Miller DS-64M SWINGARC Owner's Manual

Millerfi
Form:
October 1993
OM-1588
Effective With Serial No. KD506226
OWNERS
MANUAL
DS-64M
And
(12)
(16) Foot
Boom Mounted Wire Feeder
Boom-Mounted
Microprocessor Controlled Constant Speed
Multi-Power Source
Compatible
For GMAW. GMAW-P. And FCAW
For .023 To 1/8 in
Welding
(0.6 To 3.2 mm) Wires
Standard Wire Feed
Programmable
Dual Wire Feeder
Speed
Of 50 To 780 ipm (1.3 To 19.8
mpm)
Pulse Weld Parameters
Circuit Breaker Protected
Give this manual to the operator.
Read and follow these instructions and all
blocks carefully.
safety
Have only
trained
install, operate,
or
and
qualified persons
For
service this unit.
call your distributor if you do not understand
the directions.
cover
7/93
ST-800 172
'
1993 MILLER Electric
or:
help, call your distributor
MILLER Electric
Appleton,
Mig Cc-
WI 54912
Mfg. Co.,
P.O. Box 1079,
414-734-9821
PRINTED IN USA
I
j
MILLERS
TRUE BLUETM LIMITED WARRANTY
(Equipment
with
Effective January 1, 1992
aerial number preface of XC
a
This limited werrenty supersedes eli previous MILLER werrsntlee end is exclusive with
LIMITED WARRANTY Subject to the terms end conditions below, MILLER Electric
MIg. Co.. Appleton, Wisconsin, werrents to its original retell purcheser Ihet new
MILLER equipment sold efter the effective dete of this limited werrenfy is free of de
fects in materiel end workmanship et the time it is shipped by MILLER, THIS WAR
RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES. EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT
NESS.
other guerentees
or
werrenties expressed
or
implied.
Remote Controls
Accessory Kits
Replecement Pens
TM
MILLERS
True Blue
Limited
Werrenty
shell not
epply
to:
1.
Items furnished by MILLER, but menufectured by others, such es engines or
trede ecceesoriee. These items are covered by the menufecturers werrenty. if
eny.
2.
Coneumeble components: such
Within the werrenty periods listed below. MILLER wilt repeir or reptece any warrented perts or components that fell due to such detects in meteriel or worlrnenship.
MILLER musf be notified in
which time MILLER will
writing within thirty (30) deys of such defect or failure, et
provide instructions on the werrenty cleim procedures to be
no
newer)
or
end
followed.
MILLER shell honor werrenty cleims
on werrented equipment listed below in the
werrenty time periods, All werrenty time periode
alert on the dete that the equipment wee delivered to the origlnel retelt purcheser. or
one yeer eher the equipment is sent to the distributor.
5 Veers Pens 3
2.
pens thet fell due
es
contect
tips, cutting nozzles.
contectors
to normel weer.
thet hes been modified
by eny petty other then MILLER, or equip
improperly instelled, improperly opereted or misused
or
industry
equipment which he, not hed reesoneble
end neceseery maintenance, or equipment which he, been used tor operetion
outxide of the specificetione for the equipment.
ment thet hes been
beeed upon
etenderds,
Years Lebor
MILLER PRODUCTS ARE INTENOED FOR PURCHASE AND USE BY COMMER
CIALJINDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING EOUIPMENt
mein power rectifiers
Original
or
Equipment
3.
event of such e feilure within the
1.
releys
Perle end Lebor
3 Veers
In the event of e
Treneformer/Rectifler Power Sources
Plesme Arc
werrenty cleim covered by this werrenty, the exclusive remedies
option: (1) repeir: or (2) replecement; or. where euthorized in
shell be, et MILLERS
Cutting Power Sources
writing by MILLER
SemI-Autometic end Autometic Wire Feeders
in
eppropriete
cexes.
(3) the reesoneble
cod
of
repeir
or
replece
ment at en euthorized MILLER service station; or (4) payment of or credit for the pur
chese price (tees reesonebledeprecietlon based upon ecluel use) upon return of the
Robote
et customers risk end expense. MILLERS
optIon of repair or replecem,ant
FOB., Fectory et Appleton. Wisconsin. or FOB. etc MILLER euthorized ser
vice facility cx determined by MILLER. Therefore no compeneation or reimburse
ment for transportation costs of any kind will be allowed.
goods
3.
Pens end Lebor
2 Veers
Engine
Driven
Welding
(NOTE: Engines
*
4.
Air
will be
ere
Generetore
werrented
eeperetely by the engine menufecturer.)
Compressors
1 Veer
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN
ARE THE SOLE AND EXCLUSIVE REMEDtES. IN NO EVENT SHALL MILLER BE
Pens end Lebor
LIABLE FOR DIRECt INDIRECt SPECIAL, INCIDENTAL OR CONSEOUENTIAL
DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CON
TRACT. TORT OR ANY OTHER LEGAL THEORY.
Motor Driven Guns
Process Controllers
*
Weter Coolent
Systems
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY tMPLIED WAR
HF Unite
RANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE. AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL
THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW. CUSTOM OF TRADE OR COURSE OF DEALING, IN
Grids
Spot Welders
Loed Benks
CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EOUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.
SDX Trensformers
Running Geer/Treilere
Field
Options
TM
(NOTE: Field options ere covered under True Blue
werrenty period of the product they ere instelled in,
whichever is greeter.)
one yeer
for the
or
for
e
remelning
minimum of
Some states in the U.S.A. do not allow limitations of how long en implied warranty
feats, or the esciuxion of incidental, indirect, specisl or consequential damages, so
the above limitation
cific
5.
6 Months
6.
90
Deys
legal rights.
or
exclusion may nof apply to you. This warranty provides spe
rights may be available. but mey vary from dde to state.
and other
Befteries
Pane end Lebor
MIG Gune/TIG Torches
Plesme
Cutting Torches
In
Canada. legislation
or
remedies other then
in come
as
provinces providex for certain additional warranties
elated herein, and to the eetent that
waived, the limitations and exclusions
set out above may not
Warranty provides specific legal rights.
vary from province to province.
and other
rights
they may not be
apply. This Limited
may be available, but may
al-
i-u
RECEIVING-HANDLING
Before
unpacking equipment, check carton for any damage that may have occurred during shipment. Fi(e any Claims for loss or damage
delivering carrier. Assistance for fi)ing or Settling claims may be obtained from distributor and/or equipment manufacturers
Transportation Department.
with the
When
requesting information
Use the
or
folloWing spaces to
about this
equipment, always provide Model Designation
record Model
Designation
and Serial or
and Serial
Style Number of your unit.
or
Sty)e
Number.
The information is located
on
the
rating
label
nameplate.
Model
_________
Serial
or
Style
No.
Date of Purchase
miller 5/93a
ERRATA SHEET
FORM: OM-1 588
June 2, 1994
-
Use above FORM number when
After this manual
to data
appearing
was
printed, refinements
in
equipment design
extra manuals.
ordering
occurred. This sheet lists
exceptions
later in this manual.
CHANGES TO SECTION 3INSTALLATION
Replace
Section 3-12B.
Welding
Wire Installation: Installation Of
Optional
Wire Reel And Reel
Type
Wire
1
Retaining Ring
2
Spanner
3
Lock
4
Wire Retainer
5
Wire Reel
6
Hub
7
Hub Pin
8
ReelSupport
Nut
Remove retaining ring. Pull lock
and turn. Remove spanner nut,
wire retainer, and wire reel from
hub.
Lay wire
reel
assembly
face, and install wire
as
on
flat
sur
shown.
spanner nut until lock is in
over hole in wire retainer.
Pull lock and turn to insert locking
pin into wire retainer.
Tighten
position
Slide wire reel assembly onto hub,
and turn assembly until hub pin is
seated in hole in reel. Reinstall re
taining ring.
ST-143 478-A / ST-152 463
Figure
3-15. Installation Of
CHANGES TO SECTION 15
Replace Figure
15-1. Circuit
Replace Figure
15-2.
Optional
Wire Reel And Reel
Type
Wire
ELECTRICAL DIAGRAMS
Diagram
For Wire Feeder
(see Pages
2 and 3 on this Errata
Sheet)
Wiring Diagram
For Wire Feeder
(see Pages
4 and 5
this Errata
Sheet)
on
r
-
-
-
-
~T~&;: ~
I
C~iECTIGH FGG RE~CTE
I
(SEE FIELD DSTRLtTII)I)
PRI)IRAJ4
SELECT
DSPL2
SIDE DISPLAY
I
I
~I~I!I~I~I: ~ -1~
FRONT
CM-c
I
09
~
!~i fl~flflI! fl~i
oI~I~I~~kII
C
~I111~twiTtifl
D~DCNT
vv
o
PSIl
P842
PB44
__~.
o
0
o
RC4I/PLC4I
____________
________________
__
PARAIETER
SELECT
SELECT
I
RCIOO-I>>
PC 100-2 >>
I
I
PC6O
I
RC6O/PLG6O
H
Ii
I
~
I
I
RCIOI/PLGIOI
I
CJ
~
I
N
0000000
ci
_vvvvvvvvJ
II
I
I I~~I
P1
I
I
~I~iII~
____________
_________
__
RC6I/DATACAROJI
I
RCIOO-3))-
RCIoo-5>>-
Lvvvvv
~
RC 41
~L
RPS-8
FILTER BOARD
I
~
~
0
6
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1IP1~0cu_liC
P040
~u
P843
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)
CARD
RC6I
T
~ I
~
PARAŁTER
SELECT
PC3O
DATA
CM
o
I
6
___________
~, C1
OECRE~NT
o
I
6
________
___________
o
I
6
6
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~
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DISPLAY
IOOTO
~
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___
___________
I
~I~IdI~
_
P~AAAAAA
w
(a
C)
_______________
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LEFT/RIGHT
SELECT
~
34
o
o
P825
CM
C)
CM
0
~~777
mc
c
CABLE
PCIO
P1~GE
_______
o
o
P821
4IcR~R~ESS~ 80650
RC24
RCIO/PLGIO
LEFT
RIGHT
TRIGGER
TRIGGER
PCI I/PLGI I
PC I 2/PLC 12
uur~ ~-~
d,swxM~uRc
1
4
3
~
I IPI-G8i
~IXT40I~NT
~T.
r
C~ANT
GG
FLOW
>.IIJ
3
(CPTIGHAL)
I-I
>~
P1026
wr(~5fl ~
~l
RC23
~ 14>
>
>
)
>
13>
4
II
1 r
---H
(OPTIGHAL)
LEFT
~1W)14
~I
~)I3>
NIT)2>
>
~
TRIGGER
~fl~D
LED
TRIGGER
LEFT
SELECT
RIGHT
SELECT
PCI
LED
LEO
II
PCI
PCI
PCI
PCI
PCI 1-7
~
/7
TRIGGERDEcRE~NT
/8
TRIGGER
IICPEINT
RC2S-I
4
Rc25-e
3
L I
2
PC2O
Rc24/P1G24
~
1L
Rc25-7>
I
RC2S/P1625
CR
01
I
~
I
XTAD$NT
IPTII31
N~
~0
~Ic
I
P1G57/PLGSI
:2~I
2
~I7 ~ ~ ~I7~
~ 3~Q,3
P
I
O.E.I
<-~-<l iE-~-*I >2~<
~TICAL
:6 4-~-<6<~~6
2<14
?
GSIS.
