contact avec
to fit do soudago sont sous tension. Des matØnels ma!
installØs ou mat mis a Ia terre prØsentont un danger.
Un
ETRE CONFIES QuA
chariot pour Øviter
quelles
ne
en
les fixant a
tombent
Tenir les bouteitles a IØcart du poste de
electriques.
un
ou no
soudage
support fixe
ou
a
bascuient.
ou
dautres
sur une
bouteille
sous
pression : elte oxploserait.
bon Łtat.
Eloigner
10
visage
de Ia sortie du robinet do Ia bouteille
quand
on
louvre.
9.
10.
circuits
souder
Replacer to chapeau
sur
Ia bouteille
aprŁs
utilisation.
Lire at suivre los consignes relatives aux bouteitles do gaz compnme,
au materiel connexe ainsi quo Ia publication P-l de Ia CGA donnØe
sous Ia rubnque Pnncipales normes de scuritØ.
srl.I,1 2/94
LE SOUDAGE
Incendle
ou une
5.
Prondre garde
proximitØ.
No pas soudor sur des recipients fermØs comme des
reservoirs, dos fts ou des tuyaux: us pouvent exploser.
Des
Larc do soudage pout produire des Øtincelles.
Øtincelles, une piŁce chaudo et un materiel chaud
des
incendios
et des blossures. Le
peuvent provoquor
do lŁlectrode
des objets
contact accidentel
sur
motalliques pout produire dos Øtincelles, lexplosion, Ia
surchaufte ou un incendie. Sassurer quo 10 lieu no
prØsonte pas do danger avant deflectuer le soudago.
6.
Se rappelerquo si Ion soude sur un plafond, un planchor,
ou autre, lo lou peut prendre do lautre ctØ.
7.
No pas souder sur des recipients fermØs commo des reservoirs, des
fOts ou dos tuyaux a moms quils ne soient prepares do facon
appropnee conformØmont ala norme F4.1 do lAWS (voir Ia rubnque
peut
causer un
explosion.
1.
So protØgeretprotegerles personnos a
metal chaud.
2.
Ne pas souder dans un ondroit o
des matOriaux inflammables.
los Øtincollos pouvent atteindro
Prendro
4.
garde quo los Øtincollos et los projections no pØnØtront dans
adjacentos en sinfiltrant dans dos petites fissures et
No pas utiliser le chalumoau soudeur pour
11.
produisent
LE CARBURANT
DES MOTEURS
ou une
des gaz de
12.
1.
peut provoquer
un
Incendie
peuvent
causer
piŁces en mouvomont comme los ventilateurs, los
rotors et los courroles peuvent couper los doigts otles
mains ot happer los vŒtements amples.
place.
ArrŒter 10 moteur avant do mettro
disoositif.
place
ou
do raccorder
soi
comme un
bnquet a
un
Øcran facial
utilise
4.
un
danger.
moteur dans un local ferrnO, Øvacuer los gaz
a lextØneur et loin des pnses dair du btiment.
in
ras
lappareil
bord
se trouve
prØvoir
de
a
proximitØ
lospace pour
Ia
Ne pas renverser du carburant.
Si on ronverso du carburant,
avant do faire dØmarrer 10 moteur.
nottoyer los Iieux
3.
Seules des personnes
4.
qualifiees
los capots pour faire lentretien
doivent dØmonter los protoctours
ou los reparations nØcessairos.
Pour ompOcher un demarrage accidontol dun systŁme pendant
lontrotion ou los reparations, dØbranchor lo cable negatif () do Ia
battono.
Eloigner los
des
un
piŁces
mains, los chevoux, los vŒtemonts amplos
et los outils
en mouvement.
Replacer los capots ou les protecteurs et reformer les portes uno fois
Ientrotion ot los reparations terminØs ot avant de faire dØmarrer 10
moteur.
Los batteries contiennent
des vapeurs explosives.
Toujours ~
on
Ne pas remplir le reservoir a
dilatation du combustible.
6.
en
Si
3.
Sassurer quo los portes, los panneaux, los capots et los protectours
LES ETINCELLES peuvent faIre EXPLOSER LE
GAZ DES BA1TER~ES; LELECTROLYTE peut
brler Ia peau et es yeux.
1.
tuyaux.
dans dos lioux ouvorts at bien
Ne pas fumer en faisant le. plein ou si
dØtincelles ou do flammos nues.
5.
sont bien fermØs ot bion A leur
Utiliser le materiel a IoxtØneur,
ventilØs.
ou
Los
+
sur
presenter
2.
explosion.
LES PIECES EN MOUVEMENT
des blessures.
2.
Ne pas porter des matiŁres combustibles
ou des allumettes quand on soude.
dechappement
chapp oment focus.
ArrOter lo moteur ot 10 laissor refroidir avant de verifier lo nivoau de
carburant ou de rofaire le plein.
1.
dos
Porter dos vOtoments do protection non huileux comme dos gants en
une chemise Øpaisse,
dos pantalons sans rovers, dos
chaussures montantos of un casque.
LES MOTEURS peuvent
Le carburant est hautemont inflammable.
1.
degoler
Enlever lØlectrode enrobØo du porte-electrode ou couper le fil de
soudage au ras dii bec contact quand on no Iutilise pas.
cuir,
2.
Les motours
~
sØcuntØ).
gaz
LES GAZ DECHAPPEMENT
peuvent tre mortels.
r
cloison
9.
MISE EN GARDE
a
do
une
Raccorder 10 cable do retour a Ia piŁce, lo plus prØs possible do Ia
zone do soudage, pour empOcher quo le courant do soudago ne
suive une trajoctoiro longue et Øventuollemont inconnue at quil no
provoque dos nsques dØlectrocution et dincondio.
10.
dos zones
ouverturos.
normes
avoir Un extinctour ~
8.
proximitØ dos Øtincelles etdu
Enlovertoutes los matiŁres inflammablos dans un rayon do moms do
10 m de larc. Si cola nest pas possible, bien los rocouvnren utilisant
dos bathes approuvees.
3.
Pnncipalos
toujours
incendios et
aux
un
quand
on
produit
acido et
travaille
sur une
degagent
battene.
VAPEUR
ET
LE
DE
LIQUIDE
REFROIDISSEMENT
BRULANT
SOUS
PRESSION peuvent brler Ia peau et lee yeux.
LA
II vaut mioux verifier 10 nivoau du liquide do
ref roidissoment quand 10 moteur ost froid af in &Øviter les
brUlures.
2.
ArrØter le motour avant do brancher
Ia battene.
3.
Ne pas faire dos Øtincolles
battene.
4.
No pas utiliser Ia source do courant do soudage pour
batteries ou pour faire dØmarror un vØhicule.
5.
Ne pas intervertir Ia
lAmoflcan
Welding
polaritØ
do dØbrancher los cAbles do
los outits
quand
on
travaille
sur une
charger
los
des batteries.
1.
Si Ion doit verifier 10 nivoau quand le motour est chaud, suivro los
2.
Øtapos 2013.
Porterdoslunottesdosecuflteetdosgantsetplacorunchiffonsurle
bouchon.
3.
Toumor lentoment 10 bouchon et laissor Ia prossion
lontement avant donlever complOtoment lo bouchon.
PRINCIPALES NORMES DE
Safety in Welding and Cutting, normo ANSI Z49.1,do
Society, 550 N.W. Lojoune Rd, Miami FL 33126
avec
ou
sechapper
SECURITE
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-ide
Ia Compressed Gas Association. 1235 Jefferson Davis Highway, Suite
501, Arlington, VA 22202.
and Health Sandards, OSHA 29 CFR 1910, du
Supenntondonl of
Documents, U.S. Government Pnnting Office, Washington, D.C. 20402.
Safety
Recommended Safe Practice for the Preparation for Welding and Cutting
of Containers That Have Held Hazardous Substances, norrne AWS F4.1.
do IArnoncan Welding Society, 550 N.W. Lojoune Rd, Miami FL 33126
NationalElectncal Code, NFPA Standard 70, do Ia National Fire Protection
Association. Batterymarch Park, Quincy, MA 02269.
srl.1.1 2/94
Regles de sØcunfØ en soudage. coupage et procddds connexes, norme
CSA W117.2, do lAssociation canadienne do norrnalisation, vento do
normes, 178 Rexdalo Boulovard, Roxdale (Ontario) Canada M9W 1 R3.
Safe Practices For Occupation And Educational Eye And Face Protection,
ANSI Z87.1, de IArnencan National Standards Institute. 1430
Broadway, Now York, NY 10018.
norrne
and Welding Processes, norme NFPA 51 B, do Ia National Fire
Protection Association, Batterymarch Park, Qumncy, MA 02269.
Cutting
EMF INFORMATION
Considerations About
Fields
NOTE ~
Welding
And The Effects Of Low
Frequency
Electric And
Magnetic
The
To reduce
of the U.S.
following is a quotation from the General Conclusions Section
Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields
OTA-BP-E-53 (Washington, DC: U.S.
Background Pape4
Government Printing Office, May 1989): .
there is now a very
large volume of scientific findings based on experiments at the
procedures:
.
magnetic fields
in the
workplace,
1.
Keep cables close together by twisting
2.
Arrange
3.
Do not coil
4.
Keep welding
practical.
5.
Connect work clamp to workpiece
cables to
one
or
use
taping
the
following
them.
side and away from the operator.
.
or
drape cables
around the
body.
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 interpret 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
or
to offer clear science-based advice on
avoid
strategies to
power
source
and cables
as
as
far away
as
close to the weld
as
possible.
About Pacemakers:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your doctor for
complete information.
minimize
potential risks.
modlO.1 4/93
TABLE OF CONTENTS
SECTION 1
SAFETY INFORMATION
SECTION 2
SPECIFICATIONS
SECTION 3
INSTALLATION
2
3-5.
Equipment Connection Diagram
Installing Swivel Into Pipe Post
Installing Control Box Onto Swivel
Installing Boom And Reel Support
Installing Wire Guide Extension
3-6.
Wire Guide And Drive Roll Installation
3-7.
Welding
3-8.
Wire Feed Motor And Gas Valve Control Connections
6
3-9.
Control Connection
7
3-1.
3-2.
3-3.
3-4.
3-10.
2
3
3
4
4
6
Gas And Weld Cable Connections
3-12.
Shielding
Removing Safety Collar And Adjusting
Welding Wire Installation
3-13.
Motor Start Control
3-11.
3-14.
3-15.
5
Gun Connections
8
Boom
9
10
11
Control Tilt Bracket
Adjusting
Threading Welding
12
Wire
12
SECTION 4- GLOSSARY
14
SECTION 5- OPERATION
16
5-1.
Front Panel Controls
5-2.
Side Panel Controls
19
5-3.
Rear Panel Controls
20
5-4.
Setting
SECTION 6
Switches On 450
Ampere
lnverter Model
Welding
Power Source
STEPPING THROUGH THE MICROPROCESSOR CONTROLS
6-1.
Front Panel
6-2.
Side Panel
SECTION 7
17
Microprocessor Controls
Microprocessor Push Buttons
STANDARD PULSE
WELDING PROGRAMS
SECTION 8- GE111NG STARTED
8-1.
8-2.
Welding With Only Front Panel Controls
Setting Sequence Pulse Welding Parameters On Side Panel Display
21
22
22
24
27
35
36
37
OM-15885 -6/95
SECTION 9
9-1.
9-2.
9-3.
9-4.
TEACHING A PULSE WELDING PROGRAM
Pulse Waveform
41
Teach Points
42
Explained
Explained
Teaching A Pulse Welding Program
Changing To Adaptive Pulse Welding
SECTION 10TEACHING
10-1.
10-2.
41
43
46
A MIG WELDING PROGRAM
Changing To MIG Welding
Setting Sequence MIG Welding
47
47
Parameters On Side Panel
Display
48
SECTION 11
SETTING DUAL SCHEDULE PARAMETERS
51
SECTION 12
USING THE OPTIONAL DATA CARD
53
12-1.
12-2.
Installing Data Card
Using The Data Card
53
53
SECTION 13SETUP
13-1.
57
Setup Flow Chart
Using Setup Displays
57
58
13-13.
Selecting Process Capability
Selecting Welding Power Source Range
Selecting Security Lock
Selecting Or Changing Access Code
Selecting Voltage Correction
Selecting Voltage Sensing Method
Selecting Regular Or Hot Arc Start
Selecting Type Of Dual Schedule Switch
Selecting Trigger Program Select
Selecting Remote Increase/Decrease Capability
ResettingArcTime
13-14.
Using Self Test
13-2.
13-3.
13-4.
13-5.
13-6.
13-7.
13-8.
13-9.
13-10.
13-11.
13-12.
13-15.
13-16.
13-17.
13-18.
13-19.
58
59
60
61
62
62
63
63
64
65
65
66
Units For Wire Feed
And Motor
Selecting
Speed
Selecting Bench Or Boom Model Type
Resetting Memory
Selecting Arc Start/Volt Sense Error Shutdown
Selecting Program Name Feature
13-20. Software Version Number
SECTION 14- MAINTENANCE & TROUBLESHOOTING
Type
67
67
68
68
69
69
70
14-1.
Routine Maintenance
14-2.
Replacing
14-3.
Overload Protection
71
14-4.
Error Displays
Troubleshooting
72
14-5.
The Hub
70
Assembly
71
73
SECTION 15
ELECTRICAL DIAGRAMS
74
SECTION 16
PARTS LIST
78
Figure
Figure
Figure
Figure
Figure
Figure
Figure
16-1. Main
78
16-2.
80
16-3.
Assembly
Support, Hub & Reel
Panel, Front w/Components
16-5. Drive
16-6.
16-7.
81
82
16-4. Control Box
Wire
Assembly,
Panel, Side w/Components
Boom Assembly
Table 16-1. Drive Roll And Wire Guide Kits
84
87
88
86
SECTION 1
SAFETY INFORMATION
-
modl.1 2/93
Read all
safety messages throughout
Obey all safety messages
Learn the
1
to avoid
this manual.
injury.
meaning of WARNING and CAUTION.
2
1
Safety
Alert
2
Signal
Word
2
Symbol
WARNING moans possiblo death
or serious injury can happen.
;1~ll~Ie~
a CAUTION
3
ELECTRIC SHOCK
can
kiIi.~
~
)~
Do not touch live electrical parts.
Disconnect
input power
installing or servicing.
4
before
CAUTION
MOVING PARTS
Keep
away from
Keep
all
when
panels
operaling.
can
injury
Injure.
or
means possible minor
equipment damage can
happen.
moving parts.
and covers closed
57
3
Statement Of Hazard And
Result
4
Safety
Instructions To Avoid
Hazard
a
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
WARNING
6
5
Hazard
6
Safety Banner
Read safety blocks for each sym
bol shown.
7
7~{
NOTE
Turn Off switch when
Symbol (If Available)
using high frequency
NOTE
Special instructions for best
not related to safety.
oper
ation
1-1.
Figure
Safety
Information
SECTION 2- SPECIFICATIONS
Table 2-1. Wire Feeder
Specification
Type Of Input Power From Welding
Description
Single-Phase
24 Volts
AC,
10
Amperes, 50/60 Hertz
Power Source
Maximum Weld Circuit
Welding
Power Source
Rating
100 Volts, 750
Type
Constant
Amperes,
Speed Range
Wire Diameter
Welding
(CC) DC,
Standard: 50 To 780 ipm (1.3 To 19.8 mpm)
High Speed: 92 To 1435 ipm (2.3 To 36.5 mpm)
.023 To 1/8 in
Range
Processes
Gas Metal Arc
input Power Cord
(0.6 To
Height With
4 ft
(1.2 m)
Net: 207 lb
Vertical Lift Of Boom
wire feed
Metal Arc
-
Pulse
(GMAW-P), Flux Cored
(3.7 m)
Boom
16 ft
17ft(5.2 m)
Ship:
are
mm)
Arc
Welding (FCAW)
lOft(3.1 m)
Weight
*These
3.2
(GMAW), Gas
12 ft
Maximum
Post
Duty Cycle
With Contactor For GMAW Welding
With Contactor For GMAW-P Welding
Voltage (CV) DC,
Constant Current
Wire Feed
100%
21 ft
(144 kg)
Horizontal To 60
(6.4 m)
Horizontal To 60
Above Horizontal
speed ranges for GMAW. While Pulse welding,
Boom
Net: 280 lb (127 kg)
Ship: 411 lb (186 kg)
(94 kg)
318 lb
(4.9 m)
wire feed
speed ranges
may be
more
Above Horizontal
limited
(see Section 9).
OM-1588
Page
1
SECTION 3-INSTALLATION
3-1.
Equipment Connection Diagram
WARNING
£~
CYLINDERS
can
Keep cylinders
explode if damaged.
away trom
welding
and
ELECTRIC SHOCK
electrical circuits.
Never touch
cylinder
with
HOT SURFACES
can
Allow gun to cool before
kill.
TurnOffwirefeederandwelding power source, and
before
disconnect
input
making
power
welding electrode.
Always secure cylinder to running gear, wall,
other stationary support.
can
Do not touch live electrical parts.
other
connections.
or
The welding wire, drive rolls, drive assembly, and all
metal parts touching the welding wire are electrically
live when welding or feeding wire using gun trigger.
burn skin.
touching.
Have only
qualified
persons install this unit.
wfwam9.1
1
2/93
Welding Power Source
2
Remote 14 Connections
3
Negative ()
Weld
Output
Cable
2
4
(+)
4
Positive
Cable
5
Workpiece
Weld
Output
6
Voltage Sensing Clamp
7
Weld Control
8
Boom
9
Gun
10
Swivel
Post And Base
11
Pipe
12
Gas Hoses
13
Gas
12
Supplies
11
9
5T-800 173
Figure
OM-1588 Page 2
3-1.
Typical System
Connections
3-2.
Installing Swivel
a
Into
Pipe
Post
WARNING
FALLING
OF
SPRING
PRESSURE
RELEASE
WITHOUT BOOM ATTACHED can cause
serious personal injury.
S
Do not
remove
BOOM
can
serious
cause
personal injury and equipment damage.
Securely mount pipe post to base that can support
weight of unit with boom in horizontal position.
Use proper equipment for lifting swivel and boom
into place.
satety collar until instructed to do so.
1
Swingpak
2
Pipe
3
Steel Bolt
Base
or
CBC Cart
5
4
Post With Base
Secure as shown using as a mini
mum 1/2 in diameter SAE grade 5
steel bolts.
4
Swivel Assembly
Insert into
pipe post. Lubricate
swivel.
2
5
3
Safety Collar
Do not
remove
until instructed to.
Tools Needed:
~ 3/4 in
5T.152 382
Figure
3-3.
Installing Control
3-2. Swivel Installation
Box Onto Swivel
1
Weld Control
2
Bracket
3
Screw
Bracket and screws are installed
onto bottom of control at factory.
4
Swivel
Loosen screws. Place control on
swivel and slide forward. Tighten
screws.
2
3~
Tools Needed:
4
5T.800 174
Figure
3-3. Control Box Installation
OM-1 588
Page
3
3-4.
Installing
Boom And Reel
Support
READ SAFETY BLOCKS at start of
Sectio n 3-2 bef ore proceeding.
