Miller DS-64M SWINGARC Owner's Manual

.
Miller
October 1994
Form:
OM-1588A
Effective With Serial No. KE648703
OWNERS
MANUAL
:..:~
DS-64M (12) And (16) Foot
Boom Mounted Wire Feeder
Boom-Mounted
Microprocessor Controlled Constant Speed Dual Wire
Multi-Power Source
For GMAW,
(0.6
Standard Wire Feed
Programmable
U
cover
5/94
ST-800172
To 3.2
mm) Wires
Speed Of
50 To 780 pm
(1.3
To 19.8
blocks
Have
only
mpm)
Pulse Weld Parameters
Options And Accessories, See
Rear Cover
Read and follow these instructions and all
safety
Give this manual to the operator.
carefully.
trained and
install, operate,
U
Compatible
GMAW-P, And FCAW Welding
For .023 To 1/8 in
For
Feeder
or
qualified
persons
service this unit.
Call your distributor if you do not understand
the directions.
'
1994 MILLER Electnc
U
For
U
or~
help,
call your distributor
MILLER Electric Mfg. Co., P.O. Box 1079,
WI 54912
414-734-9821
Appleton,
Mfg.
Co.
PRINTED IN ~SA
j
I
1~
MILLERS
TRUE BLUETM LIMITED WARRANTY
I
Effective
(Equipment
This limited
with
a
wsrrsnty supsrsedes all previous MILLER
serial
January 1, 1992
number preface of KC
wsrranties snd is exclusive with
LIMITED WARRANTY
Subject to the terms snd conditions below, MILLER Electric
Mfg. Co., Appleton, Wisconsin, wsrmnts to its originsl retsil purchsser thst new
MILLER equipment sold sfter the effective dste of this limited wsrrsnty is fwe of de
fects in materisl snd workmsnship st the time it is shipped by MILLER. THIS WAR
RANTY IS EXPRESSLY IN LIEU OP ALL OTHER WARRANTIES, EXPRESS OR
no
newer)
or
other gusrantees
or
wsrrsnties
espressed
or
implied.
Remote Controls
*
Accessory Kits
Replacement Parts
MILLERS
IMPUED, INCLUDING THE WARRAN11ES OF MERCHANTABILITY AND FIT
True
BIueTM
Limited
Warranty
shall not
apply
to:
NESS.
Items fumiahed
1.
Within the
wsrranty periods listed below, MILLER
will
wpsir
or
replsce sny
which time MILLER will
provide instructions
on
MILLER shall honor wsrranty clsims
on wsrrsnted equipment listed below in the
wsnsnty time periods. All warranty time periods
equipment wss delivered to the originsl retsil purchsser, or
yesr sfter the equipment is sent to the distributor.
evenl of such s fsiluw within the
2.
Original
3 Yeam
*
Equipment
cutting nozzles,
that has been modified
contactors
by any party other than MILLER,
impmperiy installed, impmperiy operated or
or
equip
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
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER
CIALJINDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING EQUIPMENT
Parts and Labor
Transformer/Rectifier Power Sources
Plssma Arc
*
In the event of a
warranty claim covered by this warranty, the exclusive remedies
option: (1) repair or (2) replacement; or, where authorized in
appropriate cases, (3) the reaaonable cost of mpairor replace
ment at an authorized MILLER service station; or (4) payment of orcmdit forthe pur
chase price (teas reasonable depreciation based upon actual use) upon retum of the
goods at customers risk and expense. MILLERS option of repair or replacement
will be FOB., Factory at Appleton, Wisconsin, or FOB. at a MILLER authorized ser
vice facility as determined by MILLER. Therefore no compensation or reimburse
ment for trsnaportation costs of any kind will be allowed.
Cutting Power Sources
shall be, at MILLERS
writing by MILLER in
Robots
2 Years
*
4.
by others, such as engines or
by the manufacturers warranty, if
3.
ment that has been
Semi-Automatic and Automatic Wire Feeders
3.
covered
Consumable components; such as contact tips,
and relays or parts that fail due to normal wear.
5YesrxPsrta3YearsLabor
*
are
2.
stsrt on the dste thst the
1.
but manufactured
any.
the wsrrsnty claim proceduws to be
followed.
one
by MILLER,
trade accessories. These items
war
mnted psrts or components thst fsil due to such defects in msterial orworkmsnship.
MILLER must be notified in writing within thirty (30) dsys of such defect or failure, st
Parts and Labor
Engine Driven Welding Generatom
(NOTE: Engines are warranted separately by
for a period of two years.)
Air Compressors
1 YearParts
the
engine manufacturer
TO ThE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN
ARE ThE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENTSHALL MILLER BE
UABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTALOR CONSEQUENTIAL
DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CON
TRACt TORT OR ANY OTHER LEGAL ThEORY.
and Labor
Motor Driven Guns
*
Process Controllers
Water Coolant
*
Systems
HF Units
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN ANDANY IMPUED WAR
RANTY, GUARANTY OR REPRESENTA11ON AS TO PERFORMANCE, AND ANY
Grids
*
Spot
REMEDY FOR BREACH OF CONTRACT TORT OR ANY OThER LEGAL
ThEORY WHICH, BUT FOR THIS PROVISION, MIGHTARISE BY IMPLICA11ON,
Welders
Load Banks
*
OPERA11ON OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, IN
CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE, WITh RESPECT TO ANY AND ALL EQUIPMENT
SDX Transformers
Running Gear/Trailers
Plasma cutting torches (except APt ZIPCUT
Field Options
& PLAZCUT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.
models)
Some states in the U.S.A. do not allow imitations of how
(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
one
5.
6 Months
6.
go
year
whichever is
lasts,
the exclusion of incidental, indirect,
special
or
long an implied warranty
consequential damages, so
greater.)
Batteries
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
limitations
the
end
exclusions set out above may not apply. This Limited
waived,
Warranty provides specific legal rights, and other rights may be available, but may
or
Parts and Labor
MIG Guna/TIG Torches
*
or
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.
In
Days
.
APT, ZIPCUT & PLAZCUT model plasma cutting torches
vary from
province
to province.
.1
RECEIVING-HANDLING
Before
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 sealing claims may be obtained from distributor and/or equipment manufacturers
Transportation Department.
with the
When
requesting information
Use the
or
following
nameplate.
about this
equipment, always provide Model Designation
spaces to record Model
Designation and
Serial
or
and Serial
or
Style
Number,
Style Numberof your unit, The information
is located
on
the
rating label
Model
I
_________
Serial
or
Style
No.
Date of Purchase
miller 1 W94
ARC WELDING SAFETY PRECAUTIONS
WARNING
£~
ARC WELDING
can
be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In welding, 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.
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.
Touching
1.
Do not touch live electrical parts.
2.
Wear
3.
4.
5.
dry, hole-free 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. Lockoutltagout input poweraccording
to OSHA 29 CFR 1910.147 (see Safety Standards).
Properly install and ground this equipment according to its
7.
When
that cord
making input connections,
conductor first
plug
is connected to
attach proper
grounding
double-check connections.
8.
Frequently inspect input powercord fordamage or bare wiring
replace cord immediately if damaged bare wiring can kill.
9.
Tum oft all
10.
Do not
equipment
use
wom,
when not in
use.
damaged, undersized,
or
poorly spliced
cables.
drape cables over your body.
grounding of the workpiece is required, ground it directly
separate cable do not use work clamp or work cable.
11.
Do not
12.
If earth
with
a
13.
Do not touch electrode if you are in contact with the work,
ground, or another electrode from a different machine.
14.
Use only well-maintained equipment. Repair or replace
damaged parts at once. Maintain unit according to manual.
15.
safety harness if working above floor level.
panels and covers securely in place.
Wear
a
16.
Keep
all
Always verify the supply ground check and be sure that input
power cord ground wire is properly connected to ground
17.
Clamp work cable with good metal-to-metal contact
workpiece or worktable as near the weld as practical.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing; FLYING
SLAG OR SPARKS can injure eyes.
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
plugs
or ear
muffs if noise level is
2.
Welding produces fumes
these fumes and gases
health.
Wear
a
welding
helmet fitted with
a
proper shade of filter to
protect yourface and eyes when welding orwatching (see ANSI
Z49.1 and Z87.1 listed in
Safety Standards).
approved safety glasses
with side shields.
3.
Wear
4.
protective screens or barriers to protect others from flash
and glare; wam others not to watch the arc.
Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
high.
FUMES AND GASES can be hazardous
to your health.
to
ARC RAYS
5.
ear
a
outlet.
Manual and national, state, and local codes.
Owners
6.
or
properly grounded receptacle
5.
Use
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.
Work in
a
wearing
and gases. Breathing
be hazardous to your
can
confined space
an
S~a
6.
1.
2.
3.
4.
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use exhaust at the arc to
remove 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,
7.
weld area, the
CYLINDERS
I
U
containinQ these elements
2.
3.
qive off toxic fumes if welded.
welding torch over a gas cylinder.
welding electrode to touch any cylinder.
on a pressurized cylinder
explosion will result.
Never
Shielding gas cylinders
high
gas
pressure. If damaged, a cylinder can explode. Since
of
the
are
normally part
welding
gas cylinders
process, be sure to treat them carefully.
Never allow
6.
Never weld
7.
Protect
compressed gas cylinders from excessive heat,
shocks, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical
8.
mechanical
9.
Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is
r~r~
~
can
explode if damaged.
contain
under
____________
1.
can
5.
I ~r
I
is well ventilated, and if necessary, while
The coatings and any metals
4.
i.r9~~
I
area
wearing an air-supplied respirator.
cleaners, and deareasers.
I
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
circuits.
in use
io.
drape
or
a
a
connected for
use.
Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-i listed in Safety
Standards.
______________________
srl.1.1 2/94
WELDING
fire
can cause
explosion.
or
6.
Be
Welding on closed containers,
such as tanks, drums,
or pipes, can cause them to blow up. Sparks can fly
off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal
objects can
cause
fire. Check and be
any
sparks, explosion, overheating, or
sure the area is safe before doing
aware
that
can cause
fire
welding
on a
ceiling, floor, bulkhead,
or
partition
the hidden side.
on
closed containers such
tanks, drums,
7.
Do not weld
8.
pipes, unless they are properly prepared according to AWS
F4.1 (see Safety Standards).
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long,
possibly unknown paths and causing electric shock and fire
welding.
on
as
or
hazards.
1.
2.
3.
4.
5.
yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
Remove all flammables within 35 ft (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.
Protect
9.
Do not
ENGINE EXHAUST GASES
Engines produce
or
cutoff
tip when not in use.
Wear oil-free protective garments such
heavy shirt, cuffless trousers, high shoes,
11.
welding
wire at
kill.
harmful exhaust gases.
as
leather
gloves,
and
a
cap.
Remove any combustibles, such as a butane lighter
matches, from your person before doing any welding.
12.
ENGINES
can
pipes.
contact
WARNING
4~
welder to thaw frozen
use
Remove stick electrode from holder
10.
can
or
be hazardous.
outside in open, well-ventilated
1.
Use
2.
If used in
closed area, vent engine exhaust outside and
away from any building air intakes.
3.
Do not overfill tank
4.
Do not
equipment
areas.
a
~
ENGINE
FUEL
can
fire
cause
or
explosion.
Engine
fuel is
allow
for fuel t o
room
If fuel is
spill fuel.
spilled,
expand.
clean up before
starting
engine.
highly flammable.
.4
and let it cool off before
1.
Stop engine
2.
Do not add fuel while
open flan
~
smoking
or
checking
if unit is
or
near
adding fuel.
sparks or
any
es.
MOVING PARTS
can cause
3.
injury.
Have
only qualified people remove guards or
troubleshooting as necessary.
covers
for
maintenance and
Moving parts, such as fans, rotors, and belts can
fingers and hands and catch loose clothing,
4.
cut
5.
1.
Keep all doors, panels,
securely in place.
2.
Stop engine
before
covers, and
installing
guards
closed and
connecting
unit.
Batteries contain acid
and
loose
clothing,
and tools away from
moving
Reinstall
panels
or
guards and close
starting engine.
doors when
is
servicing
finished and before
generate explosive
.
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
It is best to check coolant level when
to avoid scalding.
Keep hands, hair,
.
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin,
gases.
prevent accidental starting during servicing, disconnect
negative () battery cable from battery.
parts.
6.
or
To
engine is
cold
1.
2.
Always
wear a face shield when working on a battery.
Stop engine before disconnecting or connecting battery
cables.
3.
Do not allow tools to
4.
Do not
5.
Observe correct
1.
If the
use
cause
welder to
engine
is
sparks when working on
charge
polarity (+
warm
and
batteries
and
)
checking
on
or
jump
a
battery.
start vehicles.
batteries.
is needed, follow steps 2
and 3.
2.
Wear
3.
Turn cap
safety glasses and gloves and put a rag over cap.
slightly and let pressure escape slowly before
completely removing cap.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49. 1, from
Welding Society, 550 N.W. Le,Jeune Rd, Miami FL 33126
Safety and Health Standards, OSHA
American
29 CFR
dent of Documents, U.S. Government
D.C. 20402.
1910, from Superinten
Printing Office, Washington,
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, Ameri
Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-i, from Compressed Gas Association, 1235 ,Jefferson Davis High
way, Suite 501, Arlington, VA 22202.
Safe
Code for Safety in Welding and Cutting, CSA Standard Wi 17.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou
levard, Rexdale, Ontario, Canada M9W iR3.
SafePracticesForOccupationAndEducationalEyeAndFace Protec
can
Welding Society Standard AWS F4. 1, from American Welding So
ciety, 550 N.W. LeJeune Rd, Miami, FL 33126
tion, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Code, NFPA Standard 70, from National Fire Pro
tection Association, Batterymarch Park, Quincy, MA 02269.
Cuffing And Welding Processes, NFPA Standard 51 B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
National Electrical
srl.1.1 2/94
-
CONSIGNES DE
SECURITE
POUR LE SOUDAGE
MISE EN GARDE
a
A
LE SOUDAGE
A LARC
peut Œtre dangereux.
LARC
GRAVES VOIRE MORTELLES. TENIR LES ENFANTS A LECART. LES
PERSONNES Qul PQRTENT UN STIMULATEUR CARDIAQUE NE DOIVENT PAS NON PLUS SAPPROCHER DU POSTE DESOUDAGE, A MOINS
DAVOIR CONSULTE UN MEDECIN.
SE PROTEUER ET PROTEGER LES AUTRES CONTRE LES BLESSURES
Le
soudage, comrne Ia plupart des travaux, prØsente certains dangers. Par contre, le soudago pout Łtre effectuØ en toute sØcuntØ quand on prend los
qui simposent. Los consignes de sØcuntØ donnØes ci-apres ne font que rØsumer Iinforrnation contonue dans los normes de sØcuritØ ØnumØrØos
mesures
a Ia page suivante. Lire et respecter toutes ces norrnes de sOcuntØ.
LINSTALLATION, LUllLISATION, LENTRETlEN Er LES REPARATIONS NE DOIVENT
UN CHOC
ELECTRIQUE peut tuer.
tin simple contact avec des piŁces eloctnques peut
provoquer une electrocution ou des biessures graves.
LØlectrode et le circuit de soudage sont sous tension des
que Iappareil est surON. Lo circuit dentrØe et los circuits
intomes de Iappareil soft egatement sous tension a ce
moment-l.
En
soudage semi-automatique ou
automatique, to f ii, le dØvidoir. le logement des gaiets
dentraTnement et les piŁces mØtalliques en contact avec
le fit de soudage sont sous tension. Des matØflels mal
installØs ou mat mis a a terre prOsentent un danger.
1.
2.
3.
4.
5.
6.
CONFIES
OuA
DES PERSONNES
OUALIFIEES
7.
En effoctuant los raccordomonts dentrØe fixerdabord 10 conductour
do miso a Ia terre appropnØ 01 contre-vØnfier los connexions.
8.
Verifier trequemmont to cordon dalimontation pour voir siI nest pas
endommage Cu dØnudØ remplacer 10 cordon immØdiatemont sit
cable dØnudØ pout provoquor uno
est endommage
un
electrocution.
9.
Mettre
Iappareil
hors tension
quand
pas utiliser dos cables uses,
insuffisanto Cu mat ØpissØs.
on no
lutilise pas.
do
ondommagØs,
10.
Ne
piŁces electnques sous tension.
Porter des gants et des vOtoments de protection secs no comportant
11.
pas de trous.
12.
Ne pas enrouler los cables autour du corps.
Si Ia piŁce soudØo doit Œtro mise ala torro, 10 faire directemont avoc
no pas utiliser 10 connocteur de piŁce Cu to cable
un cblo distinct
do retour.
Ne
jamais
toucher les
Sisoler
do Ia piŁce et do Ia terre au moyon de tapis ou dautres
moyens isolants suffisamment grands pour empŒcher to contact
physique Øventuol avec Ia piŁce ou Ia terre.
13.
Ialirnentation ou arrŒter to moteur avant de procOdor a
a Ia reparation Cu a lentretien
de lappareil.
linstallation,
DØvorrouillerlalimentation selon Ia norme OSHA 29 CFR 1910.147
(voir normes de sBcuntØ).
14.
15.
municipaux.
Toujours verifier
17.
16.
Ia terre du cordon dalimontation
VØnfier 01
est bien
quo le fit de terre du cordon dalimentation
Larc de soudage produit des rayons visibles 01 invisibles
intenses (ultraviolets et infrarouges) qui peuvent brUler
los yeux et Ia poau. Lo bruit produit par certains procØdØs
pout endommagor touie. Des projections de metal Cu do
Iaitier soft produitos par to piquage, le meulage ou to
refroidissement des soudures.
approuvØs
si
vapours ot des tumØos
quit
2.
manuel.
hamais do sØcuntØ
un
Maintenir solidomont
en
masque a sorre-tŁto muni dun verro tiltrant do nuance
pour protØger to visage 01 los youx quand on soude Cu
observe Ia travail do soudage (voir los normos ANSI Z49.1 et Z87.1
donnØos sous Ia rubnque Principalos normos do sŁcuritØ).
Porter
un
appropnoe
Øcrans latØraux.
3.
Porter dos lunettos do sØcuntØ
4.
Utiliser dos paravonts Cu dos barriŁros do protection pour protegor
los porsonnes a proximitØ contro los coups darc 01 IØblouissoment;
avortir los autros porsonnos do no pas rogardor larc.
5.
5.
Porter des vŁtomonts do
approuvØos
avoc
protection en tissu ignifuge durable (lame et
et dos chaussuros de sØcuritØ.
Ne travaitlor dans
un
espaco confine quo sil ost bion vontilO.
Cu Ofl
portant un apparoil rospiratoiro a adduction dair pur. Demander a un
obsorvatour ayant rou Ia bonno formation do toujours se tenir a
proximitØ. Los vapours et fumØes do soudago pouvont dØplacor lair
ost
dCxygŁne et causer dos blessuros graves voire
mortellos. Sassuror quo lair est propro a Ia rospiration.
do degraissage, do
No pas souder a proximitØ dopØrations
notloyago Cu do pulvØnsatrCn. La chalour et los rayons do Iarc
peuvont reagir avoc los vapeurs pour former dos gaz hautement
et abaissor to niveau
__I.
1.
Gardor Ia tŒte a lextØriour dos vapeurs et dos tumØes et
2.
respiror.