>-~-<6~-~-
~
>~<I~
u~~-.< 5E-~-~5
>~<I 5u(~L
I
I
~
<~
S
I
I
-I
~
(1
(1
PLG57/PLG57
C12+04
<2E-~<~
TK2
COI44AI~C
~~
I
NN
~e
a~
~
2
~
E~-< 7E-~7
>A~<1i <
69
3
~ ~ ~I3(
~
E-~--<~
<3~I
RIGHT
<I
~~ir
8/~*
GS2~
E_L
Figure
Page
2
15-1. Circuit
<II
~*ii>~LL~<1
<I6.E~<6.~-~6>--~<I6(
2<14 E_.L.<4 ~ >_L..<I 4(2
I
6
<5E~-<5E-~45)--~-(15(
L
OM-1588
I-8>>--~
>>~~
I-5>>---~
I-2>>---~~~
I-6>>-~
I_3>>___~I5
PCI I-I
LED
10
l)_____~II >~.~O~SI6PV5~A)II
PLG29
PC 11-4
PC27>
PLG83j
~I4>--~I4
L
P823
c~ANT FLOW SWITD~
swn~uPc ~
dukEmo.e4T
I 1P1G8i
~
PC 16/PLC 16
RC26>>
3
SIhWP&R)l ~>
,
PC I 5/PLC IS
0
PC I 7/PIG 17
PLC83
2
I
o
5blflQ~
PLG23
>______~1 I
o
0
P824
Diagram
6
_)
For Wire Feeder
~1
R1~CTE
PEI~OAP)T
RPS-8
(OPTION)
RPS-8
SWITcH BOARD
RD I
0/PIG I 10
SHIELD
~RClIO-4
IJI~ I
5~g/
II
~~RV
It
~RCI 10-3
-~RCI 10-I
.~RclIo-5
I
0PDCANT <<RCIIO-2
I
I
o._.~uo
~,
L
I
PC8O
FILTER BOARD
9C82/P1G82
RC89/PIG7O
RC9O/PLG9O
I
I
r
cO4lR
~aZ~
I
~F
I ~ c
RC8I-C > cC/Dy (~24V.CV(
RC8I-E>Q.RRENT FEEDBAD( (IV,I0OA)IE)–f~L~E
Ic>~c
RC8I-G>flOXTA~cE (0-IOV(
RC8I-M > VCLTAGE FEEOBAD( (tv/by) IN)~~ N CQ*ECT
TO POWER
7
RC8I-F )
/0
4
~
I
I
PIN C~O~
I
I
I
I
I
I
cOIOXTDR
I
17
C~~
5C54- I
r
:~ce~-u
PC5O
I
>
,1C82-B
INTERFACE
L
9C82-3
RCGO/PLGSO
PTIDR
RDO4/PLGO4
RC82-6
Rc55/PLGSS
RC9O- I
>>~~~8~>.<
>8 ~ >...
8(
DRIVE ASSY
PICK-IP(RIGHT)
182-Il
RCS5-l
RC9O-2
Rc55-5
-
L
1C82-8
RD55-8
RC9O-4
RD55-2
III
~
.0
RC9O-5
>~B~O(~~ ~
~
DRIVE ASSY
PI~-~ (LEFT)
____
________
RC9O-6
0
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I
I
RD82-1
Rc55-4
_
i
INSTRLCTI~G)
WITH SWIPGARC
DETA$NT
RCO2/P1652
-
(SEE FIELD
rUSED
182-0
RCS I/Pt.GS I
SD~DR
H~
IDRTIONAL)
BOARD
RCO3/PLGS3
____________
W~ ~RD~
45RC70 I PLO7O
RC87
RC9O-3
SENSE CLA~#
RC89- I >
RC89-2
PfA*~
>>~
~
RC89-3>>
acw
RC80>HF
STUD
r
14
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PIN PLL~
I
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CO4O~
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__________________________________________________________________
RcS-3:
<<RC4-4~
~
~
RcO-Io:
RC4-I
COATACTOR
P.S.
RC4-9
RCA-6
F
)H
.
I
) B
5Db-I
PC I
MOTOR BOARD
CO*ECT
I
RC I/PIG I
TO POWER
RC2/PLG2
RC3/PIG3
RC4/PLG4
RCS/PLGS
RCG/PLG6
24VACCI~O
.EP1
>~
L
SD-164 541-B
OM-1588 Page 3
Pc 10
MICROPROCESSOR
PC2O
FRONT DISPLAY
RC27
PLG27
efifiuI
690(6C37-7)
430(RC37-e)
(RC37-4 I
6&I(6C37-3)
6
2
IOA~(Rt37-2
IIE(RC37-II
6
RC37
PLG37
-
6F(RC37-5)
~II
1H(RC37-6)
PLG33
)
3
20/
~LL
C
C
~I~I ~
LA
C
Figure
OM-1588 Page 4
15-2.
Wiring Diagram
For Wire Feeder
a
Is
PCI
MOTOR BOARD
II
PLG2B
LEFT
PLG3B
RIGHT
c1P19,
SD-164 540-B
U
A
C
3
OM-1588
Page
5
CHANGES TO SECTION 16
Change
Parts List
as
Dia.
Mkgs.
83-12
PARTS LIST
follows:
Part
No.
Replaced
124905
+168 104
87-
Added
87-
Added
166594
168103
Deleted
167697
010291
167700
167633
159264
133603
165934
83-13
85-24
124904
.
PLG1O3
.
135635
87-2
161714
87-10
157 113
.87-11
097924
Description
With
Quantity
RETAINER, spool support (Eff w/KE621 826)
(consisting of)
LABEL, caution falling wire reel can cause damage
NUT, spanner retaining (Eff w/KE621 826)
Eff w/KE593886
PANEL, front (Eff
w/KE623992)
91-32
154031
91-
Added
Added
167387
165799
163281
91-
Added
165798
91-
Added
163282
155 024
91-
92-2
**First
164 842
x
.088 wire
x
1.062
...
Page
6
1
1
1
Ig
(Effw/KE644333)
SPACER, locating (Eff w/KE552693)
WASHER, flat .257 ID stl (Eff w/KE644333)
SPRING, pressure arm retaining LH
(Effw/KE644333)
SPRING, pressure arm retaining RH
(Effw/KE644333)
NUT, .250-28 stl (Eff w/KE644333)
LENS, clear anti glare
label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1588
1
1
SPRING, cprsn .573 OD
digit represents page no digits following dash represent item no.
ordering a component originally displaying a precautionary label, the
+When
1
1
WASHER, fIat .625 ID nylafil (Eff w/KE623992)
KNOB, pointer (Eff w/KE623992)
WASHER, shldr .612 ID (Effw/KE623992)
RING, ring ext .625 shaft grv x .045 thk E style
(Effw/KE623992)
91-14
1
2
2
2
2
2
2
1
ARC WELDING SAFETY PRECAUTIONS
WARNING
a
ARC WELDING
be hazardous.
can
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
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.
INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
HAVE ALL
QUALIFIED PEOPLE.
ELECTRIC SHOCK
can
kill.
5.
live electrical parts can cause fatal shocks
severe burns. The electrode and work circuit is
or
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.
6.
electrically
1.
When
dry, hole-free insulating gloves and body protection.
yourself from work and ground using dry insulating
Wear
3.
Insulate
Disconnect
input power
equipment.
or
stop engine before installing
or
this
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
~I
equipment according
to its
attach
making input connections,
grounding
proper
conductor first.
7.
Turn off all
8.
Do not
equipment
when not in
use.
damaged, undersized,
worn,
use
or
poorly spliced
cables.
Do not wrap cables around your
body.
10.
Ground the
electrical
11.
Do not touch electrode if in contact with the work
12.
only well-maintained equipment.
damaged parts at once.
13.
Wear
a
14.
Keep
all
9.
mats or covers.
servicing
this
ground
Manual and national, state, and local codes.
workpiece
Do not touch live electrical parts.
2.
4.
install and
Properly
Owners
Touching
good
to a
(earth) ground.
safety
harness if
panels and
replace
or
above floor level.
working
covers
ground.
or
Repair
Use
securely
in
place.
ARC RAYS
2.
Wear
a
helmet fitted with
welding
proper shade of filter (see
a
ANSI Z49. 1 listed in
Arc rays from the welding process produce intense
heat and strong ultraviolet rays that can burn eyes
and skin. Noise from some processes can damage
3.
4.
hearing.
Safety Standards) to protect your face and
eyes when welding or watching.
Wear approved safety glasses. Side shields recommended.
Use
protective screens or barriers to protect others from flash
glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resiŒtant
material (wool and leather) and foot protection.
and
NOISE
5.
1.
Use
approved
ear
plugs
or ear
muffs if noise level is
FUMES AND GASES
can
high.
be hazardous
5.
to your health.
Welding produces fumes and gases. Breathing these
fumes and gases
be hazardous to your health.
can
6.
Keep your
2.
If inside, ventilate the
.
remove
welding
area
and/or
use
exhaust at the
7.
If ventilation is poor,
use an
4.
Read
Safety Data Sheets (MSDSs)
the
Material
manufacturers
and
fire
5.
Watch for fire, and
6.
Be
or
burns.Accidentalcontactofelectrodeorweldingwire
objects can cause sparks, overheating, or
yourself
flying sparks
unless the
sure
the
spraying
react with vapors to
galvanized, lead,
or
is removed from the
coating
is well ventilated, and if necessary, while
that
fire
keep
welding
on
a
fire
on a
extinguisher nearby.
ceiling, floor, bulkhead,
or
partition
the hidden side.
.
7.
Do not weld
8.
Connect work cable to the work
on
closed containers such
as
tanks
as
and hot metal.
or
drums.
close to the
welding area as
traveling long, possibly
practical to prevent welding current from
unknown paths and causing electric shock
.
and others from
aware
can cause
fire.
Protect
area
explosion.
can cause
or
while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give oft toxic fumes if welded.
Sparks and spatter fly off from the welding arc. The
flying sparks and hot metal, weld spatter, hot
workpiece. and hot equipment can cause fires and
to metal
1.
coated metals, such .as
on
plated steel,
weld area, the
the
coatings,
and cleaners,
WELDING
Do not weld
cadmium
approved air-supplied respirator.
instruction for metals, consumables,
degreasing, cleaning,
near
or
used for
arc to
fumes and gases.
3.
Do not weld in locations
operations. The heat and rays of the arc can
form highly toxic and irritating gases.
head out of the fumes. Do not breathe the fumes,
1.
a confined space only if it is well ventilated,
wearing an air-supplied respirator. Shielding gases
welding can displace air causing injury or death. Be
breathing air is safe.
Work in
and fire hazards.
.
2.
Do not weld where
3.
Remove all flammables within 35 ft
flying sparks
strike flammable material.
(10.7 m) of thewelding arc.
them with approved covers,
this is not
4.
can
possible, tightly cover
Be alert that welding sparks and hot materials from welding
easily go through
small cracks and
openings
to
adjacent
can
10.
can
11.
use
welder to thaw frozen pipes.
Remove stick electrode from holder
tip when
Wear oil-free
or
1.
Wear
cut off
welding
wire at
not in use.
protective garments such
as
shirt, cuffless trousers, high shoes, and
approved face
shield
or
leather
a
gloves, heavy
cap.
safety goggles. Side
shields
recommended.
injury.
Chipping and grinding cause flying
cool, they can throw oft slag.
Do not
contact
areas.
FLYING SPARKS AND HOT METAL
cause
If
9.
metal. As welds
2.
Wear proper
body protection
to
protect skin.
Sri 9/92
CYLINDERS
explode
can
if
damaged.