1
Swivel Plates
2
Yoke
Remove
plates
hardware
and
Set boom into swivel
Install
pin
5
Bolt
bolt,
washers,
and
nut.
Tighten hardware, and back bolt off
one
half tum.
6
Locking
Install
1
shown.
pin through yoke. Install cot
and spread ends.
Install
2
as
Yoke Pin
4
ter
swivel
Boom
3
4
from
yoke.
Knob
locking
knob
but do not
tighten.
7
Reel
Support
Install reel support.
Tools Needed:
3/8,3/4in
ST-153 170
Figure
3-5.
Installing
3-4. Boom Installation
Wire Guide Extension
1
1
Wire Guide
2
Bolt
Fitting
3
Monocoil Liner
4
Wire Guide Extension
Tighten bolt to secure liner in wire
guide fitting. Do not overtighten
bolt and crush liner.
Repeat procedure for opposite
side.
Tools Needed:
~O
3/Bin
5T-152 383
Figure
OM-1 588
Page
4
3-5. WIre Guide Extension Installation
3-6.
Wire Guide And Drive Roll Installation
A~
WARNING
___
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Turn Off wire feeder and
welding
power source, and disconnect
input power before inspecting
or
installing.
wfwaml.1 2/93
A.
Wire Guide Installation
When changing wire size or type,
check guide size (see Table 16-1).
I
Drive Rolls
Remove drive rolls before install
ing wire guides (see Figure 3-7).
2
Wire Guide
Loosen wire
Securing
guide
Screws
screws.
3
Inlet Wire Guide
4
Intermediate Wire Guide
Insert
intermediate guide until
flange on guide rests against cast
ing, and secure with guide screw.
Install drive rolls
(see Figure 3-7).
Repeat procedure
for
opposite
side of wire feeder.
1
Tools Needed:
Ref. ST-137 391-F / ST.142 597-A
Figure
B.
3-6. Wire Guide Installation
Drive Roll Installation
When
check
Table
5
changing wire size
drive
roll
or
size
type,
(see
16-1).
Carrier
1
Spring Shaft
2
Drive Roll Nut
3
Drive Roll Carrier
Turn all nuts one click until lobes of
nut line up with lobes of drive roll
carrier.
4
Drive Roll
Slide drive rolls onto drive roll carri
ers. Turn nut one click.
5
Drive Assembly Cover
Close
4
cover.
Repeat procedure
.---1~i
for
opposite
side of wire feeder.
2
3
ST-142 597-A
Figure
3-7. Drive Roll Installation
OM-1 588
Page
5
3-7.
Welding
Gun Connections
WARNING
a
ELECTRIC SHOCK
can
Do not touch live electrical
Turn Off wire feeder and
kill.
parts.
welding power
source, and disconnect
input power
before
inspecting
installing.
or
wfwaml.1 2/93
1
Drive
2
Gun
3
Gun Connector
Assembly Cover
Securing
Knob
Loosen securing knob. Insert gun
connector until it bottoms against
drive assembly. Tighten knob.
4
Gun
Trigger Plug
5
Gun
Trigger Receptacle
plug into free-hanging re
ceptacle and tighten threaded col
Insert
lar.
6
Trigger Cord
7
Trigger Plug
8
Weld Control
3
Trigger
Receptacle
4
Insert plug into receptacle and
tighten threaded collar.
Repeat procedure for gun on oppo
drive assembly.
Ref. ST-152 466 / Ref. ST-800 178/ Ref. ST-800 175
Figure
3-8.
3-8. Gun And
Trigger
Lead Connections
Wire Feed Motor And Gas Valve Control Connections
I
Wire Feed Motor And Gas
Valve Control Receptacle
2
Plug From Boom
3
Cord From Boom
Insert plug from boom cord into re
ceptacle on rear of control, and
tighten threaded collar.
Repeat procedure for opposite
side of weld control.
ST-$OO 177/Ref. ST-800 175
Figure 3-9. Boom Connections
OM-1 588
Page
6
3-9.
Control Connection
1
17-Pin Receptacle
Table 3-1)
2
Keyway
(See
To connect
interconnecting cord to
receptacle, align keyway, insert
plug, and tighten threaded collar.
3
Weld Current Sensor Recep
tacle (For Use With Field Op
tion Only)
4
35 ft (10.6 m)
ing Lead
Connect
to
Voltage Sens
workpiece
(see
Figure 3-1).
5
Threaded Collar
6
14-Pin
Plug (see Table 3-2)
To connect plug to matching recep
tacle on welding power source,
align keyway, insert plug, and tight
en threaded collar.
ST-800 177 / Ref. S-0512 / $-0003-A / S-0628
Figure
3-10. Control Connections With Pin Information
Table 3-1. Remote 17 Socket Information
REMOTE 17
E ~1b
The
remaining
~
sockets
are
SOCket*
Socket Information
C
CC/CV select; +13 to +24 volts dc is CV, 0 volts dc is CC.
G
Arc control/inductance control; 0 to +10 volts dc.
E
Actual weld current output
M
Actual weld
F
Current feedback from
H
Voltage
signal;
+1 volt dc is 100 amps.
voltage output signal;
feedback from
+1 volt dc is 10 volts dc.
power source; 0 to +10 volts dc, 1 volt per 100 amperes.
welding
welding power
source; 0 to +10 volts
dc, 1 volt per 10
arc
volts.
not used.
Table 3-2. Remote 14-Pin Information
REMOTE 14
(3,
a ~
~l~
The
OUTPUT
Pin Information
~j~*
A
24 volts
B
Contact closure to A
G
Circuit
C
+10 volts dc
ac.
completes
24 volts
ac
contactor control circuit.
(CONTACTOR)
AMPERAGE
VOLTAGE
remaining pins
are
common
for 24 volts
input
ac
circuits.
to remote control.
0
Remote control circuit common.
E
0 to +10 volts dc output command
signal
from feeder
voltage control.
not used.
OM-1 588
Page
7
3-10.
Shielding
Gas And Weld Cable Connections
a
WARNING
CYLINDERS
can
Keep cylinders
explode
away from
if
ELECTRIC SHOCK
damaged.
welding
and other
electrical circuits.
Never touch cylinder with welding electrode.
Always secure cylinder to running gear, wall,
other stationary support.
can
Do not touch live electrical
kill.
parts.
TurnOffwirefeederandwelding powersource,and
disconnect input power before inspecting or
installing.
or
BUILDUP OF SHIELDING GAS
health or kill.
Shut off
shielding gas supply
can
when not in
harm
use.
wam4.1 9/91 /wfwaml.1 2/93
A.
Connecting
Weld Cables And Gas Hose
Tools Needed:
~iI
-~ 5/8in
Ref. ST-153 175-A
The weld cables and shielding gas hoses ex
tend lOft (3m) from the boom.
If the welding power source or gas supply
further from the boom, extend cables
and hoses as follows:
Bolt
together weld cables from welding pow-
and boom. Use electrical tape and
insulated sleeving to cover connection.
er source
5
are
1
Weld Cables
2
Insulated
Sleeving
Figure
OM-1588
Page
8
3-11.
Connect boom shielding gas hoses to gas
or extension. The hoses from the
boom have 5/8-18 right-hand threads.
supplies
3
Shielding
4
Boom
Y
Adapter
Connect single end filling of V adapter to gas
supply, and connect boom shielding gas
Shielding
Shielding
Supplied Shielding Gas
Gas Extension Hose
Gas
Hose(s)
hoses to
fittings
Gas And Weld Cable Connections
on
V end of
adapter.
B.
Shielding
Gas Connections To
Regulator/Flowmeter
Obtain gas cylinder and chain to
running gear, wall, or other station
ary support so cylinder cannot fall
and break off valve.
1
1
2
Cap
Cylinder Valve
Remove cap, stand to side of valve,
and open valve slightly. Gas flow
blows dust and dirt from valve.
Close valve.
.2
3
4
Cylinder
Regulator/Flowmeter
Install
5
so
face is vertical.
Gas Hose Connection
Fitting has 5/8-18 right-hand
threads. Install gas hose according
to Figure 3-11.
Flow Adjust
Typical flow rate is 20 cfh (cubic feet
per hour). Check wire manufactur
6
OR
6
.2
Argon Gas
ers
recommended flow rate.
Make
when
5
4
flow adjust
opening cylinder
is closed
to avoid
sure
damage
to the flowmeter.
7
CO2 Adapter
8
0-Ring
Install adapter with 0-ring between
and
CO2
regulator/flowmeter
cylinder.
~
5T-158 697-A
Tools Needed:
~ 5/8,1-1/8 in
CO2
Gas
-
Figure
3-11.
Removing Safety
a
L_~J
3-12.
Typical Regulator/Flowmeter
Collar And
Adjusting
Boom
WARNING
OF SPRING
RELEASE
PRESSURE
WITHOUT BOOM ATTACHED can cause
serious personal injury.
Do not
Installation
remove
FALLING
BOOM
can
cause
serIous
personal injury and equipment damage.
Adjustment
yoke.
safety collar until instructed to do so.
rod must be threaded
1
fully through
Locking Knob
Tighten
knob
to
prevent boom
movement. Loosen knob to allow
boom movement. Change knob
position to limit upward movement.
Pull boom down slightly and re
move safety collar. Boom should
balance in any position from hori
zontal to 60 degrees above hori
zontal. If necessary, adjust boom
as follows:
Q
j
Rod~
E
Tools Needed:
~
4
3
2
Increasing Spring
Decreasing Spring
Pressure For A
Pressure For A
HeavyGun
LightGun
1-1/8in
Figure
3-13. Boom
2
Threaded Rod
3
Jam Nut
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
Yoke
Retain safety collar for use in dis
assembling or moving boom.
8T-142599-B
Adjustments
OM-1 588
Page
9
3-12.
A.
Welding
Wire Installation
Installation Of
Spool-Type
Wire
1
Retaining Ring
2
Wire
3
Hub
Remove
4
spool
4
Spool
retaining ring
and slide
onto hub.
Hub Pin
Turn
spool until hub pin fits hole
spool. Reinstall retaining ring.
in
Repeat procedure for opposite
side.
3
2
E
ST-153 171
Figure
B.
Installation Of
Optional
3-14. Installation Of
Wire Reel And Reel
Type
Spool-Type
Wire
Wire
1
Retaining Ring
2
Spanner
8
Nut
3
Lock
4
Wire Retainer
5
Wire Reel
6
Hub
7
Hub Pin
8
Reel
4
Support
Remove retaining ring. Pull lock
and turn. Remove spanner nut,
wire retainer, and wire reel from
hub.
Lay
wire reel
assembly
face, and install wire
as
on
flat sur
shown.
spanner nut until lock is in
over hole in wire retainer.
Pull lock and turn to insert locking
pin into wire retainer.
Tighten
position
Slide wire reel assembly onto hub,
~1IIIiI~
.
and turn assembly until hub pin is
seated in hole in reel. Reinstall re
taining ring.
fD~
Wire Installation
ST-143 478-A / ST-152 463
Figure 3-15. Installation Of Optional Wire Reel And Reel Type Wire
OM-1 588
Page
10
C.
Hub Tension
Adjusting
Turn Off unit and
welding
power
source.
1
Hex Nut
2
Spool
2
Grasp spool in one hand and turn
while using a wrench to adjust hex
nut. When a slight force is needed
to turn spool, tension is set.
Repeat procedure
for
opposite
side.
Tools Needed:
~ 5/8in
ST-153 173
Figure
3-16.
Adjusting
Hub Tension
3-13. Motor Start Control
WARNING
a
E LECTRIC SHOCK
S
S
can
kill.
STATIC ELECTRICITY can damage parts
Do not touch live electrical parts.
on
TurnOffwirefeederandweldingpowersource,and
disconnect input power before inspecting or
S
circuit boards.
Put
on
boards
grounded wrist strap BEFORE handling
or
parts.
installing.
wfwaml.r 2/93
To
Right
change wire feed starting speed
proceed as follows:
Side
Turn Off wire feeder and
welding
source.
power
Remove wrapper.
1
Motor Board PCi
2
Motor Start Control Poten
tiometer R70
Turn
potentiometer clockwise to in
time it takes the motor to
ramp up to speed. Remove protec
tive white rubber cap before mak
crease
ing adjustment. Adjust potentiome
using a small nonconduc
ter R70
tive screwdriver.
Reinstall wrapper.
Tools Needed:
1/4 in
Non-conductive
Figure
Ref. ST-162 132 / Ref. 5B-148 862-D
3-17. Motor Start Control On Motor Control Board PCi
OM-1588
Page
11
3-14.
Adjusting Control
Tilt Bracket
1
Tilt Bracket
2
Rear Pivot Screw
3
Front Screw
Loosen
screw. Remove
Pivot control down
ward to desired viewing angle. Re
place and tighten front screw.
front
rear
pivot
screw.
Tighten pivot
screw.
2
ST-801 278
Figure
3-15.
Threading Welding
4~
3-18.
Changing
Control Tilt
Angle
Wire
WARNING
CYLINDERS can
explode
if
damaged.
Keep cylinders away from welding and other
electrical Circuits.
Never touch
cylinder
£9
WELDING WIRE
wounds.
Do not press gun
with
welding electrode.
Always secure cylinder to running gear, wall,
other stationary support.
ELECTRIC SHOCK
can
or
can
cause
puncture
trigger until instructed
to do so.
Do not point gun toward any part of the body, other
people, or any metal when threading welding wire.
kill.
Do not touch live electrical parts.
The welding wire, drive rolls, drive assembly, and all
metal parts touching the welding wire are electrically
live when welding or feeding wire using gun trigger.
HOT SURFACES
can
Allow gun to cool before
burn skin.
touching.
wfwam2.1 / wfwam7.1 9/91
OM-1 588
Page
12
1
Wire
2
Wire Tube
Spool/Reel
6
2
3
Pulley
4
Wire Guides
5
Drive Rolls
6
Jog Button
7
Gun Conduit Cable
8
Pressure Adjustment Knob
9
Drive Roll Pressure Indicator
Scale
Tools Needed:
I~I
See Figure 5-13 for
switch positions of 450
Ampere Inverter model
welding power
source or
welding
see
power
Owners Manual
for other models.
OFF
source
Wire Feeder
(see Figure 5-10)
Welding
Power Source
Pull and hold wire; cutoff end.
Set switches.
feed wire thru tube, over
and up to wire inlet guide.
Manually
pulley,
JOG
~*00
Push wire thru guides up to drive rolls;
continue to hold welding wire.Press
Select button (see Figure 5-6) to choose
active side of wire feeder. Press Jog
button (see Figure 5-8) until drive rolls
grab wire. Adjust tension until wire does
not slip. Indicator is for reference only.
Press
jog
button until wire
comes out
gun.
p
-~
Feed wire to check drive roll pressure.
Adjust knob enough
to
prevent slipping.
Cut off wire. Close cover.
for opposite side.
Repeat procedure
Ref. ST-800 178 / Ret. ST.150 922 / 5T-153 073/ Ret. 5T-157 432
Figure
3-18.
Threading Welding
Wire
CM-i 588
Page
13
SECTION 4- GLOSSARY
The
is
following
a
list of terms and their definitions
they apply
as
to this wire feeder:
General Terms
Adaptive Pulse
Background
Cold Wire
When the
adaptive pulse welding process is selected, the unit will automatically
regulate pulse frequency in order to maintain a constant arc length, regardless of
change in welding wire stickout.
Current
The lower of the two current levels in the
pulsing
wavetorm.
When current is not sensed, wire feeds for about three seconds at set wire feed
speed and then automatically opens the contactor while continuing to feed wire at
the wire jog speed.
Jog
Inductance
In short circuit
welding,
an
increase in inductance will decrease the number of short
circuit metal transfers per second (provided no other changes are made) and in
crease the arc-on time. The increased arc-on time makes the pool more fluid.
Peak Current
The
Pulses Per Second
Number of
(PPS
Or Pulse
Pulse Width
higher of
the two current levels in the
peak
current
pulses
which
pulsing
occur
in
waveform.
one
second of time.
Frequency)
(Or
Peak
Time)
Trim
Duration of the
peak
current level.
Term used to represent arc
by volts in MIG programs.
Synergic refers to the
Synergic
length adjustments
in
pulse programs. Trim is replaced
ability to use preprogrammed pulse parameters in order
pulse settings of Peak Amperage, Background Amperage,
Pulse Width at any specific wire feed speed setting.
units
to determine the actual
Pulse
Frequency
and
Front Panel Terms
Display
Control Knob
Digital Display
Gas
Purge Control
Is used for all
2-line
by
adjustable front panel displays.
16-character
liquid crystal display
Allows the gas line and gun to be
purged
with built-in LED
without
of parameters that
Parameter Select Button
Is used to select
Trigger Hold Control
When selected, allows the system to remain
to hold the gun trigger.
Wire
Jog
Control
a
variety
Allows the wire to feed without
can
energizing
be set
on
backlight.
the wire feeder.
the front
panel display.
energized without the operator having
energizing the welding power source contactor and
independent from actual wire feed speed, and is
gas valve. The wire jog speed is
displayed on the front panel.
Side Panel Terms
Digital Display
OM-1 588
Page
14
4-line
by
20-character
liquid crystal display
with built-in LED
backlight.
Dual Schedule
Allows two weld programs to be linked together when two different
tions, such as hotter and colder, are required on one wire.
Process Mode
Is used to select the type of process to be used,
welding
condi
including Pulse, Adaptive Pulse,
or
Mig.
Remote Parameter
When
Increase/Decrease
decrease
Sequence
Mode
Setup Screen
feature
this
is
turned
on,
the
operator
selected weld parameter with the
momentary-contact switch.
a
use
can
of the
remotely increase and
optional DSS-10 2-pole
Allows
a variety of sequences to be used within a weld program it required. Se
quences include, pref low gas control from 0 to 9.9 seconds, run-in control of voltage
or trim and wire feed speed from 0 to 2.5 seconds, weld time from 0 to 25 seconds,
crater control of voltage or trim and wire feed speed from 0 to 2.5 seconds, burnback
time from 0 to 0.25 seconds, and posttlow gas control from 0 to 9.9 seconds.
Terms
Access Mode
can be programmed in the access mode which restricts unautho
personnel from changing any of the security/set-up screens. NOTE: The
optional Data Card is required to activate this feature.
A three-letter code
rized
Arc Start
Provides the
option
Arc Time
Allows actual
arc
cumulated and
Dual Schedule
of
a
higher
arc
starting
amperage for
large
wires.
time up to 9,999.99 hours and weld cycles up to 999,999 to be ac
and can be reset to zero as required.
displayed on the digital display,
Is used to select the type of dual schedule switch that will be used when the dual
schedule feature is selected.
Mig Type
Selects whether
Model
Allows selection of
voltage
correction is used
boom-type
feeder
or
or not.
bench mount feeder
pulse program
parameters.
Name Feature
When
using the optional Data Card
programs written to the card
Program
Reset
Range
can
and
turning the name feature on, customized
by name, number, job number, etc.
be identified
By selecting program reset in the memory reset mode,
factory program settings for the program last active.