A lintØriour,
au
co
quand on travaille on hautour.
place tous los panneaux et capots.
Fixor to cable do rotour do faon a obtonir urr bon contact mØtat-mØtal
avoc Ia piŁce a soudorou Ia table do travail, to plus pres possible do Ia
Porter
RAVONNEMENT DE LARC
dangereuses
Lo soudage produit des
dangeroux do rospiror.
materiel en bon Øtat.
Nutilisor quun
RØparor Cu romplacer
Entrotonir lappareil
sur-lo-champ los piŁces ondommagØes.
cuir)
LES VAPEURS Er LES FUMEES peuvent Œtre
pour Ia sante.
Ia
piŁce.
souduro.
BRUIT
Utilisor dos bouche-oreilles Cu des sorre-tŒte antibruit
Ieniveau do bruit est ØlovØ.
Ne pas toucher lØlectrodo quand on ost on contact avec Ia
Cu UflO electrode provonant dune autre machine.
conformØment a
Installer et mettre ala terre correctement cet appareit conforniOment
a son manuel dutilisation et au codes nationaux, provinclaux 01
LE RAYONNEMENT DE LARC peut brler les
yeux et Ia peau. Le BRUIT peut endommager
IouIe; les PROJECTIONS DE LA~ER OU LES
ETINCELLES peuvent blesser les yeux.
grossour
terre
Couper
sassurer
1.
ETRE
raccordØ ala borne do torro du sectionnour ou quo Ia ficho du cordon
ost raccordØo a une pflso correctoment mise a Ia terre.
no
pas los
ventiler 10 posto do travail ou utiliser un dispositit place
niveau do larc pour vacuor los vapeurs ot fumØes do soudage.
6.
toxiques
et irritants.
3.
Si Ia ventilation ost mauvaise, utilisor
adduction dair pur approuve.
4.
Consultor los fiches signalØtiquos 01 los consignos du fabncant
relatives au mOtaux, produits dapport, rovŒtomonts. nettoyants 01
Ne pas soudor sur des mOtaux rovŒtus commo lacier gatvanisØ, au
p10mb Cu cadmiØ a moms quota piŁco nail ØtŁ entiŁromont decapØe,
quo le posto do travail soil bien vontilØ. Sit y a lieu, porter un appareil
rospiratoire a adduction dair pur. Los revØtomonts ot los mØtaux qul
contiennont do loIs ØlŁmonts peuvont dØgager des vapeurs toxiques
degraissants.
lors du
un
appareil respiratoiro a
LES BOUTEILLES peuvent exploser si elles
sont
1.
2.
3.
7.
endommagØes.
4.
Ne
soudago.
jamais poser un chalumoau soudeur sur une bouteillo do gaz.
jamais laissor une Ølectrodo do soudage toucher une boutoille.
jamais souder sur uno boutoillo sous pression : ollo exploserait.
5.
No
Les boutoillos contenant des gaz do protection sorit a
haute pression.
Uno bouteito ondomrnageo pout
oxploser. Etant donnØ quo les bouteilles do gaz font
normalemonl partie du matØriol do soudage, los traitor
avec to plus grand soin.
6.
No
7.
Nutitisor quo des bouteittos do gaz do protection, dos dØtondours.
dos tuyaux souplos et des raccords appropnØs conus
pour
Iapplication particutiŁro: conserver cos matØnols 01 leurs piŁces en
tes boutoitlos do gaz compnmØ contro Ia chalour intense.
los chocs. to laitier, los flammes flues. los Øtincellos ot lam.
8.
ProtØger
Placer los boutoiltos ala verticale on los fixant a un support fixe
un chariot pour Øvitor quelles no tombent ou no bascuient.
Tenir los boutoillos a lØcart du poste do
electriquos.
soudago
Cu
Cu
a
dautros circuits
bon etat.
Etoignor
10
visage
do Ia sortie du robinel do Ia boutoillo
quand
on
louvre.
9.
10.
Replacer
to
chapoau
sur
Ia boutoillo
aprØs utitisation.
Lire ot suivro los consignos relatives aux bouteillos do gaz compnme.
au materiel connoxe ainsi quota publication P-i do Ia CGA donnØe
sous
Ia rubnque
Pnncipaies
norrnos
do sØcuntØ.
srl.1.1 2194
LE SOUDAGE peut
Incendle
ou une
5.
Ne pas souder sur des recipients fermØs comme des
reservoirs, des Wits ou des tuyaux : us peuvent exploser.
Larc do soudage peut produire des Øtincelles.
Des
Øtincelles, une piŁce chaude at un materiel chaud
peuvent provoquer des incendies et des blessures. Lo
des objets
contact accidental de lØlectrode
sur
mØtalliques peut produire des Otincelles, lexplosion, Ia
surchauffe ou un incendie.
Sassurer que 10 lieu no
presento pas do danger avant deffectuer le soudage.
6.
causer un
explosion.
1.
Se protOgeret protØger los personnes a proximite des Øtincelles et du
metal chaud.
2.
Ne pas souder dans un endroit o
des matØnaux inflammables.
3.
4,
les Øtincelles
atteindre
peuvent
ou
7.
8.
Prondre garde quo los Atincelles et los projections no penetront dans
dos zones adjacentos en sinfiltrant dans dos petites fissures et
11.
Ne pas porter des matiŁres combustibles sur sol
quand on soude.
DECHAPPEMENT
LES MOTEURS peuvent
DES MOTEURS
bnquet a
comme un
danger.
un
dans des lieux ouverts ot bion
vontilØs.
produisent des gaz
d
echapp ement
LE CARBURANT peut provoquer
ou une
presenter
Utitiser le materiel a IextOneur,
1.
2.
Los moteurs
un
nocifs.
Incendie
ArrŒter le ~noteur et le laisser refroidir avant do verifier le niveau do
do refaira le ploin
LES PI¨CES EN MOUVEMENT peuvent
des blessures.
causer
piŁces en mouvement comme los ventilateurs. los
rotors et los courroies pouvont couper les doigts et les
mains at happer les vŁtements amples.
Sassurer quo los portes, los panneaux, los capots et los protecteurs
sont bien fermØs et bien a leur place.
2.
ArrŁter Ia moteur avant de mettre
ou
utiliso
moteur dans un local temiO. Øvacuer les gaz
a lextØriour et loin des pnses dair du bÆtiment.
un
2.
Ne pas fumer on faisant le plain ou si lappareil
dØtincelles ou do flammes nues.
3.
Ne pas romplir Ia reservoir a
dilatation du combustible.
4.
Ne pas renverser du carburant.
Si on renvorse du carburant,
nettoyor les lioux avant do faire dØmarrer lo motaur.
3.
4.
5.
1.
place
on
ras
bord
:
so
prØvoir
trouve a
de
proximitO
lespace
pour Ia
Seules des personnes qualifiØes doivent dØmonter les protecteurs
los capots pour faire lentretien ou los reparations nØcessaires.
ou
Los
en
Si
dechappoment
explosion.
La carburant est hautement inflammable.
I
Porterdes vØtements do protection non huileux comme des gants en
uno chemise Øpaisse, des pantalons sans revers, des
chaussures montantes ot un casque.
gaz ou des allumettes
LES GAZ
1.
degeler des tuyaux.
Enlever relectrode enrobØe du porte-electrode ou coupe, le fil de
soudage au ras du bec contact quand on no lutilise pas.
12.
MISE EN GARDE
~.
Ne pas utiliser le chalumoau soudeur pour
cuir,
peuvent Œtre mortels.
p4I
Raccorder Ia cable de retour a Ia piŁce, le plus prŁs possible do Ia
do soudage, pour empØcher quo Ia courant do soudage no
suivo une trajectoire longue et Øventuellemont inconnue et quil ne
provoque des nsques dØlectrocution et dincendie.
9.
ouvertures.
A~
autre, le lou pout prendre de lautre ctØ.
Ne pas souder sur dos recipients fermØs comme des reservoirs, des
tOts ou des tuyaux a moms quils ne soient prepares do faon
appropflee conformØment ala norma F4.1 do lAWS (voir Ia rubrique
Principales norrnes de sØcuritØ).
zone
10.
Enlevertoutes los matiŁres inflammables dans un rayon de moms do
10 m de larc. Si cola nest pas possible, bien les recouvnren utilisant
dos bchos approuvØes.
Prendre garde aux incendies at toujours avoir un extincteur a
proximitØ.
Se rappelerquo Si Ion soude sur un plafond, un plancher, une cloison
do raccorder
Pour empØcher
lentretien ou los
battene.
demarrage accidental dun systŁme pendant
reparations. dØbrancher lo cable negatif () de Ia
un
Eloignor los mains,
las cheveux, las vØtements amplos ot les outils
piŁces en mouvemont.
Replacer los capots ou les protecteurs ot rofermer los portos une fois
lentretien et les reparations torminØs at avant cIa faire demarrer le
des
6.
un
moteur.
LES ETINCELLES peuvent faire EXPLOSER LE
GAZ DES BATrERIES; LELECTROLYTE peut
brUler Ia peau et les yeux.
Les batteries contiennent
des vapeurs explosives.
1.
Touioursl
.
~
4$~~
~
~
iorter un Øcran facial
un
auand
on
produit
acido et
travaille
sur une
degagent
battene.
VAPEUR
El
LE
DE
LA
LIQUIDE
BRULANT
REFROIDISSEMENT
SOUS
PRESSION peuvent brler Ia peau et les yeux.
II vaut mieux verifier 10 niveau du liquide de
refroidissemant quand lo motour est froid attn d~Øviter los
brUlures.
2.
ArrØtor Ia moteur avant do brancher
Ia battene.
3.
Ne pas faire des Øtincelles
batterie.
4.
Ne pas utiliser Ia source do courant de soudage pour
batteries ou pour faire dØmarrer un vØhiculo.
do lAmencan
Welding
Recommenaed Safe Practice for the Preparation for Welding and Cutting
of Containers That Have Held Hazardous Substances, normo AWS F4.1.
do lAmerican Welding Socioty, 550 NW. Lejoune Ad, Miami FL 33126
National Electrical Code, NFPA Standard 70, data National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
Srl.1.1 2/94
les outils quand
on
travaille
sur une
charger
las
Ne oas intervortir Ia colantØ des batteries.
1.
Si Ion dolt verifier 10 niveau quand le moteur ost chaud, suivre los
Otapes
2 ot 3.
2.
Porter des lunottes do sØcuntØ et des gants ot placer
bouchon.
3.
Toumer lentement 10 bouchon at laisser Ia pression
lenternent avant denlever complØtemont Ia bouchon.
un
chiffon
sur
le
sechapper
SECURITE
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P.1, do
Ia Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
501.
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of
Documents, U.S. Government Printing Office, Washington, D.C. 20402.
do dØbrancher los cables cIa
5.
PRINCIPALES NORMES DE
Safety in Welding and Cutting, norme ANSI Z49.1,
Society, 550 N.W. Lojeune Ad, Miami FL 33126
avec
ou
Arlington,
Reg!es
VA 22202.
de sØcuntØ
ensoudage. coupage et procØdØs connexes, norrne
CSA W117.2, de lAssociation canadienne do normalisation, vonte do
norrnes, 178 Rexdalo Boulevard. Rexdale (Ontario) Canada M9W 1 R3.
Safe Practices For Occupation And Educational Eye And Face Protection.
ANSI Z87.1. de lAmorican National Standards Institute. 1430
Broadway, New York, NY 10018.
normo
Cutting and Welding Processes, norme NFPA 51 B, do Ia National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
EMF INFORMATION
Considerations About
NOTE D~
Magnetic
Welding
And The Effects Of Low
following is a quotation from the General Conclusions Section
Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields
Background Paper~ OTA-BP-E-53 (Washington, DC: U.S.
there is now a very
Government Printing Office, May 1989): .
large volume of scientific findings based on experiments at the
cellular level and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific
understanding does not yet allow us to 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 to offer clear science-based advice on strategies to minimize
or avoid potential risks.
reduce
The
To
of the U.S.
procedures:
.
Frequency
Electric And
Fields
magnetic fields
cables close
in
1.
Keep
2.
Arrange
3.
Do not coil
4.
Keep welding power
practical.
source
5.
Connect work
to
cables to
the
workplace,
together by twisting
one
or
use
taping
side and away from the
the
following
them.
operator.
.
or
drape
cables around the
clamp
body.
and cables
workpiece
as
as
far away
as
close to the weld
as
possible.
About Pacemakers:
The
above
procedures are among those also
pacemaker wearers. Consult your
recommended for
complete
information.
normally
doctor for
modlO 1 4/93
TABLE OF CONTENTS
SECTION 1
-
SAFETY INFORMATION
SECTION 2
SPECIFICATIONS
SECTION 3
INSTALLATION
2
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
5
3-7.
Welding
3-8.
Wire Feed Motor And Gas Valve Control Connections
6
3-9.
Control Connection
7
3-10.
8
3-12.
Shielding Gas And Weld Cable Connections
Removing Safety Collar And Adjusting Boom
Welding Wire Installation
10
3-13.
Motor Start Control
11
3-14.
Threading Welding
3-1.
3-2.
3-3.
3-4.
3-11.
3
3
4
4
Gun Connections
6
9
Wire
12
SECTION 4- GLOSSARY
14
SECTION 5-OPERATION
16
5-1.
Front Panel Controls
17
5-2.
Side Panel Controls
19
5-3.
Rear Panel Controls
5-4.
Setting
SECTION 6
Switches On 450
Inverter Model
Welding
Power Source
STEPPING THROUGH THE MICROPROCESSOR CONTROLS
6-1.
Front Panel
6-2.
Side Panel
SECTION 7
20
Ampere
8-2.
22
Microprocessor Controls
Microprocessor Push Buttons
22
STANDARD PULSE WELDING PROGRAMS
27
24
SECTION 8- GETTING STARTED
8-1.
21
Welding With Only Front Panel Controls
Setting Sequence Pulse Welding Parameters
35
36
On Side Panel
Display
37
OM-1588A- 10194
SECTION 9TEACHING
9-1.
9-2.
9-3.
9-4.
A PULSE WELDING PROGRAM
41
Pulse Waveform
Explained
Explained
Teaching A Pulse Welding Program
Changing To Adaptive Pulse Welding
41
Teach Points
42
43
46
SECTION 10- TEACHING A MIG WELDING PROGRAM
10-1.
10-2.
Changing To MIG Welding
Setting Sequence MIG Welding
SECTION 11
SECTION 12
12-1.
12-2.
-
47
Parameters On Side Panel
13-1.
13-3.
13-4.
13-5.
13-6.
13-7.
13-8.
13-9.
13-10.
13-11.
13-12.
13-13.
13-14.
13-15.
13-16.
13-17.
13-18.
13-19.
Display
48
SETTING DUAL SCHEDULE PARAMETERS
51
USING THE OPTIONAL DATA CARD
53
Installing Data Card
Using The Data Card
53
53
SECTION 13-SETUP
13-2.
47
57
Setup Flow Chart
Using Setup Displays
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
Resetting Arc Time
Using Self Test
Selecting Units For Wire Feed Speed And Motor Type
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
57
58
58
59
60
61
62
62
63
63
64
65
65
66
67
67
68
68
69
69
70
14-1.
Routine Maintenance
70
14-2.
Replacing
71
14-3.
Overload Protection
71
14-4.
Error
72
14-5.
The Hub
Assembly
Displays
Troubleshooting
73
SECTION 15- ELECTRICAL DIAGRAMS
74
SECTION 16
78
Figure
Figure
Figure
Figure
Figure
Figure
Figure
PARTS LIST
16-1. Main
16-2.
Assembly
Support, Hub &
78
Reel
16-3. Control Box
16-4.
Panel, Front w/Components
81
82
85
16-5. Boom
86
16-6.
88
16-7.
Assembly
Drive Assembly, Wire
Panel, Side w/Components
Table 16-1. Dnve Roll And Wire Guide Kits
90
91
SECTION 1
SAFETY INFORMATION
-
modl.1 2/93
Read all
safety messages throughout
Obey
safety
all
Learn the
1
messages to avoid
meaning
this manual.
injury.
of WARNING and CAUTION.
2
1
Safety
Alert
2
Signal
Word
2
\
\
WARNING
or
a WARNING
ELECTRIC SHOCK
can
kill
fi
Do not touch live electrical parts.
L t~P
Disconnect
installing
a CAUTION
~
or
input power
servicing
before
S
means
injury
possible death
happen.
can
CAUTION
MOVING PARTS
4
serious
Symbol
can
Keep away from moving parts.
Keep all panels and
wtien operating.
means possible minor
injury or equipment damage can
happen.
injure.
covers
closed
I
I
3
Statement Of Hazard And
4
Safety
I
Result
/
5
Instructions To Avoid
Hazard
. Ii~~
~
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
5
Hazard
6
Safety
Read safety blocks for each sym
bol shown.
7
7-H
~
NOTE
Turn Off switch when
using high frequency.
NOTE
Special
1-1.
Safety
instructions for best oper
not related to
ation
Figure
Symbol (If Available)
Banner
safety.
Information
SECTION 2- SPECIFICATIONS
Table 2-1. Wire Feeder
Specification
Type Of Input
Power From
Description
Welding
Single-Phase
24 Volts
AC, 10 Amperes, 50/60 Hertz
Power Source
Maximum Weld Circuit.
Welding
Power Source
Wire Feed
100
Type
Constant Voltage
Constant Current
.023 To 1/8 in
Range
Welding Processes
Input
(0.6 To
Gas Metal Arc
Power Cord
Height
Welding
Welding
With Contactor For GMAW-P
3.2
mm)
(GMAW), Gas
Metal Arc
-
Pulse
(GMAW-P),
Flux Cored Arc
Welding (FCAW)
lOft(3.1 m)
12 ft
Maximum
With Contactor For GMAW
(CV) DC,
(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)
Speed Range
Wire Diameter
Volts, 750 Amperes, 100% Duty Cycle
Rating
With 4 ft
(1.2 m)
17
(3.7 m)
16 ft
Boom
ft(5.2 m)
21
(4.9 m)
Boom
ft(6.4m)
Post
Weight
Net: 207 lb (94 kg)
318 lb (144 kg)
Vertical Lift Of Boom
These
are
wire feed
Horizontal To
speed ranges for
60
GMAW. While Pulse
Ship:
Above Horizontal
welding,
(127 kg)
(186 kg)
Net: 280 lb
Ship:
wire feed
411 lb
Horizontal To 60
speed ranges may
be
more
Above Honzontal
limited (see Section 9).
OM-1 588
Page
1
SECTION 3-INSTALLATION
3-1.
.
Equipment Connection Diagram
AA
WARNING
CYLINDERS
can
explode
if
ELECTRIC SHOCK
damaged.
Keep cylinders away from welding
and
other
electrical circuits.
Never touch
cylinder
with
Always secure cylinder
other stationary support.
HOT SURFACES
to
can
Allow gun to cool before
welding
electrode.
running gear, wall,
burn skin.
or
can
Do not touch live electrical
kill.
parts.
Turn Off wire feederand welding powersource, and
before
disconnect
input
making
power
connections.
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.
touching.
Have
only qualified persons install this
unit.
wfwamg1* 2/93
Figure
OM-1 588
Page
2
3-1.
Typical System Connections
3-2.