Keep cylinders away from any welding
3.
or
other electrical
circuits.
gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
Shielding
Never allow
Use
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
6.
Protect
1.
mechanical shocks, and
2.
excessive
7.
upright position by chaining
equipment cylinder rack to
8.
in use or connected for use.
arcs.
cylinders in
them to a stationary support
prevent falling or tipping.
Install and
from
heat,
compressed gas cylinders
a welding electrode to touch any cylinder.
only correct shielding gas cylinders, regulators, hoses, and
4.
5.
an
secure
or
Read and follow instructions
associated
Standards.
WARNING
a
ENGINE EXHAUST GASES
Engines produce harmful
ENGINE
compressed gas cylinders,
publication P-i listed in Safety
on
and CGA
equipment,
FUEL
ENGINES
can
kill.
can
fire
cause
or
equipment outside
be hazardous.
in open, well-ventilated
1.
Use
2.
If used in
a closed area, vent engine exhaust outside and
away from any building air intakes.
1.
Stopenginebeforecheckingoraddingfuel.
Do not add fuel while smoking or if unit is near any sparks
exhaust gases.
2.
explosion.
can
areas.
or
open flames.
3.
Engine
fuel is
highly
flammable.
Allow
engine to cool before fueling. If possible,
engine before beginning job.
check and add
fuel to cold
4.
Do not overfill tank
5.
Do not
allow
If fuel is
spill fuel.
for fuel to
room
spilled,
expand.
clean up before
starting
engine.
MOVING PARTS
can cause
injury.
3.
only qualified people remove guards or
troubleshooting as necessary.
Have
covers
for
maintenance and
Moving parts, such as fans, rotors, and belts can
fingers and hands and catch loose clothing.
4.
cut
5.
I.
Keep all doors, panels,
securely in place.
2.
Stoc enaine before
covers,
installing
and
guards
closed and
connecting
unit.
ir~ ~
.
.~
Reinstall
panels
or
1.
2.
Always
wear a
Stop engine
face shield when
before
Do not
gases.
5.
Observe correct
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
1.
generate explosive
can
moving
doors when
servicing
is
working
disconnecting
or
on a
battery.
connecting battery
cables.
Do not allow tools to
r adiator
and tools away from
guards and close
starting engine.
4.
The coolant in the
under pressure.
/
Keep hands, hair, loose clothing,
3.
acid and
disconnect
battery.
finished and before
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin.
Batteries contain
during servicing,
parts.
6.
or
To prevent accidental starting
negative () battery cable from
use
sparks when working
cause
welder to
charge batteries
polarity (+
and )
on
or
on a
battery.
jump start vehicles.
batteries.
Donotremoveradiatorcapwhenengineishot.Allowengine
to cool.
gloves and put a rag
2.
Wear
3.
Allow pressure to escape before
over
cap
area
when
removing
cap.
be very hot and
completely removing cap.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49.1, from
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and
American
Superinten
Printing Office, Washington,
Safe
Handling
of
Compressed Gases
in
Cylinders, CGA Pamphlet
P-i, from Compressed Gas Association, 1235 Jefferson Davis High
way, Suite 501, Arlington, VA 22202.
Health Standards, OSHA 29 CFR 1910, from
dent of Documents, U.S. Government
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 I R3.
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, Ameri
Safe Practices For OccupafionAnd EducationalEyc And Face Protec
Welding Society Standard AWS F4.i 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.
National Electrical Code, NFPA Standard 70, from National Fire Pro
Cutting And Welding Processes, NFPA Standard 518, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
can
tection Association,
srI 9/92
Batterymarch Park, Quincy,
MA 02269.
PRECAUTIONS
SECURITE
DE
MISE EN GARDE
PROTEGEZ-VOUS,
soudage,
precautions.
LE SOUDAGE
A LARC
est
dangereux.
AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES
(A MOINS QUILS NAIENT C0NSL,LTE UN MEDECIN).
AINSI QUE LES
NI LES PORTEURS DE STIMULATEUR CARDIAQUE
ENFANTS SAPPROCHER,
Le
A LARC
EN SOUDAGE
Ia plupart des activitØs industrielles, expose a certains risques. Le soudage nest pas dangereux lorsquon prend des
consignes di~ØcuritØ suivantes ne font que rØsumer linformation contenue dans les normes ØnumØrØes ci-aprŁs. Lisez et
comme
Les
respectez toutes
ces normes.
SEULES DES PERSONNES
OUALIFIEES
DOIVENT FAIRE DES TRAVAUX
DINSTALLATION,
DE
REPARATION,
DENTRETIEN
ET
DESSAI.
LELECTROCUTION
Une
peut Œtre mortelle.
decharge electrique peut
vous
tuer
briDler gravement. LØlectrode et le circuit de
sont sous tension au
dØmarrage.
ou
Le circuit dentrØe et
sous
En soudage
automatique ou semi-automatique avec fil, ce dernier, le support de
roquette, le logement des galets dentraInement et toutes les piŁces
des
metalliques
en
contact
matØriels mal installØs
avec
ou
Ia
mise
le tilde
mal mis a Ia terre sont
3.
lsolez-vous de Ia tle a souder et de Ia mise ala terre
de
4.
secs
petits tapis isolants ou autres.
prise dentrØe des matØriels
DØconnectez Ia
moteur avant de les installer
ou
et non trouŁs.
ou
au
arrŒtez leur
ultraviolets intenses,
soudage produit
susceptibles
I
proteger le visage
11.
=~
3.
4.
A
de brler
et les yeux
que laire
Le SOUDAGE peut
FUMEES
sont
causer un
incendie
explosion.
metallique peut provoquer des Øtincelles,
avec
le
contact
ou
remplacez
es
travaillez
vous
en
hauteur.
panneaux et les capots.
un
Øchauffement
blessures
ou
de cloisons de
IØblouissement; avertissez
pas regarder arc.
tissus ignifuge durable
en
(lame
et
cuir)
ou
Ia mort. Assurez-vous que
air
approuvØs
est propre a Ia
respiration.
6.
Ne soudez pas a
proximitØ dopØrations
de
dØgraissage,
de
nettoyage ou de pulvØrisation. La chaleur et les rayons de Iarc
peuvent reagir avec des vapeurs et former des gaz hautement
toxiques
7.
et irritants.
Ne soudez pas de tOles galvanisØes ou plaquees en p10mb ou
en cadmium sans es avoir grattees a fond, car ces mØtaux, et
tout revØtement
qui en contient, peuvent alors dØgager des
fumØes toxiques. Assurez-vous dune bonne ventilation et portez
5.
respirateur a adduction dair si
7.
cest
Mefiez-vous des incendies et gardez
Ia main.
un
nØcessaire.
extincteur a
portee de
Noubliez pas quune
soudure sur un plafond, un plancher, une
paroi peut en enflammer Iautre ctØ.
Ne soudez pas un recipient termØ, comme un reservoir ou un
cloison
ou une
tonneau.
8.
Connectez le cable de soudage le plus pres possible de Ia tote
de soudage pour empOcher le courant de suivre un parcours
long et inconnu, et prØvenir ainsi tes risques dOlectrocution et
dincendie.
9.
Ne faites pas degeler des tuyaux avec un chalumeau.
Videz votre carquois porte-electrodes ou coupez le fit au tubecontact aprŁs le soudage.
2.
Ne soudez pas dans un endroit oiD des Øtincelles peuvent
atteindre des matØriaux inflammables.
10.
Enlevez toutes les matiŁres intlammables dans un rayon de
10,7 metres autour de Iarc, ou couvrez-les soigneusement avec
11.
Øtincelles et les
approuvØes.
ne
Portez des vØtements
rideaux
ou
Ne travaillez dans un espace confine que sit est bien ventilØ;
sinon, portez un reSpirateur adduction dair. Les gaz protecteurs
de soudage peuvent dØplacer loxygŁne de lair et causer des
ou un
MØfiez-vous des Øtincelles et des Øclats brCilants, susceptibles
de pØnØtrer dans des aires adjacentes par de petites ouvertures
observateurs de
de
coups darc
5.
ProtØgez-vous,
projections.
es
soudage
es
Portez un casque antibruit ou des bouchons doreille
site niveau de bruit est ØlevØ.
1.
autres, contre
de
5.
incendie.
fissures.
en
et des chaussures de sØcuritØ.
6.
elles peuvent causer un incendie et des brlures. Le
accidentel de IØlectrode avec un objet
ou
Œtes
vous
harnais de sØcuritØ Si
Entourez Iaire
es
4.
contact
des bches
un
protection contre
de
produit des Øtincelles et des projections. Avec Ia
chaleur intense degagee par Ia tote et es matØriels,
4.
de
sont recommandØes.
3.
Larc
3.
prise
que vous observez IexØcution dune soudure.
Portezdes lunettes de sØcuritØ approuvØes. Des Øcrans latØraux
un
es
de
-
2.
lorsque vous soudez ou
soudage est bien
ventilØe ou que les fumØes et es vapeurs sont aspirØes a arc.
Si Ia ventilation est mauvaise, portez un respirateur a adduction
dair approuve.
Lisez es fiches signalØtiques et les consignes du fabricant
relatives aux mØtaux, aux produits consummables, aux
revŒtements et aux produits nettoyants.
ainsi que
si
Nutilisez que des matØriels en bon Øtat. ROparez
les piŁces endommagØes.
Fermez solidement tous
chaleur et des rayons
les yeux et a peau. Le
Ia sante.
soudage dØgage des vapeurs et des fumØes quil
est dangereux de respirer.
1. Ecartez le visage pour Øviter de respirer les
ou une
ou
soudage (terre).
Portez
Le
assurez-vous
Ne touchez pas a lØlectrode
13.
une
Les VAPEURS ET LES
lintØrieur,
ØpissØs
pas de cables autour de votre corps.
Mettez ala terre Ia tote a souder au moyen dune bonne
12.
fumØes.
2.
mat
et
sur-le-champ
dangereuses pour
I!
provinciaux
terre.
peut
bruit cause par certains procØdØs peut endommager louIe.
1. Portez un casque de soudeur avec Øcran filtrant de teinte
appropriee (consultez Ia norme ANSI Z49 indiquØe ci-apres),
pour vous
ala terre selon le
den faire Ientretien.
Le RAYONNEMENT DE LARC
de
aprŁs utilisation.
endommagØs,
Nenroulez
9.
es mettre
codes nationaux,
8.
moyen
brUler les yeux et Ia peau; le BRUIT peut
endommager IouIe.
Larc
locaux applicables.
ArrŒtez tous les matØriels
circuit de
2.
es
Nutilisez pas de cables uses,
calibre trop petits.
10.
dangereux.
matØriels eta
ces
7.
sont sous tension. Des
soudage
Ne touchez pas a des piŁces sous tension.
Portez des gants et des vØtements isolants,
1.
6.
marche.
en
Veillez a installer
manuel dutilisation et
soudage
les circuits internes des matØriels sont aussi
tension
5.
vous
Portez des vOtements protecteurs non huileux, tels des gants en
cuir, une chemise Øpaisse, un pantalor, sans revers, des
chaussures montantes et
un
casque.
ETINCELLES
LES
causer
Le
meulage produisent
et le
des Øclats de
endommagØes peuvent
Les bouteilles contiennent des gaz protecteurs sous
haute pression. DesbouteillesendommagŁespeuvent
exploser. Comme les bouteilles font normalement
de
procede
soudage,
traitez-les
avec
2.