The wire feeder
source
requires that the voltage
the unit defaults to
and amperage range of the
be entered. Obtain this information from the
welding
power
original
welding power
source
Owners
Manual.
Remote Parameter
When the Remote Parameter Inc/Dec is on, a dual schedule switch can also be used
increasing or decreasing weld parameters when the front panel display cursor is
for
at
Security
Trim, Volts,
or
1PM.
Is used to limit what the
operator can control. This includes accessing the number of
the program, 1 through 8, and also the range of welding parameters within the pro
gram selected. NOTE: The optional Data Card is required to activate this feature.
Software Screen
Selection of this function will
System
This unit
can
display
be used either with
GMAW
(Pulse/Mig)
pulse
Only) welding only.
and
a
the software version of the unit.
welding power source capable of regular GMAW
welding power source capable of GMAW (Mig
or a
OM-1588
Page
15
System
Reset
By selecting system reset in the memory reset mode, the unit defaults to original fac
tory settings for all programs and all set up excluding System, Arc Time, and Model
Type.
Trigger Program
Select
Allows programs to be selected
Self Test Mode
Voltage
Control Feedback
remotely
with the gun
trigger.
A built-in
diagnostic feature to check a variety of wire feeder and power source func
tions if
malfunction
a
occurs.
Allows
voltage to be monitored at the output terminals by two methods. This can be
through the 17-pin cord connection if the welding power source has a
17-pin receptacle, or through the use of the units optional external voltage sense
selected
lead.
Arc StartlVolt Sense
When this feature is on, the system immediately shuts down if no arc voltage is
sensed. An error message is displayed. When this feature is off, wire feeds even
when there is no arc voltage sensed.
Shutdown
Wire Feed Mode
Allows the selection of inches per minute or meters per minute for wire feed speed.
This mode is also used to select motor type; standard speed, low speed, or high
speed. High and low speed motors are available as factory options.
SECTION 5-OPERATION
WARNING
A~
____
ELECTRIC SHOCK
can
kill.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
Do not touch live electrical parts.
Always
wear
yourself
Keep
panels
all
Wear
dry insulating gloves.
Insulate
from work and
and
covers
FUMES AND GASES
to your health.
Keep your head
Ventilate area,
S
ground.
securely
in
out of the fumes.
or use
breathing
MOVING PARTS
,~~~IIItii~
can cause
Do not weld
fire
S
or
explosion.
Keep
away from
Keep all doors,
and securely in
device.
Read Material Safety Data Sheets (MSDS5) and
manufacturers instructions for material used.
WELDING
body protection.
can cause
pinch points
panels,
place.
injury.
such
covers, and
as
drive rolls.
guards closed
MAGNETIC FIELDS FROM HIGH CUR
RENTS can affect pacemaker operation.
Pacemaker
wearers
flammable material.
near
with correct shade of filter.
place
be hazardous
can
welding helmet
Wear correct eye, ear, and
keep away.
Wearers should consult their doctor before
Watch for fire;
keep extinguisher nearby.
Do not locate unit
Do not weld
on
Allow work and
over
near
any
going
welding operations.
combustible surfaces.
closed containers.
equipment
to cool before
handling.
See Safety Precautions at beginning of manual forba
sic welding safety information.
~am3 1 8/92
Wear the
following
while
welding:
1
Dry, Insulating Gloves
2
Safety Glasses
12
With Side
Shields
3
Welding Helmet With Correct
Shade Of Filter (See ANSI
Z49.1)
______
~b3.1 1194
Figure
OM-1588
Page
16
5-1.
Safety Equipment
1
Work
Clamp
Connect work clamp to a clean,
paint-f ree location on workpiece,
as close to weld area as possible.
Use wire brush or sandpaper to
clean metal at weld joint area. Use
chipping hammer
after welding.
Tools Needed:
2
to remove
slag
Voltage Sensing Clamp
Connect to workpiece, if applicable
(see Section 3-9).
Use chipping hammer
slag after welding.
to remove
sb41
Figure
5-1.
5-2. Work And
2/93
Voltage Sensing Clamps
Front Panel Controls
_iI~
2
3
10
1
Display
2
Parameter Select Button
3
Display Control
4
Right
5
Right Side Trigger
Hold
Button And Indicator Light
6
Side Select Button
7
Left Side Trigger Hold Button
And Indicator Light
8
Left Side Indicator
9
Jog
10
Purge Button
Knob
Side Indicator
Light
Light
~
ckO~
9
8
o/pss\o
Iv
Button
See Section 6 for information
4
using microprocessor
on
controls.
\\\\
7
6
5
ST-162 127
Figure
5-3. Front Panel Controls
1
Parameter Select Button
Press button to move indicator
on
display.
R.f. 91.187 703
Figure
5-4. Parameter Select Button
OM-1588 Page 17
1
Display Control
Turn
knob
selected.
Spin
to
knob
to
parameters
by clicks
Knob
value
change
quickly
or move
to fine tune
change
slowly
parameters.
knob
1
Figure
5-5.
Display Control
Knob
2
\
~
6
'
Side Select Button
2
Side Indicator
Light
Push button to select active side of
wire feeder. Indicator light is on for
active side.
The feeder remembers the last
used program for each side, and
returns to that program when the
active side is changed.
TRIGGER
r=
1
HOLD
0
Note: gun
trigger may also be used
change active side of
to select or
wire feeder.
RECEPTACLE
%__~_
-~
Figure
5-6. Select Button And Side Indicator
Lights
Trigger
2
2
o,>~
0
Hold Button
Indicator
Light
To weld without holding gun trigger
throughout weld cycle, press and
release button to turn on indicator
light and hold circuit.
To start weld
cycle, and feed weld
ing wire, press and release gun
trigger within the first three sec
TRIGGER
onds after an arc has been struck.
If gun trigger is not released within
the first three seconds after arc ini
tiation, trigger hold stops, but is still
active for next weld cycle. To end
weld cycle, press and release gun
HOLD
trigger.
Trigger
hold
while gun
cannot
be
started
trigger is pressed.
If the Trigger hold button is pushed
for the nonactive side of the feeder
(see Figure 5-6), the trigger hold
RECEPTACLE
indicator light turns on, but Trigger
Hold does not become active until
that side is selected.
Figure
OM-1 588 Page 18
5-7.
Trigger
Hold Button
I
Jog
Jog
Push Button
works
side
active, or selected
feeder
only
(see
on
of
Figure 5-6). Separate jog speeds
be set for each side of the
feeder.
can
Push to momentarily feed welding
wire without energizing welding cir
cuit
or
shielding gas
valve.
Jog speed is varied using the Dis
play Control knob while Jog button
is pressed. Default setting is 200
2.
1pm.
When
Jog button is released, unit
displays preset wire feed speed,
and previously selected parameter
is active.
Jog
does not work when gun
trig
ger is pressed.
Jog
2
50
Tr
im
Prg
Push Button
Purge
Purge works
on
active,
or
selected
-.
side
>200
I
PM
Tr
im
Jog
of
feeder
only
(see
Figure 5-6).
Push to
Jog
momentarily energize gas
purging of air
from gun shielding gas line, and
adjusting shielding gas regulator
without energizing the welding
valve. This allows
>50
260
Prg
I
Pulse
circuit.
Front panel controls, side panel
controls, and gun trigger do not
work when
Jog
or
Purge
button is
pressed.
Figure
5-2.
5-8.
Jog
And
Purge
Buttons
Side Panel Controls
1
Parameter Increase Button
2
Parameter Decrease Button
3
Parameter Select Button
4
Mode Select Button
5
Mode
6
Parameter
Display
Display
See Section 6 for information
using microprocessor controls.
on
3
Ref. ST-182 133
Figure
5-9. Side Panel Controls
OM-1588
Page
19
5-3.
Rear Panel Controls
Power Switch
1
Use power switch to turn unit On
and Ott.
2
Circuit Breaker (See Section
2
14-3)
1
5T-800 177
Figure
5-10. Power Switch
I
BUILDUP OF SHIE LDING GAS can harm health
t
Shut off
when not in
shielding gas supply
or
kill.
use.
waml.1 2/93
1
Shielding Gas Cylinder
2
Valve
3
Gun
Trigger
Open vave
welding.
on
Gun
turns weld
and off.
trigger
gas flow
on
cylinder just
before
output
and
3
Close valve on
ished welding.
cylinder
when fin
sb5.1 6/92S-0621-C
Figure
H IGH FREQUENCY will
Turn Off
J
high frequency
Completely disconnect this
~\
)
Page
20
Gas
using
unit from power source when
~~\
System
) )
II (See Figure 3-~J ,
)
unit.
this unit.
Install Welding
)
using high frequency.
Put On
Personal Safety
Equipment
~~Turn On Shiel~i~\\
Turn On
Feeder And ) )
Power Source JJ
) ) Wire
JJ
Gas
)
)
(If Applicable) J J
Set All
Controls
(See Figure 5-13
Begin
Welding
Figure
OM-1588
damage this
when
Install &
Connect
Wire Feeder
Shielding
CAUTION
a
S
5-11.
5-12.
Metal Arc (GMAW), Gas Metal Arc
And Flux Cored Arc Welding (FCAW)
Sequence Of Gas
-
Pulse
(GMAW-P),
5-4.
Setting Switches On
450
Ampere Inverter Model Welding Power Source
Always
use
switch
settings
shown for all
welding
processes when using this wire feeder.
/
A/V
o
PANEL
~J~I7
~D~JZ
ONI
G*ouTPuT~oR
o
PAP~L
ARC FOR~ /INDUCTAN~
N~
~C/CV
4
Ref. ST-150 171-C/Ref. SC-154 197
Figure
5-13.
Setting Switches
On 450
Ampere
Inverter Model
Welding
Power Source
OM-1588
Page
21
SECTION 6- STEPPING THROUGH THE
MICROPROCESSOR CONTROLS
WARNING
£~
.
ELECTRIC SHOCK
S
S
can
kill.
WELDING WIRE
Control circuit and feeder operational power are On
when
using
or
changing
the
can
cause
puncture
wounds.
Do not touch live electrical parts.
S
Do not point gun towards any part of the body, other
people, or any metal when programming.
The welding wire is electrically live and moves out of
microprocessor
settings.
the gun whenever the power switch is On and the gun
trigger is pressed.
N OT E LI~T~
This unit is
equipped with eight (8) pulse welding programs (see Section 7).
When
the unit is turned On for the first time program 1 comes up, therefore, program 1 is
i/lustrated throughout this manual. Instructions are given later in this manual (see
Section 9) on how to select or change a program.
6-1.
Front Panel Micr oprocessor Controls
Turn On welding power source and
wire feeder. Follow along with the
controls as shown.
1
Front Panel
2
Parameter Select Button
Display
Press parameter select button to
indicator.
move
The indicator points to parameters
that are selected for change.
ooO
00
0
Parameter select button can move
indicator between Trim (arc length)
and 1PM while welding.
0
Go to
00000
50
200
Tr
im
>Prg
I
PM
Pulse
Trim
>50
200
1PM
Prg
Figure
6-2.
1
Pulse
e
Trim
50
>200
1PM
Prg
1
Pulse
ST-162 127
Figure
OM-1 588
Page
22
6-1. Front Panel Parameter Select Button
1
Front Panel
Display
Select parameter to be
changed
(see Figure 6-1).
2
__
Display
Control Knob
Turning knob one click causes the
following changes to selected
2
setting:
00
Trim
00
00
(arc length) increases/de
by one.
creases
00000
The trim (arc
length) value being
changed also changes on the side
panel parameter display (see
Figure 8-3).
Wire feed speed (1PM) increases/
decreases by one inch per minute.
>50
200
Trim
Prg
1PM
1
The wire feed speed value being
changed also changes on the side
Pulse
panel parameter
Figure 8-3).
Program number
ses/decreases by
j~5~
>55
200
~
The program number cannot be
changed while welding, with ex
ception of Dual Schedule Mode
(see Section 11).
Front Panel
Parameter
Select
All
accessible
are
programs
either side of the feeder,
and any program is available to ei
ther side of the feeder at the same
time.
through
e
55
>200
Trim
Prg
Display Control knob can be used
Jog speed when Jog button
is pressed (see Figure 5-8).
to set
Puls~J
1PM
Pulse is a default setting. To
change type of program (Pulse,
Adaptive Pulse, or MIG) use side
panel controls (see Sections 9-4
and 10-1).
Display
Control
Go to
55
>300
Trim~
IPMJ
Prg
increa
one.
number
program
being
changed also changes on the side
panel parameter display (see
Figure 6-5).
Prg
1PM
(Prg #)
(see
The
ii
Pulse]
Trim
display
Figure
6-3.
1
Pulse
Front Panel
Parameter
Select
55
300
50
200
Trim
1PM
Trim
1PM
>Prg
1
Pulse
>Prg
2
Pulse
ST-162 127
Figure
6-2. Front Panel
Display Control
Knob
CM-i 588
Page
23
6-2.
Side Panel
Microprocessor
Push Buttons
1
Mode
2
Mode Select Button
Display
Press Mode button to
tor in left window
Go to
Figure
move
indica
display.
6-4.
Side Panel
Process
>S
e q u e n c e
Dua I Schd
Card
Process
Sequence
>Du
a
IS
c
h d
Card
Process
Sequence
L..__i
Dual Schd
>C
a
r
d
Ref. ST-154 109
Figure
OM-1 588 Page 24
6-3. Side Panel Mode Select Button
1
Parameter
2
Moving
Display
Line
Moving line is
be changed.
under value that
can
Side Panel Parameter Select
Button
3
Press side panel parameter select
button to move indicator in right
window display.
Side Panel
Prg
>E
u
I
1
~ e
O35~SteeI
ArgonO
I
L
Figure
xy
Pulse
I 035Steel
7 ArgonOxy
I>Teach Qff
6-4. Side Panel Parameter Select Button
OM-1588
Page
25
Use side
panel mode select button
changed (see
Figure 6-3).
to select mode to be
Use side panel parameter select
button to select parameter to be
changed (see Figure 6-4).
1
Increase Button
Press button to increase value that
is underlined by the moving line.
2
Decrease Button
Press button to decrease value
that is underlined by the moving
line.
Side Panel
1
~
>Prg
~
I
Increase
Increase
>Prg
3
Pulse
2
052Stee
ArgonO
I
xy
Decrease
>Prg
2
Pulse
045Steel
ArgonO
xy
Ref. ST-154 109
Figure
OM-1 588 Page 26
6-5. Side Panel Parameter Increase And Decrease Buttons
SECTION 7- STANDARD PULSE WELDING PROGRAMS
The
following eight (8) pulse welding programs are in the memory of the wire feeder. Use this information if it is neces
sary to change a standard program, or as a basis to build your own custom program. If at any time while changing a
standard program, or while building your own custom program, you want to revert back to the standard program in the
wire feeder memory, see Section 13-17, Resetting Memory.
Program
Program
# 1
Program
Name: .035
Wire
Size/Type: .035
Steel, Argon
-
1
S-3
Gas: 98 Ar
-
2
Oxy
or
95Ar
-
5
Oxy
Card #_________________________
Oxy
Gun Model: MILLER GW
Flowrate: 40 CFM
1PM I MPM
ApK
AbK
PPS
PWms
750/19.1
490
105
200
2.0
700/17.8
480
100
190
1.9
650/16.5
470
95
185
1.9
600 / 15.2
465
93
180
1.9
550/14.0
460
90
175
1.8
500/12.7
450
85
170
1.8
450/11.4
430
80
160
1.8
400/10.2
410
75
150
1.7
350 / 8.9
390
70
140
1.7
300/7.6
370
65
130
1.6
250/6.4
350
50
120
1.6
200/5.1
330
47
110
1.6
150/3.8
315
45
90
1.5
100/2.5
300
45
40
1.5
80/2.0
290
40
35
1.5
COMMENTS
Preflow: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:__________________________
CraterTrim:50
1PM: 200
Sec.:______________________
Postflow: 0 Sec.
OM-1588
Page
27
Program
Program
Wire
#2
SizeiType:
Program Name: .045 Steel, Argon
-
.045
2
S-3
Gas: 98Ar
Oxy
-
2
Oxy
or
95 Ar
-
5
Oxy
Card #_________________________
Gun Model: MILLER GW
Flowrate: 40 CFM
1PM I MPM
ApK
AbK
PPS
PWms
750/19.1
540
110
220
3.2
700/17.8
530
110
210
3.2
650/16.5
520
110
200
3.2
600/15.2
510
110
190
3.2
550/14.0
500
110
180
3.1
500/12.7
490
105
170
3.0
450/11.4
470
105
160
2.9
400/10.2
450
100
150
2.8
350/8.9
440
100
140
2.7
300/7.6
430
95
130
2.6
250/6.4
420
90
120
2.5
200/5.1
400
80
100
2.5
150/3.8
380
70
80
2.4
100/2.5
345
50
60
2.4
80/2.0
310
30
38
2.2
COMMENTS
.
Preflow: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:__________________________
Crater Trim: 50
1PM: 200
Sec.:___________________________
Postf low: 0 Sec.
OM-1588
Page 28
Program
Program
# 3
Program
Name: .052
Wire
Size/Type:
Steel, Argon
-
.052
3
S-3
Gas: 98Ar
Oxy
-
2
Oxy
or
95 Ar
-
5
Oxy
Card #_________________________
Gun Model: MILLER GW
Flowrate: 40 CFM
1PM / MPM
ApK
AbK
PPS
PWms
750/19.1
565
145
260
3.1
700/17.8
565
140
260
3.1
650/16.5
560
135
260
3.1
600 /15.2
560
130
255
3.1
550/14.0
560
125
240
3.1
500/12.7
550
120
225
3.0
450/11.4
540
115
210
2.9
400/10.2
530
110
195
2.8
350/8.9
520
105
170
2.7
300/7.6
510
100
155
2.7
250/6.4
500
90
140
2.6
200/5.1
480
80
120
2.6
150/3.8
460
70
100
2.5
100/2.5
420
50
80
2.4
50/1.3
350
32
50
2.2
COMMENTS
Preflow: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:__________________________
Crater Trim: 50
1PM: 200
Sec.:___________________________
Postf low: 0 Sec.
OM-1588
Page
29
Program
Program
# 4
Wire
Program Name:
.035
Size/Type:
309, Argon
-
.035
4
309
Gas: 98 Ar
CO2
-
2
CO2
or
95Ar
-
5
CO2
Card #________________________
Gun Model: MILLER GW
Flowrate: 40 CFM
1PM I MPM
ApK
AbK
PPS
PWms
750/19.1
390
95
210
2.2
700/17.8
380
95
200
2.1
650/16.5
370
90
190
2.0
600/15.2
360
85
180
1.9
550/14.0
350
80
170
1.9
500 / 12.7
340
75
160
1.9
450/11.4
330
70
150
1.8
400/10.2
320
65
140
1.8
350/8.9
310
60
130
1.7
300/7.6
300
55
120
1.6
250/6.4
290
50
100
1.6
200/5.1
280
45
80
1.6
150/3.8
270
40
60
1.6
100/2.5
270
36
40
1.5
80/2.0
260
30
30
1.5
COMMENTS
Pref low: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:___________________________
Crater Trim: 50
1PM: 200
Sec.:__________________________
Postf low: 0 Sec.