Installing
Swivel Into
Post
WARNING
4~
41
Pipe
RELEASE
OF
SPRING
PRESSURE
WITHOUT BOOM ATTACHED can cause
serious personal injury.
Do not
remove
safety collar until
FALLING
BOOM can cause
and equipment
personal injury
serious
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.
instructed to do so.
1
Swingpak
Base
or
CBC Cart
5
4
2
Pipe
3
Steel Bolt
Secure
mum
Post With Base
as
shown
using
as a
1/2 in diameter SAE
mini
grade
5
steel bolts.
4
Swivel
Insert
Assembly
into
pipe post.
Lubricate
swivel.
5
3
Safety
Do not
Collar
remove
until instructed to.
Tools Needed:
~ 3/4 in
ST-152382
Figure
3-3.
Installing
3-2. Swivel Installation
Control 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
swivel and slide forward.
on
Tighten
screws.
2
3~
Tools Needed:
4
ST-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
Section 3-2 before proceeding.
1
Swivel Plates
2
Yoke
Remove
plates
3
.
3
hardware
and
Set boom into swivel
Install
pin
5
shown.
pin through yoke. Install
and spread ends.
cot
Bolt
Install
*0
as
Yoke Pin
4
2
swivel
Boom
4
ter
from
yoke.
bolt,
washers,
Tighten hardware,
one
half turn.
6
Locking
Install
and nut.
and back bolt off
Knob
locking
knob
but do
not
~ghten.
7
Reel
Support
Install reel support.
Tools Needed:
~ 3/8, 3/4 in
ST-153 170
Figure
3-4. Boom Installation
.
3-5.
Installing
Wire Guide Extension
.
Figure
OM-1588
Page
4
3-5. Wire Guide Extension Installation
3-6.
Wire Guide And Drive Roll Installation
A~
WARNING
ELECTRIC SHOCK
can
Do not touch live electrical
Turn Off wire feeder and
kill.
parts.
welding power
source, and disconnect
input power
before
inspecting
or
installing.
wfwarnl.i 2/93
A.
Wire Guide Installation
When
check
1
changing wire size or type,
guide size (see Table 16-1).
Drive Rolls
Remove drive rolls before install
ing wire guides (see Figure 3-7).
2
Wire Guide
Loosen wire
Securing
guide
Screws
screws.
3
InletWire 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.
Tools Needed:
Ref. ST-137 391-F/ST-142 597-A
Figure
B.
3-6. Wire Guide Installation
Drive Roll Installation
When
changing
check
drive
Table
wire size
roll
or
size
type,
(see
16-1).
Garner
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
ers. Turn nut one click.
5
Drive
Close
Assembly
cam
Cover
cover.
Repeat procedure for opposite
side of wire feeder.
2
3
ST-i 42 597-A
Figure
3-7. Drive Roll Installation
OM-1588
Page
5
3-7.
Welding
Gun Connections
WARNING
AA
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.
wfwarni.i 2193
1
Drive
2
Gun
3
Gun Connector
Assembly
Securing
Cover
Knob
Loosen securing knob. Insert gun
connector until it bottoms
drive
4
assembly. Tighten
Gun Trigger Plug
5
Gun
Insert
against
knob.
Trigger Receptacle
plug
ceptacle
into free-hanging re
and tighten threaded col
lar.
Cord
6
Trigger
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-i 52 466/ 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
1
Wire Feed Motor And Gas
Valve Control
Receptacle
From Boom
2
Plug
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-800 177 / Ref. 5T-800 175
Figure
OM-1 588
Page
6
3-9. Boom Connections
3-9.
Control Connection
17-Pin
1
2
Table
Receptacle (See
3-1)
Keyway
2
interconnecting cord to
receptacle, align keyway, insert
plug, and tighten threaded collar.
To connect
3
Weld Current Sensor Recep
tacle (For Use With Field op
tion Only)
4
35 ft
ing
(10.6 m) Voltage Sens
Lead
Connect
3.
to
workpiece
(see
Figure 3-1).
5
Threaded Collar
6
14-Pin
Plug (see
Table
3-2)
plug matching recep
welding power source,
align keyway, insert plug, and tight
To connect
tacle
en
to
on
threaded collar.
ST-800 177/Ref. S-051 2/ S-0003-A / 5-0828
Figure
3-10. Control Connections With Pin Information
Table 3-1. Remote 17 Socket Information
REMOTE 17
E ~l
Socket*
Socket Information
C
CCICV select; +13 to +24 volts dc is
G
Arc control/inductance control; 0 to +10 volts dc.
E
Actual weld current output
M
Actual weld
F
Current feedback from
H
feedback from
signal;
CV, 0 volts dc is CC.
+1 voltdc is 100 amps.
.
The
remaining
sockets
are
Voltage
voltage output signal;
+1 voltdc is 10 volts dc.
welding power
source; 0 to +10 volts
dc, 1 volt per 100 amperes.
power source; 0 to +10 volts dc, 1 volt per 10
welding
arc
volts.
not used.
Table 3-2. Remote 14-Pin Information
REMOTE 14
()g~
A Al
I
The
OUTPUT
~j~*
Pin Information
A
24 volts ac.
B
Contact closure to A
completes
24 volts
ac
contactor control circuit.
(CONTACTOR)
AMPERAGE
VOLTAGE
remaining pins
are
G
Circuit
C
+10 volts dc
D
Remote control circuit
E
Oto +10 volts dc
for 24 volts
common
input
ac
circuits.
to remote control.
common.
output command signal from feeder voltage control.
not used.
OM-1 588
Page
7
Shielding
3-10.
Gas And Weld Cable Connections
AA
WARNING
CYLINDERS
can
explode if damaged.
Keep cylinders away from welding
and
ELECTRIC SHOCK
other
electrical circuits.
Never touch
can
Do not touch live electrical
.
kill.
parts.
Turn Off wire feederand
cylinder with welding
Always secure cylinder
other stationary support.
to
electrode.
disconnect
welding powersource, and
input power before inspecting or
installing.
running gear, wall,
BUILDUP OF SHIELDING GAS
health or kill.
Shut off
shielding gas supply
can
when not in
harm
use.
wam4.1 9/91 I wfwaml.1 2/93
A.
Connecting
Weld Cables And Gas Hose
.
Tools Needed:
~ 5/8in
Ref. ST-i 53 175-A
Theweldcablesandshieldinggashosesextend 10 ft (3m) from the boom.
ersource
and boom. Use electrical
If the
insulated
sleeving
welding power source or gas supply
further from the boom, extend cables
and hoses as follows:
Bolttogetherweldcablesfromwelding
to cover connection,
are
1
Weld Cables
2
Insulated
Sleeving
OM-1588
Page
8
3-11.
Connect boom
supplies
3
Shielding Gas
Boom
or
shielding gas hoses to gas
extension. The hoses from the
boom have 5/8-18
5
4
Figure
pow-
tape and
right-hand
Supplied Shielding Gas
V
threads.
Adapter
Extension Hose
Connect single end
Shielding Gas Hose(s)
Shielding Gas
fitting
of V
adapterto gas
supply, and connect boom shielding gas
hoses to fittings on V end of adapter.
And Weld Cable Connections
.
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.
2
Close valve.
3
4
Cylinder
Regulator/Flowmeter
Install
5
face is vertical.
so
Gas Hose Connection
Fithng
5/8-18
has
threads. Install gas hose
to Figure 3-11.
right-hand
according
Flow Adjust
Typical flow rate is 20 cfh (cubic feet
per hour). Check wire manufactur
6
6
.2
Argon
Gas
ers
recommended flow rate.
Make
flow adjust is closed
opening cylinder to avoid
damage to the flowmeter.
7
CO2 Adapter
8
0-Ring
Install adapter with 0-ring between
and
regulator/flowmeter
CO2
cylinder.
ssb3.1 5/94
ST-158 697-A
5
sure
when
4
Tools Needed:
~ 5/8,
1-1/8 in
CO2
Figure
3-11.
Removing Safety
a
I.
3-12.
Typical Regulator/Flowmeter
Collar And
Adjusting
Installation
Boom
WARNING
RELEASE
OF
SPRING
PRESSURE
WITHOUT BOOM ATTACHED can cause
serious personal injury.
Do not
Gas
remove
safety collar until
FALLING
BOOM
personal injury
Adjustment
yoke.
instructed to do so.
can
and
cause
rod must be threaded
1
serious
equipment damage.
Locking
Tighten
fully through
Knob
knob
to
prevent boom
movement. Loosen knob to allow
boom movement.
Change knob
position to limit upward movement.
Pull boom down
move
Tools Needed:
1~
3
2
Increasing Spring
Decreasing Spring
Pressure ForA
Pressure ForA
HeavyGun
LightGun
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
vent boom falling.
Rod
r 1-1/8in
slighfly and re
collar. Boom should
balance in any position from hori
zontal to 60 degrees above hori
zontal. If necessary, adjust boom
as follows:
0
E
safety
4
yoke
to pre
Yoke
Retain safety collar for use in
assembling or moving boom.
dis
ST-142599-B
Adjustments
OM-1588
Page
9
3-12.
A.
Welding
Wire Installation
Installation Of
Spool-Type
Wire
4
1
Retaining Ring
2
Wire
3
Hub
Remove
spool
4
.
Spool
retaining nng
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 Wire
3-14. Installation Of
Reel And Reel
Type
Spool-Type
Wire
Wire
1
Retaining Ring
2
Spanner
3
Lock
4
Wire Retainer
5
Wire Reel
6
Hub
7
Hub Pin
8
Reel
8
1
Nut
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
Tighten
position
pin
into wire retainer.
Slide wire reel
and turn
C
assembly onto hub,
assembly until hub pin is
seated in hole in reel. Reinstall
re
taming ring.
.
Wire lnstallat~on
ST-143 478-A/ ST.152 463
Figure
OM-1 588
Page
10
3-15. Installation Of
Optional
Wire Reel And Reel
Type
Wire
C.
Adjusting
Hub Tension
Turn Oft unit and
welding
power
source.
1
Hex Nut
2
Spool
2
Grasp spool in one hand arid turn
using a wrench to adjust hex
nut. When a slight force is needed
to turn spooi, tension is set.
while
Repeat procedure
for
opposite
side.
Tools Needed:
~
5/8 in
ST-i 53 173
Figure
3-16.
Adjusting
Hub Tension
3-13. Motor Start Control
WARNING
4~
ELECTRIC SHOCK
can
Do not touch live electrical
STATIC ELECTRICITY
circuit boards.
kill.
can
damage parts
on
parts.
Put
Tum0ffwirefeederandweldingpowersource,and
disconnect input power before inspecting or
installing.
on
boards
grounded
or
wrist
strap BEFORE handling
parts.
wfwaml.1
2/93
To
change wire feed starting speed
proceed as follows:
Right Side
~II
Turn Oft wire feeder and
~
welding
source.
power
Remove wrapper.
1
2
Motor Board PCi
Motor Start Control Poten
tiometer R70
-
Turn
~
~:
~
~
~
E~D
~~
.~
~
~\
~
Tools Needed:
EIZJ~tI
i/4in
1
~4_~
potentiometer clockwise to in
crease
ing adjustment. Adjust potentiome
using a small nonconduc
ter R70
tive screwdriver.
Reinstall wrapper.
2
Non-conductive
Figure
time it takes the motor to
ramp up to speed. Remove protec
tive white rubber cap before mak
Ref. ST-162 i32IRef. SB-146 862-0
3-17. Motor Start Control On Motor Control Board PCi
CM-i 588
Page
ii
3-14.
Threading Welding
a
Wire
WARNING
CYLINDERS
can
Keep cylinders
explode
away from
if
damaged.
welding
and
other
electrical circuits.
Never touch
cylinder
WELDING WIRE
Do not press gun
with
welding
electrode.
Always secure cylinder to running
other stationary support.
ELECTRIC SHOCK
can
gear, wall,
can
cause
puncture
wounds.
trigger
until instructed to do
S
so.
point gun toward any part of the body, other
people, or any metal when threading welding wire.
Do not
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 I wfwarn7.1 9/91
S
S
OM-1588
Page
12
1
Wire Spool/Reel
2
Wire Tube
3
Pulley
4
Wire Guides
5
Drive Rolls
6
Jog Button
7
Gun Conduit Cable
8
Pressure
9
Drive Roll Pressure Indicator
Scale
Adjustment Knob
7
Tools Needed:
See
Figure 5-13 for
positions of 450
Ampere Inverter model
welding power source or
see welding power
ON
switch
~
OFF
source
Owners
....*
Manual
for other models.
Wire Feeder
( Figure 5-10)
Welding
Power Source
I
Pull and hold wire; cut off end.
Set switches.
Manually feed
wire thru tube, over
and up to wire inlet guide.
pulley,
JOG
~
010
SELECT
-4
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.
-4
U
Feed wire to check drive roll pressure.
knob enough to prevent slipping.
Adjust
Cutoff wire. Close
cover.
Repeat procedure for opposite side.
Ref. ST-800 178/ Ref. ST-150 922 / ST-153 073/ Ref. ST-157 432
Figure
3-18.
Threading Welding
Wire
OM-1 588
Page
13
SECTION 4- GLOSSARY
The
following
is
a
list of terms and their definitions
they apply
as
S
to this wire feeder:
General Terms
Adaptive
Pulse
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.
Background Qurrent
The lower of the two current levels in the
Cold Wire
When current is not sensed, wire feeds for about three seconds at set wire feed
Jog
speed
and then
the wire
Inductance
automatically
jog speed.
In short circuit
welding,
an
pulsing
waveform.
opens the contactor while
continuing
to feed wire at
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
Synergic refers to the
length adjustments
in
pulse programs.
Trim is
replaced
units
ability to use preprogrammed pulse parameters in order
pulse settings of Peak Amperage, Background Amperage,
Pulse Width at any specific wire feed speed setting.
to determine the actual
Pulse
Frequency
and
Front Panel Terms
Display
Control Knob
Is used for all
adjustable front panel displays.
Digital Display
2-line
Gas
Allows the gas line and gun to be
Purge
Control
Parameter Select Button
Trigger
Hold Control
by
16-character
Is used to select
Jog
Control
with built-in LED
purged without energizing
vanety of parameters that
When selected, allows the
to hold the gun
Wire
a
liquid crystal display
system
to remain
can
be set
energized
on
backlight.
the wire feeder.
the front
panel display.
without the operator
Allows the wire to feed without
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
having
trigger.
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
welding
condi
used, including Pulse, Adaptive Pulse,
or
Mig.
Remote Parameter
When
Increase/Decrease
decrease
Sequence
Mode
this
feature
is
turned
on,
the
operator
selected weld parameter with the
momentary-contact switch.
a
use
can
of the
remotely
optional
increase
DSS-10
and
2-pole
Allows
a variety of sequences to be used within a weld program if required. Se
quences include, preflow 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
time from 0 to 0.25 seconds, and
postflow
speed from
0 to 2.5
seconds, burnback
gas control from 0 to 9.9 seconds.
SetuD Screen Terms
Access Mode
A three-letter code
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.
rized
Arc Start
Provides the
Arc Time
Allows actual
option
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 tobe ac
on the digital display, and can be reset to zero as required.
displayed
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
feeder
boom-type
or
or
not.
bench mount feeder
pulse program
parameters.
Name Feature
When
using
the
optional
Data Card and
programs written to the card
Program
Reset
Range
can
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 unit defaults to
original
The wire feeder
source
requires that the voltage and amperage range of the welding power
be entered. Obtain this information from the welding power source Owners
Manual.
Remote Parameter
When the Remote Parameter Inc/Dec is on, a dual schedule switch can also be used
for increasing or decreasing weld parameters when the front panel display cursor is
at
Security
Tnm, 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
and
can
display
be used either with
pulse GMAW (Pulse/Mig)
Only) welding only.
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
A built-in
diagnostic feature
tions if
malfunction
a
remotely
to check a
with the gun
variety of wire
.
trigger.
feeder and power source func
occurs.
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
Allows
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
Shutdown
when there is
Wire Feed Mode
no arc
voltage
sensed.
Allows the selection of inches per minute or meters per minute for wire feed
This mode is also used to select motor type; standard speed, low speed,
speed. High and
low
speed
motors are available as
speed.
high
or
factory options.
SECTION 5-OPERATION
WARNING
a
ELECTRIC SHOCK
kill.
can
Do not touch live electrical parts.
Always
wear
yourself from
Keep
panels
all
and
work and
covers
FUMES AND GASES
.b
/~
dry insulating gloves.
Insulate
in
be hazardous
Keep
or use
breathing
MOVING PARTS
0
Keep away
can cause
Do not weld
Watch for
near
fire
device.
or
Do not weld
on
Allow work and
over
body protection.
can cause
pinch points
injury.
such
as
drive rolls.
guards closed
covers, and
explosion.
Pacemaker
wearers
keep away.
Wearers should consult their doctor before
~
L_~..
near
any
going
welding operations.
combustible surfaces.
closed containers.
equipment to
cool before
See Safety Precautions at beginning of manual for ba
sic welding safety information.
~am3.1
handling.
8/92
Wear the
1
2
3
~
~
~
~
while
following
Dry, Insulating
welding:
Gloves
Safety Glasses
With Side
Shields
:
welding Helmet
Shade Of Filter
with Correct
(See ANSI
Z49.1)
.
sb3.1 1/94
Figure
OM-1588
Page
16
.
MAGNETIC FIELDS FROM HIGH CUR
RENTS can affect pacemaker operation.
flammable material.
fire; keep extinguisher nearby.
Do not locate unit
from
Keep all doors, panels,
and securely in place.
Read Material Safety Data Sheets (MSDSs) and
manufacturers instructions for material used.
WELDING
helmet with correct shade of filter.
Wear correct eye, ear, and
~
your head out of the fumes.
Ventilate area,
welding
place
to your health.
I.ciili
Wear
~
ground.
securely
can
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
p
5-1.
Safety Equipment
1
Work
Clamp
Connect work
clamp to a clean,
paint-free location on workpiece,
as close to weld area as possible.
Use wire brush
sandpaper to
joint area. Use
to remove slag
or
clean metal at weld
chipping hammer
after welding.
Tools Needed:
2
2
Voltage Sensing Clamp
Connect to workpiece, if
(see Section 3-9).
applicable
Use chipping hammer
slag after welding.
to remove
sb4.1
Figure
5-1.
5-2. Work And
2/93
Voltage Sensing Clamps
Front Panel Controls
2
1
Display
2
Parameter Select Button
3
Display Control
4
Right
Side Indicator
Right
Side
5
Knob
Button And Indicator
6
7
Light
Hold
Trigger
Light
Side Select Button
Left Side
Trigger Hold
Light
Button
And Indicator
3
10
8
Left Side Indicator
9
Jog Button
10
Purge
Light
Button
See Section 6 for information
9
4
using microprocessor
on
controls.
8
6
7
5
ST-162 127
Figure
5-3. Front Panel Controls
1
Parameter Select Button
Press button to
move
indicator
on
display.
1
Ret. ST-167 703
Figure
5-4. Parameter Select Button
OM-1588
Page
17
1
Display Control
Turn
knob
to
Knob
value
change
selected.
Spin
knob
parameters
by clicks
Figure
5-5.
Display
to
change
slowly
parameters.
quickly
or move
to fine tune
knob
Control Knob
2
2
\
\
1
Side Select Button
2
Side Indicator
___________________
Light
_
~6
6
~o
b
Push button to select active side of
wire feeder. Indicator
light
is
on
for
active side.