3.
cadre fixe pour es empŒcher de tomber ou dŒtre renversØes.
les bouteilles de tout circuit Ølectrique ou de soudage.
6.
7.
8.
P-i de Ia
DECHAPPEMENT DES MOTEURS
ETRE MORTELS.
Les moteurs
1.
produisent des gaz dØchappement
2.
Le CARBURANT peut causer
incendie
un
3.
Le carburant est hautement inflammable.
1. ArrŒtez le moteur avant de verifier le niveau de
carburant ou de faire le plein.
en
fumant
dune
proche
.ou
4.
Si
vous
utilisez des machines dans un. endroit confine, les
dØtincelles ou dune flamme nue.
Si cest possible, laissez le moteur refroidir avant de faire le plein
de carburant Cu den verifier le niveau au debut du soudage.
Ne faites pas le plein de carburant a ras bord :~prevoyez de
son
expansion.
Faites attention de ne pas renverserde carburant. NettOyez tout
carburant renversØ avant de faire dØmarrer le moteur.
protecteurs ou des capots pourfaire lentretien
des blessures.
4.
3.
dangereux.
Utilisez des machines a lextØrieur dans des aires ouvertes et
bien ventilØes.
lespace pour
5.
source
PIECES EN MOUVEMENT peuvent
Des
causer
publication
ci-dessous.
dØchappement doivent Œtre envoyØes a lextØrieur, loin
des prises dair du btiment.
ou
explosion.
Ne faites pas le plein
normes
fumØes
nocifs.
une
et aux matØriels connexes, ainsi que Ia
CGA, ŁnumØrees dans les
Les MOTEURS peuvent Œtre
PEU VENT
2.
ces matØriels et les piŁces connexes doivent Œtre en
bon etat.
Ne mettez pas le visage devant le robinet de bouteille en
louvrant.
Remettez le chapeau de bouteille aprŁs utilisation.
Lisez et respectez los consignes relatives aux bouteilles de gaz
Eioignez
Les GAZ
1.
tout contact entre une bouteille et une electrode.
Nutilisez que des bouteilles de gaz protecteur, des dØtendeurs,
des flexibles et des raccords concus pour chaque application
comprimØ
MISE EN GARDE
2.
Portez
spØcifique;
soin.
Les bouteilles doivent Œtre protegees contre les sources de
chaleur intense, les chocs et les arcs de soudage.
EnchaInez verticalement es bouteilles a un support ou a un
1.
EmpŒchez
5.
exploser.
du
4.
1.
des blessures.
piquage
Les BOUTEILLES
partie
2.
metaL En refroidissant, Pa soudure peut projeter du laitier.
un Øcran facial ou des lunettes a coques approuvees.
Des Øcrans latØraux sont recommandØs.
Portez des vŒtements de protection individuelle appropriØs.
ET LES
PROJECTIONS BRULANTES peuvent
Des piŁces en mouvement, telles des ventilateurs,
des rotors et des courroies peuvent couper les doigts
et es mains, ou accrocher des vŁtements amples.
5.
Assurez-vous que les portes, les panneaux, les capots et les
protecteurs sont bien fermŁs.
Avant dinstaller ou de connecter un systeme, arrŒtez-en le
6.
ou le depannage
nØcessaire.
Pour empecher un demarrage accidentel dun systŁme pendant
lentretien, dŁbranchez le cable daccumulateur a Ia borne
negative.
moteur.
pas les mains ou les cheveux do piŁces en
mouvement; elles peuvent aussi accrocher des vØtements
amples et des outils.
RŁinstallez les capots ou es protecteurs et fermez les portes
aprŁs des travaux dentretien et avant de faire dØmarrer le
Seules des personnes qualifiees doivent dØmonter des
moteur.
Des
ETINCELLES peuvent
lelectrolyte
et
4.
travaillant
sur
5.
un accumulateur.
ArrŒtez le moteur avant de connecter ou de dŁconnecter des
cables daccumulateur.
Nutilisez que des outils anti-Øtincelles pour travailler sur un
accumulateur.
Nutilisez pas un paste de soudage pourchargerun accumulateur
Cu connecter provisoirement un vØhicule.
Utilisez Ia polarite correcte (+ et -) de laccumulateur.
DE
1.
Ntez
FAIRE EXPLOSER
UN ACCUMULATEUR; LELECTROLYTE
DUN
ACCUMULATEUR peut brUler Ia peau et les
2.
3.
yeux.
Les accumulateurs contiennent de
degagent des
1.
vapeurs
Portez toujoUrs
La
VAPEUR
un
explosives.
Øcran facial
ET
LE
en
LIQUIDE
REFROIDISSEMENT BRULANT SOUS
PRESSION peuvent brler
Napprochez
Ia peau et les
pas le bouchon de radiateur tant que le moteur
refroidi.
2.
Mettez des
3.
Laissez Pa
eux
na
pas
gants et posez un torchon sur le bouchon pour lter.
pression sØchapper avant dter completement le
bouchon.
liquide de refroidissement dun radiateur peut etre
brlant et sous pression.
Le
PRINCIPALES NORMES DE
Welding and Cutting norme ANSI Z49. 1, American Welding
Society, 550, N.W. LeJeune Rd., Miami FL 33128.
Safety in
Safety and Health Standards OSHA 29 CFR 1910, Superintendent
of Documents, U.S. Government Printing Office, Washington D.C.
20402.
Recommended Safe Practices For the Preoaration For Welding and
Cutting of Containers That Have Held Hazardous Substances norme
AWS F4.1, American Welding Society, 550. NW. LeJeune Rd.,
SECURITE
Safe Handling of Compressed Gases in Cylinders document P-i,
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, Va 22202.
Code for Safety in Weldina and Cutting norme CSA Wi 17.2, Asso
ciation canadienne de normalisation, Standards Sales, 176 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1 R3.
Miami FL 33128.
Safe Practices for Occupation and Educational Eve and Face Protec
norme ANSI Z87. 1 ,American National Standards Institute, 1430
Broadway, New York, NY 10018.
National Electrical Code norme 70 NFPA, National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
Cutting and Welding Processes norme 51B NFPA, National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
srlf 9/91
Ii~n,
EMF INFORMATION
Considerations About Welding And The Effects Of Low
NOTE ~
Magnetic
The
To
of the U.S.
procedures:
following is a quotation from the General Conclusions Section
Congress. Office of Technology Assessment, Biological
Effects of Power Frequency ~lectric & Magnetic Fields
Paper, OTA-BP-E-53 (Washington, DC:
there is now
Government Printing Office, May 1989): .
large volume of scientific findings based on experiments
.
cellular level and from studies with animals and
Electric And
reduce
fields
magnetic
in
the
workplace,
1.
Keep cables
2.
Arrange
3.
Do not coil
4.
Keep welding power
practical.
5.
Connect work clamp to workpiece
together by twisting
close
or
use
taping
the
following
them.
U.S.
Background
.
Frequency
Fields
a
very
at the
people which clearly
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 ofter clear science-based advice on strategies to minimize
or avoid potential risks.
establish that low
cables to
or
one
side and away from the operator.
drape cables around the body.
source
and cables
as
as
far away
as
close to the weld
as
possible.
About Pacemakers:
The
above
procedures
recommended for
are
pacemaker
among
wearers.
complete information.
those
also
normally
Consult your doctor for
modlo.1 4/93
TABLE OF CONTENTS
SECTION 1
SAFETY IN FORMATION
SECTION 2
SPECIFICATIONS
SECTION 3INSTALLATION
3-5.
Equipment Connection Diagram
Installing Swivel Into Pipe Post
Installing Control Box Onto Swivel
Installing Boom And Reel Support
Installing Wire Guide Extension
3-6.
Wire Guide And Drive Roll Installation
3-1.
3-2.
3-3.
3-4.
2
3
3
4
4
5
Gun Connections
3-7.
Welding
3-8.
Wire Feed Motor And Gas Valve Control Connections
6
3-9.
Control Connection
7
6
Gas And Weld Cable Connections
3-12.
Shielding
Removing Safety Collar And Adjusting
Welding Wire Installation
3-13.
Motor Start Control
3-10.
3-11.
3-14.
Threading Welding
8
Boom
9
10
11
Wire
12
SECTION 4GLOSSARY
SECTION 5
14
OPERATION
5-1.
Front Panel Controls
5-2.
Side Panel Controls
19
5-3.
Rear Panel Controls
20
5-4.
Setting Switches
SECTION 6STEPPING
17
On 450 Ampere lnverter Model
Welding
Power Source
21
THROUGH THE MICROPROCESSOR CONTROLS
6-1.
Front Panel Microprocessor Controls
22
6-2.
Side Panel
24
Microprocessor
Push Buttons
SECTION 7- STANDARD PULSE WELDING PROGRAMS
SECTION 8
8-1.
8-2.
27
GETTING STARTED
Welding With Only Front Panel Controls
Setting Sequence Pulse Welding Parameters On Side
36
Panel
Display
37
OM-1580
10/93
SECTION 9-TEACHING A PULSE WELDING PROGRAM
9-1.
Pulse Waveform
9-2.
Teach Points
9-3.
9-4.
Teaching
Changing
41
Explained
Explained
42
Welding Program
Adaptive Pulse Welding
43
A Pulse
To
46
SECTION 10.- TEACHING A MIG WELDING PROGRAM
47
SECTION 11
SETTING DUAL SCHEDULE PARAMETERS
SECTION 12
USING THE OPTIONAL DATA CARD
12-1.
12-2.
Installing Data Card
Using The Data Card
51
53
53
SECTION 13SETUP
13-1.
Setup
Flow Chart
57
13-2.
Using Setup Displays
58
13-3.
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
58
13-4.
13-5.
13-6.
13-7.
13-8.
13-9.
13-10.
13-11.
13-12.
13-13.
13-14.
Units For Wire Feed
Speed
13-15.
Selecting
13-16.
Selecting Bench Or Boom Model Type
Resetting Memory
Selecting Voltage Error Shutdown
Selecting Program Name Feature
13-17.
13-18.
13-19.
And Motor
13-20. Software Version Number
SECTION 14
14-1.
Routine Maintenance
Replacing
Overload Protection
14-4.
Error
62
62
63
63
64
65
65
66
Type
67
67
68
68
69
69
Displays
Diagnostic Indicator
Troubleshooting
72
LEDs
SECTION 16
PARTS LIST
Reel
16-3. Control Box
16-4. Panel, Front
76
80
16-1. Main
Assembly
Support, Hub &
73
74
ELECTRICAL DIAGRAMS
16-2.
71
71
SECTION 15
Figure
Figure
Figure
Figure
Figure
61
70
The Hub Assembly
14-3.
14-6.
60
MAINTENANCE & TROUBLESHOOTING
14-2.
14-5.
59
83
84
w/Cornponents
87
Assembly
Assembly
Side
16-7.
Panel,
w/Components
Figure
88
Table 16-1. Drive Roll And Wire Guide Kits
93
16-5. Boom
Figure 16-6. Wire
Drive
90
92
SAFETY IN FORMATION
SECTION 1
modl.1 2/93
Read all
Obey
all
this manual.
safety messages throughout
safety messages
Learn the
meaning
to avoid
injury.
of WARNING and CAUTION.
1
Safety
Alert
2
Signal
Word
2
2
a WARNING
L~
ELECTRIC SHOCK
can
kiII.~~
beforej~
WARNING means possible death
or serious injury can happen.
a CAUTION
~
nstalling
input
or
power
servicing
CAUTION
_______________________________
MOVING PARTS
Oo not touch live electrical parts
Oisconnect
Symbol
injury
injure.
can
and
covers
means possible minor
equipment damage can
happen.