OM-1 588
Page
30
Program
Program
# 5
Wire
Program
Name: .045
Size/Type:
Steel, 309, Argon
.045
-
5
Gas: 98 Ar
309
-
2
CO2
or
95Ar
-
5
Co2
Card #_________________________
CO2
Gun Model: MILLER GW
Flowrate: 40 CFM
1PM / MPM
ApK
AbK
PPS
PWms
750/19.1
490
115
290
2.3
700/17.8
480
115
280
2.3
650/16.5
450
115
270
2.1
600/15.2
435
112
260
2.0
550/14.0
430
110
240
2.0
500/12.7
425
105
230
1.9
450/11.4
420
105
220
1.9
400/10.2
415
105
200
1.8
350/8.9
410
100
180
1.8
300/7.6
400
95
160
1.7
250/6.4
380
88
140
1.7
200/5.1
360
85
115
1.7
150/3.8
340
68
88
1.6
100/2.5
320
50
70
1.6
80/2.0
310
45
60
1.5
COMMENTS
Preflow: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:__________________________
Crater Trim: 50
1PM: 200
Sec.:__________________________
Postflow: 0 Sec.
OM-1 588
Page
31
Program
Program
# 6
Program
Name: 3/64
Wire
Size/Type:
3/64
6
4043
Gas:
Argon
Card #_________________________
4043, Argon
Gun Model: MILLER GW
Flowrate: 40 CFM
1PM / MPM
ApK
AbK
PPS
PWms
750/19.1
510
150
190
3.5
700/17.8
485
150
180
3.4
650/16.5
485
150
180
3.4
600 / 15.2
470
145
180
3.3
550/14.0
445
140
170
3.1
500/12.7
420
135
160
2.9
450/11.4
400
130
150
2.8
400/10.2
360
120
140
2.7
350/8.9
340
115
130
2.6
300/7.6
310
100
120
2.5
250/6.4
277
87
110
2.4
200/5.1
250
68
100
2.3
150/3.8
215
50
90
2.1
100/2.5
190
30
80
2.0
80/2.0
190
27
45
2.0
COMMENTS
Preflow: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:___________________________
CraterTrim:50
1PM: 200
Sec.:_____________________
Postf low: 0 Sec.
OM-1588
Page
32
Program
Wire
Program
# 7
Program
Name: 3/64
Size/Type: 3/64
7
5356
Gas:
Argon
Card #_________________________
5356, Argon
Gun Model: MILLER GW
Flowrate: 40 CFM
1PM I MPM
ApK
AbK
PPS
PWms
750/19.1
515
130
190
2.8
700/17.8
510
120
190
2.8
650/16.5
490
120
180
2.7
600/15.2
470
115
170
2.7
550/14.0
450
110
160
2.6
500/12.7
430
100
150
2.5
450/11.4
410
90
140
2.5
400 / 10.2
390
80
130
2.4
350/8.9
370
65
112
2.4
300 / 7.6
340
52
103
2.3
250 / 6.4
325
47
90
2.3
200/5.1
300
40
80
2.2
150/3.8
277
35
53
2.2
100/2.5
260
24
40
2.2
50/1.3
230
20
35
2.0
COMMENTS
Preflow: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:__________________________
CraterTrim:50
1PM: 200
Sec.:______________________
Postflow: 0 Sec.
OM-1 588
Page
33
Program
Wire
Program
# 8
Program
Name: .035
Size/Type:
Nickl, Argon
-
.035
8
Gas: 75 Ar
Nickl
He
-
25 He
Card #________________________
Gun Model: MILLER GW
Flowrate: 40 CFM
1PM / MPM
ApK
AbK
PPS
PWms
750/19.1
390
110
130
3.5
700/17.8
380
105
130
3.5
650 / 16.5
370
100
125
3.4
600/15.2
360
90
120
3.4
550/14.0
350
85
115
3.3
500/12.7
345
80
110
3.3
450/11.4
340
75
105
3.3
400 / 10.2
335
65
90
3.2
350/8.9
332
60
75
3.1
300 / 7.6
320
55
65
3.0
250 / 6.4
310
50
58
3.0
200/5.1
297
44
52
2.9
150/3.8
282
37
42
2.9
100/2.5
262
29
33
2.8
50/1.3
225
23
30
2.7
COMMENTS
Preflow: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:__________________________
CraterTrim:50
1PM: 200
Sec.:_____________________
Posti low: 0 Sec.
OM-1 588
Page
34
SECTION 8- GETTING STARTED
WARNING
a
ELECTRIC SHOCK
can
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
kill.
Do not touch live electrical parts.
Always
wear
Insulate
Wear
dry insulating gloves.
yourself
from work and
Keep all panels and
covers
or use
MOVING PARTS
near
fire
or
can cause
Keep all doors, panels,
and securely in place.
breathing device.
can cause
Do not weld
body protection.
Keep away from pinch points
Read Material Safety Data Sheets (MSDSs) and
manufacturers instructions for material used.
WELDING
helmet with correct shade of filter.
securely in place.
FUMES AND GASES can be hazardous
to your health.
Keep your head out of the fumes.
Ventilate area,
welding
Wear correct eye, ear, and
ground.
injury.
such
covers, and
as
drive rolls.
guards closed
MAGNETIC FIELDS FROM HIGH CUR
RENTS can affect pacemaker operation.
explosion.
Pacemaker
wearers
keep away.
flammable material.
Wearers should consult their doctor before going
Watch for fire;
keep extinguisher nearby.
Do not locate unit
Do not weld
on
Allow work and
NOTE ~
over
near arc
welding, gouging,
or
spot welding opera
tions.
combustible surfaces.
closed containers.
See Safety Precautions at beginning of manual for ba
sic welding safety information.
~am61 8/92
equipment to cool before handling.
Set up
equipment according
to
Figure
5-12. Use the standard
program in Section 7 that is closest to your application
gas type) when setting up.
(by
wire
pulse welding
type and size and
OM-1 588
Page
35
8-1.
Welding
With
Only
Front Panel Controls
Turn On
wire
welding
power source,
feeder, and gas.
Use Select button or gun trigger to
select active side of feeder.
1
~1
Display
Program
1 is the default program
the first time the unit is turned on,
at other times the last program
-p
>Prg
200
Front Panel
number selected is displayed. Use
the front panel parameter select
button to select the Prg #.
Pulse
2
Display
Control
2
Prg3
Select the weld program from
Section 7 (1 through 8) which is
closest to your needs (by wire and
gas).
Strike
an
arc
and
try
a
sample
weld.
Trim
50
200
>Prg
1PM
3
3
Pulse
If
Trim (Arc
Length)
necessary, select Trim, and
to achieve the best arc.
adjust
4
U
Front Panel
Parameter Select
If
1PM
necessary,
select 1PM, and
the best arc.
adjust to achieve
Go to Section 8-2.
I
F50
Trim
200
Prg
1PM
3
Pulse
Display
3
Control
~Ij
I
I
Trim
>55
200
Prg
1PM
3
Pulse
Front Panel
U
Parameter Select
Trimi
1>200
J
1PM
Prg
3
Pulse
g~
Trim
55
>250
1PM
Prg
3
Pulse
-
/
Figure
OM-1 588
Page
36
8-1.
Welding
With
Only
Front Panel Controls
8-2.
Pulse
Setting Sequence
Welding
Parameters On Side Panel
Display
WARNING
a
ELECTRIC SHOCK
can
WELDING WIRE can cause
wounds.
kill.
Do not touch live electrical parts.
Do not point gun towards any part of the body, other
people, or any metal when programming.
The welding wire is electrically live and moves out of
the gun whenever the power switch is On and the gun
trigger is pressed.
S
Control circuit and feeder operational power are On
when using or changing the microprocessor
settings.
NOTE ~
puncture
Figure 8-2 is a graphic layout of a weld cycle. Follow examples in Figure 8-3
through Figure 8-8 to adjust sequence welding parameters to fit your needs.
Weld Time 0-25 Sec.
Run-In Time
0-2.5 Sec.
a,
a)
o.
CraterTime
0-2.5 Sec.
Run-In
a)
Speed
a)
I
/
a.
ci
~a,I
a)
Pref low
0-9.9 Sec.
Oci
Tim!_,J
Trigger
Arc
Start
U
Trigger
Released
Bumback Time
0-0.25 Sec.
/~
Postflow Time
0-9.9
Arc
Ot
u
Sec.~
~
Time
Pressed
Ref. S-0271
Figure
8-2. Weld
Cycle
OM-1588
Page
37
Mode Select Button
1
Process
>S
e
q
When unit is turned On, Process is
the default mode, at other times,
use mode select button to select
>WQ I ~
50.
u e n c e
Trim
Dual Schd
200
1PM
Card
0.0
Sec
Sequence.
2
Side Panel Parameter Select
Button
Use side panel parameter select
button to select parameters.
2
3
Weld Parameters
Display
Parameter ranges
are as
Trim
0-99
(Arc Length),
Changes
are
also
to Weld
displayed
follows:
Sequence Trim
on
front
panel
display.
Wire Feed Speed, 50-780 Inches
Per Minute, 1PM
Changes
are
also
to Weld
displayed
display.
Set Desired Weld
Sequence Voltage
Seconds, 0-25.0 Sec. If value set is
(0), welding will continue until
welding gun trigger is released.
zero
Or
lncrease/
Decrease
use
I
front
We I d
panel parameter
1>50
select to move
indicator to trim.
I
Trim
be fine tuned
while welding,
see Figure 6-2.
can
Trim
200
1PM
0.0
Sec
Side Panel
Parameter
Select
Set Desired Weld Sequence
Wire Feed Speed
Or
~
use
front
panel parameter
select to move
indicator to 1PM.
lncrease/
Decrease
1PM can be fine
tuned while welding,
see
Figure
6-2.
Side Panel
Parameter
Select
Set Desired Weld Sequence
Time, If Applicable
We I d
Trim
60
300
1PM
>0.0
Sec
lncrease/
Decrease
~
Side Panel
Parameter
Select
We I d
60
Increase
Proceed to next
Figure
OM-1588
Page
38
Sequence 1PM
on front panel
8-3.
Trim
300
1PM
>3.5
Sec
figure.
Setting
Weld
Sequence Display
Go to
Figure
8-4.
1
Crater Parameters
Parameter ranges
>Gr~ter
50
I
I
Triml
200
1PM
0.00
Sec
~
7
Crater
I>~Q
~
200
~
1PM
0.00
Trim
Crater
I
Trim
Sec
60
0.00
1PM
1
Sec
I
(Arc Length), 0-99
Seconds, 0-2.50 Sec. If value set is
(0),
zero
Side Panel
Parameter
Select
Side Panel
Parameter
Select
Set Desired
Trim
lncrease/
>Cr~t~r
150
Go to
I
is
Crater
no
Figure
8-5.
Side Panel
Parameter
Select
TrimLJ
60
~
1PM
0.20
there
sequence.
Crater
TrimL
60
Set Desired
Wire Feed Speed
lncrease/
Decrease
Decrease
follows:
Wire Feed Speed, 50-780 Inches
Per Minute, 1PM
Trim
>2Q0
Display
are as
Sec
150
1PM
>
Sec
Side Panel Set Desired lime
Parameter
Select
Increase
Proceed to next figure.
Figure
8-4.
lncrease/
Decrease
Setting
Crater
Sequence Display
1
Burnback Parameters Dis
play
__/
__
__
i~~urn.b~Qh
Bu rnback
ii r n
Sec
0.12
b
~
Ic
Burnback can be adjusted from
0-0.25 seconds. If value set is zero
there
is
Burnback
no
(0),
sequence.
0.00
Sec
>Q~QQ
Sec
Go to
Figure
8-6.
____________
Side Panel
Parameter
Select
Set Desired lime
Side Panel
Parameter
Select
Increase
Proceed to next
lncrease/
Decrease
Figure
8-5.
SettIng
Burnback
figure.
Sequence Display
1
______/
______
______
Postflow
>~Q~tfIQW
0.0
Sec
~
Side Panel
Parameter
Select
>~Q~IfIQ~
Postf low Parameters
Go to
Sec
Set Desired lime
1.2
Increase
Proceed to next
Setting
8-7.
Sec
~ncrease/
8-6.
Figure
Side Panel
Parameter
Select
Decrease
Figure
Display
Postflow can be adjusted from
0-9.9 seconds. If value set is zero
(0), there is no Postf low sequence.
Postf low
figure.
Sequence Display
OM-1 588
Page
39
Pref low Parameters
1
Display
Pref low can be adjusted from 0-9.9
seconds. It value set is zero (0),
there is no Pref low sequence.
Go to
Figure 8-8.
/
______
L0
______
Preflow
Sec
~
>?reJlQw
Sec
Side Panel
Parameter
Select
lncrease/
Decrease
Figure
8-7.
Setting
Preflow
Sec
1.2
Side Panel
Parameter
Select
Set Desired Time
Increase
Proceed to next figure.
Sequence Display
Run-In Parameters
1
Parameter ranges
Display
are as
follows:
Trim, 0-99.
Wire Feed
Speed,
50-780 inches
per minute, 1PM
Seconds, 0-2.5 Sec. If value set is
(0), there is no Run-In
zero
sequence.
~
Side Panel
Parameter
Select
Set Desired
Wire Feed Speed
O
Increase!
Decrease
Increase!
Decrease
I
Runin
Trim
55
Side Panel
Parameter
Select
Increase
150
1PM
~
Sec
Set Desired Time
Increase!
Decrease
Figure
OM-1 588
Page
40
8-8.
Setting
Run-in
~
Sequence Display
Side Panel
Parameter
Select
SECTION 9
TEACHING A PULSE WELDING PROGRAM
WARNING
a
ELECTRIC SHOCK
can
4
kill.
Do not touch live electrical parts.
Control circuit and feeder operational power are On
when
using
or
changing
the
microprocessor
I
settings.
NOTE ~
9-1.
L~(
~
~/I
See GMAW-P
information.
Pulse Waveform
(Pulsed MIG)
WELDING WIRE
can
cause
puncture
wounds.
Do not point gun towards any part of the body, other
people, or any metal when programming.
The welding wire is electrically live and moves out of
the gun whenever the power switch is On and the gun
trigger is pressed.
Process Guide
supplied with
unit for
more
Explained
The wire feeder, not the welding
power source, controls weld output
for pulsed welds.
1
Peak Current Of
100-565 Amperes
Apl(
is the high pulse of welding
Peak current melts the
ApK
current.
welding wire and forms a droplet.
The droplet is forced into the weld
puddle.
2
AbK Background Current
Of 10-200 Amperes
AbK is the low weld current. Back
ground
C
0
(0
0.
E
;~\3~
current
preheats welding
wire and maintains the arc. When
background current Is too low, the
is unstable and hard to
arc
maintain.
I
_/ ~
PPS
3
Pulses Per Second Of
20-400
PPS, pulse rate, and frequency
are used interchangeably. A
PPS or pulse rate of 60 Hz means
60 pulses of current are produced
each second.
(Hz)
4
PWms
Pulse Width Of
1.0-5.0 Milliseconds
Time
PWms is the time spent at peak
(1.2 ms is .0012 seconds).
This time must be long enough to
form a droplet of welding wire. The
stiffness or fluidity of the molten
weld puddle is controlled by
PWms.
current
Ast. S.0259
Figure
9-1. Pulse Waveforms And
Explanation Of Terms
OM-1 588
Page
41
Teach Points
9-2.
Explained
1PM
780
750
700
650
600
550
Example Of A Synergic
Setting For 425 1PM With
500
All Teach Points Set At
50 1PM Increments
450
400
350
300
250
r
200
o
AbK
o
pps
150
100
PWms
50
100
180
210
240
270
300
330
360
370
420
450
480
510
540
565
ApK
10
20
30
40
50
60
70
80
90
100
110
120
130
140
200
AbK
20
55
80
105
130
160
185
210
235
260
290
315
340
365
400
PPS
1
2
The teach mode allows the user to create
custom pulse MIG welding programs. The
teach mode has 15 teach
points. At each
point, the user can adjust four parameters: peak amperage (ApK), background
amperage (AbK), pulses per second (PPS),
and pulse width in milliseconds (PWms) to
shape the pulse waveform of the weld
teach
output.
teach points can range
from the minimum to the maximum wire feed
speed of the feeder. When using a standard
speed motor, wire feed speed teach points
typically range from 50 to 750 ipm. The wire
Wire feed
speed
4
3
speed of the lowermost
teach point, and above the wire feed speed
of the uppermost teach point, the unit may
limit wire feed speed settings in pulse MIG to
maintain all pulse parameters within the caBelow the wire feed
pability
tered for all 15 teach points. The operator
can relocate and modify the setting of one, or
any number of the 15 teach points if the factory set information is not appropriate for a
specific application,
pulse parameters at any wire feed
speed setting.
wire feeder to learn the arc voltage length
associated with the taught pulse parame-
OM-1588
Page
9-2.
Typical
arc
length represents a Trim (arc
of 50. Increasing the value of
Trim, increases the actual arc length. Like
wise, decreasing the value of Trim will de
length) setting
crease
actual
arc
length.
In the Pulse mode, the unit does not maina constant arc length with variations in
tam
electrical stick-out. In the
After the parameters for each teach point are
established, an arc must be struck and maintamed for at least 5 seconds. This allows the
Figure
a proper arc length reading,
electrical stick-out must be carefully maintamed, and the weld must be terminated by
releasing the gun trigger, not by pulling the
welding gun away from the workpiece.
The taught
Pulse MIG programs made by the manufacturer have pulse waveform information en-
speed of a teach point can be redefined
to any wire speed setting between adjacent
teach points (see Section 9-3). The feeder
uses pulse parameters at teach points to es-
42
ters. To ensure
of the unit.
feed
tablish the
PWms
5
Adaptive Pulse
mode, the unit adjusts pulse frequency
Teach Point
Settings
And
maintain
a
constant
arc
to
length regardless of
variations in electrical stick-out.
Proceed to next
figure
to teach a
program.
Resulting Synergic Setting
pulse MIG
9-3.
Teaching
A Pulse
Welding Program
~H~i
A.
Selecting
And/Or
Redefining
READ SAFETY BLOCKS at start of
Section 9 before proceeding.
Teach Point Wire Feed
Speed
1
point (1PM) can be selected on either the side panel or front panel displays,
but the wire feed speed of a teach point can only be redefined with the Purge button
and Display Control knob while 1PM is selected on the front panel display.
A teach
Process
Display
When unit is first turned On, Pro
cess is the default screen, at other
times use mode select button to
select Process.
2
Teach
Display
Use parameter select button to
lect Teach.
se
Use increase/decrease buttons to
select On.
3
1PM
(Teach Point)
You can also select a teach point
with the front panel Display Control
knob if the cursor on the front panel
display is pointing at 1PM.
To redefine the wire feed speed of
a teach point, proceed as follows:
Increase/
Decrease
4
>Teach
Qfl
Display
se
Press and hold Purge button while
turning Display Control knob to re
define the teach point wire feed
speed. For example, if teach points
reside at 150, 200, and 250 ipm,
the teach point at 200 can be ad
justed to a wire feed speed of 151
to 249 ipm.