TRIGGER
8~=
@
The feeder remembers the
TRIGGER
HOLD
HOLD
0
0
last
used program for each side, and
returns to that program when the
active side is changed.
r
Note: gun
trigger may also be used
change active side of
to select or
wire feeder.
.
RECEPTACLE
RECEPTACLE
-
Figure
5-6. Select Button And Side Indicator
2
Lights
1
Trigger
2
Indicator
Light
To weld without
holding
cycle,
gun trigger
press and
release button to turn on indicator
light and hold circuit.
throughout
0
Hold Button
weld
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
ED
active for next weld
weld
cycle,
trigger.
Trigger
hold
while gun
OM-1588
Page
18
To end
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
indicator light turns on, but Trigger
Hold does not become active until
that side is selected.
RECEPTACLE
Figure
cycle.
press and release gun
5-7.
Trigger
Hold Button
.
1
Jog
Jog
Push Button
works
on
of
active,
or
selected
feeder
(see
only
Figure 5-6). Separate jog speeds
side
~
PURGE
can
I
Push to momentarily feed welding
wire without energizing welding cir
cuit or shielding gas valve.
o3p
2
~~~~1
o~
no
be set for each side of the
feeder.
JOG
Jog speed is varied using the Dis
play Control knob while Jog button
is pressed. Default setting is 200
ipm.
Jog button is released, unit
displays preset wire feed speed,
and previously selected parameter
When
~-,
is active.
Jog
does not work when gun
trig
ger is pressed.
Jog
2
T
50
im
r
Prg
Purge
-a
side
I
>200
PM
Jog
Push Button
Purge
works
on
active,
feeder
of
or
selected
(see
only
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
Tr
im
Prg
I
PM
Pulse
260
circuit.
Front panel controls, side panel
controls, and gun trigger do not
work when
Jog
or
Purge
button is
pressed.
5-8.
Figure
5-2.
Jog
And
Purge
Buttons
Side Panel Controls
I
I
I
I
1
Parameter Increase Button
2
Parameter Decrease Button
3
Parameter Select Button
4
Mode Select Button
5
Mode
6
Parameter
Display
Display
I
See Section 6 for information
using microprocessor
on
controls.
3
Ref. ST-162 133
Figure
5-9. Side Panel Controls
OM-1 588
Page
19
5-3.
Rear Panel Controls
Power Switch
1
Use power switch to turn unit On
and Off.
2
2
Circuit Breaker
Section
(See
14-3)
ST-Boo 177
Figure
BUILDUP OF SHIE LDING GAS
Shut off
shielding gas supply
can
when not in
5-10. Power Switch
harm health
or
kill.
use.
waml.12a3
1
Shielding Gas Cylinder
2
Valve
3
Gun
Trigger
Open valve
welding.
on
Gun
turns weld
trigger
gas flow
on
cylinder just
before
output and
and off.
3
Close valve on
ished welding.
when fin
cylinder
sb5.1 6/92
Figure
H IGH FREQUENCY will
high frequency
Completely
J
~\
using
20
unit.
source
Install Welding
)
) )
System
J J (See Figure 3-1) J I
when
using high frequency.
Put On
Personal Safety
) )
Equipment ~/J
On~\\Turn
Turn
Wire Feeder And ) )
Power So~~/ J
Shieldin~\\
On
Gas
Set All
Controls
) )
(If Applicable) J I (See Figure 5-13
~\
Weldin~~,
Figure
Page
Gas
this unit.
)
Begin
)
OM-1 588
damage this
when
disconnect this unit from power
Install &
Connect
Wire Feeder
Shielding
CAUTION
£~
Turn Off
5-11.
5-0621-C
5-12.
Sequence
Of Gas Metal Arc (GMAW), Gas Metal Arc
And Flux Cored Arc Welding (FCAW)
-
Pulse
(GMAW-P),
5-4.
Setting
Switches On 450
Ampere Inverter Model Welding
Always
use
switch
processes when
o
PANEL
Power Source
settings shown for all welding
using this wire feeder.
~J~ii
~J14
ONI
~
0.OUTPUTcaff#CTOR
o
~NEL
~J~17
ARC FORCE/INDUCTANCE
AND CC/CV
Ref. ST-150 171-C/Ref. SC-154 197
Figure
5-13.
Setting
Switches On 450
Ampere
Inverter Model
Welding
Power Source
OM-1 588
Page
21
SECTION 6- STEPPING THROUGH THE
MICROPROCESSOR CONTROLS
WARNING
a
ELECTRIC SHOCK
kill.
can
Do not touch live electrical
parts.
Control circuit and feederoperational power are On
when
using
or
changing
the
L~(
~
~I ~
microprocessor
I
settings.
WELDING WIRE
wounds.
can
puncture
cause
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
tngger is pressed.
NOTE ~
This unit is
6-1.
Front Panel
equipped with eight (8) pulse welding programs (see
Section
When
7)
the unit is turned On for the first time program 1 comes up, therefore, program us
illustrated throughout this manual. Instructions are given later in this manual (see
Section 9) on how to select or change a program.
_____________________
Microprocessor Controls
Turn On
welding power source and
wire feeder. Follow along with the
controls
.
I~=
I
2
~O
as
shown.
1
Front Panel
2
Parameter Select Button
Display
Press parameter select button to
move indicator.
The indicator
that
O
00
are
points
selected for
to
parameters
change.
Parameter select button
indicator between Trim
o
o
00
r~
Tr
5 0
200
>50
200
0
00
im
1PM
0
and 1PM while
Go to
0
Figure
.
can move
(arc length)
welding.
6-2.
>Prg
Pulse
Tr
im
Prg
I
PM
Pulse
1
e
50
>200
Tr
im
Prg
I
PM
Pulse
1
.
ST-162 127
Figure
OM-1 588
Page
22
6-1. Front Panel Parameter Select Button
1
1~&~b=
Front Panel
(see Figure 6-1).
2
Display
Control Knob
knob
Turning
following
setting:
2
0
0
Trim
00
0
0
(arc length)
by one.
Prg
1PM
>55
200
Trim
Program number
ses/decreases by
display
(Prg #)
(see
increa
one.
Display
The
number
being
program
changed also changes on the side
panel parameter display (see
Figure 6-5).
Control
The program number cannot be
changed while welding, with ex
ception of Dual Schedule Mode
(see Section 11).
Pulse
0 Front Panel
~
speed (1PM) increases/
by one inch per minute.
panel parameter
Figure 8-3).
Prg
1PM
increases/de
The wire feed speed value being
changed also changes on the side
Pulse
~
the
selected
(arc length) value being
changed also changes on the side
panel parameter display (see
Figure 8-3).
decreases
200
causes
to
The trim
Wire feed
Trim
click
one
changes
creases
00000
>50
Display
Select parameter to be changed
All
Parameter
Select
programs
through
are
accessible
either side of the
feeder,
and any program is available to ei
ther side of the feeder at the same
time.
55
Trim
Prg
Display Control knob can be used
Jog speed when Jog button
is pressed (see Figure 5-8).
to set
>200
1PM
Pulse
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).
Go to
55
300
50
200
Trim
6-3.
>Prg
1PM
Pulse
Trim
1PM
Figure
>Prg
2
Pulse
ST-162 127
Figure
6-2. Front Panel
Display
Control Knob
OM-1 588
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
Dual Schd
Card
Process
Sequence
>D
u a
I S
c
h d
Card
Process
Sequence
j
Dual Schd
>Ca
r
d
Ref. ST-i 54 109
Figure
OM-1 588
Page
24
6-3. Side Panel Mode Select Button
I
1
Parameter
2
Moving
I
Display
Line
Moving line is
changed.
under value that
can
be
Side Panel Parameter Select
3
Button
Press side panel parameter select
button to move indicator in right
window display.
Side Panel
Prg
>P
u
I
1
s e
035Stee
ArgonO
Pulse
I
L
I
xy
I
fl
035Steel
ArgonO
I>Teach
xy
Qfl
Ref. ST-154 109
Figure
6-4. Side Panel Parameter Select Button
OM-1 588
Page
25
Use side
panel
mode select button
to select mode to be
changed (see
Figure 6-3).
I
I
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
2
the
by
moving
line.
Decrease Button
Press button to decrease value
by the moving
line.
that is underlined
Side Panel
-~
Increase
Increase
>Prg
~
Pulse
2
052Stee
ArgonO
I
xy
Decrease
>Prg
P
u
I
~
S e
045Stee
ArgonO
I
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
Wire
Program
# 1
Program
Name: .035
Size/Type:
Steel, Argon
-
.035
1
S-3
Gas: 98 Ar
-
2
Oxy
or
95Ar
-
5
Oxy
Card #_________________________
Oxy
Gun Model: MILLER GW
Flowrate: 40 CFM
IPM/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
Pref low: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:__________________________
Crater Trim: 50
1PM: 200
Sec.:__________________________
Posttlow: 0 Sec.
OM-1 588
Page
27
Program
Wire
Program
# 2
Program
Name: .045
Size/Type:
Steel, Argon
-
.045
2
S-3
Gas: 9BAr
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
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
28
Program
Wire
Program
# 3
Program
Name: .052
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 I 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
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
29
Program
Wire
Program
#4
Program
Name: .035
Size/Type:
309, Argon
-
.035
4
309
Gas: 98 Ar
-
2
Co2
or
95Ar
-
5
Co2
.
Card #________________________
CO2
Gun Model: MILLER GW
Flowrate: 40 CFM
1PM / 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.:_________________________
CraterTrim:50
1PM: 200
Sec.:_____________________
Postf low: 0 Sec.
OM-1 588
Page
30
.
Program
Wire
Program
# 5
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
Pref low: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:__________________________
Crater Trim: 50
1PM: 200
Sec.:__________________________
Postflow: 0 Sec.
OM-1588
Page
31
Program
Program
Wire
#6
Program Name: 3/64
SizelType:
3/64
6
4043
Gas:
Argon
Card #________________________
4043, Argon
Gun Model: MILLER GW
Flowrate: 40 CFM
1PM I 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-1 588
Page
32
.
Program
Wire
Program
# 7
Program
Name: 3/64
Size/Type:
3/64
7
Gas:
5356
Argon
Card #_________________________
5356, Argon
Flowrate: 40 CFM
Gun Model: MILLER GW
1PM / 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
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
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
Pref low: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:_________________________
Crater Trim: 50
1PM: 200
Sec.:__________________________
Postf low: 0 Sec.
OM-1588
Page
34
SECTION 8- GETTING STARTED
WARNING
£~
ELECTRIC SHOCK
Always
wear
Insulate
Keep
all
ARC RAYS can burn eyes and
NOISE can damage hearing.
parts.
Wear
dry insulating gloves.
yourself
panels
from work and
and
covers
FUMES AND GASES
to your health.
Keep your
kill.
can
Do not touch live electrical
securely
or use
Read Material
Safety
breathing
near
fire
or
can cause
pinch points
doors, panels,
Keep
securely in place.
injury.
such
covers, and
as
drive rolls.
guards
closed
and
device.
Data Sheets
can cause
Do not weld
from
all
(MSDS5)
and
manufacturers instructions for material used.
WELDING
MOVING PARTS
Keep away
head out of the fumes.
Ventilate area,
body protection.
place.
be hazardous
can
helmet with correct shade of filter.
Wear correct eye, ear, and
ground.
in
welding
skin;
explosion.
MAGNETIC FIELDS FROM HIGH CUR
RENTS can affect pacemaker operation.
Pacemaker
wearers
keep away.
flammable material.
Wearers should consult their doctor before
Watch for fire;
keep extinguisher nearby.
Do not locate unit
Do not weld
on
Allow work and
N OTE
~
over
near arc
combustible surfaces.
welding, gouging,
or
going
spot welding opera
tions.
closed containers.
equipment to
cool before
handling.
See Safety Precautions at beginning of manual for ba
sic welding safety information.
1
wfwarn6
8/92
Set up equipment according to Figure 5-12. Use the standard pulse welding
program in Section 7 that is closest to your application (by wire type and size and
gas type) when setting up.
CM-i 588
Page
35
8-1.
Welding
With
Only
Front Panel Controls
Turn On welding power source,
wire feeder, and gas.
Use Select button
trigger to
gun
or
select active side of feeder.
1
Front Panel
.
Display
1 is the default program
the first time the unit is turned on,
Program
at other times the
number selected is
the front
last program
displayed. Use
panel parameter
Prg #.
select
button to select the
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.
3
If
Trim
(Arc Length)
necessary, select Trim, and
to achieve the best arc.
adjust
4
If
1PM
necessary, select 1PM, and
to achieve the best arc.
adjust
Go to Section 8-2.
.
Trim
55
>200
1PM
Prg
Puls_ej
~:r0~
Trim
55
>250
1PM
Prg
3
Pulse
I
.
/
Figure
OM-1 588
Page
36
8-1.
Welding
With
Only
Front Panel Controls
8-2.
Setting Sequence
a
Pulse
Welding
Parameters On Side Panel
Display
WARNING
ELECTRIC SHOCK
can
Do not touch live electrical
kill.
WELDING WIRE
wounds.
parts.
Control circuit and feeder operational
using or changing the mi
can
cause
puncture
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
Do not
when
settings.
the gun whenever the power switch is On and the gun
trigger is pressed.
NOTE ~
I
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.
Crater flme
0-2.5 Sec.
Bumback Time
0-0.25 Sec.
Trigger
Trigger
~
Time
Released
Pressed
Ref. S-0271
Figure
8-2. Weld
Cycle
OM-1588
Page
37
Mode Select Button
1
Process
When unit is turned On, Process is
the default mode, at other times,
>W~!~
>Sequence
50.
DualSchd
200
1PM
Card
0.0
Sec
Trim
mode select button to select
use
Sequence.
2
Side Panel Parameter Select
Button
Use side
/
/
panel parameter select
parameters.
button to select
2
3
Weld Parameters
Display
Parameter ranges
are as
Trim
0-99
(Arc Length),
Changes
are
also
follows:
displayed
Sequence Trim
on front panel
Speed,
50-780 Inches
to Weld
display.
Wire Feed
Per
Minute, 1PM
Changes
are
also
to Weld
displayed
Weld
front
panel parameter
Increase!
Decrease
select to move
indicator to trim,
>50
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
(~)
~
We I d
Or
use
front
60
panel parameter
select to move
indicator to 1PM.
Increase!
Decrease
Trim
>200
1PM
0.0
Sec
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
60
Trim
300
1PM
>0.0
Sec
Increase!
Decrease
cI
Side Panel
Parameter
Select
We I d
60
Increase
Proceed to next
Figure
OM-1 588
Page
38
front
1PM
panel
Seconds, 0-25.0 Sec. If value set is
(0), welding will continue until
welding gun trigger is released.
zero
use
on
display.
Set Desired Weld
Sequence Voltage
Or
Sequence
8-3.
Trim
300
1PM
>3.5
Sec
figure.
Setting
Weld
Sequence Display
Go to
Figure
8-4.
.
1
1
Crater Parameters
Parameter ranges
Crater
50
200
0.00
Triml
1PM
b
200
Sec
1PM
0.00
Per
1PM
>200
Sec
Wire Feed
Trim
60
0.00
(Arc Length),
Trim
Crater
I
Trim
>~
Speed,
Display
are as
follows:
0-99
50-780 Inches
Minute, 1PM
Seconds, 0-2.50 Sec. If value set is
(0), there is no Crater
Sec
zero
Side Panel
Parameter
Select
Side Panel
Parameter
Select
Set Desired
Trim
lncrease/
Decrease
Set Desired
Wire Feed Speed
sequence.
Go to
Figure
8-5.
Side Panel
Parameter
Select
Increase!
Decrease
Side Panel Set Desired lime
Parameter
Select
Increase
Proceed to next figure.
Figure
8-4.
Increase/
Decrease
Selling
Crater
Sequence Display
1
1
Burnback Parameters Dis
play
I
Burnback
>B ~ r a
Bu rnback
a
>B
u
r
n
b
a c
k
can
be
adjusted from
0-0.25 seconds. If value set is zero
Burnback
is
no
(0), there
sequence.
0.00
Sec
>QQ~
Sec
0.12
Sec
Go to
Figure
8-6.
____________
___
Side Panel
Parameter
Select
Set Desired lime
___
Side Panel
Parameter
Select
Increase
Increase!
Decrease
Figure
8-5.
Selling
Proceed to next
Burnback
figure.
Sequence Display
1
______/
______
Postflow
>~aat11aw
0.0
Sec
______
~
Side Panel
Parameter
Select
~>0.0
>~Qatf!aw
Go to
Sec
Set Desired lime
1.2
8-6.
Selling
Display
Figure
8-7.
Sec
Side Panel
Parameter
Select
Increase!
Decrease
Figure
Postf low Parameters
Postflow can be adjusted from
0-9.9 seconds. If value set is zero
(0), there is no Postflow sequence.
Increase
Proceed to next
Postflow
figure.
Sequence Display
OM-1 588
Page
39
1
Preflow Parameters
Display
Preflow can be adjusted from 0-9.9
seconds. If value set is zero (0),
there is no Preflow sequence.
Goto
Figure
8-8.
/
_____
>Er~f!Qw
0.0
Sec
_____
Preflow
~
Sec
Side Panel
Parameter
Select
Set Desired Time
lncrease/
Decrease
Figure
8-7.
Pref low
Setting
Sec
1.2
Side Panel
Parameter
Select
Increase
Proceed to next figure.
Sequence Display
Run-In Parameters
1
Parameter ranges
Display
are as
follows:
Trim, 0-99.
Wire Feed
per
minute,
Speed,
50-780 inches
1PM
Seconds, 0-2.5 Sec. If value
zero
(0),
there
is
no
set is
Run-In
sequence.
Run in
55
Side Panel
Parameter
Select
1PM
0.0
Sec
Side Panel
Parameter
Select
Set Desired Trim
Trim
~200
~
Set Desired
Wire Feed Speed
Increase!
Decrease
I ncrease/
Decrease
~
Side Panel
Parameter
Select
I
160
I
Trim
300
1PM
3.5
Sec
~>Runin
I
Run in
55TrimI
150
1PM
1.1
Sec
___________
55
Side Panel
Parameter
Select
Increase
Trim
j
~
Set Desired Time
Increase!
Decrease
Figure
OM-1 588
Page
40
8-8.
Setting
Run-In
Sequence Display
SECTION 9- TEACHING A PULSE WELDING PROGRAM
a__WARNING
ELECTRIC SHOCK
can
Do not touch live electrical
kill.
WELDING WIRE
wounds.
parts.
Control circuit and feeder operational power are On
using or changing the microprocessor
when
I
settings.
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.
NOTE ~
See GMAW-P
unit for
(Pulsed MIG) Process Guide supplied with
more
information.
______________________
9-1.
Pulse Waveform
Explained
The wire
feeder,
not the
welding
power source, controls weld output
for pulsed welds.
1
ApK
Peak Current Of
100-565
Ampere~
is the high pulse of welding
current. Peak current melts the
ApK
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
current
preheats welding
wire and maintains the arc. When
background current is too low, the
is
arc
/\
a)
0
PPS
3
_/ ~
C
Co
unstable
and
hard
to
maintain.