Keep away from moving parts.
4
Keep all panels
or
closed
3
Statement Of Hazard And
Result
4
Safety
when operating
/
Instructions To Avoid
Hazard
5
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
5
Hazard
6
Safety
Read
~
NOTE
Turn Off switch when
safety
using high frequency.
NOTE
Special
ation
1-1.
Figure
SECTION 2
Safety
blocks for each sym
bol shown.
7
7H
Symbol (If Available)
Banner
instructions for best oper
not related to
safety.
Information
SPECIFICATIONS
Table 2-1. Wire Feeder
Specification
Type Of Input
Power From
Description
Welding
24 Volts AC. 10
Single-Phase
Amperes, 50/60 Hertz
Power Source
Maximum Weld Circuit
Welding
Power Source
Wire Feed
100 Volts, 750
Type
Constant
Amperes,
Voltage (CV) DC,
.023 Thru 1/8 in
Range
Gas Metal Arc
Processes
With Contactor
(0.6 To 3.2 mm)
(GMAW). Gas
12 ft
Height
Duty Cycle
Metal Arc
-
Pulse
(GMAW-P), Flux Cored
Arc
Welding (FCAW)
lOft(3.1 m)
Input Power Cord
Maximum
100%
Standard: 5OTo 780 ipm (1.3 To 19.8 mpm)
High Speed: 92 To 1435 ipm (2.3 To 36.5 mpm)
Low Speed: 13 To 213 ipm (0.3470 5.38 mpm)
Speed Range*
Wire Diameter
Welding
Rating
With 4 ft
(1.2 m)
16 ft
(3.7 m) Boom
17ft(5.2 m)
21 ft
Net: 207 lb
Net: 280 lb
(4.9 m) Boom
(6.4 m)
Post
Weight
Ship:
Vertical Lift Of Boom
These
are
wire feed
(94 kg)
(144 kg)
Ship:
318 lb
Horizontal To
60
Above Horizontal
speed ranges for GMAW. While Pulse welding.
wire feed
411 lb
(127 kg)
(186 kg)
Horizontal To
speed ranges may be
more
60
Above Horizontal
limited
(see Section 9).
OM-1588
Page
1
SECTION 3INSTALLATION
3-1.
Equipment Connection Diagram
WARNING
a
CYLINDERS
can
explode
if
ELECTRIC SHOCK
damaged.
electrical circuits.
Never touch
cylinder
with
Always secure cylinder
other stationary support.
HOT SURFACES
can
Allow gun to cool before
welding
to
kill.
Turn Off wire feeder and welding power source, and
before
disconnect
input
power
making
connections.
electrode.
running gear, wall,
can
Do not touch live electrical parts.
Keep cylinders away from welding and other
or
The welding wire, drive rolls, drive assembly, and all
metal parts touching the welding wire are electrically
live when welding or feeding wire using gun trigger.
burn skin.
touching.
Have
only qualified persons
install this unit.
wfwarn91
2/93
Power Source
1
Welding
2
Remote 14 Connections
3
Negative ()
Weld
Output
Cable
2
4
Positive (+) Weld
Output
Cable
4
5
Workpiece
6
Voltage Sensing Clamp
7
Weld Control
8
Boom
9
Gun
10
Swivel
11
Pipe Post
12
Gas Hoses
13
Gas
And Base
12
Supplies
11
10
9
5T-800 173
Figure
OM-1 588
Page
2
3-1.
Typical System Connections
3-2.
Installing Swivel
a
I.
Into
Pipe
Post
WARNiNG
FALLING
PRESSURE
SPRING
OF
RELEASE
WITHOUT BOOM ATTACHED can cause
serious personal injury.
Do not
remove
safety collar until
instructed to do
BOOM
personal injury
can
and
serious
cause
equipment damage.
mount pipe post to base that can support
of unit with boom in horizontal position.
Securely
weight
so.
Use proper
into place.
for
equipment
lifting
1
Swingpak
2
Pipe
3
Steel Bolt
swivel and boom
Base
or
CBC Cart
5
4
Secure
Post With Base
as
shown
using
as a
mini
1/2 in diameter SAE grade 5
mum
steel bolts.
4
Swivel
Insert
Assembly
into
pipe post.
Lubricate
swivel.
5
3
Safety Collar
Do not
remove
until instructed to.
-
Tools Needed:
~ 3/4
in
ST-152382
Figure
3-3.
Installing Control
3-2. Swivel Installation
Box Onto Swivel
1
Weld Control
2
Bracket
3
Screw
Bracket and
onto
4
installed
screws are
bottom of
control at
factory.
Swivel
Loosen screws. Place control on
swivel and slide forward.
Tighten
screws.
2
3~
4
ST-BOO 174
Figure
3-3. Control Box Installation
OM1588
Page 3
3-4.
InstaHing
Boom And Reel
Support
READ SAFETY BLOCKS at start of
Section 3-2 before proceeding.
1
Swivel Plates
2
Yoke
Remove
plates
3
7
hardware
and
swivel
Boom
Set boom into swivel
shown.
as
Yoke Pin
4
Install
ter
from
yoke.
Install cot
pin through yoke.
pin and spread ends.
5
Bolt
Install
bolt,
one
half turn.
6
Locking
Install
and nut.
and back bolt off
washers,
lighten hardware,
Knob
locking
knob
but
do
not
tighten.
7
Reel
Support
Install reel support.
Tools Needed:
~ 3/8,3/41n
S~-153 170
Figure
3-5.
Installing Wire Guide
3-4. Boom Installation
Extension
1
Wire Guide
2
Bolt
Fitting
3
Monocoil Liner
4
Wire Guide Extension
lighten bolt to secure liner in wire
guide fitting. Do not overtighten
bolt and crush liner.
Repeat procedure
for
opposite
side.
Tools Needed:
~T.~~J==~O
3/8 in
5T-152 383
Figure
OM-1588
Page
4
3-5. Wire Guide Extension Installation
Wire Guide And Drive Roll Installation
3-6.
a
WARNING
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Turn Off wire feeder and
welding
power
source,
and disconnect input power before
inspecting
installing.
or
wtwłrnl.1 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
wire
2
installing
guides (see Figure 3-7).
Wire Guide
Loosen wire
Securing Screws
guide
screws.
3
Inlet Wire Guide
4
Intermediate Wire Guide
Insert
intermediate guide until
flange on guide rests against cast
ing. and secure with guide screw.
Install drive rolls (see
Figure 3-7).
for
Repeat procedure
opposite
side of wire feeder.
Tools Needed:
Ref. ST-137 391.F / ST.142 597A
Figure 3-6. Wire Guide
B.
Installation
Drive Roll Installation
When
chaRging
check
drive
Table
5
wire size
roll
or
size
type,
(see
16-1).
1
Spring Shaft
2
Drive Roll Nut
3
Drive Roll Carrier
Turn all nuts
one
Carrier
click until lobes of
nut line up with lobes of drive roll
carrier.
4
Drive Roll
Slide drive rolls onto drive roll carri
ers.
Turn nut
5
Drive
Close
4
one
click.
Assembly Cover
cover.
Repeat procedure
~
for
opposite
side of wire feeder.
2
3
ST.142 597-A
Figure
3-7. Drive Roll Installation
OM-1588
Page
5
3-7.
Welding
Gun Connections
WARNING
a
___
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Turn Off wire feeder and welding power
source, and disconnect
input power before inspecting
installing.
or
wfw~rn1 .1 2/93
I
Drive
2
Gun
3
Gun Connector
Loosen
Assembly Cover
Securing Knob
securing knob.
Insert gun
connector until it bottoms
drive
4
assembly. Tighten
Gun Trigger Plug
5
Gun
Trigger Receptacle
Insert plug into
free-hanging recep
tacle and
3
against
knob.
6
tighten threaded
Trigger Cord
7
Trigger Plug
8
Weld Control
collar.
Trigger
Receptacle
4
Insert plug into receptacle and
tighten threaded collar.
Repeat procedure for gun on oppo
site drive assembly.
Ref. ST 152 466 / Ref. ST.800 178 / Ref. ST.800 175
Figure
3-8.
3-8. Gun And
Trigger
Lead Connections
Wire Feed Motor And Gas Valve Control Connections
Figure
OM-1588
Page
6
3-9. Boom Connections
3-9.
Control Connection
1
17-Pin
2
Keyway
Receptacle
To connect
interconnecting cord to
receptacle, align keyway, insert
plug, and tighten threaded collar.
Weld Current Sensor
3
tacle
35 ft
ing
Recep
Op
With Field
Only)
tion
4
(For Use
(10.6 m) Voltage Sens
Lead
Connect
workpiece
to
(see
Figure 3-1).
5
Threaded Collar
6
14-Pin
Plug
To connect
plug to matching recep
tacle on welding power source,
align keyway. insert plug, and tight
en
To
Signals Supplied
14-Pin Plug:
threaded collar.
Welding
Power
Source
Through
Contactor Control
A
24 volts
B
Contact closure to pin A completes the 24 volts
ac.
ac con
tactor control circuit.
G
Circuit
common
for 24 volts
ac
circuit.
Voltage Control
C
Command
D
Control circuit
E
signal;
+10 volts dc.
common.
Remote power
command
feeder
0 to +10 volts
source voltage
(potentiometer wiper or
Signals Supplied
17-Pin Receptacle:
To
Welding
Power
Source
dc).
Through
Output Control
Remote
CV, 0 volts dc
C
CC/CV select; +13 thru +24 volts dc
CC.
G
Arc control/inductance control; 0 to +10 volts dc.
Signals Supplied By Welding
Remote
E
from
signal
=
=
Power Source:
Metering
Actual weld current output
signal;
i-i
volt dc
=
100
amps.
M
Actual weld
voltage output signal;
+1 volt dc
=
10 volts
dc.
Feedback
Signals
F
Current feedback 0-10 volts dc; I volt per 100 amperes.
H
Voltage
The
feedback 0-10 volts dc; 1 volt per 10
remaining pins
are
arc
volts.
not used.
5T.800 177 I Ref. 5-0512/ S-0003-A / S-0628
Figure
3-10. Control Connections With Pin Information
OM-1588
Page
7
Shielding Gas
3-10.
And Weld Cable Connections
WARNING
a
CYLINDERS
can
explode
from
Keep cylinders away
if
E LECTRIC SHOCK
damaged.
and
welding
other
electrical circuits.
Never touch
cylinder
Turn Off wirefeeder and
with
Always secure cylinder
other stationary support.
welding
to
electrode.
running gear, wall,
k11.
can
Do not touch live electrical parts.
disconnect
input
powersource, and
before inspecting or
welding
power
installing.
or
BUILDUP OF SHIELDING GAS
health or kill.
Shut off
shielding gas supply
can
when not in
harm
use.
warn4 I 9/91 / wfwarnl.1 2/93
A.
Connecting
Weld Cables And Gas Hose
Tools Needed:
~ 5/8
in
Ref. ST-153 175.A
The weld cables and
tend 10 ft
(3m) from
gas hoses
the boom.
shielding
ex
If the welding power source or gas supply are
further from the boom, extend cables and
hoses as follows:
I
Bolt
together weld
cables from
welding
pow
Connect boom
and boom. Use electrical tape and
supplies
insulated
sleeving
boom have 5/8-18
to cover connection.
5
3
Shielding Gas
Sleeving
4
Figure
OM-1588
Page
8
3-11.