Side Panel
Parameter
Select
Selecting A Teach
Front Panel
Use parameter select button to
lect 1PM (teach point).
Repeat the procedure for as many
of the 15 teach points as desired.
Point
To
set
or
adjust
teach
point
parameters, go to Figure 9-4.
Redefining A Teach Point
50
450
Trim
1PM
i~
>Prg
Pu
Tr
50
I_ser9j>45
0
im
1PM
Front Panel
Parameter
Select
And
50
>4 6 0
Figure
9-3.
T rim
1PM
Selecting
And/Or
Prg
iL
i
Puse
Redefining
A Teach Point
OM-1588
Page
43
B.
Setting
Teach Point Parameters On The Side Panel
Side Panel
Parameter
Select
I2
3
I
U
Side Panel
Parameter
Select
lncrease/
Decrease
I
343
I
U]
Apk~
92
Abk
280
PPS
>
PWm
9
_______
~
Or
-.~I
I
343
Apk
92
Abk
280
PPS
~
PWm
S
____
~ ~Teach
Pulse
~
460
1PM
343
Apk
92
Abk
035~Stee
Argon-Oxyi
>Teach
Qf
____________
Side Panel
Parameter
Select
I
I
lncrease/
Decrease
~
4
Side Panel
Parameter
Select
5
IPrgl
I
Pulse
I
035Steel
I Argon-Ox~j
When the Process Teach mode is On, and
one of the following pulse parameters is se
lected: ApK, AbK, PPS, or PWms, the front
panel displays the selected pulse parameter
instead of Trim (arc length). When the pulse
parameter is selected on the front panel, the
value can be changed with the front panel
Display Control knob, or the side panel as
follows:
Figure
OM-1588
Page
44
9-4.
1
ApK Display
2
AbK
Display
3
PPS
Display
4
PWms
until
custom
program
is
complete (see
Figure 9-2).
Turn Teach mode Off.
Display
When values have been set for a teach
point, strike and maintain an arc for five sec
onds. Repeat procedure at each teach point
Setting Teach
5
Custom Pulse Screen
The letter C will appear in the upper
ner of all customized programs.
To set Sequence
Section 8-2.
Point Parameters On The Side Panel
right cor
Welding Parameters,
see
N OTE LI~
Program #__________
Make
Wire
copies
of this chart for future
use.
Size/Type________________________ Gas__________________________
Program Name__________________________________________
Card #_______________________
Gun Model_____________________________________________ Flowrate
1PM
ApK
AbK
PPS
PWms
CFM
COMMENTS
Pret low:__________________ Sec.
Run-In Trim:_______________ 1PM:___________________________ Sec.:_________________________
Crater Trim:_______________ 1PM:___________________________ Sec.:_________________________
Postf low:________________ Sec.
OM-1588
Page
45
9-4.
Changing
To
Adaptive
Pulse
Welding
i~~H~J
READ SAFETY BLOCKS at start of
Section 9 before proceeding.
Welding parameters are the same
for both a Pulse and an Adaptive
Pulse welding program. While
welding adaptively, the unit uses
feedback to attempt to maintain a
constant arc length. To change to
Adaptive Pulse welding, proceed
as shown:
1
Side Panel
Mode Select
/
>Process
>Prg
1
Pulse
Sequence
DualSchd
035Steel
Card
ArgonOxy
~
>Process
Side Panel
Parameter
Select
1
Prg
Sequence
>?u1~e
DualSchd
035Steel
Card
ArgonOxy
Increase/
Decrease
,
>Process
Prg 1
>A~aptEuLs.e
Sequence
DualSchd
035Steel
Card
ArgonOxy
Figure
OM-1 588
Page
46
9-5.
Side Panel
Display
Default display when unit is first
turned On, at other times use side
panel mode select button to select
Process.
Changing
To
Adaptive
Pulse
Welding
SECTION 10-TEACHING A MIG WELDING PROGRAM
WARNING
a
ELECTRIC SHOCK
can
kill.
WELDING WIRE
wounds.
Do not touch live electrical parts.
Control circuit and feeder operational power are~
using or changing the microproces~
can
cause
puncture
Do not
point gun towards any part of the body, other
people, or any metal when programming.
The welding wire is electrically live and moves out of
when
settings.
the gun whenever the power switch is On and the gun
trigger is pressed.
10-1.
Changing
To MIG
Welding
1
L.J
Side Panel
Display
Default display when unit is first
turned On, at other times use side
panel mode select button to select
Process.
Side Panel
Mode Select
1
Goto
Figure
10-2.
/
>Process
>Prg
Sequence
1
Pulse
DualSchd
035Steel
Card
ArgonOxy
Side Panel
Parameter
Select
,
>Process
Prg
Sequence
1
>EiaI~
DualSchd
035Steel
Card
ArgonOxy
Increase/
Decrease
e
>Process
Prg
Sequence
1
>M1~
Dual Schd
Card
Figure
10-1.
Changing
To MUG In The Process Mode
OM1588
Page
47
10-2.
Setting Sequence
MIG
Welding
Parameters On Side Panel
Display
Side Panel
1
Display
When unit is turned On, Process is
the default mode. Use mode select
button to select Sequence.
Side Panel Parameter Select
Button
2
>Process
>Prg
Sequence
1
Use side panel parameter select
button to select parameters.
MIG
Dual Schd
Ca
r
3
d
Weld Parameters
Parameter ranges
Display
are as
follows:
Volts, 10.0-38.0 Volts
C1J
Wire Feed Speed, 50-780 Inches
Per Minute, 1PM
Mode
Select
Seconds, 0-25.0 Sec. If value set is
(0), welding continues until
welding gun trigger is released.
zero
~
Inductance, 0-99%
Process
>Sequence
>WeI
Changes
to voltage and wire feed
speed (1PM) parameters in the
weld sequence are also displayed
on front panel display.
18. OVol t
DualSchd
200
1PM
Card
0.0
Sec
Go to
Set Desired
Figure
10-3.
3
Voltage
We I d
>1~QVoI
Increase/ Weld Sequence Volts
Decrease
can be fine tuned
while
200
1PM
0.0
Sec
welding
t
Side Panel
Parameter
Select
Set Desired Wire Feed
Set Desired Weld Time,
If
Applicable
Speed
rWe
20.OVolt
~
lncrease/
Decrease
>2QQ
1PM
0.0
Sec
Increase!
Decrease
Side Panel
Parameter
Select
1PM
be fine tuned
while welding
Weld
Sequence
can
Set Desired Inductance,
If
Applicable
Increase/
Decrease
Side Panel
Parameter
Select
Figure
OM-1 588 Page 48
10-2.
Increase
Proceed to next
Setting Weld Sequence Display
figure.
1
Crater Parameters
Parameter ranges
Display
are as
follows:
Volts, 10.0-38.0 Volts
1
Wire Feed Speed, 50-780 Inches
Per Minute, 1PM
r a
I
18.OVolt
I
2 0 0
Seconds, 0-2.50 Sec. If value set is
I PM
(0),
zero
0.OOSec
there
is
Crater
no
sequence.
Go to
I
U
I
R~ater
Crater
I>1~QVolt
1PM
1PM
0.OOSec
Crater
24.OVolt
24.OVolt
0.OOSec
200
10-4.
Side Panel
Parameter
Select
rV1
I
Figure
I
1PM
400
__
__
Side Panel
Parameter
Select
Set Desired
Voltage
__
Side Panel
Parameter
Select
Set Desired
Wire Feed
lncrease/
Decrease
Speed
I
Set Desired Time
Increase/
Decrease
I
I
Increase/
Decrease
I
I
I
>
~ a
I ~ r
24. OVo I
400
1
.
t
1PM
l2Sec
Side Panel
Parameter
Select
~
Increase
Proceed to next
Figure
10-3.
Setting
Crater
figure.
Sequence Display
1
Burnback Parameters Dis
play
Parameter ranges
are as
follows:
Volts, 10.0-38.0 Volts
Seconds, 0-0.25 seconds. If value
(0), there is no Burnback
set is zero
sequence.
I
Goto
_______________I,,,
I>~urn~aQk
I 18.0
I
Burnback
Volt~
0.00
>
0.00
Sec
I
Burnback
Vo~t~
16.0
Sec
>
Figure
I
10-5.
~>~ufnbaQk
VoltL
Sec
I
16.0
VoltI
0.12
Sec
___________
__________
__________
Side Panel
Parameter
Select
Set Desired
Bumback Volts
___________
Side Panel
Parameter
Select
lncrease/
Decrease
lncrease/
Decrease
Figure
10-4.
Setting
Set Desired
Bumback Time
Burnback
Side Panel
Parameter
Select
Increase
Proceed to next
figure.
Sequence Display
OM-1588
Page
49
1
______/
______
______
Postflow
Sec_F ~
0.0
Sec_F
Side Panel
Parameter
Select
Go to
Increase
Proceed to next
SettIng
Postf low
Sequence Display
______
______
Preflow
Sec
sec]~H
>Q__0
___
_______________
Pref low Parameters
Display
Pref low can be adjusted from 0-9.9
seconds. If value set is zero (0),
there is no Pref low sequence.
______/
0.0
10-6.
figure.
1
>Er~f IQW
Figure
Sec
1.2
lncrease/
Decrease
10-5.
Display
Side Panel
Parameter
Select
Set Desired Time
Figure
Posttlow Parameters
Postflow can be adjusted from
0-9.9 seconds. If value set is zero
(0), there is no Postf low sequence.
Go to
Figure
10-7.
Sec
1.2
_______________
Side Panel
Parameter
Select
Side Panel
Parameter
Select
Set Desired Time
Increase
Proceed to next figure.
Increase!
Decrease
Figure
10-6.
Setting
Preflow
Sequence Display
1
1
Run-In Parameters
Parameter ranges
Display
are as
fo!~ows:
Volts, 10.0-38.0 Volts
Wire Feed
Speed,
50-780 inches
per minute, 1PM
Side Panel
Parameter
Select
Set Desired Voltage
Side Panel
Parameter
Select
Increase/
Decrease
I>W~I~
I 20.OVoIt
I 420 1PM
2.2
Sec
F
I
H
Increase
>Bunin
20.OVoIt
150
1PM
0.5
Sec
Set Desired
Wire Feed Speed
Increase!
Decrease
Runin
F
20.OVoIt
Side Panel
Parameter
Select
150
1PM
>0~
Sec
Set Desired Time
Increase!
Decrease
Figure 10-7. Setting Run-In Sequence Display
OM-1588
Page
50
I
I
Seconds, 0-2.5 Sec. If value
zero
(0),
there
sequence.
Side Panel
Parameter
Select
is
no
set is
Run-In
SECTION 11
a
-
SETTING DUAL SCHEDULE PARAMETERS
WARNING
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Control circuit and feeder operational power are On
when
using
settings.
or
changing the microprocessor
WELDING WIRE
wounds.
can
cause
puncture
Do not point gun towards any part of the body, other
people, or any metal when programming.
The welding wire is electrically live and moves out of
the gun whenever the power switch is On and the gun
trigger is pressed.
Dual Schedule can only be used
with two consecutive weld pro
grams such as: 1 & 2, or 3 & 4, or
5 & 6, or 7 & 8. Any program type
MIG, Adaptive Pulse, or Pulse can
be combined in dual schedule. For
example, Prg I is MIG, Pig 2 is
Pulse, or Prg 1 is Adaptive Pulse,
and Prg 2 is Pulse, etc.
1
Mode Select Button
2
Mode
Display
Use mode select button to select
Dual Schedule, then proceed as
shown:
3
Dual Schedule Parameters
Display
panel increase/decrease
Display Control knob
(see Figure 11.2) to select dual
schedule pairs.
Use side
buttons,
or
lncrease/
Decrease
~&4~
Display
Control
If the two desired
welding programs are not in the proper program order (1 & 2, or 3 & 4, etc.), the
get them in the proper order would be to write one program to a data card,
most common method to
and then read the program from the card into the desired program number. See Section 12 for data
card information.
Figure 11-1. SettIng Dual Schedule Pairs On Side Panel Display
OM-1 588
Page
51
1
Front Panel Parameter Select
Button
2
Front Panel
Display
Press parameter select button to
select program number on front
panel display.
-1
24.
1
OV
1PM
250
>Prg
1
Dual
A
-3
Display
Welding Gun
Trigger
OR
Control
Knob
Welding Gun
DSS-Type
Switch
3
Front Panel
Knob
4
Welding Gun Trigger, Or
DSS-Type Switch
~I
~>Prg
2
Dual
Ar~~1Dual
B
~
Control
The dual schedule programs can
be alternately selected between
active programs A or B by turning
the Display Control knob one click
clockwise or counterclockwise, or
by squeezing and releasing the
welding gun trigger, or by an exter
nal mounted DSS-type switch
mounted on the welding gun. See
Section 13-10 for specific switchtype instructions. The settings
shown on the front panel display
are
>Prg
Display
for the active weld program.
When program B is active, turn
Display Control knob one click
clockwise to select another pair of
dual schedule programs.
Display
Control
Knob
When dual schedule is On, and Process is selected on the
side panel display, then the side panel increase/decrease
buttons can be used to change program numbers.
Figure
OM-1 588
Page
11-2.
52
Selecting Between
Active Dual Schedule
Programs
A And B On Front Panel
Display
SECTION 12
12-1.
Installing
USING THE OPTIONAL DATA CARD
Data Card
1
Label
Peel
backing from label
and
apply
by
to data card with THIS SIDE UP
metal
pins.
Write the names of the programs
stored on the card on the label.
Write the name of the piece of
equipment the card is used with on
the label.
2
Data Card
3
Card Slot
Insert card into slot. To format
card,
turn On power to the unit. Select
Card from menu. Data card for
mats when unit enters Card mode.
Exit Card mode and turn Off power.
2
ST.156 266-B I Ref. S-155 823
Figure
12-2.
Using The
12-1.
Installing
Data Card
Data Card
Use Mode Select button to select
Card.
Process
Sequence
DualSchd
Press
6
Card Display
Write
Used to transfer program data from
unit to card. The program card can
hold up to 32 programs. When writ
ing to the card, the next available
program number is automatically
Below
>Card
1
2
Side Panel
Parameter
Select Once
assigned.
3
Read
Used to transfer program data from
card to unit.
4
Delete
Used to delete program data from
card.
3
5
Done
Used to exit card
display.
4
6
Moving Line
Moving line is
be changed.
Figure
12-2. Card
under value that
can
Displays
OM-1 588
Page
53
NOTE ~
Al/program types (Pulse, Adaptive Pulse,
_____________________
and
MIG)
can
be stored
on a
data card
and retrieved.
Card
1
Display
Use Mode Select button to select
Card.
Moving
2
Line
Moving line is under value that can
changed.
Process
be
Sequence
DualSchd
Pr
>Card
3
ess
If
Name
Display
is desired, press side
panel Parameter Select button to
continue the write procedure.
Be low
no name
naming a program, the front
panel Display Control knob can be
used to speed selection of charac
When
Side Panel
Parameter
Select
2
ters.
*1~ulse
>Write
Read
035Stee
Dele te
ArgonOxy
Done
..--J
I
Press
Allowable characters include: 0 thru 9, :,
>?,
,AthruZFJ,A,_,,athruz,!,#,$,
%,&,,(,),*,+,_,.,I,
Side Panel
Parameter
Select
Name?
Name?
NQ
~
035~Steel
Yes
ArgonOxy
Press
Increase
No
0
~I
TWr
Side Panel
Parameter
Select
Side Panel
Side Panel
Parameter
Select
I teDone
to
Prg 1
CardPrg
Parameter
Select
Name?
Wr i teDone
fj~
502
1
Press
Side Panel
Parameter
Select
Q
c
Side Panel
Parameter
Select
Pulse
#1
I
035Stee
ArgonOx
y
Pulse
#1
5007992
F
54
r ame
Press
Figure
Page
Side Panel
Parameter
Select
~
Press
OM-1588
Increase
12-3.
Naming Programs And Writing
To Card
Use Mode Select button to select
Card.
Process
Sequence
DualSchd
Pr
>Card
ess
1
Card Display
2
Moving Line
Moving line is
be changed.
Be low
3
Mode
Select
Once
Read
under value that
can
Display
Select desired card program to
download. Select feeder program
number where the card program
Side Panel
Parameter
Select Once
goes.
WARNING:
Wi
Prgl
~
I
Prgl
Lost
Be
Lose?
Be
Will
Lost
NO~~Lose?
y~
Press
NQ
Increase
Pulse
035Steel
~
Argon-Oxy
J
Press
Yes
1
#
,~
Press
Side Panel
Parameter
Select
Side Panel
Parameter
Select
________________
I
I
Read
Done~
Card
I
Side Panel
Parameter
Select
#
12-4.
I
Pu I set
ArgonOxyl
Press
Figure
1
035Steell
Prgl
Prg 1
to
________________
Press
Reading
From Card
1
Wr i t
e
>Re ad
De I
e
WARNING:
Car
dEmp
t y
Press
t e
Be I
Done
ow
~rI
Wr i
Side Panel
Parameter
Select Once
>Process
t e
Sequence
Read
De I
Warning Display
If there are no programs on the
card, this series of displays appear.
>Pr g
Ml G
2
Dual Schd
e t e
Press
>Done
Card
Side Panel
Parameter
Select
Figure
12-5.
Reading (Or Deleting) From An Empty Card
OM-1 588
Page
55
Use Mode Select button to select
Card.
1
Card
2
Moving
Display
Line
Moving line is
be changed.
3
Process
DualSchd
Pr
ess
Be low
Mode
Select
Twice
~J
Side Panel
Parameter
Select Once
---~
WARN I NG:
-t-j___
I
Side Panel
Parameter
Select
De let
e
Card
Prg2
Lose?
Ye~
I
No
Press
Increase
Yes
~
Side Panel
Parameter
Select
Side Panel
Parameter
Select
#.~
MIG
Press
Side Panel
Parameter
Select
Figure
OM-1 588
Page
56
12-6.
can
Display
Select program number to be de
leted from card.
Sequence
>Card
Delete
under value that
Deleting Programs
From Card
SECTION 13SETUP
Setup
13-1.
Flow Chart
2
r~
>Pulse/Mi1~
i~~~_
>s y
s
p
t e m
Range
Secu
r
Display
2
Features
3
Settings
e ~
Selections
To set up features that customize
b I
a
I
1
operation,
y
use
the
setup displays.