Pulses Per Second Of
20-400
PPS, pulse rate, and frequency
used interchangeably. A
pulse rate of 60 Hz means
pulses of current are produced
(Hz)
are
PPS
or
_
60
each second.
a.
E
4
7
Pulse Width Of
PWms
1.0-5.0 Milliseconds
Time
PWms is the time spent at peak
(1 .2 ms is .0012 seconds).
current
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.
Ref. S-0259
Figure
9-1. Pulse Waveforms And
Explanation
Of Terms
OM-1 588
Page
41
9-2.
Teach Points
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
200
L~
ApK
E
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
pulse MIG welding programs. The
teach mode has 15 teach points. At each
teachpoint,theusercanadjustfourparameters: peak amperage (ApK), background
amperage (AbK), pulses per second (PPS),
and pulse width in milliseconds (PWms) to
shape the pulse waveform of the weld
output.
custom
Wire feed speed 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
feed 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 establish the pulse parameters at any wire feed
speed setting.
Figure
OM-1 588
Page
42
9-2.
Typical
3
4
Below the wire feed
speed of the lowermost
point, and above the wire feed speed
of the uppermost teach point, the unit may
limitwirefeedspeedsettingsinpulseMlGto
maintain all pulse parameters within the capability of the unit.
teach
PWms
5
ters. To
length reading,
carefully maintamed, and the weld must be terminated by
releasing the gun tngger, not by pulling the
welding gun away from the workpiece.
ensure a proper arc
electrical stick-out must be
The
Pulse MIG programs made by the manufacturer have pulse waveform information entered for all 15 teach
points. The operator
modifythe setting of one, or
any number of the 15 teach points if the fac
tory set information is not appropriate for a
specific application,
can
relocate and
taught arc length represents a Trim (arc
length) setting of 50. Increasing the value of
Trim, increases the actual arc length. Like
wise, decreasing the value of Trim will de
crease actual arc length.
In the Pulse
tam
a
mode, the unit does
constant arc
length
electrical stick-out. In the
not main-
with variations in
Adaptive
Pulse
mode, the unit adjusts pulse frequency to
Afterthe parameters foreach teach pointare
established, an arcmustbestruckand maintamed for at least 5 seconds. This allows the
variations in electrical stick-out.
wire feeder to leam the
Proceed to next
associated with the
program.
Teach Point
arc voltage length
taught pulse parame-
Settings
And
maintain
a
constant arc
figure
length regardless of
to teach
Resulting Synergic Setting
a
pulse
MIG
9-3.
Teaching
A Pulse
Welding Program
READ SAFETY BLOCKS at start of
Section 9 before proceeding.
A.
Selecting And/Or Redefining
Teach Point Wire Feed
Speed
Process
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
Display
When unit is first turned On, Pro
cess is the default screen, at other
times
use
mode select button to
select Process.
2
1~
>P
1~r
r
>Prg
0 c e S S
Teach
Display
Use parameter select button to
lect Teach.
Use increase/decrease buttons to
Pulse
1
se
select On.
Sequence
Pu I
Dual Schd
035 Steel
se
1PM
3
(Teach Point)
a teach point
panel Display Control
knob if the cursor on the front panel
display is pointing at 1PM.
You
Card
can
also select
with the front
Side Panel
Parameter
Select
Side Panel
Mode Select
To redefine the wire feed
a
teach
point, proceed
4
Front Panel
Use
parameter select
lect 1PM
as
speed
of
follows:
Display
button to
se
(teach point).
button while
Press and hold
Purge
turning Display
Control knob to
re
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.
define the teach
Side Panel
Parameter
Select
Selecting
Repeat the procedure for as many
points as desired.
of the 15 teach
A Teach Point
To
set or adjust teach point
parameters, go to Figure 9-4.
Redefining
50
450
Tr
A Teach Point
im
1PM
Front Panel
Parameter
Select
Purge
And
50
>4 60
Figure
9-3.
Trim
1PM
Selecting
And/Or
il
Prg
P
u
I
Redefining
s
e~
A Teach Point
OM-1 588
Page
43
B.
Setting
Teach Point Parameters On The Side Panel
Increase!
Decrease
>Process
Teach
On
Sequence
>460
DualSchd
340
Apk
70
Abk
Card
On
Teach
1PM
1PM
460
Apk
>~40
7,~,,/A
Side Panel
Parameter
Select
.
I
Teach
Hor~>343
460
1PM
Apk
Abk
70
b k
On
I
1
~rea~~
lncrease/
Decrease
Increase/
Decrease
r
343
Apk
92
Abk
>280
pp~
I
I
I
I
I
343
Apk
92
Abk
I
I
i~i~s ~
~-Or--1>i6o
~
1.9
/PWms~
PWmsI
1.9
/
~>
460
1PM
460
1PM
343
Apk
343
Apk
g~
Abk
z~
Abk
160
PPS
160
PPS
--Or
>
2
Side Panel
Parameter
Select
/
3
I ncrease/
Decrease
-~
I
Pulse
035Steel~
Argon-Oxyl
>
Qff~
Increase/
Decrease
Q
ri
4
Prgl
Side Panel
Parameter
Select
C
Pulse
035Steel
Argon -Oxy
When the Process Teach mode is
one
of the
On, and
following pulse parameters
is
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-1 588
Page
44
1
ApK Display
2
AbK
Display
3
PPS
Display
4
PWms
se-
9-4.
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 seconds. Repeat procedure at each teach point
Setting
5
Custom Pulse Screen
The letter C will appear in the upper
ner of all customized programs.
To set Sequence
Section 8-2.
Teach Point Parameters On The Side Panel
right cor
Welding Parameters,
see
~iN OTE
~
Make
copies of this
chart for future
use.
Program #__________ Wire SizelType________________________ Gas_________________________
Program Name__________________________________________ Card #______________________
Gun Model______________________________________________ Flowrate
1PM
ApK
AbK
PPS
PWms
CFM
COMMENTS
Pref 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
READ SAFETY BLOCKS at start of
Section 9 before proceeding.
.
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:
Welding parameters
1
Side Panel
Display
4
Side Panel
Mode Select
Default
display
turned On, at other times use side
panel mode select button to select
Process.
/
V
>Process
>Prg
Sequence
1
Pulse
DualSchd
035Stee
Card
Argon
I
Ox y
Side Panel
Parameter
Select
trJ
>Process
DualSchd
035Steel
Card
ArgonOxy
Figure
OM-1 588
Page
46
lncrease/
Decrease
Prg 1
>A~Rt?ML~
Sequence
9-5.
when unit is first
Changing
To
Adaptive
Pulse
Welding
SECTION 10- TEACHING A MIG WELDING PROGRAM
WARNING
4~
ELECTRIC SHOCK
can
Do not touch live electncal
.
kill.
WELDING WIRE
wounds.
parts.
Control circuit and feeder operational power are On
using or changing the microprocessor
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
Side Panel
Display
Default display when unit is first
turned On, at other times use side
panel mode select button to select
Side Panel
Mode Select
Process.
1
Goto
Figure
10-2.
/
e
>Process
>Prg
Sequence
1
Pulse
DualSchd
035Stee
I
Card
ArgonOx
y
Side Panel
Parameter
Select
~1~J
>Process
Prg
Sequence
lncrease/
Decrease
1
>M!~
Dual Schd
Card
Figure
10-1.
Changing
To MIG In The Process Mode
OM-1 588
Page
47
10-2.
MIG
Setting Sequence
Welding
Parameters On Side Panel
Display
1
Side Panel
Display
When unit is turned On, Process is
the default mode. Use mode select
button to select
2
Sequence.
.
Side Panel Parameter Select
Button
>P rg
>Process
1
Use side
M IG
Sequence
panel parameter
select
button to select parameters.
Dual Schd
3
Card
Weld Parameters
Parameter ranges
Display
are as
follows:
Volts, 10.0-38.0 Volts
Wire Feed
Speed,
50-780 Inches
I
Per Minute, 1PM
Mode
Select
Seconds,
0-25.0 Sec. ltvalue set is
(0), welding continues until
welding gun trigger is released.
zero
Inductance, 0-99%
Changes to voltage and wire feed
speed (1PM) parameters in the
weld sequence are also displayed
on front panel display.
Go to
Figure
10-3.
3
Set Desired
Voltage
I
.
Weld
I>1~.~Volt
lncrease/ Weld Sequence Volts
Decrease
can be fine tuned
I
I
while welding
2 0 0
0
.
0
I PM
S
e C
I
Side Panel
Parameter
Select
Set Desired Weld Time,
If Applicable
I
Weld
420
1PM
I>~~
Sec
I
I
I
Increase/
Decrease
Weld
420
1PM
2.2
Sec
Page
Sec
lncrease/
Decrease
~>Welt~
>~Q~lnduc
Sequence 1PM
be fine tuned
while welding
Weld
can
I
420
1PM
2.2
Sec
Increase
Figure
48
1PM
0.0
20.OVoItsI
Side Panel
Parameter
Select
CM-i 588
>2~O
Side Panel
Parameter
Select
Side Panel
Parameter
Select
Set Desired Inductance,
If Applicable
Speed
20.OVolt
30%lnduc
I ncrease/
Decrease
Set Desired Wire Feed
Weld
10-2.
Setting
Weld
Proceed to next
Sequence Display
figure.
1
Crater Parameters
Parameter ranges
Display
are as
follows:
Volts, 10.0-38.0 Volts
Wire Feed Speed, 50-780 Inches
Per Minute, 1PM
Seconds, 0-2.50 Sec.
(0), there is
If value set is
zero
Crater
no
sequence.
Goto
10-4.
Figure
Crater
~~24.OVolt ~
Set Desired
Voltage
Set Desired
Wire Feed Speed
Increase/
Decrease
Increase/
Decrease
Side Panel
Parameter
Select
I
I
Set Desired Time
I
I
lncrease/
Decrease
>Qr~t~t
I
24.OVolt
Side Panel
Parameter
Select
Increase
Proceed to next figure.
Figure
10-3.
Setting
Crater
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
set is
zero
(0),
there is
no
Burnback
sequence.
1
Go to
/
I>Burnback
I
18.0
Volt
0.00
Sec
Burnback
>16.0
0.00
Figure
Burnback
Volt
16.0
Sec
>Q12
10-5.
~~I4rnback
Volt
Sec
16.0
Volt
0.12
Sec
I
__________
___________
___________
Side Panel
Parameter
Select
Set Desired
Bumback Volts
Side Panel
Parameter
Select
Increase!
Decrease
Increase!
Decrease
Figure
10-4.
Setting
Set Desired
Bumback Time
Burnback
Side Panel
Parameter
Select
Increase
Proceed to next figure.
Sequence Display
OM-1 588
Page
49
1
______/
______
______
Postflow
0.0
~
Sec
Side Panel
Parameter
Select
~>P~
>~Q~tf1Q!~
Goto
Sec
1.2
Figure
10-6.
Setting
Postflow
figure.
Sequence Display
1
Preflow Parameters
Display
1
Preflow can be
______/
______
~
I I
0.0
P
Sec
r e
f
I
ow
Sec
>0.0
H~H
>E!
~
~ I
there is
Go to
1.2
adjusted from
seconds. If value set is
______
>E!
.
Sec
Increase
Proceed to next
Increase/
Decrease
10-5.
Display
Side Panel
Parameter
Select
Set Desired Time
Figure
Postflow Parameters
Postflow can be adjusted from
0-9.9 seconds. If value set is zero
(0), there is no Posiflow sequence.
no
0-9.9
zero
(0),
Preflow sequence.
Figure
10-7.
Sec
___
Side Panel
Parameter
Select
Side Panel
Parameter
Select
Set Desired Time
Increase
Proceed to next figure.
I ncrease/
Decrease
.
Figure
10-6.
Setting
Preflow
Sequence Display
1
Run-In Parameters
Parameter ranges
Display
are as
follows:
Volts, 10.0-38.0 Volts
Wire Feed
Speed,
50-780 inches
per minute, 1PM
Seconds, 0-2.5 Sec. If value
Side Panel
Parameter
Select
Set Desired
Set Desired
Wire Feed Speed
Voltage
Increase/
Decrease
zero
sequence.
Q
Increase/
Decrease
~
-J
Side Panel
Parameter
Select
Increase
Set Desired Time
Increase/
Decrease
Figure
OM-1588
Page
50
10-7.
Setting
Run-In
(0),
Sequence Display
Side Panel
Parameter
Select
there
is
no
set is
Run-In
SECTION 11
4~
-
SETTING DUAL SCHEDULE PARAMETERS
WARNING
ELECTRIC SHOCK
can
kill.
WIRE
WELDING
wounds.
Do not touch live electrical parts.
Control circuit and feeder operational power are On
when using or changing the microprocessor
~I ~
I
settings.
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
with two
can
only be
consecutive
used
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 1 is MIG, Prg 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:
2
3
3
Dual Schedule Parameters
Display
Use side
panel increase/decrease
Display Control knob
(see Figure 11-2) to select dual
schedule pairs.
buttons,
or
Display
Control
If the two desired
welding programs are not in
the proper program order
(1
& 2,
or
3 & 4,
etc.),
the
most common method to get them in the proper order wo uld be to write one program to a data card~
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.
24.
Panel
Parameter
OV
I
250
PM
>Prg
1
Dual
A
Front Panel
Knob
4
Welding Gun Trigger,
DSS-Type Switch
/
\Select.~/
Display Control
3
Or
The dual schedule programs can
be alternately selected between
active programs A or B by turning
Display Control knob one click
the
or counterclockwise, or
by squeezing and releasing the
welding gun trigger, or by an exter
clockwise
Display
Control
Knob
Welding Gun
Trigger
OR
I>Prg
31
ID
A~~j
u
a
I
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 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
side
panel display,
buttons
Figure
11-2.
can
be used to
Selecting
On, and Process is selected on the
panel increase/decrease
then the side
change program
numbers.
Between Active Dual Schedule
Programs
A And B On Front Panel
Display
.
OM-1 588
Page
52
SECTION 12- USING THE OPTIONAL DATA CARD
12-1.
Installing
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 fomiat 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 Oft power.
ST~i 56 266-B! Ref. S-i 55 823
Figure
12-2.
Using
12-1.
Installing
Data Card
The Data Card
Use Mode Select button to select
Card.
Process
Sequence
DualSchd
>Card
1
Card
2
Write
Display
Press
Used to transfer program data from
Below
unit to card. The program card can
hold up to 32 programs. When writ
to the card, the next available
program number is automatically
ing
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
3
card.
5
Done
Used to exit card
4
6
Moving
Moving line is
be changed.
Figure
12-2. Card
display.
Line
under value that
can
Displays
OM-1 588
Page
53
NOTE ~
All 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.
2
Moving
Line
Moving line is
be changed.
Process
Sequence
DualSchd
>Card
Press
3
Below
If
-----n
Name
under value that can
Display
is desired, press side
Parameter Select button to
no name
panel
continue the write
procedure.
When
__________
2
naming a program, the front
panel Display Control knob can be
used to speed selection of charac
Side Panel
Parameter
Select
ters.
#1/puise
>Write
Read
035Stee
I
Dele te
ArgonOx
y
Done
Press
Allowable characters include: 0 thru 9, :, ;, <,
----s
I
3
=,
,?,@,AthruZ,,I,],A,_,,athruz,I.,,#,$,
I
Side Panel
Parameter
Select
Name?
.
N~
035 Steel
Yes
ArgonOxy
Press
No
0
~
Wr
i
Side Panel
Parameter
Select
Side Panel
Parameter
Select
teDone
to
Prg 1
CardPrg
1
Press
~
Side Panel
Parameter
Select
Pulse
#1
Side Panel
Parameter
Select
~
#1
Pulse
035Stee
I
5007992
g o n Ox
Press
y
F
A
r
Figure
OM-1 588
Page
54
r ame
Press
12-3.
Naming Programs
And
Writing
To Card
Use Mode Select button to select
Card.
1
Card
2
Moving
Moving
be
3
Display
Line
line is under value that
can
changed.
Read
Display
Select desired card program to
download. Select feeder program
number where the card program
goes.
Will
Prgl
Be
Lost
Lose?
Y~
Press
Yes
Increase
Side Panel
Parameter
Select
Side Panel
Parameter
Select
Side Panel
I Parameter
________________
I
Read
I
Card
I
to
Done~5elect
Prgl
Prg 1
________________
I
1
#
ArgonOxyl
Press
Figure
12-4.
PuIsel
035Steelj
Reading
Press
From Card
1
Write
WARNING:
>Re ad
De I
e
Card
t
Empty
Press
e
Done
Be I
ow
~
Wr i
Side Panel
Parameter
Select Once
t e
>Proces
Read
De I
e
Sequen
t
Warning Display
If there are no programs on the
card, this series of displays appear.
S
ce
>P rg
M IG
~
Dual Sc hd
e
>Done
Press
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
line is under value that
Moving
changed.
can
be
3
Process
Sequence
DualSchd
Pre
>Card
ss
Below
Mode
Select
Twice
I Write
I Read
I>Delete
~J
I
2
~p
Done
Side Panel
Parameter
Select Once
MIG
WARNING:
ress
Side Panel
Parameter
Select
2
Delete
Card
#2
Prg2
Lose?
~
No
Press
~
Card
-~Side Panel
Parameter
Select
Side Panel
Parameter
Select
Prg2
#3
MIG
Deleted
Press
Press
Side Panel
Parameter
Select
Figure
OM-1588
Page
56
MIG
Press
Increase
Yes
I
Delete
12-6.
Display
Select program number to be de
leted from card.
Deleting Programs
From Card
SECTION 13- SETUP
13-1.
Setup
Flow Chart
2
1
r~
1~~~EI1_
>s y
R
s
p
t em
a n
g
Secu
r
I
>P
t
2
Features
3
Settings
ocess
Ca p
e
u
I
a
b i
s e
I
i
Display Selections
To set up features that customize
operation, use the setup displays.
t y
/ M i g
Features that
Access
are as
can
be customized
follows:
Example Of Setup Display On Side Panel
Features
Display
Settings
Section
-j
>System
Features
Display
Settings
Section
Selection
Selection
Process
Capability
Pulse/Mig
Mig Only
13-3
>Remote
Parameter
Oft/On
13-12
lncrease/
Decrease
Press Mode Se
I
lect To Go To Next
>Arc Time
Setup Display
Run Hours
~
>Range
Volt Mm
0.0
Volt Max
25.0
AmpMiri
0-50A
AmpMax
50-999A
Program
Number
Lock
Off/On
-
25.0 V
-
1 3-4
Hours
0999,999
Cycles
13-13
No Reset
99.9 V
Reset
>Self Test
,
>Secunty
09999.99
]
13-14
I
13-5
>Wire Feed
Display
IPM/MPM
Motor
Standard
Type
Low
>Access
Code
Off/On
13-6
>Mig Type
Voltage
DVC On/Off
13-7
13-15
Speed
High Speed
~1~
Correction
>Voltage
Model
>Model
Type
I
Control
17-Pin
Feedback
Volt Sense
13-8
>Memory
Bench
13-16
Boom
No Reset
13-17
Reset
T
,
>Arc Start
Arc Start
Type
Standard
13-9
Hot Start
~Shutdown
No Volt Sense
Off/On
13-18
~Name
Card
Oft/On
13-19
I
I
>Dual Schedule
Switch
Type
Momentary
2-Pole
13-10
Programs
Maintained 2-Pole
Maintained 1-Pole
>Software
Version
Numbe4
13-20
Tngger
>Thgger
Program Select
Off/On
13-11
Figure
13-1.