Boom
Shielding
Shielding
right-hand
Supplied Shielding
Connect
Weld Cables
Insulated
or
Gas V
threads.
Adapter
Extension Hose
supply,
2
shielding gas hoses to gas
extension. The hoses from the
er source
Gas
Hose(s)
single
end
fitting
of V
adapter to gas
shielding gas
of adapter.
and connect boom
hoses to
fittings
Gas And Weld Cable Connections
on
V end
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
Cap
2
Cylinder
Remove
2
Valve
stand
cap,
valve, and open valve
to
side
of
slightly. Gas
flow blows dust and dirt from valve.
Close valve.
I--
3
Cylinder
4
Regulator/Flowmeter
3
Install
face is vertical.
so
Gas Hose Connection
5
Fitting
has
5/8-18
threads. Install gas hose
to Figure 3-11.
OR
Argon
Gas
6
.2
Flow
right-hand
according
Adjust
Typical flow
rate is 20 cfh
(cubic
feet per hour). Check wire
ufacturers
recommended
L
man
flow
rate.
4
7
CO2 Adapter
8
0-Ring
.3
7
8
Install
adapter with 0-ring between
and
regulator/flowmeter
CO2
Tools Needed:
~ 5/8. 1-1/8
in
CO2 Gas
Figure
3-11.
Removing Safety
A
3.12.
Do not
ssb31
ST-158 697.A
12/92
Typical Regulator/Flowmeter Installation
Collar And
Adjusting
Boom
WARNING
RELEASE
OF
SPRING
PRESSURE
WITHOUT BOOM ATTACHED can cause
serious
cylinder.
personal injury.
remove
safety collar until
instructed to do
FALLING
BOOM
personal
in jury and
Adjustment rod
yoke.
so.
can
be threaded
must
1
cause
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
Pull boom down
move
Tools Needed:
.~
as
3
Threaded Rod
3
Jam Nut
jam nut and turn threaded
rod until boom balances. Tighten
jam nut. Be sure several full
threads are through yoke to pre
vent boom falling.
4
Increasing Spring
Decreasing Spring
Pressure For A
Heavy Gun
Pressure For A
3-13. Boom
re
follows:
2
2
Figure
and
Loosen
Rod
1-1/8 in
slightly
collar. Boom should
balance in any position from hori
zontal to 60 degrees above hori
zontal. If necessary, adjust boom
Iv
E
safety
movement.
Light Gun
Yoke
Retain
safety collar for use in
assembling or moving boom.
dis
ST.142 599-B
Adjustments
OM-1588
Page
9
3-12.
A.
Welding Wire Installation
Installation Of
Spool-Type
Wire
1
Retaining Ring
2
Wire
3
Hub
Remove
spool
Spool
retaining ring
and slide
onto hub.
Hub Pin
4
Turn
spool until hub pin fits hole
spool. Reinstall retaining ring.
for
Repeat procedure
in
opposite
side.
2
ST-153
Figure
B.
Installation Of
Optional
3-14. Installation Of
Wire Reel And Reel
Type
Spool-Type
171
Wire
Wire
Retaining Ring
1
6
7
2
Spanner Nut
3
Wire Retainer
4
Wire Reel
5
Hub
6
Hub Pin
7
Reel
Remove
Support
retaining ring
and wire
reel
assembly (wire reel, wire re
tainer, and spanner nut) from hub.
4~
8
Wire Installation
Lay
wire reel
assembly
on
flat
sur
face. and install wire as shown.
Slide wire reel assembly onto hub,
and turn
assembly
until hub
pin is
seated in hole in reel. Reinstall
re
taining ring.
Repeat
procedure for opposite
side.
3
2
/~ ~ffl
ST-i 43 478 / ST-I 52 463
Figure
OM-1588
Page
10
3-15. Installation Of
Optional Wire
Reel And Reel
Type
Wire
C.
Hub Tension
Adjusting
Turn Off unit and
welding
power
source.
1
Hex Nut
2
Spool
2
Grasp spool
using
while
a
in one hand and turn
wrench to
adjust
hex
force is needed
to turn spool, tension is set.
nut. When
a
slight
Repeat procedure
for
opposite
side.
Tools Needed:
~
5/6 in
ST-153 173
Figure
3-16.
Adjusting
Hub Tension
3-13. Motor Start Control
WARNING
a
E LECTRIC SHOCK
can
Do not touch live electrical
S
kill.
parts.
Turn Off wire feeder and welding power source, and
disconnect input power before inspecting or
STATIC ELECTRICITY
on
ca n
damage parts
circuit boards.
Put
on
boards
grounded
or
wrist
strap BEFORE handling
parts.
installing.
wfwarnl.1
2/93
To
change wire feed starting speed
proceed as follows:
Turn Oft wire feeder and
welding
source.
power
Remove wrapper.
1
2
Motor Board PCI
Motor Start Control Poten
tiometer R70
Turn
potentiometer clockwise to
crease
in
time it takes the motor to
ramp up to speed. Remove protec
tive white rubber cap before mak
ing adjustment. Adjust potentiome
using a small nonconduc
ter R70
tive screwdriver.
Reinstall wrapper.
Tools Needed:
cii~i==n
1/4 in
~=
Non-conductive
Figure
Ref. ST-162 132 / Ref. SB-146 862D
3-17. Motor Start Control On Motor Control Board PCi
OM-1588
Page
11
3-14.
Wire
Threading Welding
a
WARNING
CYLINDERS
can
explode
if
damaged.
Keep cylinders away from welding
and
other
electrical circuits.
Never touch
cyhnder
WELDING
wounds.
WIRE
Do not press gun
with
Always secure cylinder
other stationary support.
ELECTRIC SHOCK
welding
electrode.
to
running
can
kill.
gear, wall,
Do not
or
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.
people,
can
trigger
cause
puncture
until instructed to do
so.
toward any part of the body, other
any metal when threading welding wire.
point gun
or
HOT SURFACES
can
Allow gun to cool before
burn skin.
touching.
wfwarn2.1 / wtwam7.1 9/91
OM-1588
Page
12
6
3
Spool/Reel
1
Wire
2
Wire Tube
3
Pulley
4
Wire Guides
5
Drive Rolls
6
Jog
Button
7
Gun Conduit Cable
8
Pressure
9
Drive RoIl Pressure Indicator
Scale
2
Adjustment Knob
7
Tools Needed:
_~ci_
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
(see Figure 5-10)
Welding
Power Source
Pull and hold wire; cut off end.
Set switches.
feed wire thru tube, over
and up to wire inlet guide.
Manually
pulley,
JOG
~
SELECT
-4
010
+
/
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
Feed wire to check drive roll pressure.
knob enough to prevent slipping.
Adjust
Cut off wire. Close
Ref. ST-BOO
Figure
3-18.
cover.
Repeat procedure for opposite
I 79
side.
/ Ref. ST-i 50922 / ST-i 53073 / Ref. 51.157 432
Threading Welding Wire
OM-1588
Page 13
SECTION 4- GLOSSARY
The
is
following
a
list of terms and their definitions
as
they apply
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.
Current
Background
The lower of the two current levels in the
In short circuit
Inductance
welding,
an
waveform.
pulsing
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
(PPS
Or Pulse
Pulse Width
higher
Number of
of the two current levels in the
peak
current
pulses
pulsing
which 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
length adjustments
in
pulse programs. Trim is replaced
refers to the units
ability to use preprogrammed pulse parameters in order
pulse settings of Peak Amperage, Background Amperage,
Pulse Frequency and Pulse Width at any specific wire feed speed setting.
to determine the actual
Front Panel Terms
Display Control Knob
Is used for all
Digital Display
2-line
Gas Purge Control
Allows the gas line and gun to be
Parameter Select Button
Is used to select
Trigger
Wire
Hold Control
Jog
Control
adjustable front panel displays.
by 16-character liquid crystal display
a
purged
with built-in LED
without
variety of parameters that
When selected, allows the system to remain
to hold the gun trigger.
can
energizing
be set
energized
on
backlight.
the wire feeder.
the front
panel display.
without the operator
having
Allows the wire to feed without
energizing the welding power source contactor and
gas valve. The wire jog speed is independent from actual wire feed speed, and is dis
played on the front panel.
Side Panel Terms
Digital Display
4-line
Dual Schedule
Allows two weld programs to be linked together when two different
tions, such as hotter and colder, are required on one wire.
Process Mode
Is used to select the type of process to be used,
Mig.
OM-1588
Page
14
by
20-character
liquid crystal display with built-in LED backlight.
welding condi
including Pulse, Adaptive Pulse,
or
this
Remote Parameter
When
Increase/Decrease
decrease
a
feature
turned
is
on,
the
operator
selected weld parameter with the
use
can
of the
increase
remotely
and
optional DSS-10 2-pole
momentary-contact switch.
Sequence
Mode
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,
Allows
crater control of
voltage
or
trim and wire feed
speed from Oto 2.5 seconds, burnback
time from 0 to 0.25 seconds, and postflow gas control from 0 to 9.9 seconds.
Setup Screen Terms
Access Mode
A three-letter code can be
programmed in the access mode which restricts unautho
changing any of the security/set-up screens. NOTE: The
required to activate this feature.
rized personnel from
optional Data Card is
Arc Start
Provides the option of
Arc Time
Allows actual
arc
mulated and
displayed
Dual Schedule
a
higher
arc
starting amperage for large wires.
time up to 9,999.99 hours and weld cycles up to 999,999 to be accu
on
the
and
digital display,
can
be reset to
zero as
required.
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 voltage correction is used
Model
Allows selection of
boom-type
feeder
or
or
not.
bench mount feeder
pulse program
parameters.
Name Feature
When
using
the
optional Data Card and turning the name feature on, customized
can be identified by name, number, job number, etc.
programs written to the card
Program
Reset
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 requires that the voltage and amperage range of the welding power
source be entered. Obtain this information from the welding power source Owners
Range
Manual.
Remote Parameter
Security
When the Remote Parameter Inc/Dec is on,
for
increasing
at
Trim, Volts,
or
or
decreasing
a
dual schedule switch
weld parameters when the front
can
also be used
panel display
cursor
is
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 display the software version of the unit.
System
This unit
and
can
be used either with
pulse GMAW
(Pulse/Mig)
a
welding power source capable of regular GMAW
welding power source capable of GMAW (Mig
or a
Only) welding only.
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.
OM-1588
Page
15
Allows programs to be selected
Trigger Program Select
Self Test Mode
Voltage Control Feedback-
with the gun
remotely
to check a
trigger.
variety of wire feeder
and power
A built-in
diagnostic feature
tions if
a
malfunction
func
Allows
voltage to be monitored at the output terminals by two methods. This can be
through the 1 7-pin cord connection if the welding power source has a 17-pin
source
occurs.
selected
receptacle,
or
through
the
of the units
use
optional external voltage
lead.
sense
When this feature is on, the system immediately shuts down if no arc is initiated upon
gun trigger actuation. When this feature is off, the system (wire feeder), when actu
Voltage Sense Shutdown
by the gun trigger, feeds wire for approximately three seconds at set welding
speed and then automatically switches to cold wire jog speed for approximately one
minute. The off feature is normally selected to allow threading wire with the gun
ated
trigger.
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,
Wire Feed Mode
speed. High and low speed
motors are available as
speed.
high
or
factory options.
SECTION 5-OPERATION
WARNING
a
ELECTRIC SHOCK
can
kill.
p
Do not touch live electrical parts.
Always
wear
Insulate
~
dry insulating gloves.
yourself from
Keep all panels and
work and
covers
FUMES AND GASES
to your health.