Features that can be customized
are as follows:
Access
Example Of Setup Display On Side Panel
Features
Display
Settings
Features
Display
Section
Selection
Section
Settings
Selection
>System
Process
Capability
Pulse/Mig
Mig Only
>Remote
13-3
Off/On
Parameter
13-12
lncrease/
Decrease
Press Mode Se
lect To Go To Next
Setup Display
>Arc Time
Run Hours
~
>Range
Volt Mm
0.0- 25.0 V
Volt Max
25.0
AmpMin
0-50A
AmpMax
50-999A
Program
Number
Lock
Off/On
-
13-4
Hours
0999,999
Cycles
13-13
No Reset
99.9 V
Reset
F
>Self Test
+
}
}
13-14
,
>Secunty
13-5
>Wire Feed
IPM/MPM
Display
Type
Motor
>Access
Code
Off/On
13-6
>Mig Type
Voltage
DVC On/Off
13-7
Speed
High Speed
>Model
Model
Type
Correction
~r~ontrol
13-15
Standard
Low
+
>Voltage
09999.99
Bench
13-16
Boom
17-Pin
Feedback
Volt Sense
>Arc Start
Arc Start
Standard
Hot Start
>Dual Schedule
Switch
~1emorY }~ese~f__
13-8
13-17
I
Type
Type
~Shutdown
13-9
Momentary 2-Pole
~Jame
13-10
Maintained 2-Pole
Maintained 1-Pole
>Software
No Volt Sense
Off/On
13-18
Card
Off/On
13-19
Programs
Version
Number)
)
13-20
Trigger
>Trigger
Program Select Off/On
13-11
_J
I
Figure
13-1.
Setup
Flow Chart
OM-1588 Page 57
13-2.
Using Setup Displays
1
Front Panel
Front
Setup Display
panel display during setup.
2
Side Panel Mode And Para
meter Select Buttons
3
Power Switch On Rear Panel
Press and hold down both buttons
while turning On unit.
4
Side Panel
Setup Display
Follow this procedure any time ac
cess is required. Once in the setup
displays, use the Mode Select but
ton to select a
/
/
/
/
I
I
I
/
/
particular display.
To save any or all of the changes
made while in the setup dispays,
and/or to exit the setup displays,
turn power to the unit off and back
on or press the gun trigger to retum
to the Process display.
4
/
.1
>System
Range
Security
Process
Capab i I i t y
>Pulse/Mig
Access
Side Panel Display
13-2.
Figure
13-3.
Selecting
N OTE ~
Process
Accessing Setup Displays
Capability
This selection allows the wire feeder to be used with a variety of welding power
Pulse
This selection also determines whether Gas Metal Arc Welding
sources.
(Pu!se/Mig)
GMAW-P Is available.
1
Example Welding Power Sources:
Pulse/Mig 450 Ampere lnverter Model
Mig Only 450 Ampere Non-Inverter Model
=
System Display
When Process Capability is Pulse/
Mig, the wire feeder works with the
=
welding power source to produce
either pulse GMAW-P or regular
GMAW welds.
When in Mig Only, the wire feeder
works with the welding power
source to produce regular GMAW
welds.
1
Select the process the welding
power source is able to do.
When Mig Only is selected, some
of the setup choices are automati
cally made and are not available
for selection by the operator.
Figure
OM-1588
Page
58
13-3.
System Display
13-4.
Selecting Welding
N OTE ~
Power Source
Range
Welding power source minimum and maximum voltage
required. Amperage values are required for pulse welding.
1
I
Acces
~lay~
Setup
>Vo 11
Range Display
age ranges. Set values to match
welding power source ranges.
Mm
2
Minimum
Range
Access
3
Press Mode
Select
0
Side Panel
Parameter
Select
~
4
Mm
>1Q~flVol
Voltage Display
is 25.0 to 99.9 volts.
Minimum
Amperage Display
(Available When System Set
For Pulse/Mig)
Range
5
Voltage Display
is 0 to 25.0 volts.
Maximum
Range
Volt
always
welding power source Own
ers Manual for voltage and amper
10 .OVo It
Default values are for 450 Ampere
Inverter Model. Do not change values
if using 450 Ampere Inverter ModeL
are
See
I
System
>Range
Security
values
is 0 to 50 amperes.
Maximum
Amperage Display
(Available When System Set
For Pulse/Mig)
Range
is 150 to 999 amperes.
2
Increase/Decrease
Side Panel
Parameter
Select
Increase
3.
~
Side Panel
Parameter
Select
~ ~ Arnp~~
Side Panel
________________
Parameter
Select
*Use side
Parameter Select
panel
button to select
voltage
or amperage.
Use Increase/Decrease buttons to change value.
Figure
13-4.
Range Display
OM-1 588
Page
59
13-5.
Selecting Security
NOTE ~
Lock
Security lock
works
when
only
a
data card is inserted
(see Section 12-1).
I
Security Display
Use this display to lock a programs
weld parameters so that changes
not be made
controls.
can
2
Program
using front panel
Number
Choose the program number (1
through 8) to be locked. A program
can be locked on one or both sides.
2
3
Program
Lock
When lock is off of
operator
Increase
a
program, the
change all weld pa
rameters of that program without
restriction. The operator can also
change
Press Mode
Select
can
Display
sides without restriction.
With lock
on a
program, the opera
change parameters of that
program but the range of change is
restricted. If only one side is
tor can
locked,
the
operator cannot
sides or program number.
If both sides are locked, the opera
change
changes sides but
change program number.
tor can
I
Prog
l>Lock
21
~~~>Lock
~Hirim
OJ
1PM
21
Prog
Q~I
In the
~ft~
cannot
example displays in this fig
operator could change the
ure, the
value of trim –10% and wire feed
speed –100 ipm from programmed
___________
values, If the settings are left at 0,
the operator cannot change values
~
from those programmed. If both
sides are locked, they automatical
Side Panel
Parameter
Select
ly have the
Prog
2
Lock
On
>Trim
Q
1PM
0
ci
31
I>Prog
Lock
Of
~
21
On
10~~
>Prog
Lock
Trim
1PM
iool
Figure
Page
60
,~
Prog
Lock
Trim
>
Side Panel
Parameter
Select
Increase
OM-1588
range of change.
If dual schedule is on, the paired
programs are locked and unlocked
together.
L...J
same
13-5.
Security Display
lncrease/
Decrease
21
OnI
iOI
1QQ~
13-6.
Selecting
NOTE ~
Or
Changing
Access Code
Access code works
only
when
data card is inserted
a
(see Section 12-1).
1
Code
With code
displays
~1
Display
off,
access to
With code on, the
know and enter the
i
the setup
is not restricted.
access or
change
must
code to
any of the setup
operator
access
displays.
Range
Cod
Securi ty
>Qf f
>A
e
2
Access
With
Display
code set, this display ap
pears when power is turned on
while holding the side panel Mode
and Parameter Select buttons.
c c e S s
Mig__Type
Press Mode
Select
a
Press side panel Parameter Select
button to enter access code. When
the correct letter is entered, the
Increase
automatically
moves to
the
next character. When the final
ac
cursor
code letter is entered, the dis
play automatically changes to the
initial setup display.
cess
Code
>Qn
AAA
$
Cod
Increase/Decrease
To Set Code
Parameter Select
To Move Cursor
a
On
>ZW?~
~P
r a $ S
Turn Power Off And Back On
And Access Security Display
2
I
/
Enter
>Code
AAA
Access
Code
~P
Figure 13-6.
r a s S
Access Code
Display
OM-1588
Page
61
13-7.
Selecting Voltage
Correction
1
Mig Type Display
With DVC Voltage Correction On,
the unit uses closed-loop feedback
from the 17-pin cord or voltage
sensing
leads to maintain set volt
age parameters.
Press
Mode Select
I
Setup
With DVC
Voltage Correction Off,
feedback from the arc is not used
for closed-loop feedback to main
tain voltage parameters. Feed
back from the arc is still used for
other functions.
L
\~isp~,,1~
Be sure voltage sensing leads are
connected or voltage feedback is
available from welding power
source
through
the
17-pin recep
tacle.
Vo I t
Co
r
g
e
t
>D~
FIgure
13-8.
Selecting Voltage Sensing
NOTE
13-7.
a
r e c
i
o n
Off
Mig Type Display
Method
Voltage sensing feedback
setting is Mig Only.
is
automatically
set for V. Sense when the
1
System
Voltage Feedback Display
When using the 17 Pin setting, arc
voltage feedback is through the
welding power source, and the
feedback signal is sent through the
17-pin cord
~_~
/ Access~\
Press
Mode Select
to the feeder.
If the 17 Pin
setting is used, it is rec
ommended that the voltage sens
ing terminals on the welding power
source be used to monitor arc volt
age at the workpiece.
Setup
Display
using the V. Sense setting,
voltage feedback is through the
voltage sense leads connected to
the feeder. Use this setting when
there is more than 50 ft (15 m) of
When
arc
weld cable used.
Figure
OM-1588
Page
62
13-8.
Voltage Feedback Display
13-9.
Selecting Regular
NOTE ~
Or Hot Arc Start
Arc Start selection is not available when th e
Do not
use
the Hot Start
setting
for .035 in
System setting
(9 mm)
1
or
is
Mig Only.
smaller wire.
1
Arc Start
Display
Use the Hot Start mode for pulse
welding with 450 Ampere Inverter
Model when high initial weld cur
rent is necessary to start large
diameter welding wires. When in
Hot Start, the 450 Ampere Inverter
Model starts the arc in the CV
mode and switches to CC once the
arc is started. Do not use Hot Start
unless using 450 Ampere lnverter
Access
Setup
Display
Model.
Figure
13-10.
Selecting Type
13-9. Arc Start
Display
Of Dual Schedule Switch
1
1
Dual Schedule
Display
Choose type of external dual
schedule switch or use of the trigger as the dual schedule switch.
-I
L~
Swi
ITyp
~>Ir
tch
e
!gg~r
F
Increase
Figure
13-10. Dual Schedule
Displays
OM-1588
Page
63
Momen 2P (Momentary
Contact 2-Pole Switch Or
1
(DSS-10)
1
>
1
(DSS-9M)
1
>
1
DSS-10)
>
Maint 2P (Maintained-Contact
2-Pole Switch Or DSS-9M)
2
2
2
2
>
2
>
Maint 1 P Or
3
Trigger (Maintai
ned-Contact 1-Pole Switch
Or DSS-9 Or DSS-8)
A
3
1
2
0
C
B
4
A
3
B
4
p
3
L
(DSS-9)
1
>
Adapter
~,
2
2
>~
3
2
>
2
2
3
3
A\y~~>
Figure
13-11.
3
13-11. Dual Schedule Switch
3
>
BO
>
2
>
3
4
~
>
2
TB
>
4
Adapter
1
>
>
BO
A
(DSS-8)
1
4
>
Diagrams
Selecting Trigger Program Select
1
/
I
Press
Mode Select
Access
Setup
Display
-~--~
ArcStar t
Prog
DualSch d
Sele Ct
>Q1f
>Trigger
Remo t
ram
e
Trigger Display
When
Program
trigger
can
Select is On, the
be used to switch be
tween programs that have at least
0.2 seconds of preflow time.
Briefly pressing and releasing the
trigger switches programs. For
example: it programs 1, 2, and 6
have preflow time of at least 0.2 se
conds, pressing the trigger will
gun
switch from program ito 2, 2 to 6,
and 6 to 1.
Figure
OM-1588
Page
64
13-12.
Trigger Display
13-12.
Selecting
Remote Increase/Decrease
Capability
1
Remote
Display
When Parameter Inc/Dec is On,
the
dual
momentary-contact
schedule switch can be used for
weld parameters as well
for
between
as
switching
changing
programs.
For example: when the
the front panel display is
cursor on
on
Trim
Volts, the dual schedule switch
or
can
be used to remotely change the
value. When the front panel pa
rameter select is on Prg, the dual
schedule switch can be used to
change the program number. A
DSS-1O dual schedule switch is
recommended for this purpose.
Figure
13-13.
Resetting
13-13. Remote
Display
Arc Time
1
Arc Time
Display
The unit accumulates arc hours up
to 9999.99 hours or 999999 weld
cycles before rolling over to zero
(0). The arc timer can be reset us
ing this display.
Press
Mode Select
Figure 13-14.
Arc Time
Display
OM-1588
Page
65
13-14.
Using Self
Test
1
Have
only Factory Authorized
perform
tests
or
persons
Switch A
This checks the gun switch in
replace parts.
crease
2
position.
Switch B
This checks the gun switch de
crease
3
position.
Trigger
This checks the gun
Press
Mode
Select
4
trigger.
Wire Feed
This checks the wire feed motor.
5
Gas
This checks the gas valve.
6
Contactor
This checks the
source
7
welding
power
contactor.
CVICC
This tests the pin at the 17-pin re
ceptacle that controls whether the
unit is in CC (constant current) or
CV (constant voltage).
3
>1
r
I g g
s £
Off
5
~
>Wi
£ S
f
s
Press
d
Increase
~
>~s
s
Of
f~
Press
Side Panel
Parameter
Select
I~
~
p
~.
The welding wire and all metal parts in contact with
it carry weld output when the welding power source
contactor is energized.
r e ~
On
p
_______
~
Side Panel
Parameter
Select
7
6
________________
_________________
I~n
I
Increase
I
Press
>~V
Side Panel
Parameter
Select
Onft~H
I
~
___
Figure
OM-1588
Page
66
I
Increase
~
~
13-15. Self Test Procedure
1
oj
r e s
si
13-15.
Selecting
Units For Wire Feed
Speed And
Motor
Type
Wirefeed
1
Display
The
displayed unit of wire speed
(1PM or MPM) can be changed
along with the wire feed motor type
(Standard, Low Speed, or High
Speed).
A low
speed motor is not
available for this unit.
1
Increase
Display
Display
L
1PM
1PM
Motor
ype~
Motor
>
~
>
Type
~
Increase
Figure
13-16.
Selecting
NOTE ~
Parameter
Select
Increase
13-16. Wirefeed
Bench Or Boom Model
Decrease
Display
Type
This selection is not available when the
System setting
1
is
Mig Only.
Model
The unit is
Type Display
shipped from the factory
set to Bench for bench
feeders
Boom for
or
Swingarc model feeders. The set
ting loads the proper pulse param
eters into memory for the model
used.
properly
model
This selection does not change
when a memory reset is done.
Figure
13-17. Model
Type Display
OM-1588
Page
67
13-17.
Resetting Memory
1
No Reset
Memory
Setup
cannot be reset.
1
Press
Mode Select
2
Program
Reset
Press Parameter Select button to
)-_-
reset last active program to
\~Display~lay
factory program settings.
original
All other
program and setup information
mains the same.
3
re
System Reset
Press Parameter Select button to
reset programs and setup to origi
nal factory settings. System, Arc
Time, and Model Type settings are
not affected by the system reset.
4
r
4\
Reset
(Default) Displays
2
>Process
>Prg
Sequence
Pul
Side Panel
Parameter
Select
1
se
DualSchd
035 St
ee
Card
Argon
Oxy
I
Increase!
Decrease
3
Side Panel
Parameter
Select
Figure
13-18.
Selecting
13-18.
Resetting Memory
Arc StartNolt Sense Error Shutdown
1
I
Arc StartNolt Sense Shut
down Display
With Arc StartNolt Sense on, the
unit shuts down when no arc volt
age is sensed. If the unit shuts
Press
Mode Select
down,
an error
message appears
(see Section 14-4).
With Arc Start/Volt Sense off, the
unit continues to feed wire even
when there is no arc voltage
sensed.
Figure
OM-1588
Page
68
13-19.
Voltage Shutdown Display
13-19.
Selecting Program
Name Feature
1
Name
When
Display
program card is used, the
programs written from the unit to
the card can be named.
Press
Mode Select
~
Setup
a
)__.
\~Dis~ay,/
Figure
13-20.
13-20.
Naming
Card
Programs
Software Version Number
1
1
/
I
Press
Mode Select
Setup
1.
\~Dis~a~,J
Memory
Shutdo
Ver sian
wn
#12 3456Z
Example Version
Display
Number
When talking with service person
nel, this number may be required.
(Check actual unit display for num
ber.) The factory keeps this num
ber on file with the serial number of
the unit.
Name
>Sof twa
Figure
re
13-21. Version Number
Display
OM-1 588
Page
69
SECTION 14- MAINTENANCE & TROUBLESHOOTING
a
WARNING
ELECTRIC SHOCK
can
Do not touch live electrical
kill.
HOT PARTS
Allow
parts.
can cause severe
cooling period
before
burns.
servicing gun
or
unit.
Turn Off wire feeder and welding power source, and
disconnect
input power before inspecting,
maintaining,
or
servicing.
MOVING PARTS
can cause
Keep away
from
moving parts.
Keep away
from
pinch points
injury.
Maintenance
such
as
drive rolls.
to
be
performed only by qualified
persons.
wfwam4.1 8/92
14-1. Routine Maintenance
=
3 Months
Turn Ott all power before
maintaining.
Tape Or
Replace
Cracked
Weld
Cable
Replace
~
Cracked
Parts
14-Pin Cord
~ose~
Figure
OM-1 588
Page
70
Gun Cable
14-1. Maintenance
-~
6 Months
14-2.
Replacing
The Hub
Assembly
I~*P~i~
READ SAFETY BLOCKS at start of
Section 14 before proceeding.
Turn Off wire feeder and welding
power source. Retract wire onto reel
and remove. Take hub apart as
shown.
1
Retaining Ring
2
Hex Nut
3
Washer
4
Spring
5
Keyed Washer
6
Fiber Washer
7
Brake Washer
8
Hub
9
HubSupportShaft
Replace
worn or broken parts, and
slide parts onto shaft in order shown.
9
Tighten
hex nut until a slight force is
needed to turn hub. Install welding
wire (see Section 3-12).
6
7
7
6
5
4
Tools Needed:
~
15/16 in
1
ST.142 709
Figure
14-2. Hub
Assembly
14-3. Overload Protection
i~H
READ SAFETY BLOCKS at start of
Section 14 before proceeding.
Turn Off wire feeder and
power
1
1
welding
source.
Circuit Breaker CB1
CB1 protects the wire feeder from
overload, If CB1 trips, the wire
feeder shuts down.
Allow
cooling period and manually
reset breaker.
Ref. ST-800 177
Figure
14-3. CircuIt Breaker CB1
OM-1588
Page
71
14-4. Error
Displays
I
Release
Trigger Error Display
This appears if the trigger is closed
when the unit power is turned on, or
if the trigger is stuck or defective.
2
The
No Volt Sensed Error
Display
circuit is not
receiving feedback. Check voltage
sensing connections. Check con
nections at 17-position plugs/recep
tacles at the unit and welding power
voltage
arc
sense
source.
Turn unit off and back
on
after
cor
recting problem.
Release
If this error continues to
Trigger
pulse welding, it may help to select
Hot Start (see Section 13-9).
2
3
No
Memory CRC
Perform
Er
Display
a
system
reset.
ror
4
:~
when
The data in the program indicated is
not the same data that was saved.
Volt
S ensed
Error
occur
Memory Range Error Display
The data in the program indicated is
out of usable range.
Memory
CRC
Prg
Er
00
ror
Go through pulse parameters to
make sure they do not exceed set
tings of the Range display (see Sec
tion 13-4 and Section 7) or perform a
system
5
Memory
No Tach Sensed Error
Prg
The
Range
reset.
reaching
Error
Display
tach feedback is not
the control. Check connec
motor
tions.
Press front
panel Parameter Select
to clear error.
No
Tach
Sensed
6
Er
Arc Start Error
Display
This appears when pulse welding
and current is detected but the arc
cannot be started. Check and correct
program pulse parameters and volt
age settings. Check voltage sensing
ror
connections.