Setup
Flow Chart
OM-1 588
Page
57
13-2.
Using Setup Displays
1
2
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 particular display.
To save any or all of the changes
made while in the setup displays,
and/or to exit the setup displays,
turn power to the unit off and back
/
/
I
I
I
/
/
on or press the gun trigger to return
to the Process display.
4
/
>System
Range
Process
Security
Capabi I i ty
>Pulse/Mig
Access
Side Panel
Figure
13-3.
Selecting
NOTE ~
Process
13-2.
Display
.
Accessing Setup Displays
Capability
This selection allows the wire feeder to be used with
sources.
variety
a
of
This selection also determines whether Gas Metal Arc
(Pulse/Mig)
welding
Welding
power
Pulse
GMAW-P is available.
1
System Display
Example Welding Power Sources:
When Process
Puise/Mig
45OAmpere
Non
Setup
Mig, the
welding
either
Capability
is Pulse/
wire feeder works with the
power
source
pulse GMAW-P
to
or
produce
regular
GMAW welds.
When in
works
I
Mig Only,
with
source to
1
welding power
produce regular GMAW
welds.
Select the
power
When
of the
Mig Only is selected, some
setup choices are automati
for selection
Figure
Page
58
13-3.
System Display
process the welding
is able to do.
source
cally made
OM-1 588
the wire feeder
the
and
by
are
the
not available
operator.
13-4.
Selecting Welding
N OTE ET
Power Source
Welding
power
Range
source
required. Amperage
minimum and maximum
values
are
voltage
required for pulse welding.
1
1
values
are
always
Range Display
See welding power source Own
ers Manual for voltage and amper
age ranges. Set values to match
source ranges.
welding power
Access
Setup
Display
2
-s-
Minimum
Range
3
Press Mode
Select
Maximum
Range
4
are
for 450
5
Ampere
Volt
Inverter Model. Do not change values
if using 450 Ampere lnverter Model.
Mm
>10. OVo I
t
2~___
Voltage Display
is 25.0 to 99.9 volts.
Minimum
Amperage Display
(Available When System Set
For Pulse/Mig)
Range
Default values
Voltage Display
is 0 to 25.0 volts.
is 0 to 50 amperes.
Amperage Display
(Available When System Set
For Pulse/Mig)
Maximum
Range
is 150 to 999 amperes.
Side Panel
Parameter
Select
Increase
3*
4*
5*
>Arnp
565
M~
Amp
________________
Side Panel
Parameter
Select
*Use side panel Parameter Select
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
only
when
a
data card is inserted
(see
1
Section
12-1).
.
Security Display
Use this
display to lock a programs
so that changes
using front panel
weld parameters
can not be made
controls.
2
Program
Number
Choose the program number (1
to be locked. A program
2
through 8)
can
3
be locked
on one or
Program
Lock
When lock is off of
operator
Display
a
change
can
both sides.
program, the
all weld pa
rameters of that program without
Increase
restriction. The
change
Press Mode
Select
operator
can
also
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
change
sides or program number.
If both sides are locked, the opera
changes
change program
tor can
I
Prog
I>Lock
21
flHTrim
11PM
2
Prog
On
>L
Lock
example displays in this fig
operator could change the
value of trim –10% and wire feed
speed –100 ipm from programmed
Increase
values. If the
______
Side Panel
Parameter
Select
the
3
sides
ly
Parameter
Select
are
left at 0,
programmed.
If both
locked, they automatical
have the
together.
~
lncrease/
Decrease
Lock
21
On
Trim
101
Prog
>IPM
I
I
Side Panel
Parameter
Select
lncrease/
Decrease
31
l>Prog
Lock
>Prog
Of
1PM
2~
Lock
10
Trim
100
>IPM
Side Panel
Parameter
Select
Increase
Figure
60
Prog
On
Lock
Trim
Page
are
same
range of change.
If dual schedule is on, the paired
programs are locked and unlocked
I
OM-1588
settings
operator cannot change values
from those
Side Panel
Li
In the
ure, the
01
________
~
21
>Prog
k
o c
sides but cannot
number.
13-5.
Security Display
21
On
101
.
13-6.
Selecting
NOTE LII~
Or
Changing
Access Code
Access code works
only
when
data card is inserted
a
(see Section 12-1).
1
Code
Display
off, access to the
is not restricted.
With code
displays
With code on, the
know and enter the
access or
setup
operator
access
must
code to
change any of the setup
displays.
2
Access
With
Display
code set, this display ap
pears when power is turned on
while holding the side panel Mode
Press Mode
Select
a
and Parameter Select buttons.
Press side
panel Parameter Select
button to enter access code. When
the correct letter is entered, the
cursor automatically moves to the
next character. When the final ac
cess
code letter is entered, the dis
to the
play automatically changes
initial setup display.
(J
~
Co d
Increase/Decrease
To Set Code
Parameter Select
To Move Cursor
e
On
>z wx
=~P
r e S S
Turn Power Off And Back On
And Access Security Display
2
/
0~
Enter
>Code
AAA
Access
Code
=~P
Figure
r e S S
13-6. Access Code
Display
OM-1 588
Page
61
13-7.
Selecting Voltage
Correction
1
Mig Type Display
With DVC
1
the unit
from the
sensing
Voltage Correction On,
closed-loop feedback
17-pin cord or voltage
uses
.
leads to maintain set volt
age parameters.
Press
Mode Select
(
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.
With DVC
Setup
\\D~p~,,J~
Be
sure
voltage sensing
leads
are
connected or voltage feedback is
available from
welding power
source through the 17-pin recep
tacle.
Figure
Selecting Voltage Sensing
13-8.
NOTE ~
13-7.
Mig Type Display
.
Method
Voltage sensing feedback
setting is Mig Only.
is
set for V. Sense when the
automatically
1
Voltage
Feedback
System
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 to the feeder.
1
I
Press
Mode Select
A
I
Setup
L_
\.Disp~,J
~
-.
I
c c e s s
M i g
I >v
a
I
A
r
c
e
t a g e
S t
a
r
I Co
n
t
I
I Fe
e
d b
I
1>1 Z
~
I
T y p
I
r o
I
I
a c
If the 17 Pin
I
k
ing terminals on
I
I
I
I
When
Increase
weld cable used.
I
I
IControl
Feedback
~
Page
13-8.
Voltage
Feedback
rec
Display
arc
volt
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
arc
I
Figure
used, it is
be used to monitor
age at the workpiece.
4
62
is
voltage sens
the welding power
source
t
~
OM-1588
setting
ommended that the
I
13-9.
Hot Arc Start
Selecting Regular Or
N OTE ~
Arc Start selection is not available when the
Do not
the Hot Start
use
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
welding
with 450
Ampere
pulse
Inverter
Model when high initial weld cur
rent is necessary to start large
diameter welding wires. When in
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
Hot
unless
using
450
Ampere
lnverter
Model.
Figure
13-10.
Selecting Type
13-9. Arc Start
Display
Of Dual Schedule Switch
1
1
Display
Increase
I
I
Swi
Dual Schedule
Choose type of external dual
schedule switch or use of the trigger as the dual schedule switch.
H~
tch
~f\]Type
>1
r
I g g
~ r
Increase
Figure
13-10. Dual Schedule
Displays
OM-1 588
Page
63
Momen 2P (MomentaryContact 2-Pole Switch Or
DSS-1 0)
1
(DSS-1 0)
(DSS-9M)
1
>,
1
>
Maint 2P
2
2
2
2
>
(Maintained-Contact
DSS-9M)
2-Pole Switch Or
2
>
3
Maint 1 P Or
Trigger (Maintai
.
ned-Contact 1-Pole Switch
Or DSS-9 Or DSS-8)
A
3
1
2
p
A
3
p
C
0B
4
B
p
4
p
3
(DSS-9)
1
1
Adapter
~
2
2
>3
2
2
2
3
3
2
2
3
3
>
BO
A\~>
4
>
13-11.
1
>
TR
3
Figure
Adapter
~
>
4
1
>
>
BO
A
(DSS-8)
1
13-11. Dual Schedule Switch
Selecting Trigger Program
4
>
.
Diagrams
Select
1
Trigger Display
When
Program Select
trigger
can
is
On, the
be used to switch be
tween programs that have at least
0.2 seconds of preflow time.
Press
Mode Select
Briefly pressing and releasing
triggerswitches programs.
the
For
example: if programs 1, 2, and 6
have pref low time of at least 0.2 se
conds, pressing the trigger will
switch from program 1 to 2, 2 to 6,
and6tol.
Access
Setup
Display
gun
-s-
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
dua!
momentary-contact
schedule switch can be used for
Press
Mode Select
Setup
l-_
\\~DisP~)
D
u a
I Sc h d
Tr i gger
~
>Remote
Arc
Pa
r ame
Inc IDe
/
changing
I
programs.
as
weld
for
parameters
as
well
between
switching
For example: when the cursor on
the front panel display is on Trim or
Volts, the dual schedule switch can
be used to remotely change the
value. When the front panel pa
t e r
c
>~f f
Time
rameter select is
on
schedule switch
can
Prg,
the dual
be used to
the program number. A
DSS-1O dual schedule switch is
change
Increase
recommended for this purpose.
Pa
r ame
t e
r
Inc / Dec
>0
Figure
13-13.
Resetting
n
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
Access
Setup
Display
-w
Increase
0. OOH
>Bg
~
r
5
OCyc
I
t
Press
Figure
13-14. Arc Time
Display
OM-1 588
Page
65
13-14.
Using Self
Test
1
Have
only Factory Authorized persons
perform tests or replace parts.
Switch A
in-
This checks the gun switch
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
welding power
source contactor.
7
CVICC
This tests the
ceptacle
pin
at the
17-pin
unit is in CC
CV
(constant current)
(constant voltage).
5
Increase
The welding wire and all metal parts in contact with
it carryweld outputwhenthewelding power source
contactor is energized.
Figure
CM-i 588
Page
66
13-15. Self Test Procedure
re
that controls whether the
>Gas
OJ
~
r e s S
or
13-15.
Selecting
Units For Wire Feed
Speed
And Motor
Type
Wirefeed
1
Display
displayed unit of wire speed
(1PM or MPM) can be changed
along with the wire feed motor type
(Standard, Low Speed, or High
Speed).
The
A low speed motor is not
available for this unit.
Increase
Figure
13-16.
Selecting
NOTE ~
Parameter
Select
Increase
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 or
for
Boom
Swingarc model feeders. The set-
properly
model
finn 1n21s th~
nrnn~r
niiIs~
n2r~m-
eters into memory for the model
used.
This selection does not change
when a memory reset is done.
Figure
13-17. Model
Type Display
OM-1588
Page
67
Reset
13-17.
Resetting Memory
1
No Reset
Memory
Press
Mode Select
Wi
refeed
>No
2
Reset
cannot be reset.
Program
Reset
Press Parameter Select button to
reset last active program to original
Model
--~
>Memo
r y
Shutdown
factory program settings.
All other
program and setup information
mains the same.
3
lncrease/
Decrease
System
Reset
Press Parameter Select button to
reset programs and setup to origi
nal factory settings. System, Arc
Time, and Model Type settings
not affected
4
4
\
re
Reset
by
the
system
are
reset.
(Default) Displays
Press
>Process
SidePanel
Parameter
Select
1
>Prg
Sequence
Pu I
DualSchd
035 St
ee
Card
Argon
Oxy
I
se
I
lricrease/
Decrease
3
.
Side Panel
Parameter
Select
Figure
13-18.
Selecting
13-18.
Resetting Memory
Arc Start/Volt Sense Error Shutdown
1
Arc Start/Volt Sense Shut
down
/~
Press
Mode Select
Setup
)__.
\\D~play,J
Mode I
-~
Arc
Memo ry
>Shut down
Volt
Star t/
Sense
>On
Display
With Arc Start/Volt Sense on, the
unit shuts down when no arc volt
age is sensed. If the unit shuts
an error message appears
(see Section 14-4).
down,
With Arc Start/Volt Sense off, the
unit continues to feed wire even
Name
when
there
sensed.
is
no
arc
voltage
Increase
Arc
Volt
Star t/
Sense
I
>0 f
Figure
OM-1 588
Page
68
13-19.
Voltage
Shutdown
Display
13-19.
Selecting Program Name Feature
1
Name
Display
program card is used, the
programs written from the unit to
When
a
the card
can
be named.
Press
Mode Select
Access
Setup
Display
Increase
Ca
r
d
Programs
>0 f
Figure
13-20.
13-20.
Naming Card Programs.
Software Version Number
1
1
Example
Display
Version Number
When talking with service person
nel, this number may be required.
(Check actual unit display for num
ber.) The factory keeps this num
Press
Mode Select
Access
beron file with the serial number of
Setup
Display
the unit.
--s-
Figure
13-21. Version Number
Display
OM-1 588
Page
69
SECTION 14- MAINTENANCE & TROUBLESHOOTING
a
.
WARNING
ELECTRIC SHOCK
can
kill.
HOT PARTS
Do not touch live electrical parts.
Allow
can cause severe
cooling period
before
burns.
servicing gun
or
unit.
Turn Off wire feederand
welding power source, and
input power before inspecting,
maintaining, or servicing.
disconnect
MOVING PARTS
Keep away
from
can cause
injury.
moving parts.
Keep away from pinch points
Maintenance
such
as
drive rolls.
persons.
to
be
performed only by qualified
wfwa~.1 8/92
14-1. Routine Maintenance
-=
Turn Off all
3 Months
6 Months
power before
maintaining.
Tape Or
Replace
Cracked
Weld
Cable
Replace
\
Cracked
Parts
14-Pin Cord
Gas Hose
Figure
OM-1588
Page
70
Gun Cable
14-1. Maintenance
.
14-2.
Replacing
The Hub
Assembly
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
6
Fiber Washer
7
Brake Washer
8
Hub
9
HubSupportShaft
Washer
Replace
worn or broken parts, and
slide parts onto shaft in order shown.
9
Tighten
hex nut until
a
slight
needed to turn hub. Install
wire
(see
Section
force is
welding
3-12).
7
8
7
6
4
Tools Needed:
3
2
~
15/l6in
ST-142 709
Figure
14-2. Hub
Assembly
14-3. Overload Protection
READ SAFETY BLOCKS at start of
Section 14 before proceeding.
Turn Off wire feeder and
power
1
I
welding
source.
Circuit Breaker CB1
CB1 protects the wire feeder from
overload. If CB1 tnps, 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
1
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
voltage sense circuit is not
receiving feedback. Check voltage
arc
sensing connections. Check con
nections at 17-position plugs/recep
tacles at the unit and
welding
power
source.
Turn unit off and back
after
on
cor
recting problem.
Re
I
ease
If this
Trigger
2
3
No
error
Volt
ens
ed
occur
Memory
CRC Error
when
select
Display
The data in the program indicated is
not the same data that was saved.
Perform
S
continues to
pulse welding, it may help to
Hot Start (see Section 13-9).
Er
a
system
reset.
ror
4
Memory Range
Error
Display
3
The data in the program indicated is
out of usable range.
Memory
CRC
Prg
1
00
Error
4
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
N
5
Memo
ry
Prg
1
The
Range
reset.
No Tach Sensed Error
reaching
Error
Display
feedback is not
the control. Check connec
tach
motor
tions.
S
5
Press front
N
panel Parameter
Select
to clear error.
N
S
o
Tach
ens
e
6
Arc
Start
7
Arc
Stop
d
1Error
~Error
1Error
6
Arc Start Error
Display
This appears when pulse welding
and current is detected but the arc
cannot be started. Check and correct
program pulse parameters and volt
age settings. Check voltage sensing
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 oft. A motor brake circuit problem
can also cause this error.
Press front
panel Parameter Select
to clear error.
I
Ref. ST-155 2~
Figure
OM-1588
Page
72
14-4. Error
Displays
14-5.
Troubleshooting
WARNING
£~
ELECTRIC SHOCK
kill.
can
Do not touch live electrical
HOT PARTS
Allow
parts.
can cause severe
burns.
cooling period before servicing gun
or
unit.
Turn Off wire feederand
welding powersource, and
input power before inspecting,
maintaining, or servicing.
disconnect
MOVING PARTS
can cause
injury.
shooting
to be
performed only by qualified
Keep away from moving parts.
Keep away from pinch points
such
drive rolls.
as
Table 14-1.
wfwam4.1 8/92
Troubleshooting
Trouble
Wire
feeds, shielding gas flows, but
electrode wire is not
pull
power
Section
cord connections.
3-9
~
-~
Check
~
-~
Check and reset CB1.
~
-~
Check gun
trigger connection.
-..
Check gun
trigger.
--a
interconnecting
energized.
Wire feeder is on, meter(s) do not light
up, motor does not run, gas valve and
welding
Remedy
source
Electrode wire feeding stops
erratically during welding.
or
feeds
14-3
-.~
contactor do not
in.
I
3-7
I
Readjust
drive roll pressure.
-a
Readjust
hub tension.
---
Change
Clean
to correct size drive roll.
or
replace dirty
Incorrect size
Replace
or worn
contact
tip
or worn
wire
drive roll.
guides.
liner.
or
Remove weld spatter
or
3-14
--a
3-SB
--a
3-SB
--~
3-6A
--a
foreign
matter from
around nozzle
--a
opening.
Have
Factory Authorized
check drive motor
Motor
runs
Check for correct
slowly.
Wire does not feed until trigger is pulled,
but continues to feed after trigger is re
leased, and trigger hold is
---a
a
Service
Station/Service
Distributor
--~
-
input voltage.
short between
Repair short
~
Unit does
i-..
out
of
Run-In
Speed.
-a
Check for
cable.
a
or
welding gun trigger
replace welding gun.
short between
Repair short
InstaU, reconnect,
or
or
--
motor control board PCi.
leads and weld
welding gun trigger
replace welding gun.
1-i
replace voltage sensing lead.
I
*
leads and weld
I
--
- H
not on.
Gas valve in feeder is rattling loudly
along with possible erratic or slow wire
feed speed.
not switch
Check for
cable.
or
~
I
___________________________________________________
Wire feeder power is on, displays
up, but unit is inoperative.
light
i-
-~
Check
welding gun trigger leads for continuity,
replace gun.
and
repair leads
or
I
*
-~
I
_____________
*See gun Owners
Manual.
OM-1588
Page
73
SECTION 15- ELECTRICAL DIAGRAMS
-
C~#1ECTIB1 FOR REMOTE
PR~M-l SELECT
(SEE FIELD INSTRUCTION)
I
DSPL2
SIDE DISPLAY
DC
IOOTO
BACON
I
I
I
i
i
I
I
I
I
6
6
6
6
6
123486
FRONT
DISPLAY
I,
~
DATA
CuICuI~-koI,I*IMICuII
J ~
I U! ii
~
II~ERE?4ENT
8C60/Pt.G60
RC6I/DATA CARD
Cu
0
Cu
~
MICE
SELECT
PARAMETER
SELECT
P831
______
~
Cu
Cu
MO
CV
2
LEFT/RIGHT
SELECT
ca~UCTORL
0
0
P825
~
CABLE
0000
34
CONDUCTOR
CABLE
-
I RC2O
JOG
I
~ETGH
CABLE
0
P821
0
PC ID
I H
-
0
~
I
PURGE
-
RC24I~
0
P822
MICROPROCRSSC8 BOARD
8110
________________________
8110/PLO 10
#122
lIFT
TRIGGER
HOLD
L
CONDUCTOR
CABLE
I
_~__
0
~T.