Keep your head
Ventilate area,
can
in
welding
Wear
MOVING PARTS
be hazardous
Keep
$
out of the fumes.
breathing device.
Safety Data Sheets (MSD5s)
manufacturers
instructions for material used.
away from
fire
or
and
I
injury.
covers, and
as
drive rolls.
guards
closed
explosion.
MAGNETIC FIELDS FROM HIGH CUR
RENTS can affect pacemaker operation.
on
Allow work and
wearers
flammable material.
over
keep away.
Wearers should consult their doctor before
I
keep extinguisher nearby.
Do not locate unit
Do not weld
can cause
pinch points such
Keep all doors, panels,
and securely in place.
Pacemaker
near
Watch for fire;
body protection.
or use
can cause
Do not weld
helmet with correct shade of filter.
Wear correct eye, ear, and
place
Read Material
WELDING
S
~
ground.
securely
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
near
..
any
going
welding operations.
combustible surfaces.
closed containers.
equipment
to cool before
See Safety Precautions at
handling.
sic
welding safety
beginning
of manual for ba
information.
welding
1 8/92
helmet
shade of filter
with
a
correct
(se e ANSI Z49.1).
sb3.l 10/91
Figure
OM-1 588
Page
16
5-1.
Safety Equipment
I
Work
Clamp
Connect work clamp to a clean,
paint-free location on workpiece,
as
close to weld
Use wire brush
area as
or
clean metal at weld
2
possible.
sandpaper
joint
to
area.
Voltage Sensing Clamp
Tools Needed:
Connect to
if
workpiece,
applicable
(see Figure 3-11).
=~
Use chipping hammer
slag after welding.
to remove
Ref. ST.158 931-A
Figure
5-1.
5-2. Work And
Voltage Sensing Clamps
Front Panel Controls
2
I
Display
2
Parameter Select Button
3
Display
4
Right Side Indicator Light
5
Right Side Trigger Hold
Button And Indicator Light
6
Side Select Button
7
Control Knob
Left Side
Trigger Hold
Light
Button
And Indicator
3
8
Left Side Indicator
9
Jog
10
Purge
Light
Button
Button
See Section 6 for information
using microprocessor
7
6
on
controls.
5
ST-162 127
Figure
5-3. Front Panel Controls
I
Parameter Select Button
Press button to
move
indicator
on
display.
Ref. ST~181 713
Figure
5-4. Parameter Select Button
OM-1588
Page
17
1
Display Control
knob
Turn
to
Knob
change
value
selected.
Spin knob to quickly change
parameters or nove knob slowly
by clicks to fine tune parameters.
Figure
Display
5-5.
2
Control Knob
2
\
1
Side Select Button
2
Side Indicator
___________________
~o
o~
~o
b
Light
Push button to select active side of
wire feeder. Indicator light is on for
active side.
-
TRIGGER
r
The
feeder remembers the last
used program for each side, and
TRIGGER
HOLD
HOLD
1~
returns to that program when the
active side is
@
0
0
RECEPTACLE
~
@
changed.
Note: gun trigger may also be used
to select or change active side of
wire feeder.
RECEPTACLE
~.,
Figure
5-6. Select Button And Side Indicator
2
Lights
Hold Button
1
Trigger
2
Indicator
Light
without holding gun trigger
throughout weld cycle, press and
To weld
release button to turn
light
on
indicator
and hold circuit.
To start weld
cycle, and feed weld
ing wire, press and release gun
trigger within the first three sec
onds after
an arc
has been struck.
If gun trigger is not released within
the first three seconds after arc ini
tiation, trigger hold stops, but is still
active for next weld
cycle. To end
cycle, press and release gun
trigger.
weld
Trigger
hold
while gun
If the
cannot
trigger
Trigger
is
be
started
pressed.
hold button is
pushed
for the nonactive side of the feeder
(see Figure 5-6),
dicator
the
trigger hold
in
turns on, but Trigger
Hold does not become active until
light
that side is selected.
Figure
OM-1588
Page
18
5-7.
Trigger
Hold Button
-
I
POsh Button
J~
works
side
of
Jog
active,
feeder
on
or
selected
(see
only
Figure 5-6). Separate jog speeds
,~
can
PURGE
be set for each side of the
JOG
feeder.
9j0
wire without
Push to
19
cuit
2
~o
o~
_~._
1
or
momentarily feed welding
energizing welding cir
shielding gas valve.
Jog speed is varied using the Dis
play Control knob while Jog button
is pressed. Default setting is 200
ipm.
When
Jog button is released, unit
displays preset wire feed speed,
and previously selected parameter
is active.
Jog does not work when gun trigger
is pressed.
Jog
2
Tr
50
Prg
rn
1
Purge Push
Purge
of
side
>200
I
PM
Jog
works
Button
active, or selected
feeder
only
(see
on
Figure 5-6).
Push to
Jog
>5 0
260
momentarily energize gas
purging of air
from gun shielding gas line, and ad
justing shielding gas regulator
without energizing the welding
valve. This allows
Tr
rn
I
PM
Prg
1
Pulse
circuit.
Front panel controls, side panel
controls, and gun trigger do not
work when
Jog
or
Purge
button is
pressed.
Figure
5-2.
5-8.
Jog
And Purge Buttons
Side Panel Controls
1
Parameter Increase Button
2
Parameter Decrease Button
3
Parameter Select Button
4
Mode Select Button
5
Mode
6
Parameter
Display
Display
See Section 6 for information
using microprocessor
on
controls.
3
Pet. 5T-162 133
Figure
5-9. Side Panel Controls
OM-1588
Page
19
Rear Panel Controls
5-3.
Power Switch
1
Use power switch to turn unit On
and Off.
Circuit Breaker
2
(See Section
14-3)
ST-800 177
5-10. Power Switch
Figure
:i
BUILDUP OF SHIELDING GAS
S
~
Shut off
shielding
gas
supply
w hen
harm health
can
not in
or
kill.
use.
warnl12/93
2
1
Shielding
2
Valve
3
Gun
Gas
Cylinder
1
Trigger
Open
welding.
valve
~~==
Gun
trigger
gas flow
on
on
cylinder just before
turns weld
output and
and off.
3
Close valve on
ished welding.
cylinder when
sb5.1 6/92
Figure
H IGH FREQUENCY will
high frequency
Completely disconnect
Install &
Connect
J
Wire
damage
when
Figure
using
this unit.
this unit from power
source
)
when
using high frequency.
Put On
Personal Safety
Equipment
On~\\Turn
) )
JJ
Turn
Wire Feeder And ) J
Power Sourcej /
Page
20
Shielding~\\
On
Gas
Set All
Controls
) )
(If Applicable) J / (See Figure 5-13
Begin
Welding
5-12.
Sequence
Of Gas Metal Arc
Welding (GMAW), Gas Metal
Welding (FCAW)
And Flux Cored Arc
OM-1588
Gas
this unit.
Install Welding
)
System
) )
Feed~~, , (See Figure 3-1) ~/ J
)
Shielding
CAUTION
a
Turn Off
5-11.
Arc
-
Pulse
(GMAW-P),
fin
s-o621-c
5-4.
Setting Switches On
450
Ampere
Inverter Model
Welding
Power Source
A/V
0
~17
PANEL
~
ONI
G~.OuTPuT(~HrfrcT~)
0
PANEL
ARC FORCE /INDUCTAN~
AJID
ccicv
~ef ST-I 50
Figure
5-13.
Setting
Switches On 450 Ampere Inverter Model
I
7l~9 / Ref. ST-145 332-D
Welding Power Source
OM-1588
Page
21
SECTION 6 STEPPING THROUGH THE
MICROPROCESSOR CONTROLS
WARNING
a
I
ELECTRIC SHOCK
Do not touch live electrical
WELDING WIRE
wounds.
kill.
can
parts.
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
Control circuit and feeder operational power are On
when using or changing the microprocessor
settings.
the gun whenever the power switch is On and the gun
trigger is pressed.
N OTE
This unit is equipped with eight (8) pulse welding programs (see Section 7). When
comes up, therefore, program 1 is
are given later in this manual (see
Section 9) on how to select or change a program.
the unit is turned On for the first time program 1
illustrated throughout this manual. Instructions
6-1.
Front Panel Micr oprocessor Controls
Turn On welding power source and
wire feeder. Follow along with the
-
controls
as
shown.
1
Front Panel
2
Parameter Select Button
Display
Press parameter select button to
indicator.
move
The indicator points to parameters
that are selected for change.
00O
0
o
0
Parameter select button can move
indicator between Trim (arc length)
and 1PM while welding.
0
Go to
00000
rH
50
200
>50
200
Tr
im
~>Prg
I
PM
L!u
Figure
6-2.
e
s
Tr
im
Prg
I
PM
Pulse
1
~
Tr
50
>2 0 0
I
1
Prg
~ fr_u_I
s
e
ST162
FIgure
OM-1 588
Page
22
6-1. Front Panel Parameter Select Button
127
1
Front Panel
Display
Select parameter to be
changed
(see Figure 6-1).
2
o
0
o
o
~
Display Control
2
Trim
0
Knob
Turning knob one click causes the
following changes to selected
setting:
0
(arc length)
by one.
increases/de
creases
00000
The trim
(arc length) value being
changes on the side
parameter display (see
changed
panel
also
Figure 8-3).
Wire feed
speed (1PM) increases/
decreases
>50
200
Trim
Prg
1PM
by
one
The wire feed
speed value being
changed also changes on the side
panel parameter display (see
Figure 8-3).
Pulse
Program
number
ses/decreases
by
Display
Control
>55
Trim
increa
number
program
being
changed also changes on the side
panel parameter display (see
Figure 6-5).
Prg
1PM
(Prg #)
one.
The
The program
200
inch per minute.
changed
Pulse
number cannot be
while
welding,
with
ex
ception of Dual Schedule Mode
(see Section 11).
0 Front
Panel
Parameter
All
acessible
are
programs
either side of the feeder,
through
Select
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
Go to
55
>300
Trim
55
300
Pulse
Front Panel
Parameter
Select
Trim~]
J
1PM
6-3.
Prg
1PM
0
Figure
>Prg
1
Pulse
Display
Control
50
200
Trim
1PM
>Prg
2
Pulse
sT-162 ~27
Figure
6-2. Front Panel
Display
Control Knob
OM-1588
Page
23
6-2.
Side Panel
MFcroprocessor Push
Buttons
1
Mode
2
Mode Select Button
Display
Press Mode button to
-
tor in left window
move
indica
display.
Go to Figure 6-4.
Side Panel
Process
Sequence
u
a
I S
C
h d
Card
Process
Sequence
L_
_i
DualSchd
a
r
d
Ret, ST-154 109
Figure
OM-1 588
Page
24
6-3. Side Panel Mode Select Button
1
Parameter
2
Moving
Display
Line
Moving line is
changed.
under value that
can
be
3
Side Panel Parameter Select
Button
Press side
button to
window
panel parameter
move
select
indicator in
right
display.
Side Panel
2
Ref. 5T-~54 109
Figure
6-4. Side Panel Parameter Select Button
OM-1588
Page
25
Use side panel mode select button
to select mode to be
changed (see
Figure 6-3).
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
by
the
moving
line.
Decrease Button
Press button to decrease value
that is underlined
by
the
moving
line.