Press front
panel Parameter Select
to clear error.
7
Arc
Stop
Error
Display
This appears when pulse welding
and the motor does not stop at the
end of the weld. If there is high fre
quency being used in the area, turn
it off. A motor brake circuit problem
can also cause this error.
Press front
panel Parameter Select
to clear error.
Ref. ST.155 222
Figure
OM-1588 Page
72
14-4. Error
Displays
14-5.
Troubleshooting
£~
WARNING
ELECTRIC SHOCK
can
Do not touch live electrical
kill.
HOT PARTS
Allow
parts.
can cause severe
burns.
cooling period before servicing gun
or
unit.
Turn Oft wire feeder and welding power source, and
disconnect
input power before inspecting,
maintaining,
or
servicing.
MOVING PARTS
can cause
injury.
shooting
to be
performed only by qualified
Keep away from moving parts.
Keep away from pinch points
such as drive rolls.
Table 14-1.
wtwam4.1 8/92
Troubleshooting
Trouble
Wire
Remedy
feeds, shielding gas flows, but
energized.
~.
-~
Section
I
Check interconnecting cord connections.
electrode wire is not
3-9
-~
I
______________
1
Wire feeder is on, meter(s) do not light
up, motor does not run, gas valve and
welding power source contactor do not
pull in.
~
-~
Check and reset CB1.
Electrode wire
i.
-~
Check gun trigger connection.
feeding stops
erratically during welding.
or
feeds
-~
14-3
-~
3-7
Readjust
drive roll pressure.
-~
3-14
Readjust
hub tension.
-~
Check gun trigger.
Change
Clean
or
to correct size drive roll.
replace dirty
Incorrect size
Replace
-~
or worn
contact
tip
or
or worn
wire
drive roll.
guides.
liner.
Remove weld spatter
or
-~
3-6B
-~
3-6B
-~
3-6A
-~
foreign
*
matter from around nozzle
-~
opening.
Have Factory Authorized Service Station/Service Distributor
check drive motor or motor control board PCi.
i..
IP
Wire does not feed until trigger is pulled,
but continues to feed after trigger is released, and trigger hold is not on.
~
-~
Gas valve in feeder is rattling loudly
along with possible erratic or slow wire
1
-~
feed
J
Motor
runs
slowly.
speed.
-~
~
-
Check for a short between welding gun trigger leads and weld
cable. Repair short or replace welding gun.
~
-~
Check for a short between welding gun trigger leads and weld
cable. Repair short or replace welding gun.
1
Check for correct input
voltage.
*
*
-~
_____________________________________________
Unit does not switch out of Run-In
~
Speed.
I
-~
Install, reconnect,
or
___________
~.
replace voltage sensing lead.
I
-~
3-9
I
____________
Wire feeder power is on, displays
up, but unit is inoperative.
light
~
-~
Check welding gun
replace gun.
trigger leads for continuity,
and
repair leads or
*
-~
I
_____________
See gun Owners
Manual.
OM-1588
Page
73
SECTION 15- ELECTRICAL DIAGRAMS
I
CU~6CTIGH
FOG RE(CTE
PROGRAM SELECT
(SEE
L
DSPL2
SIDE DISPLAY
TLJ
DSPL I
FRONT DISPLAY
lCd1
01
~19~ H~H+i
IOOTO
1
I~E~TGEGRDe~
DATA
0
0
P841
0
P642
~U)E
SELECT
PARASETER
SELECT
~rMf~iH~L
I
~I
.1-i
~lL~L
___________
~
PLPGE
0
0
P821
0
0
P822
SC I 0/PLC 10
LEFT
RIGHT
~OD
TRIGGER
~O
0
0
P824
0
0
P823
LEFT
TRIGGER
~D
LED
RCI 1/PIGI I
SC I 2/PIG I 2
SC IS/PLO IS
/0
RC26 >)
SC I 6/PLC 16
2
PcI
RCIi-S>>~~55
PcI I~S >>___*I5V
PcI
RIGHT
N
SELECT
LED
____________
>
PLG83I
~
3>
I
I
>...........~
-
-
-
SC25-I~
4
RC256
I
SI0A8V~&K>I
II
N
I>
2
I
II
5020
PC2O
~4~024RC25-7
>>-~-
I
L'J
r
-i
USED WITH SWDGARC
OG CTAOIENT
OGTIGH
I
I
~g
~
P1027/PIGS I
2~-<I
I
2
~ 2~-~2 >~l2~
7
~ i~-~i
~~
~~
1
Ii
OGTICAL
DEOGER
GSI~
16 ~
~i 4~4~4>~<14~L
~
I
I
I
I
I
I
I
i;~
0
~o
~
I
UI
P1G57/PIGS7
~
p
TK2
<24-~.<~
2
<I
7
E~-< ~-~--~ >-~-<
~
~
5
AR
RIGHT
<:1
&K
2
GS2~
Figure
OM-1 588
Page
74
N
N
vvvvvv
5025-I
~I
MIT)I21>
P1029
IflENT
-
RC2I
>
N
-
~I
4
(OGTIGHAL)
N
~T1J~
TRIGGER GECREINT
/7
I 1P1G81
N
Rd
PcI
L
5025-2
~
I-8>>--~
>>~~~
PcI I-I
LED
LEFT
SELECT
LED
I
N
J I
~~
I4>~
SC 11-4
SC I 7/PLC Ii
RIGHT RC27>
TRIGGER
~O
3
II
L
PC 10
MIEROGR~SSOG ROARD
SC I 0
RC24
TRIGGER
_______
P1028
CABLE
___
14>
3>5JI3>~
I)
34
RC23
~ 2>2>-~~
I
~ I)~I >.~.~~IOAB~&*.)I>
RCIOO-5>>
_________~ ~
~OQANT FLOW SWIT0I
GRW
RCIOO-6>>
c0~.ETOG
0
0
P825
1 r
GRV
RCIOO/PLGIOO
RCIOI/PLGIOI
RCIOO-3 >
~AAAAAA
C.ETOG
P10831
ARC
St
~
Cd
RC2O
(GRTIOGAL)
FILTER
LEFT/RIGHT
SELECT
RC29
4?9114>
6
00000000
SELECT
CA8LE
P1023,
6
~
~
______________
I
2 ~~1t~TGG
~T.
I
6
RC4I/PLG4
___
______________
I IPLG8I
i
6
PCIOO
PC4O
Cd
p944
00
P831
IfETM)INT
i
6
RC6I/DATACARD
~
~
00
~
SUIPG~BC ~
i
RCIOO-l>>
CARD
~o
I
~
0
p843
PARAIETER
wr~ ~im
?
i
SC 100-2 >
Vvvvvvvvvvvvvvv
__
~
II
~
I
23406
I
pC30
FIELD I~GTRI.CTIGH)
I
15-1. Circuit
~
I
6
<IIE-~.~II>.LL<:I
~
<I ~ .E_.L.< 44~)~4 >_L<I4 ~
I
(IS~
Diagram
~
2
For Wire Feeder
5
I-7))--~
-I
POCTE PEI~CANT
I
RPS-8
(OPTION)
I
PCII0
BPS-B
SWITCH BOARD
I
RCIIO/Pt.GIl0
I
ISHIELD
.w,,
RCI 104
-
Ii
i
~-((RCl
I
ID-I
~< PC 110-5
I
0PE~OANT ~ PC 110-2
L
J
PCBO
FILTER BOARD
PCR2/PLG82
~jp~8~
RC89/PLG7S
RC90.PIG9O
i
~F
Ic>~!~.c
RC8I-C>~C/CV
.24V-CVI
RC8I-E>Q.J1RENT FEEO6AO( (IV/I0OA)IE).~E
RC8I-G > DO.CTAl~ b-by)
~ ~
RCRI-H
V~TA~ FEEDBAcK (IV/IOVI I ~
~
RC8I-F >
17
I
PIN ~34~4
I
I
I
I
I
I
UFAPPLICA&EIJ
I
r
45RC70 I
~o C~PENT ~
I
>
PC5O
INTERFACE
-i
P1070
BOARD
L
RCSO/PL000
rIJSED.!Th SWIP1~A
~ DBTADINT ~TIDB
RCS I/PIGS I
RCS2/PLGS2
I
I
L
~
l~?r~
RCS3/PLGS3
~
PC04/PIGS4
Rc554
Fi
I~TID4AL)
(SEE FIELD D~TRt~TICNS)
DBIVE
ASSY
_______
Rc25/PIG5S
PID(-LP(RISHT)
-(< FEED-I
<<Rcos-5
,<<PcSS-2
>8
________
-<<ps-6.~C~,.2W~_~.
:~,C
RC83>)
L
~
DBIVE ASSY
>~?
PID(-LP(LEFT)
a_Alp
RCO9- I >>-
RCR9-2>>
I_____
RCB9-3>>
acw
RC8O)HF
STUD
PIN
.
~
ccwAA~
I
aot
PLLAI
Pt.69
)C
) E
P.S.
C
,
,~
C
N
,~
~
acw
F
.0
P1019
191L0V
) F
2>I>
I
PCI
MOTOR BOARD
PCI/PIG I
io POWER
PC2/PLG2
PC3/PLG3
PC4/PLG4
RCD/PLG5
RCA/PLED
L
SD.164 541-B
OM-1588
Page
75
PC 10
MICROPROCESSOR
PC2O
FRONT DISPLAY
RC37
PLG33
OM-1588
Page
76
15-2.
Wiring Diagram
4
ii~Oa
TE~TP~
Figure
PLG37
For Wire Feeder
~
PC,
MOTOR BOARD
PLG28
LEFT
PLG38
RIGHT
SD-164 540-B
OM-1 588
Page
77
SECTION 16- PARTS LIST
Co
/
N-.
C~)
r
Co
0)
C.,
CD
U-
C~J
Co
=
Co
Co
C)
Co
U-
CO
C)
U-
ST-800 272-B
Figure
OM-1 588
Page
78
16-1. Main
Assembly
Quantity
Item
No.
Model
Part
No.
Dia.
Mkgs.
Figure
1
1
PLG21 ,23
.
.
12
Description
16-1. Main
Assembly
CABLE, trigger (consisting of)
CABLE, trigger (consisting of)
079 878.... CONNECTOR & PINS, (consisting of)
079 535
CONNECTOR, circ pin push-in 14-l8ga Amp 66359-6
079 531
CONNECTOR, circ clamp str rlf sz 11 Amp 206358-2
605 156.... CABLE, port No. 184/c (order by ft)
080 328.... CONNECTOR w/SOCKETS, (consisting of)
079 534
CONNECTOR, circ skt push-in 14-l8ga Amp 66358-6
See Note
CONTROL BOX, (Fig 16-4)
164 475
CABLE, interconnecting (consisting of)
164 474... CABLE, interconnecting (consisting of)
149 251
...
149 252
...
2
2
1
.
..
.
.
2
3
3
1
2
CONNECTOR & PINS,
4
5
5
CONNECTOR, circ clamp
....
str rlf sz 17-20
7
8
9
10
10
11
12
13
13
..
.
.
PLG11,17
PLG33,34
20
31
....
2
17ft
1
....
..
....
8
....
4
...
4
...
1
...
1
...
1
....
....
30ft
8
4
4
....
....
4
1
1
1
1
1
....
....
....
....
2
....
2
....
1
1
1
2
2
14.... 14
2
....
2
2
....
2
8
....
8
...
2
....
2
....
8
....
8
...
...
...
1
2
1
2
2
8
2
2
...
LINER, monocoil inlet wire
BUS BAR, connecting weld current
....
....
....
1
2
1
....
2
....
2
....
8
....
....
2
2
3ft.... 3ff
1
1
2
4
...
082 050...
164 969
2
21ft
1
(consisting of)
...
GS1 ,2
2
1
1
...
1
1
4
16-7... BOOM ASSEMBLY
CONNECTOR, circ skt push-in 14-l8ga Amp 66358-6
048 144... CONNECTOR, circ pin plug keying Amp 200821-1
115 092
CONNECTOR & SOCKETS, (consisting of)
113 746.... CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & PINS, (consisting of)
135 409
114 656
CONNECTOR, rect pin 24-l8ga Molex 39-00-0040
139 813
COVER, protector motor
125 785
VALVE, 24VAC 2 way custom port 1/8 orE
139816... PANEL,endcover
159 647... INSULATOR, motor clamp
156243... CLAMP, motortop
159 360
INSULATOR, screw machine
159 646
CLAMP, motor base
145 639... STRIP, buna N compressed sheet .062 x 4.000sq
134 834... HOSE, SAE .187 ID x .410 OD (order by ft)
167 774... DRIVE ASSEMBLY, wire RH (Fig 16-5)
.167 776... DRIVE ASSEMBLY, wire RH (high speed) (Fig 16-5)
157295...GUIDE,monocoil
604 612
SCREW, set stl sch 8-32 x .125 cup point
1
4
2
...
...
2
2lft
14.... 14
...
079 534....
1
4
2
...
17.... RC27,37
32
....
..
605227... NUT, nyl hex jam .75ONPST
CONNECTOR & SOCKETS,
047 637
29
....
26ft
16
28
29
....
...
Fig
26
27
..
....
15
25
..
...
14
...24
....
...
13
23
206322-2
..
...
13
...22
Amp
....
...
6
21
2
(consisting of)
CONNECTOR, circ pin push-in 14-l8ga Amp 66359-6
....
2
CABLE, port No. 18/14 8/c (order by ft)
159 297... HOSE ASSEMBLY, gas
139600... HOSE, gas
139 599
HOSE, gas
600 324
CABLE, weld cop strd No. 4/0 (order by ft)
602 243
WASHER, flat stl std .375
602 213
WASHER, lock stl split .375
601 872
NUT, sti hex full .375-16
080 947
BRACKET, spring retaining
151 626... BRACKET, spring retaining
132053... SCREW, cap stl hexhd .375-16 x 1.500 Ig
SUPPORT, hub & reel
Fig 16-2
.149838... PIPE POST, 4ft w/base or
.149 839... PIPE POST, 6ft w/base
PIPE POST, 4ft w/base or
.078 264
PIPE POST, 6ft w/base
079 216
PIPE POST, 4ff w/o base
.075 078
079217...PIPEPOST,6ftw/obase
163 519
4
...
047 636....
079 739
19...
1
..
...
079 535
18...
l7tt
.
PLG27,28,
37,38
4
2
....
PLG28,29
16
2
1
....
....
....
....
....
....
1
1
2
4
2
1
OM-1 588 Page 79
Quantity
Item
No.
Model
Part
No.
Dia.
Mkgs.
Description
Figure
16-1. Main
33
.167 782
...
NOTE: When ordering Control Box contact
OPTIONAL
Factory
16
Assembly (Continued)
167780... DRIVE ASSEMBLY, wire LH
DRIVE ASSEMBLY, wire LH
..33
12
Service
1
(Fig 16-5)
(high speed) (Fig 16-5)
Department
1
....
....
1
1
for proper number.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Item
No.
Part
No.
Description
Figure
1
....
2
....
3
....
2
WASHER, flat stl keyed 1.500dia x .l25thk
WASHER, fbr .656 ID x 1.500 OD x .125thk
WASHER, brake stl
2
HUB, spool
SUPPORT, reel
REEL, wire 60 lb (consisting of)
SUPPORT~ reel spool
RETAINER, spool support (consisting of)
LABEL, caution falling wire reel can cause damage
2
010191
....
058628
....
058428
080393
10... 108008
...11.... 124900
....
12... +168 104
13....
12)
2
....
9
16-1 Item
slflkg 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
6
8
(Fig
RING, retaining spool
....
7
Hub & Reel
NU1 stl
5
....
Support,
058427
136684
605941
010233
057971
4
16-2.
Quantity
166594
168103
NU1
spanner
2
2
4
4
1
2
1
1
1
1
retaining
2
8
7
9
ST-081 760-C
Figure
.
16-2.
Support,
Hub & Reel
OPTIONAL
+When
ordering
a
component originally displaying
a
precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1 588 Page 80
Item
Dia.
No.
Mkgs.
Part
No.
Figure
2
167697..
.
147 139
164 842
144 844
6
....
171 814
PC2O,30.
PLG25
165 484
147 995
PLG24....
...8
167 633
10
089 032
153 169
010291
11
167 700
16-3. Panel, Front
w/Components (Fig
16-4 Item
28)
NAMEPLATE, (order by model and serial number)
PANEL, front
TAPE, adh acrylic double sided .010 x .500 x 3.000
METER LENS, w/gasket
STAND-OFF, 6-32 x .875 Ig
CIRCUIT CARD, schd front
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-1 8ga Amp 770904-3
See
159 264
Quantity
Description
Figure
1
1
2
1
9
1
1
8
16-2 Item 35
RING, ext .625 shaft grv x .O4Sthk E style
WASHER, shldr .612 ID
LENS, LED 4341 red panel mtg
ACTUATOR, switch
WASHER, flat .625 ID nylafil
KNOB, pointer
1
1
4
6
1
1
4
1
9
13
12
ST-800 112-C
11
Figure
16-3. Panel, Front
w/Components
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM~1588 Page 81
N.
cJ
C
0)
c~4
C.)
Co
0)
U-
0)
C
Co
0)
U-
0
C)
e
C)
C~J
c5
C.)
C)
C.)
ST-800 273-A
Figure
OM-1 588
Page
82
16-4. Control Box
Dia.
No.
Mkgs.
Part
No.
Description
Quantity
-
Item
Figure
2
....
RC3O,40.
162 253
047 637
079 534
048 144
PCi
134 201
155 114
PLG1
115 092
113 746
PLG2
115 093
113 746
PLG4
115 091
113 746
PLG6
CB1
8
..