I IPLO8
PLG23
I
>
~I
3)9J
13
~I
2)SJ
12 >
01
~
H
P1.0831
app
~
>14>
)I
>
I
3>
T>I
4
I
1I>~~1
1 r
wr~ WI~
~ ~
d swuc~c ~
(OPTIONAL)
PLG83
.uIrErAcI4NT
I IPLG8I
~
)
13
>
RC 12/PLO 12
0
~
LEFT
TRIGGER
HOLD
RC26>>-~-
RI 16/PLO 16
~I
3>)J
2
>............~J 12
811
HELD
LED
LED
LEFT
SELECT
RIlSIT
SELECT
LEO
LED
811
00
TRIG~ DECREMENT
7
>
4
~~~)I3
3
_j
#125-3
#121
PLG29
L___J
~/7>121>
I~>
)
~ >~~~O9~OARV&X>
-
00
fJ
RC2Sl
2
#125-8
PC2O
#124/PLG248C257>>4_
I
~J
R125/PLG2S
r~j~----i
I
OR DETAIl-WENT
~PTION
0.
00.
~
~
~)Cu
PLCS7/PLGGI
2~-<I
:1
2
~-~-< 2~-~2 )-~<I 24~-
~z~<7 ~ ~
awr
<II
OPTICAL
>~<l 7~?2
~
~
G.E. I
.E__~._<II~~!3II>_Z_<II~
<16
~-
2<14 ~ >~<I~
y
GSIs.~
I
~-
~<~5 ~
I
I
I
I
I
I
~
0
0
4~I
~
v~
CV
~o
0*
Cu~
aN
~
P1257/PLG57
~+39
0
11<2
<2~E~<~2 ~
IlI4W~~
I.E.~<I
7
~
~
69
+I08<3~~3
#IGIT
~
<
GS2~
I
~E~<I
I-E~I
I>_~L_<1
I
<
6 ~ 6 E~~-6~6 >~-<I 6<
2<14 ~E~_L.<4.E~~4 )_
I
L
Figure
Page
74
15-1. Circuit
Diagram
/
2
I
6<15 .
For Wire Feeder
00
f~~
RC2S-5
101
OM-1 588
I-4>>~
I~8>>-~~I2~
8111-I ~
811 l-5>>~
811 I~2>>~~~I51I
811 1-6X)~~~151
811
RIGHT 8C27>
TRIGGER
#125-2
I
~ITF~j
811 5/PLO IS
0
P82
-
14
8111/PLC II
3
2
__________
_______
PLG28
J
811 7/PLO 17
I
I>~
J
SWITDI
(OPTIONAL)
~
-e)I 4>9114
FLOW
RIGHT
TRIGGER
HOLD
_-_
P824
-1 r
COOLANT
000
Cu
6
______
d
*I~E1ADMINt
Cu
____________________________________________
_______________
wr~ ~im~
I
BC lOG-S
0
PC
________________I~RC2N
II
___________________
1~
I
I
0
#1)00-3>)-
RCIGO-6>>~-~
~~C4l
___
-
RCIOO/PLGIOO
RCIOI/PLGIOI
I
CU
*
0000
Cu
I
RPS-8
FILTER BOARD
P842
vv,
PC3O
I
PC6O
~
~
P841
PARAMETER
SELECT
#1100-2>>
DEcREPNT
36
0~00000
#1100-I>>
PCIOO
I
#161
________________
I
)
CARD
6
811
1_7>>_........-ISV
_________
&
-I
REMOTE PE)CAJIT
I
.
PPs-8
(OPTION)
P1110
I
SWIDARD
I
I
PCI 10/PLO) 10
I
I
,SHLD
&v
104
-.
I)
M0
I
1103
Ii
Z1
I
a~
H
-
0i
--
1105
I
I
0P0-CANT //O~<PCI)o2
0~tY-PANEL
L
P080
FILTER BOARD
RC82/PL082
RC8R/PLG7S
r
IF>~F
Ic>~> C
ILPRENT F~AD( (IV/IOOA)IE)~> E
I0)a~ 0
INOLICTANCO (0-IOV(
VOLTAOE F~SAD( (IV/IOVI IH>~> H1F~,~
8181F>?
PIN 118*C~
8181-C) CC/CV
/0
RCRI-E >
8181-0>
8181-H>
J
14
(.24V=CV)
~
COPOETOR
CABLE
I7~~fRDT &aji
r
(IF
L
8115.4-3)
APPLICABLE(J
r
a#c~o I
pt.oio
WELD CLRRENT
I
RC87>
P050
L.
SENSOR1
H1
I
(DPTI01AAL)
INTERFACE
BOARD
L
RISO/PL050
(~1I~DJN!_~T~E–
~
r~~jp~ ~iia~n~
#15)/PLOD I
R
LtTAD-INT
8152/PL052
I
DPTIa-1
N
8153/PL053
/0
~
R1S4/PLGS4
a
DRIVE
-
Rcos-~
RC9O-I >>~8
8185/PLODS
#155-8
><
IC
CC #155-5
#190-5
CC 8155-6
#183
.
<<#155-3
C
3
C
V
C
C
C
C
C
C
C
C
C
C
V
I
V
V
V_V
C
8<
>8 >~ >
ABBE
_________
C
PIO(-1P(R1014T)
N
~
~&
>)dE_?,B~-~~CB*Y~ >! ~t!J>
DRIVE ASSY
PICK-UP (LEFT)
>)-~
~GE D,M
________
C
C
C
8189-I >
C
C
C
#189-2>>
-3
V
ppa
8189-3>)
RC8O>HF
STUD
r
14
,
PIN PLLE
PLG9
+IOV
IDICIAND
P!M~
&tiil
>E
PS.
cDVBIDN
ap~
>0
-
C
C
C
C
N
CA
-
8114-4
&&w
C
) F
0
I
I)
815-10:
814-9
<
814-6
816-I
#16-2
PC I
MOTOR
BOARD
811/PLO I
816-3
TO POWER
813/PLO3
8C4/PLO4
P15/PLOD
816/PLO6
24VAC
816-4
101.0
3ctp
J
L
SO-i 64 541-B
OM-1 588
Page
75
.
PC I 0
MICROPROCESSOR
PC2O
FRONT DISPLAY
683
Pc~I-68
IOW
Pc51-IO
P
3
PLG57
2
2F(GSI)
1-8)41
O
70F(RC277)
448 (LEfl
~IVE I~2)ING)
448(PLGI I -8)
~i~1~iii
708)PLDRI-I)
68C(PLGI
3)
8
LEFT
IOY(PLGII2)
68C(PLG5I-3)
DRIVE
HOUSING
708(PLGII7)
IOY(PLG5I-2)
8
26
~1~Ill
WHT(M))
PLG5I
44D(RC278
21 (RC27-4)
7J(RC27Il)
-
PLGI I
WHT(PLGII-I)
8LK)MI)
5F)pc27-5)
9C)Rt27-6)
RC27
U
10
5C)PLGII-5)
LEFT
MI
GSI
2Q/~
3
0
~PLGII-4
LEFT
~1~1
PLG34
SI,
,,l
~
¶31
~
0
RC37
4
PLG33
PLG57
Figure
OM-1588
Page
76
15-2.
Wiring Diagram
PLG37
For Wire Feeder
28A)~RIOI-6)
77A(PLGR 1-9)
IOD(PLGGI-6
I
~.----.
7ASPLI~
T~IOI.A
ID(PLGGI-7)
~B(PL.G5 I -
2:l:~i
0
75A(PLGR I
-
I
O~
RC4/
0
39A)~I)
PLG4
d~~Th
POWER
~VOFF
~si
p
36A(PLGGI-I I
36
~RC2/
~!J~–J
PC I
MOTOR BOARD
lb
(GE I -AC)
1~0A)SR I -I~EG)
35A)GEI-POS
2A(GEI-AC)
39A(SI)
p
CBI
:~RC6,
~PLG6
IA(SRI-AC)
J
p
1
2C)P1.G25-7)
cPIoIi
I)
2D(PLGA-4
-AC)
8A(PLGEI-2)
YELLOW)P1.G19-2)
5A)RC8-5)
LRAIPIORG-A1
49A)PLG82
BLUE(PLG7G-2)
II
ORANGE (P1575-3)
5 ~ I
B6~
A
hA
RC7
I
I
PDK)PLG75-I I
NN28APLG46)~46
55A)PL.G823)
52A)PL5829)
PLGI9
REO(PLG4-9)
PLG9
54A(PLG825)
53A)PLG82I)
I.
IBIPLG6-I(
IC(PLG2R-BI
I O.J(RC85)
~
IOA(PLG6-2
C
0
a
SRI
AC
-~
2A)PLG64)
~AC
28(RC86(
PL.G28
LEFT
PLRPLE(PLG9-G)
LIL
+
Y
-
RC3O
t
~
8C90\
P1090
35A(PLG6-3)
I
~ ~
5E)Rc3Q5)
9B(RC3O6
~
7occRc3o-7
~
44C(RC3O8
~1~75~~__
PC8O
~0l
NO
__PLG29
RC89\~_
RC8
511
RC82/
P1682
8
~O
!~!
I
I
~,
~-lc~
?
~
0~Ju~
C
PLG3B
RIGHT
RC7O
RC4O
0
w'I
61~fic~
~
~5A
00
RC7
N~1
43C(RC4O8
69C(RC4O7
70(RC406)
,~
ci
~1
I
0
0
RC87
6E(RC4O-5)
I
~ffl
SD-i 64 540-B
OM-1 588
Page
77
SECTION 16- PARTS LIST
S
C.,
U,
Co
C)
U-
.
C.)
Co
\
U-
C.,
N
N
U)
L
\
N-
N
(0
Co
C)
Co
U-
CD
C)
iiST-BOO 272-B
Figure
OM-1588
Page
78
16-1. Main
Assembly
Quantity
Item
No.
Model
Part
No.
Dia.
Mkgs.
Description
Figure
1
1
PLG21 ,23
..
.
16-1. Main
12
Assembly
CABLE, trigger (consisting of)
CABLE, trigger (consisting of)
079 878.... CONNECTOR & PINS, (consisting of)
149 251
...
149 252
...
CONNECTOR,
079 535
circ
2
2
1
pin push-in 14-l8ga Amp
66359-6
CONNECTOR, circ clamp str rif sz 11 Amp 206358-2
605 156
CABLE, port No. 184/c (order by if)
080 328
CONNECTOR w/SOCKETS, (consisting of)
079 534
CONNECTOR, circ skt push-in 14-l8ga Amp 66358-6
See Note
CONTROL BOX, (Fig 16-3)
164 475
CABLE, interconnecting (consisting of)
164 474... CABLE, interconnecting (consisting of)
..
079 531
PLG28,29
2
.
17ff
1
..
..
....
1
....
4
....
2
21ff
..
....
1
4
4
1
1
2
...
3
4
2
...
3
16
2
PLG27,28,
047 636
37,38
....
079 535
079 739
....
CONNECTOR & PINS, (consisting of)
CONNECTOR, circ pin push-in 14-l8ga Amp 66359-6
CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2
2
..
..
CABLE, port No. 18/14 8/c (order byft)
HOSE ASSEMBLY, gas (consisting of)
159 297
010 604
FITTING, hose brs bushing 1/4NPT x .625-18RH
044 858
FITTING, pipe brs Y short 1/8NPT ml x 1/4NPT
073 432
FITTING, brs barbed M 3/l6tbg x 1/8NPT
056 108
FITTING, hose brs ferrule .425 ID x .718 Ig
134834.... HOSE, SAE .187 IDx.4100D (orderbyff)
010 606
FITTING, hose brs nut .625-18RH
056 851
FITTING, hose brs barbed nipple 3/l6tbg
139 600
HOSE, gas (consisting of)
139 599
HOSE, gas (consisting of)
010 603
FITTING, hose brs barbed nipple 1/4tbg
010 606
FITTING, hose brs nut .625-18RH
603 106
HOSE, nprn brd No. 1 x .250 ID (order by if)
056 112
FITTING, hose brs ferrule .475 ID x .718 Ig
600 324... CABLE, weld cop strd No. 4/0 (order by if)
602 243
WASHER, flat stl std .375
602 213
WASHER, lock stl split .375
163519....
4
1
2
....
7
8
....
1
....
2
9
1
....
1
601 872
....
2
....
26ff
2
8
...
4
151 626
11
132 053...
12
Fig
16-2
...
...
13
.149838...
13
149
839
13
078
264...
13
079
216...
14
075
078...
14
079
15
Fig
16
RC27,37
....
26ff
...
10
...
217...
NUT stl hex full .375-16
4
BRACKET~ spring retaining
BRACKET, spring retaining
SCREW, cap stl hexhd .375-16
SUPPORT~ hub & reel
PIPE POST, 4ftw/base or
PIPE POST, 6ftw/base
PIPE POST~ 4ff w/base or
PIPE POST, 6ff w/base
PIPE POST, 4ff w/o base
PIPE POST, 6ff w/o base
1
1.500
4
Ig
1
PLG11,17
...
048 144
...
115 092
...
PLG33,34
...
135 409
GS1,2
...
CONNECTOR,
rect skt
CONNECTOR & PINS,
....
...
....
....
2
2
30ff
..
....
2
..
30ff
....
8
....
4
....
4
....
4
1
2
(consisting of)
(consisting of)
24-l8ga
....
1
1
1
Molex 39-00-0038
(consisting of)
CONNECTOR, rect pin 24-l8ga Molex 39-00-0040
139 813... COVER, protector motor
125 785
VALVE, 24VAC 2 way custom port 1/8 orf
139 816... PANEL, end cover
159 647... INSULATOR, motor clamp
114 656
20
....
1
1
CONNECTOR, circ skt push-in 14-l8ga Amp 66358-6
CONNECTOR, circ pin plug keying Amp 200821-1
CONNECTOR & SOCKETS,
1
1
1
...
113 746
23
....
1
2
079 534....
22
....
1
x
16-5... BOOM ASSEMBLY
605227... NUT~ nyl hex jam .75ONPST
047 637
CONNECTOR & SOCKETS,
1
2
2
2
...
1
2
....
080 947...
21
....
1
2
1ff.... 1ff
....
10
19
....
1
....
18
..
....
...
6
17....
2
21ff
....
...
5
....
....
....
5
2
17ff
...
2
14.... 14
....
....
....
....
....
....
1
1
1
2
2
14.... 14
2
....
2
2
....
2
8
....
8
2
....
2
8
1
2
1
2
....
8
....
1
....
2
....
....
OM-1 588
1
2
Page
79
Quantity
Item
No.
Dia.
Mkgs.
Model
Part
No.
Description
Figure
24
156 243...
25
159 360...
16-1. Main
Assembly (Continued)
CLAMP, motor top
INSULATOR, screw machine
CLAMP motor base
145 639
STRIP, buna N compressed sheet .062 x 4.000sq
134834... HOSE, SAE .187 ID x .410 OD (order by ft)
26
159 646
27
28
30
31
33
2
167 774... DRIVE
1
1
ordering Control
Box contact
Factory Service Department
....
....
2
8
2
2
3ft.... 3ft
.167 776... DRIVE
...
NOTE: When
....
...
...
33
....
8
2
...
32
2
...
ASSEMBLY, wire RH (Fig 16-6)
ASSEMBLY, wire RH (high speed) (Fig 16-6)
157 295... GUIDE, monocoil
604 612
SCREW, set stl sch 8-32 x .125 cup point
082 050... LINER, monocoil inlet wire
BUS BAR, connecting weld current
164 969
167 780... DRIVE ASSEMBLY, wire LH (Fig 16-6)
DRIVE ASSEMBLY, wire LH (high speed) (Fig 16-6)
.167 782
29
29
16
12
....
2
1
....
2
4
....
2
....
1
....
1
1
1
....
....
....
4
2
1
1
1
for proper number.
OPTIONAL
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
S
OM-1 588
Page
80
Item
No.
Part
No.
Figure
1
2
3
4
5
6
7
....
....
....
058427
136684
605941
....
010233
....
057971
....
010191
....
058628
8
....
058428
9
....
080393
10... 108008
11
....
124900
12... +168 104
16-2.
Support,
Hub & Reel
(Fig
16-1 Item
12)
RING, retaining spool
NUT, stl slflkg hex reg .625-11 w/nyl insert
2
WASHER, flat stl .640 ID x 1.000 OD x 1 4ga thk
SPRING, cprsn .970 OD x .120 wire x 1.250
WASHER, flat stl keyed 1 .SOOdia x .l2Sthk
WASHER, fbr .656 ID x 1.500 OD x .1 25thk
WASHER, brake stl
HUB, spool
SUPPORT, reel
REEL, wire 60 lb (consisting of)
SUPPORT, reel spool
RETAINER, spool support (consisting of)
2
166594
13....
Quantity
Description
LABEL, caution falling wire reel
NUT, spanner retaining
168103
can cause
2
2
2
4
4
2
2
1
1
1
damage
1
7
6
9
10
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
81
.
C.)
cJ
N
c.J
/
/
/
/
/
c..J
1
/
CD
0)
U-
a)
C%J
N
CD
C)
U-
0
C.)
C.,
ST-800 273-A
Figure
OM-1 588
Page
82
16-3. Control Box
073
147995
151
162
134464
010325
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure
RC3O,40.
134 201
STAND-OFF SUPPORT, PC card .3121.375
CIRCUIT CARD, motor control
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-1 8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
113 746
115 093
113 746
115 091
113 746
136 810
PLG82
158 720
113 746
147 995
153 501
756
13...
163 519
141 162
134731
079 739
158 719
147 995
17...
601 222
18...
603 106
19...
600 399
138 044
107 983
048 282
079 534
...25
000 527
CR101
072 817
SRi
035 704
...26
030 170
...27
145 948
...28
Fig
29
PLG12,50
16-4
155 629
154 938
097 132
...32
PC5O
PLG51
1
Molex 39-00-0038
6
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
1
10
1
1
131 204
...23
1
8
1
PLG75
RC7O
1
BUSHING, strain relief .840 ID x .875mtg hole
LABEL, warning general precautionary
CABLE, port No. 18/14 8/c (order by ft)
CONNECTOR & PINS, (consisting of)
CONNECTOR, circ pin push-in 14-l8ga Amp 213603-1
CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-1 8ga Amp 770904-3
CLAMP, univ50A
HOSE, nprn brd No. 1 x .250 ID (order by ft)
WIRE, strd l4ga blk 600V 105c (order by ft)
BUSHING, strain relief .120/.150 ID x .500mtg hole
BLANK, snap-in nyl .SOOmtg hole
CONNECTOR w/SOCKETS, (consisting of)
CONNECTOR, circ skt push-in 14-i8ga Amp 66358-6
BLANK, snap-in nyl .875mtg hole
RELAY,encI24VACDPDT
RECTIFIER, integ 40A 800V
BUSHING, snap-in nyl .750 ID x 1 .000mtg hole
BRACKET, mtg control box
PANEL, front w/components
CABLE, ribbon l4posn
STRlP~ mtg PC card
STAND-OFF, 6-32 x .375 Ig
CIRCUIT CARD, interface
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-lBga Amp 770904-3
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-1 8ga Amp 770904-3
CONNECTOR & SOCKETS, (consisting of)
163 921
PLG19
8ga
10
WRAPPER
PC8O, RC81
PLG9
rect skt 24-1
Amp
14
20082 1-1
364
111 997
14...
CONNECTOR,
pin plug keying
in sockets
187
083 432
11
circ
CONNECTOR, rect skt 20-l4ga Amp 350536-1
CASE SECTION, bottom/rear
CIRCUIT BREAKER, man reset 1P 10A250V
SWITCH, rocker SPST 1OA 25OVAC
CIRCUIT CARD, HF filter dual
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 22-l8ga Amp 770904-3
STAND-OFF, 6-32 x .625 Ig
LATCH, slide flush mtg hole 1.000 wide x 1.500 Ig
114 066
161 706
PLG9O
2)
CONNECTOR,
115 092
...CB1
16-1 Item
048 144
PLG1
PLG6
(Fig
079 534
155 114
PLG4
16-3. Control Box
PANEL, side lower
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, circ skt push-in 14-l8ga Amp 66358-6
162 253
047 637
PCi
PLG2
Quantity
163 917
158 720
147 995
PLG52
158 719
147 995
PLG53
131 204
PLG54
113 746
148 439
147 995
CONNECTOR,
rect skt 24-1
4
1
1
1
1
1
3
1
12
1
6
2
1
1
12ft
1
14
1
1
2
1
itt
35ft
1
1
1
4
1
1
1
3
1
1
1
1
4
1
1
12
1
2
1
Molex 39-00-0038
3
1
8ga
(consisting of)
22-l8ga Amp 770904-3
CONNECTOR & SOCKETS,
CONNECTOR,
rect skt
10
OM-1 588
Page
83
Item
No.
Dia.
Mkgs.
Part
No.
Figure
PLG55
115 092
113 746
126 689
PC1O
161 781
PLG11
115 092
113 746
PLG15
153 501
147 995
PLG17
115 093
113 746
...35..
...36..
PLG1O,24
PLG16,41
...37..
170 980
155 023
Fig
16-7
158 373
097 868
116 964
600 343
097 866
Quantity
Description
16-3. Control Box
(Fig
16-1 Item
2) (Continued)
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-lBga Molex 39-00-0038
1
8
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 w/components
CABLE, interconnecting pwr (consisting of)
CONNECTOR, circ l7skt plug Amphenol MS-3106A-20-295
CONNECTOR, circ clamp slf sz 20-22 Amphenol MS-3057-1012
CABLE, port No. 16 5/c (order by ft)
CONNECTOR, circ 17 pin plug Amphenol MS-3106A-20-29P
CLIP, component .437d1a mtg adh back
CLAMP, nyl .500 clamp dia
4
1
1
8
1
6
1
6
1
1
1
1
1
.
....
059 712
010 145
+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-1588
Page
84
2
lOft
1
2
1
Dia.
Item
No.
Mkgs.
Part
No.
Figure
167697..
147 139
164 842
144 844
6
....
PC2O,30.
PLG25
160 804
165 484
147 995
159 264
167 633
089 032
153 169
11
010 291
13
167 700
16-4.
Panel, Front w/Components (Fig 16-3 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 lg
CIRCUIT CARD, schd front
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-l8ga Amp 770904-3
See
PLG24....
...8
Quantity
Description
Figure
1
1
2
1
9
1
1
8
16-2 Item 35
RING, ext .625 shaft grv x .O45thk E style
WASHER, shldr .612 ID
LENS, LED 4341 red panel mtg
ACTUATOR, switch
WASHER, flat .625 ID nylafil
KNOB, pointer
3
1
1
4
6
1
1
4
2
s~~
9
13
12
ST-BOO 112-C
Figure
16-4.
Panel, Front w/Components
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1 588
Page
85
0)
0
C\1
.
0
C\J
C~)
~
~?
0)
cJ
(%1
C,)
CJ
/
/
C%J
0)
CJ
ST-142
Figure
OM-1588
Page
86
16-5. Boom
Assembly
3O6~E(
Quantity
Item
No.
Model
Part
No.
Description
Figure
.1.
010 313
.2.
010 910
.3.
139 590
.4.
079 667
.4.
080 812
.5.
079 632
6
079 665
6
080 811
7
079 664
8
139 633
9
159 999
9
160 513
10
073 742
11
073 741
12
079 029
13
075 462
14
602 250
15
079 020
16
155 335
17
149 858
17
151 625
18
150 258
19
024 605
20
075 101
21
079 030
22
+139 831
080 157
23
142 804
24
134 327
25
602 246
26
047 224
27
073 666
28
010 493
29
139 818
+When
ordering
a
16-5. Boom
Assembly (Fig
16-1 Item
4
4
....
8
2
....
2
....
10
2
2
8
2
2
2
2
....
2
....
2
1
1
1
NUT, stl hex full fnsh .750-16
SHAFT, boom counterbalance
WASHER, fIatstlSAE .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 .750-16x 1.250
WASHER, lock stl ext tooth .750
BASE, swivel boom (consisting of)
FITTING, grease 1/8NPT
LABEL, Swingarc caution heavy spring
LABEL, warning general precautionary
WASHER, flat stl std .500
KNOB, T-bar .500-l3thd
BOLT, mach stl hexhd .750-16 x 2.750
BUSHING, snap-in nyl .625 ID x .875mtg hole
GUARD, motor protector
2
precautionary label,
....
8
PIN,clevis.7500Dx2.1561g
CLEVIS, .812 yoke 6.062 Ig .750-l6thd
a
16
15)
PIN, cotterhair .072x1.437
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 .500x 181 .750
BOLT, U stl .250-20 x .875 wide x 1.375 deep
GUIDE, wire
GUIDE, wire
GUIDE, wire inlet
LINER, monocoil 3/32-1/8 wire x 15.687
BOOM, dual
BOOM, dual
component originally displaying
I
12
1
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
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1588
Page
87
Item
No.
Dia.
Mkgs.
Part
No.
Figure
..
1
..
2
010 668
...
150 147
...
149 962
149 486
...
...
163282
...
163 281
...
165 798
165 799
132750
...
..
.
...
..
9
150 520
...
..
10
133 493
...
11
133350
...
Quantity
Description
...
16-6. Drive
Assembly,
Wire
(Fig
16-1 Items 29 &
33)
SCREW, cap sti sch .250-20 x 1.500
CARRIER, drive roll w/components
SPACER, carrier drive roll
PIN, rotation arm rocker
NU1~ .250-28st1
SPRING, pressure arm retaining LH
SPRING, pressure arm retaining RH painted end (shown)
WASHER, fIat .257 ID stl
ARM, pressure
SPACER, rotation pin
RING, retaining ext .250 shaft x .O25thk
PIN, hinge
4
4
4
2
2
2
2
2
2
2
2
1
17
8
SeeTablel6-1 For
Drive Roll & Wire Guide Kits
15
7
12
23
24
26
28
31
30
29
6
3
2
Figure
OM-1 588
Page
88
16-6. Drive
Assembly,
Wire
I
Item
No.
Part
No.
Dia.
Mkgs.
Figure 16-6.
(Continued)
12
12
M1,2
M1,2
...
153 491
PLG29,39
...
Drive
Assembly, Wire (Fig
16-1 Items 29 &
33)
156354... MOTOR, gear
353... MOTOR, gear
156
13
Quantity
Description
1
1/8hp 24VDC 272RPM (consisting of)
1/8hp 24VDC 500RPM (consisting of)
replacement (consisting of)
1
KIT, brush
153492
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
155100
SCREW,cover
154 031
SPACER, locating
133 493
RING, ring ext .250 shaft grv x .O25thk
115 092
CONNECTOR & SOCKETS, (consisting of)
113 746
CONNECTOR, rect skt 24-l8ga 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 stl split No. 8
604772 ...WASHER,flatstlSAENo.8
165 934
SPRING, cprsn .573 OD x .088 wire x 1.062 Ig
132 746
BUSHING, spring
132 824
SHAFT, spring
132747...CARRIER,shaft
152 241
KNOB, extension
133 739
WASHER, flat .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 skI 24-1 8ga Molex 39-00-0038
604 311
GROMMET, rbr .250 ID x .375mtg hole
....
1
2
2
1
1
1
5
2
1
1
...
8
....
PLG51,57
...
1
...
3
....
RC7,8
1
...
8
....
14
15
16
17
1
...
1
...
1
1
...
18
...22
...23
...24
25..
...
TK1 ,2/PC51
PLG57
1
...
2
...
2
...
1
1
...
1
...
1
...
1
1
3
1
....
...26
132 611
...27
149 959
...28
149 746
...
149 745
...29
108940...
604 538
151 437
...32
128 237
...34.
601872...
...35.
602213...
...36.
602243...
...37.
149964...
...38.
601966...
167387...
149 527
...39.
133530...
133308...
OPTICAL ENCODER DISC
FITTING, brs barbed M 3/l6tbg
1
x
1
.312-24
ADAPTER, gun/feeder LH
ADAPTER, gun/feeder RH
SCREW, cap stl hexwhd .250-20 x .750
WASHER, flat stl SAE .312
KNOB, plstcT 1.125 Ig x .312-18 x 1.500 bar
SCREW, hexwhd-slt stl slffmg 10-32 x .500
COVER, drive roll
NUT, stl hex full .375-16
WASHER, lock stl split .375
WASHER, flat stl .375
PIN, groove .25Odia x .500 Ig
SCREW, cap stl hexhd .375-16 x 1.250
SPACER, locating
DRIVE, pinion
RING, retaining ext .375 shaft x .O25thk...
1
1
4
1
1
2
1
1
1
1
2
1
2
1
1
Optional High Speed Motor
Spare Paris.
*Recommended
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1 588
Page
89
Item
No.
Dia.
Mkgs.
Part
No.
Figure
147139
155024
154933
PC6O
156623
PLG6O
153501
147995
PLG41
PC4O
144844
154109
153169
16-7. Panel, Side
w/Components (Fig
16-3 Item
37)
TAPE, adh acrylic double sided .010 x .500 x 3.000
LENS, clear anti-glare
PANEL, inner control
CIRCUIT CARD, data card
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-1 8ga Amp 770904-3
See
158160
Quantity
Description
Figure 16-3,
2
1
1
1
1
6
Item 40
CIRCUIT CARD, side display
STAND-OFF, 6-32 x .875 Ig
4
PLATE, ident inner control
ACTUATOR, switch
4
1
1
6
1
2
7
9
8
ST-800 113-B
Figure
16-7. Panel, Side
wlComponents
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1588
Page
90
Table 16-1. Drive Roll And Wire Guide Kits
~i
~
Wire Size
E~5
E~
IR
~(j
~
Fraction
Metric
V-GROOVE
łi
4 Roll
~
Kit
Drive
Roll
U-GROOVE
4 Roll
Kit
Drive
Roll
VK-GROOVE
4 Roll
Kit
Drive
Roll
UC-GROOVE
4 Roll
Drive
Roll
Kit
.023-025 in
0.6
mm
150993
149518
151 024
087 130
.030 in.
0.8
mm
150993
149518
151 025
053695
.035 in.
0.9
mm
150993
149518
151 026
053700
151 036
072000
151 052
132958
.045in.
1.1mm
150994
149519
151027
053697
151037
053701
151053
132957
151070
083489
.052in.
1.3mm
150994
149519
151028
053698
151038
053702
151054
132956
151071
083490
1.6mm
150995
149520
151029
053699
151039
053706
151055
132955
151072
053708
1.8mm
150995
149520
151 056
132959
2.0mm
150995
149520
151040
053704
151057
132960
151073
053710
2.4
mm
150996
149521
151 041
053703
151 058
132961
151 074
053709
2.8
mm
150996
149521
151 042
053705
151 059
132962
151 075
053711
3.2mm
150997
149522
151043
053707
151060
132963
151076
053712
(.062in.)
.068-.072in
.
5/64 in.
(.079in.)
3/32 in.
(.094 in.)
(.110irL)
s-0549-c
Each Kit Contains An Inlet Guide, Intermediate Guide, And 045 233 Antiwear Guide With 604 612 Setscrew 8-32
With 4 Dnve Rolls.
2 Kits
Required
x
.125, Along
For Dual Models.
OM-1588
Page
91
NOTES
I
NOTES
.
OPTIONS AND ACCESSORIES
~WELD CURRENT SENSOR
RPS-8 REMOTE PROGRAM
SELECTOR
WATER FLOW SAFETY SWITCH
Used with the water hose kits.
MIG power sources that do not
have 17-pin receptacle.
(#160 977)
Eight-position rotary switch used
remotely select weld programs.
Includes a 33 ft. (10 m) cord.
POWER SOURCE DATA CARDS
WIRE STRAIGHTENER
(#160 963)
Required when using
the 64M
feeder with Miller conventional
(#164 583)
to
Protects water-cooled gun from
overheating by shutting down
system if
water does not flow.
DUAL SCHEDULE SWITCHES
For .035
Data card is inserted into feeder,
and with a push of a button, the
-
.045 in.
(0.9-
1.1
Used with Dual Schedule
mm)
Control in 64M feeder.
wire
DSS-8
(#141 580)
feeder is
automatically
programmed for the power source
being used. Each data card
contains eight factory-written
wire
programs and 24 unused spaces
for customer-developed programs.
wire
For 1/16
1/8 in.
-
For lOft.
(3 m) gun
(#079 691)
For 15 ft. (3 m) gun
(#079 693)
Requires adapter cord (#157 364).
Two-position trigger switch that
easily attaches to the welding gun.
Used in place of the standard
trigger for dual scheduling.
(1.6-3.2 mm)
(#141 581)
Reduces cast in wire.
Improves
and
feeding performance
increases life of gun liner and
tip.
contact
Data Cards for Conventional
MIG Power Sources:
(#164
(#164
(#164
(#164
(#164
(#164
IP
162)
161)
160)
163)
164)
165)
HIGH-SPEED MOTOR
for Deltaweldfi 300
for Deltaweldfi 451
For
for Deltaweldfi 651
for Dimensionfi 400
for Dimensionfi 650
for XMTfi 200 CC/CV
single
and
right
side of dual
DSS-9M
models.
For 10 ft.
(#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 m/min.). 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
lmportant:Same speed motor must be
used
on
models.
each side of the dual wire
Factory-written synergic
Pulse
MIG programs will not operate with
eight synergic pulse
(3 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!
high-speed motor.
DECREASE SWITCH
WATER HOSE KIT
(#042 749)
Two-position, momentary
.045 in. steel wire with
For 12 ft.
switch that attaches to the
Argon/Oxygen shielding
gas
.035 in. 309L stainless steel
feeders
using Argon/CO shielding gas
For 16 ft.
.045 in. 309L stainless steel wire
feeders
programs:
.035 in. steel wire with
Argon/Oxygen shielding
gas
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
Argon shielding
(3 m) Swingarc style
(#159 288) 23 ft (7 m)
(4.9 m)Swingarc style
(#159 289)
27 ft.
(8.2 m)
guns. Can be used with or
without optional water flow safety
welding
switch.
feature to fine tune parameters at
the welding gun while welding.
trigger operates
standard
WIRE REEL ASSEMBLY
(#108 008)
Accommodates 60 lb.
(27 kg) coil
of wire.
Note:lf water kit is to be used
using
gas
64M DATA CARD
(#155 910)
as
tngger.
sides of a dual wire
feede,~
a
on
both
kit must be
ordered for EACH side of the feeder.
EXTENSION CORDS
For
optimum performance,
extend MM feeder
I~
welding
gun. Used with the Remote
Parameter Increase/Decrease
Gun
Used with Miller coolant systems
and GW Series water-cooled
contact
Blank Card
tores up to 32
Y
ft.
WATER HOSE KIT
(#165 491)
Required when using
kit
programs and
feeder. Connects both kits to
transferring
programs to other 64M feeders.
each side of
water coolant
a
a
water hose
dual wire
system.
from power
do not
than 60
source.
14-Pin Extension Cord
complete weld
for saving custom
Ideal
programs.
on
(18 m)
more
one
(#122 973) 25
(#122974)50
ft.
ft.
(7.6 m)
(15 m)
17-Pin Extension Cord
(#042 120)
25 ft.
(7.6 m)
11193
OPTIONS AND ACCESSORIES
MILLER GMAW
(MIG) GUNS
Water-Cooled Guns
Refer to literature Index No.
M/13.4.
COOLANT SOLUTION
(#042 493)
1.5 gal. (5.7 L)
(For Extra Freezing Protection)
(#128 705)
Resists freezing to 00 F (-18 C).
tank
capacity.
Watermate~ 1A, 115 VAC
Air-Cooled Guns
Refer to literature Index No. M/9.O.
I
Radiator 2A, 230 VAC
2
(#042 495)
gal. (7.6 L)
tank
Important
capacity.
Distilled water is recommended.
CooImate~ 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
tank
capacity.
capacity.
Systems
literature, Index No. AYI7.2.
MOUNTING EQUIPMENT FOR SWINGARC BOOMS
One of the
following is required for
mounting the SS-64M and DS-64M
Swingarc~ booms:
Swingpak~ Base and pipe post
with base plate
CBC Cart (for use with 12 ft.
3.7 m] model only) and pipe post
without base plate
Pipe Post
coolant system, and gas cylinder.
plate is solid to help
ft.
better
Note: To mount a 12 ft. (3.7 m) Swingarc
feeder system on a CBC Cart, a 6 ft. (1.8
The base
organize components
cables. Base includes
The entire unit
a
can
and
a
three-compartment storage
locker.
be moved with
forklift truck.
CBC CARTS
(#085 276)
for 12 ft.
(3.7 m)
2000 lb.
a
the standard model with 10 in.
boom
SWINGPAK-1 6
(#085 934)
for 16 ft.
(4.9 m)
boom
pipe post
required and must be
separately.
Note: A
with
a
base
plate
is
ordered
(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
m) pipe post is required (#079 217). The
(1.2 m) pipe post is NOT
recommended. The 16 ft. (4.9 m)
Swingarc feeder cannot be used.
CBC CART FEATURES
(3.7 m) boom only
Designed to provide mobility and
neat, orderly arrangement of
welding equipment. The CBC is
SWINGPAK-1 2
and
4 ft.
For 12 ft.
SWlNGPAK~ BASES
(3.7 m) Swingarc feeder,
cylinders.
two gas
a
power source, 12
(907 kg) load capacity
Multi-position boom
Swing-out outriggers
II
Wide front wheel stance and
automotive
Mounting
CV power
type steering
facilities for most Miller
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
1lI~3
ERRATA SHEET
After this manual
appearing
was
printed,
refinements in
November 15, 1994
FORM: OM-1588A
Use above FORM number when
ordering
equipment design occurred.
This sheet lists
extra manuals.
exceptions to data
later in this manual.
CHANGES TO SECTION 16- PARTS LIST
Change
Parts List
as
Part
No.
**
88-2.... 150 147
89-40
follows:
...
133 530
Replaced
With
Description
....
172 075
..
....
168 825
..
Quantity
CARRIER, drive roll w/components 24 pitch (Eff wIKE754598)
DRIVE, pinion 40T 24P .376 bore (Eff w/KE754598)
....
First
digit represents page no digits following dash represent item no.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
~
1~1~j
4
1