Si
PC8O, RC81
PLG75
PLG82
PLG9O
136810
114 066
161 706
083 432
111 997
163 921
131 204
113 746
158 720
147 995
153501
147 995
073756
10
151 187
ii
+162 364
010 325
13
134 464
14
163519
141 162
PLG9
134 731
079 739
16
PLG19
17
158719
147 995
601 222
176 089
19
...22
...23
...24
...25
600 399
138 044
RC7O
000 527
CR101
SRi
...26
072 817
035 704
030 170
145 948
Fig 16-3
...27
...28
29
107 983
048 282
079 534
PLG12,50
155 629
154 938
...32
PC5O
PLG51
PLG52
PLG53
PLG54
097 132
163 917
158 720
147 995
158 719
147 995
131 204
113 746
148 439
147 995
16-4. Control Box
(Fig
16-1 Item
2)
PANEL, side lower
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, circ skt push-in 14-l8ga Amp 66358-6
CONNECTOR, circ pin plug keying in sockets Amp 200821-1
STAND-OFF SUPPORT, PC card .3121.375
CIRCUIT CARD, motor control
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-1 Bga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-1 8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
1
2
14
4
10
1
1
8
1
6
1
10
1
CONNECTOR, rect skt 20-l4ga Amp 350536-1
CASE SECTION, bottom/rear
CIRCUIT BREAKER, man reset 1P 1OA 250V
SWITCH, rocker SPST 1OA 25OVAC
4
1
CIRCUIT CARD, HF filter dual
CONNECTOR & SOCKETS, (consisting
1
1
1
of)
24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-l8ga Amp 770904-3
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-l8ga Amp 770904-3
STAND-OFF, 6-32 x .625 Ig
LATCH, slide flush mtg hole 1.000 wide x 1.500 Ig
CONNECTOR,
1
rect skt
3
1
12
1
6
2
1
WRAPPER
1
BUSHING, strain relief .840 ID x .875mtg hole
LABEL, warning general precautionary
CABLE, port No. 18/14 8/c (order by if)
CONNECTOR & PINS, (consisting of)
CONNECTOR, circ pin push-in 14-lBga Amp 21 3603-1
CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-l8ga Amp 770904-3
CLAMP, univ5oA
TUBING, plstc PVC .250 ID x .375 OD x 9.000
WIRE, strd l4ga blk 600V 105c (order by if)
BUSHING, strain relief .120/.150 ID x .SOOmtg hole
BLANK, snap-in nyl .500mtg hole
CONNECTOR w/SOCKETS, (consisting of)
CONNECTOR, circ skt push-in 14-lBga Amp 66358-6
BLANK, snap-in nyl .875mtg hole
RELAY, encl24VAC DPDT
RECTIFIER, integ 40A 800V
BUSHING, snap-in nyl .750 ID x 1 .000mtg hole
BRACKET, mtg control box
PANEL, front w/components
CABLE, ribbon l4posn
STRIP, mtg PC card
STAND-OFF, 6-32 x .375 Ig
CIRCUIT CARD, interface
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, red skt 22-l8ga Amp 770904-3
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-l8ga Amp 770904-3
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-l8ga Amp 770904-3
1
1
12ft
1
14
1
1
2
1
1
35ft
1
1
1
4
1
1
1
3
1
1
1
1
4
1
1
12
1
2
1
3
1
10
OM-1588
Page
83
Item
No.
Dia.
Part
Mkgs.
No.
Description
Figure
PLG55
115 092
113 746
PC1O
126 689
161 781
PLG11
115 092
113 746
PLG15
153 501
147 995
PLG17
115 093
113 746
35...
36...
PLG1O,24
PLG16,41
170 980
155 023
Fig
16-6
158 373
097 868
116 964
600 343
097 866
059 712
010 145
+When
ordering
a
Quantity
16-4. Control Box
(Fig
CONNECTOR & SOCKETS,
16-1 Item
2) (Continued)
(consisting of)
1
CONNECTOR, rect skt 24-1 8ga Molex 39-00-0038
STAND-OFF, 6-32 x 1.500 Ig
CIRCUIT CARD, processor w/proms
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-l8ga Amp 770904-3
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CABLE, ribbon 34posn
CABLE, ribbon 24posn
PANEL, side
8
4
1
1
8
1
6
1
6
1
1
1
w/components
CABLE, interconnecting pwr (consisting of)
CONNECTOR, circ l7skt plug Amphenol MS-3106A-20-29S
CONNECTOR, circ clamp slf sz 20-22 Amphenol MS-3057-1012
CABLE, port No. 165/c (order by ft)
CONNECTOR, circ 17 pin plug Amphenol MS-3106A-20-29P
CLIP, component .437dia mtg adh back
CLAMP, nyl .500 clamp dia
1
1
.
....
component originally displaying
a
precautionary label, the label should also
2
lOft
1
2
1
be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
17
.18
9
20
SeeTablel6-1 For
Drive Roll & Wire Guide Kits
16
22
6
8
10
12
24
25
7
31
6
4
5
2
ST-152 711-D
Figure
OM-1 588
Page
84
16-5. Drive
Assembly,
Wire
Item
No.
Dia.
Part
No.
Mkgs.
Description
Figure
3
4
Wire
(Fig
16-1 Items 29 &
33)
6
6
7
8
9
10
11
M1,2
M1,2
...
4
...
4
4
PIN, rotation arm rocker
NUT, .250-28 stl
163 281
SPRING, pressure arm retaining LH
165 798... SPRING, pressure arm retaining RH painted end (shown)
165 799
WASHER, flat .257 ID sti
132 750
ARM, pressure
150 520
SPACER, rotation pin
133 493
RING, retaining ext .250 shaft x .O25thk
133 350... PIN, hinge
156 354
MOTOR, gear 1/Bhp 24VDC 272RPM (consisting of)
156 353... MOTOR, gear 11Bhp 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, rtngext.2soshaftgrvx.O2Sthk
115 092
CONNECTOR & SOCKETS, (consisting of)
113 746
CONNECTOR, rect skt 24-1 8ga Molex 39-00-0038
131 203
CONNECTOR & PINS, (consisting of)
114 656
CONNECTOR, rect pin 24-l8ga Molex 39-00-0040
135 409
CONNECTOR & PINS, (consisting of)
114 656
CONNECTOR, rect pin 24-l8ga Molex 39-00-0040
010 837... PIN, spring CS .093 x .625
137 248... SPRING, indicator
129 351
SCREW, hexwhd-slt stl slffmg 8-32 x .500
602 200
WASHER, lock sti split No. 8
604 772
WASHER, flat stl SAE No.8
165 934
SPRING, cprsn .573OD x .088 wire x 1.062 Ig
149 486
163 282
5
12
Assembly,
010 668
SCREW, cap sti sch .250-20 x 1.500
172 075... CARRIER, drive roll w/components
149 962
SPACER, carrier drive roll
1
2
12
16-5. Drive
Quantity
...
2
...
2
...
2
2
...
2
...
2
...
2
...
2
1
1
...
...
1
1
....
13
PLG29,39
...
2
2
1
1
1
5
2
1
1
...
B
....
PLG51,57
...
1
...
3
....
RC7,8
1
...
8
....
14
15
16
17
18
19
1
1
...
1
...
1
...
1
...
2
BUSHING, spring
spring
132747...CARRIER,shaft
152 241
KNOB, extension
133 739
WASHER, fIat .375 ID x .625 OD x .062
CIRCUIT CARD, digital tach (consisting of)
153 631
131 204.... CONNECTOR & SOCKETS, (consisting of)
113 746
CONNECTOR, rect skt 24-lBga Molex 39-00-0038
604 311
GROMMET, rbr .250 ID x .375mtg hole
20
132 746...
2
21
132 824... SHAFT,
1
...22
23
24
25
TK1 ,2/PC51
PLG57
..
....
1
...
1
...
1
...
1
1
3
1
....
...
OPTICAL ENCODER DISC
FITTING, brs barbed M 3fl6tbg
ADAPTER, gun/feeder LH
26
132 611
...
27
149 959
...
28
28
149 746
149 745
...
29
108 940
...
30
604 538
...
31
151437...
32
128237...
149 527... COVER, drive roll
601 872
NUT, stl hex full .375-16
602 213
WASHER, lock stl split .375
33
34
35
36
37
38
...
1
x
.312-24
1
1
ADAPTER, gun/feeder RH
SCREW, cap sti hexwhd .250-20
WASHER, flat stl SAE .312
1
x
.750
4
1
KNOB,plstcTl.l25Igx.312-lBxl.500bar
SCREW, hexwhd-slt stl slftmg 10-32 x .500
1
2
1
...
1
...
1
602 243
WASHER, flat stl .375
149 964... PIN, groove .25Odia x .500 Ig
601 966
SCREW, cap stl hexhd .375-16
1
...
...
2
x
1.250
1
OM-1588
Page
85
Item
No.
Dia.
Part
No.
Mkgs.
Description
Figure 16-5.
(Continued)
Drive
Assembly,
167 387... SPACER, locating
168 825
DRIVE, pinion
133 308... RING, retaining ext .375 shaft
39
40
Quantity
Wire
(Fig
16-1 Items 29 &
33)
2
1
...
41
x
.O25thk
1
Optional High Speed Motor
Spare Parts.
*Recommended
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
Table 16-1. Drive Roll And Wire Guide Kits
G)
~
Wire Size
~
~
V-GROOVE
U-GROOVE
VK-GROOVE
~
4 RoIl
Kit
Drive
Roll
149518
151024
087130
150993
149518
151025
053695
0.9mm
150993
149518
151026
.045in.
1.1mm
150994
149519
.052in.
1.3mm
150994
1.6mm
1.8
4 RoIl
Kit
Drive
Roll
4 Roll
Kit
Drive
Roll
053700
151036
072000
151052
132958
151027
053697
151037
053701
151053
149519
151028
053698
151038
053702
150995
149520
151029
053699
151039
053706
mm
150995
149520
(.079in.)
2.0mm
150995
149520
151040
(.094in.)
2.4mm
150996
149521
2.8mm
150996
3.2mm
150997
Metric
.023-.025in
0.6mm
150993
.03Gm.
0.8mm
.035in.
(.062in.)
.068-072 in
4 RoIl
Kit
Drive
Roll
132957
151070
083489
151054
132956
151071
083490
151055
132955
151072
053708
151 056
132959
053704
151057
132960
151073
053710
151041
053703
151058
132961
151074
053709
149521
151042
053705
151059
132962
151075
053711
149522
151043
053707
151060
132963
151076
053712
~
Fraction
UC-GROOVE
E~
5/64 in.
S-0549-C
Each Kit Contains An Intet Guide, Intermediate Guide, And 045 233 Antiwear Guide With 604612 Setscrew 8-32
With 4 Drive Rolls.
2 Kits
Required For Dual Models.
OM-1588
Page
86
x
.125, Along
Item
No.
Part
No.
Dia.
Mkgs.
Description
Figure
147 139
155 024
154 933
PC6O
PLG6O
156 623
153501
147 995
PLG41
...6
PC4O
158 160
144 844
154 109
...8
153 169
16-6. Panel, Side
Quantity
w/Components (Fig
TAPE, adh acrylic double sided .010
LENS, clear anti-glare
PANEL, inner control
CIRCUIT CARD, data card
x
.500
x
16-4 Item
37)
3.000
2
1
1
1
CONNECTOR & SOCKETS, (consisting of)
1
CONNECTOR, rect skt 22-l8ga Amp 770904-3
6
See Figure 16-3, Item 40
CIRCUIT CARD, side display
1
STAND-OFF, 6-32 x .875 lg
PLATE, ident inner control
ACTUATOR, switch
4
1
4
5
6
7
9
8
9
ST-800 113-B
Figure
16-6. Panel, Side
w/Components
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1 588
Page
87
C)
cJ
c~,
~
\
u~
\
I-
CD
cJ
c..J
F
c.J
ST-142 306-F
Figure
OM-1588
Page
88
16-7. Boom
Assembly
Quantity
Model
Part
Item
No.
No.
Description
Figure
16-7. Boom
Assembly (Fig
I
12
16-1 Item
16
15)
.1.
010 313
PIN, cotter hair .072x1.437
4
....
4
.2.
010 910
8
....
8
.3.
139 590
2
....
2
.4.
079 667
.4.
080 812
.5.
079 632
9
160 513
WASHER, flat stl SAE .375
PULLEY, V sgl grv 8.875dia x 8.000P x .375 bore
PIPE, plstc .500 x 133.750
PIPE, plstc.500x181.750
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
10
073 742
PIN,clevis.7500Dx2.156Ig
1
11
073 741
1
12
079 029
13
075 462
14
602 250
15
079 020
16
155 335
17
149 858
17
151 625
18
19
150 258
024 605
20
075 101
21
079 030
22
+174 754
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
6
079 665
6
080 811
7;
079 664
8
139 633
9
159 999
080 157
174 688
23
142 804
134 327
24
073 666
25
047 224
26
602 246
27
010 493
28
139 818
+When
ordering
a
component originally displaying
a
precautionary label,
2
2
8
....
10
2
2
2
....
2
2
....
2
1
1
2
1
2
1
....
....
....
....
....
....
1
1
2
1
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
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1 588
Page
89
OPTIONS AND ACCESSORIES
WELD CURRENT SENSOR
(#160 963)
Required when using
the 64M
feeder with Miller conventional
MIG power
have
sources
that do not
17-pin receptacle.
POWER SOURCE DATA CARDS
RPS-8 REMOTE PROGRAM
SELECTOR
WATER FLOW SAFETY SWITCH
(#160 977)
Eight-position rotary switch used
remotely select weld programs.
Includes a 33 ft. (10 m) cord.
Used with the water hose kits.
Protects water-cooled gun from
WIRE STRAIGHTENER
For .035 .045 in. (0.9- 1.1
wire
-
Data card is inserted into feeder,
and with a push of a button, the
feeder is automatically
programmed for the power source
being used. Each data card
contains eight factory-written
programs and 24 unused spaces
for customer-developed programs.
(#164 583)
to
overheating by shutting
system if
DUAL SCHEDULE SWITCHES
Used with Dual Schedule
Control in 64M feeder.
mm)
DSS-8
(#141 580)
For 1/16
-
1/Bin.
(1.6-
3.2
For 10 ft.
(3 m) gun
(#079 691)
For 15 ft. (3 m) gun
(#079 693)
Requires adapter cord (#157 364).
Two-position trigger switch that
eÆ~ily attaches to the welding gun.
Used in place of the standard
trigger for dual scheduling.
mm)
wire
(#141 581)
Reduces cast in wire. Improves
wire feeding performance and
increases life of gun liner and
tip.
contact
Data Cards for Conventional
MIG Power Sources:
(#164 162) for Deltaweldfi 300
(#164 161) for Deltaweldfi 451
(#164
(#164
(#164
(#164
160)
163)
164)
165)
HIGH-SPEED MOTOR
For single and right side of dual
for Dimensionfi 400
for Dimensionfi 650
for XMTfi 200 CC/CV
DSS-9M
For 10 ft. (3
models.
for Deltaweldfi 651
(#132 129) Factory only
For left side of dual wire models.
(#132 130) Factory only
speed range of 90
1400 1PM (2.3 35.6 rn/mm.). Not
recommended for wire sizes larger
than 5/64 in. (2.0 mm).
Provides wire
-
-
Data Card for Pulse MIG and
Conventional MIG Power
Source:
(#164 166)
for XMTfi 300 CC/CV
XMT 300 CC/CV data card
includes
eight synergic pulse
programs:
.035 in. steel wire with
Argon/Oxygen shielding
gas
each side of the dual wire
Factory-written synergic Pulse
MIG programs will not operate with
high-speed motor.
gas
using Argon/CO shielding
gas
.045 in. 309L stainless steel wire
using Argon/CO shielding gas
3/64 in. 4043 aluminum wire
using Argon shielding gas
3/64 in. 5356 aluminum wire
using Argon shielding gas
.035 in. nickel wire using
Argon/Helium shielding gas
.035 in. silicon bronze wire using
Argon shielding gas
64M DATA CARD
Blank Card
Stores up to 32 complete weld
programs. Ideal for saving custom
programs and transferring
programs to other 64M feeders.
(3 m) Swingarc style
feeders
(#159 288) 23 ft. (7 m)
(4.9 m)Swingarc style
For 16 ft.
feeders
(#159 289)
27 ft.
m) gun
(#041 792)
For 15 ft. (4.6 m) gun
(#041 793)
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.
DSS-10 REMOTE INCREASE!
DECREASE SWITCH
(#042 749)
Two-position, momentary
WATER HOSE KIT
.035 in. 309L stainless steel
(#155 910)
on
modeis.
For 12 ft.
.045 in. steel wire with
Argon/Oxygen shielding
lmportant:Same speed motor must be
used
down
water does not flow.
(8.2 m)
Used with Miller coolant systems
and GW Series water-cooled
welding guns. Can be used with or
without optional water flow safety
switch.
contact
switch that attaches to the welding
gun. Used with the Remote
Parameter Increase/Decrease
feature to fine tune parameters at
the welding gun while welding.
Gun
trigger operates
as
standard
trigger.
WIRE REEL ASSEMBLY
(#108 008)
Accommodates 60 lb.
(27 kg) coil
of wire.
Note:If water kit is to be used on both
sides of a dual wire feeder, a kit must be
ordered for EACH side of the feeder.
Y
WATER HOSE KIT
(#165 491)
Required when using
EXTENSION CORDS
For optimum performance, do not
extend 64M feeder more than 60
ft. (18 m) from power source.
14-Pin Extension Cord
a
water hose
kit on each side of a dual wire
feeder. Connects both kits to one
water coolant system.
(#122 973) 25
(#122974)50
ft.
(#042 120)25
ft.
(7.6 m)
ft. (15 m)
17-Pin Extension Cord
(7.6 m)
11n3
OPTIONS AND ACCESSORIES
MILLER GMAW
(MIG) GUNS
Water-Cooled Guns
Refer to literature Index No.
Mu 3.4.
Radiator 2A, 230 VAC
COOLANT SOLUTION
(#042 493)
1.5 gal. (5.7 L)
(For Extra Freezing Protection)
(#128 705)
Resists freezing to 00 F (-18 C).
capacity.
Watermate~ 1A, 115 VAC
Air-Cooled Guns
Refer to literature Index No. M/9.O.
tank
2
(#042 495)
gal. (7.6 L)
tank
important: Distilled
capacity.
water is recommended.
Coolmate~ 4, 115 VAC
WATER COOLANT SYSTEMS
(#042 288)
gal. (15.1 L)
tank
Radiator 1A, 115 VAC
4
(#042 492)
1.5 gal. (5.7 L)
Refer to Water Coolant Systems
literature, Index No. AY/7.2.
tank
capacity.
capacity.
MOUNTING EQUIPMENT FOR SWINGARC BOOMS
One of the following is required for
mounting the SS-64M and DS-64M
Swingarc~ booms:
Swingpakmi Base and pipe post
with base
two gas
better organize components and
cables. Base includes a
Note: To mount
three-compartment storage locker.
plate
CBC Cart (for
with 12 ft.
3.7 ml model only) and pipe post
without base plate
use
Pipe Post
The entire unit
a forktift truck.
can
be moved with
CBC CARTS
For 12 ft. (3.7
m) boom only
provide mobility and
SWINGPAKm BASES
Designed
SWINGPAK-1 2
neat, orderly arrangement of
(#085 276)
for 12 ft.
(3.7 m)
to
welding equipment.
SWINGPAK-1 6
(#085 934)
for 16 ft.
(4.9 m)
boom
Note: A pipe post with a base plate Is
required and must be ordered
separately.
a
The CBC is
(254 mm) diameter by 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
Accommodates
wheels. Both models
Swingarc
accommodate
a power source,
feeder system, water
a
a
12 ft.
and
(3.7 m) Swlngarc
feeder system on a CBC Cart, a 6 ft (1.8
m) pipe post is requIred (#079217). The
4 ft (1.2 m) pipe post Is NOT
recommended. The 16 ft. (4.9 m)
Swlngarc feeder cannot be used.
CBC CART FEATURES
2000 lb. (907 kg) load capacity
the standard model with 10 in.
boom
(3.7 m) Swingarc feeder,
cylinders.
coolant system, and gas cylinder.
plate is solid to help
ft.
The base
power source, 12
Multi-position boom
Swing-out outriggers
Wide front wheel stance and
automotive type steering
Mounting facilities for most Miller
CV power
sources
Compartment in base of cart to
add ballast weight when using
lightweight power sources.
Minimum ballast weight of 300
lbs. (136 kg) required
Fold-up gas bottle loading ramp
11193