Side Panel
>Prg
~f~
J
~_
Pulse
~
1
045Steel
ArgonO
Increase
>Prg
a_
Pulse
2
052St
Argon,O
eel
xy
Decrease
Pet. ST-154 109
Figure
OM-1588
Page
26
6-5. Side Panel Parameter Increase And Decrease Buttons
STANDARD PULSE WELDING PROGRAMS
SECTION 7
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.
The
Program
Program
# 1
Program
Name: .035
Wire
Size/Type:
Steel, Argon
-
.035
1
Gas: 98 Ar
S-3
-
2
Oxy
or
95Ar
-
5
Oxy
Card #________________________
Oxy
Flowrate: 40 CFM
Gun Model: MILLER GW
1PM
ApK
AbK
PPS
PWms
750
490
105
200
2.0
700
480
100
190
1.9
COMMENTS
.
650
470
95
185
1.9
600
465
93
180
1.9
550
460
90
175
1.8
500
450
85
170
1.8
450
430
80
160
1.8
400
410
75
150
1.7
350
390
70
140
1.7
300
370
65
130
1.6
250
350
50
120
1.6
200
330
47
110
1.6
150
315
45
90
1.5
100
300
45
40
1.5
80
290
40
35
1.5
Preflow: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:__________________________
Crater Trim: 50
1PM: 200
Sec.:__________________________
Postflow: 0 Sec.
OM-1588
Page
27
Program
Program
Wire
# 2
Size/Type:
Program Name: .045 Steel, Argon
-
.045
2
Gas: 98Ar
S-3
-
2
Oxy
or
95 Ar
-
5
Oxy
Card #________________________
Oxy
Flowrate: 40 CFM
Gun Model: MILLER GW
1PM
ApK
AbK
PPS
PWms
750
540
110
220
3.2
700
530
110
210
3.2
650
520
110
200
3.2
600
510
110
190
3.2
550
500
110
180
3.1
500
490
105
170
3.0
450
470
105
160
2.9
400
450
100
150
2.8
350
440
100
140
2.7
300
430
95
130
2.6
250
420
90
120
2.5
200
400
80
100
2.5
150
380
70
80
2.4
100
345
50
60
2.4
80
310
30
38
2.2
COMMENTS
.
Preftow: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:__________________________
Crater Trim: 50
1PM: 200
Sec.:__________________________
Postflow: 0 Sec.
OM-1 588
Page
28
Program
Wire
Program
# 3
Program
Name: .052
Size/Type:
Steel, Argon
-
.052
3
Gas: 98Ar
S-3
-
2
Oxy
or
95 Ar
-
5
Oxy
Card #________________________
Oxy
Gun Model: MILLER GW
Flowrate: 40 CFM
PPS
1PM
ApK
AbK
750
565
145
700
565
140
260
3.1
650
560
135
260
3.1
600
560
130
255
3.1
550
560
125
240
3.1
260
PWms
COMMENTS
3.1
-
.
500
550
120
225
3.0
450
540
115
210
2.9
400
530
110
195
2.8
350
520
105
170
2.7
300
510
100
155
2.7
250
500
90
140
2.6
200
480
80
120
2.6
150
460
70
100
2.5
100
420
50
80
2.4
50
350
32
50
2.2
Preflow: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:__________________________
Crater Trim: 50
1PM: 200
Sec.:___________________________
Postflow: 0 Sec.
OM-1588
Page
29
Program
Program #
Program
Wire
4
Name: .035
Sizeilype:
309, Argon
-
.035
4
Gas: 98 Ar
309
-
2
CO2
or
95Ar- 5
CO2
Card #________________________
CO2
Flowrate: 40 CFM
Gun Model: MILLER GW
1PM
ApK
AbK
PPS
PWms
750
390
95
210
2.2
700
380
95
200
2.1
650
370
90
190
2.0
600
360
85
180
1.9
550
350
80
170
1.9
500
340
75
160
1.9
450
330
70
150
1.8
400
320
65
140
1.8
350
310
60
130
1.7
300
300
55
120
1.6
250
290
50
100
1.6
200
280
45
80
1.6
150
270
40
60
1.6
100
270
36
40
1.5
80
260
30
30
1.5
COMMENTS
Pretlow: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:__________________________
Crater Trim: 50
1PM: 200
Sec.:___________________________
Postflow: 0 Sec.
OM-1588
Page
30
Program
Wire
Program
# 5
Program
Name: .045
Sizeilype:
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
ApK
AbK
PPS
PWms
750
490
115
290
2.3
700
480
115
280
2.3
650
450
115
270
2.1
600
435
112
260
2.0
550
430
110
240
2.0
500
425
105
230
1.9
450
420
105
220
1.9
400
415
105
200
1.8
350
410
100
180
1.8
300
400
95
160
1.7
250
380
88
140
1.7
200
360
85
115
1.7
150
340
68
88
1.6
100
320
50
70
1.6
80
310
45
60
1.5
COMMENTS
.
Preflow: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:__________________________
Crater Trim: 50
1PM: 200
Sec.:__________________________
Posttlow: 0 Sec.
OM-1 588
Page
31
Program
Program
Wire
# 6
Program Name: 3/64
Size/Type: 3/64
6
Gas:
4043
Argon
Card #________________________
4043, Argon
Flowrate: 40 CFM
Gun Model: MILLER GW
1PM
ApK
AbK
PPS
PWms
750
510
150
190
3.5
700
485
150
180
3.4
650
485
150
180
3.4
600
470
145
180
3.3
550
445
140
170
3.1
500
420
135
160
2.9
450
400
130
150
2.8
400
360
120
140
2.7
350
340
115
130
2.6
300
310
100
120
2.5
250
277
87
110
2.4
COMMENTS
.
.
200
250
68
100
2.3
150
215
50
90
2.1
100
190
30
80
2.0
80
190
27
45
2.0
Preflow: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:__________________________
Crater Trim: 50
1PM: 200
Sec.:__________________________
Postflow: 0 Sec.
OM-1588 Page 32
Program
Wire
Program
# 7
Program
Name: 3/64
Size/Type: 3/64
7
Gas: Argon
5356
Card #_________________________
5356, Argon
Gun Model: MILLER GW
Flowrate: 40 CFM
1PM
ApK
AbK
PPS
PWms
750
515
130
190
2.8
700
510
120
190
2.8
650
490
120
180
2.7
600
470
115
170
2.7
550
450
110
160
2.6
500
430
100
150
2.5
450
410
90
140
2.5
400
390
80
130
2.4
350
370
65
112
2.4
300
340
52
103
2.3
250
325
47
90
2.3
200
300
40
80
2.2
150
277
35
53
2.2
100
260
24
40
2.2
50
230
20
35
2.0
COMMENTS
.
Preflow: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:__________________________
Crater Trim: 50
1PM: 200
Sec.:__________________________
Postflow: 0 Sec.
OM-1 588
Page
33
Program
Program
Wire
# 8
Program Name: .035
Size/Type:
NIcki, Argon
-
.035
8
Gas: 75 Ar -25 He
Nickl
Card #________________________
He
Flowrate: 40 CFM
Gun Model: MILLER GW
1PM
ApK
AbK
PPS
PWms
750
390
110
130
3.5
700
380
105
130
3.5
650
370
100
125
3.4
600
360
90
120
3.4
550
350
85
115
3.3
500
345
80
110
3.3
450
340
75
105
3.3
400
335
65
90
3.2
350
332
60
75
3.1
300
320
55
65
3.0
250
310
50
58
3.0
200
297
44
52
2.9
150
282
37
42
2.9
100
262
29
33
2.8
50
225
23
30
2.7
COMMENTS
Pref low: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:__________________________
Crater Trim: 50
1PM: 200
Sec.:___________________________
Postflow: 0 Sec.
OM-1588
Page
34
SECTION 8- GETTING STARTED
WARNING
a
ELECTRIC SHOCK
can
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
kill.
Do not touch live electrical parts.
Always
wear
Insulate
Keep
all
Wear
dry insulating gloves.
from work and
yourself
panels and
covers
FUMES AND GASES
to your health.
Keep your head
Ventilate area,
ground.
securely
in
breathing
can cause
Do not weld
fire
device.
or
away from
Keep all doors,
and securely in
Read Material Safety Data Sheets (MSDSs)
manufacturers instructions for material used.
WELDING
MOVING PARTS
Keep
out of the fumes.
or use
helmet with correct shade of filter.
body protection.
place
be hazardous
can
welding
Wear correct eye, ear, and
explosion.
can cause
injury.
pinch points such
panels,
place.
covers, and
as
drive rolls.
guards
closed
MAGNETIC FIELDS FROM HIGH CUR
RENTS can affect pacemaker operation.
Pacemaker
wearers
keep away.
flammable material.
near
Wearers should consult their doctor before
Watch for fire;
keep extinguisher nearby.
Do not locate unit
Do not weld
on
Allow work and
NOTE ~
over
near arc
combustible surfaces.
closed containers.
equipment
to cool before
handling.
welding, gouging,
or
going
spot welding opera
tions.
See Safety Precautions at beginning of manual for ba
sic welding safety information.
wtwam8 1 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.
OM-1588
Page
35
8-1.
Welding With Only
Front Panel Controls
Turn On
wire
welding
Use Select button
or~
Select
50
200
Tr
rn
I
PM
power source,
feeder, and gas.
or
gun
trigger
to
select active side of feeder.
I
/1
Program
Display
1 is the default program
the first time the unit is turned on,
at other times the last program
>Prg
Pu
Front Panel
I
1
number selected is displayed. Use
the front panel parameter select
button to select the Prg #.
se
2
Prg3
Select
Display
Control
2
gas).
/
50
Tr
rn
I
PM
>Prg
the weld program from
Section 7 (1 through 8) which is
closest to your needs (by wire and
Strike
3
3
If
200
Pulse
an arc
Trim
and
try a sample weld.
(Arc Length)
necessary, select Trim, and
to achieve the best arc.
adjust
4
If
Front Panel
Mode Select
1PM
necessary, select 1PM, and
to achieve the best arc.
adjust
Go to Section 8-2.
Prg
Pu
I
3
se
Display
Control
Prg
Put
3
se
Front Panel
Mode Select
+
55
>200
Tr
irn
Prg
I
PM
Pulse
3
Display
Control
55
>250
Tr
im
Prg
I
PM
Put
3
se
A___
/
Figure
OM-1588
Page
36
8-1.
Welding
With
Only
Front Panel Controls
8-2.
Setting Sequence
Pulse
Welding
Parameters On Side Panel
WARNING
a
ELECTRIC SHOCK
can
WELDING
wounds.
kill.
Do not touch live electrical parts.
Control circuit and feeder operational power
when
using
or
changing
the
are
~
WIRE
can
cause
puncture
Do not point gun towards any part of the body, other
people, or any metal when programming.
On
microprocessor
settings.
N OTE
Display
welding wire is electrically live and moves out of
the gun whenever the power switch is On and the gun
trigger is pressed.
The
Figure 8-2 is a graphic layout of a weld cycle. Follow examples in Figure
through Figure 8-8 to adjust sequence welding parameters to fit your needs.
8-3
Weld Time 0-25 Sec.
Crater Time
0-2.5 Sec.
Burnback Time
0-0.25 Sec.
Trigger
Arc
Arc
Start
Trigger
Time
Out
Released
Pressed
Ref. S-0271
Figure
8-2. Weld
Cycle
OM-1588
Page
37
Side Panel Mode Select
1
Button
On, Process is
the default mode, at other times,
use side panel mode select button
to select Sequence.
When unit is turned
Side Panel Parameter Select
Button
2
2
Use side panel parameter select
button to select parameters.
Process
~aneI
>W~1d
Trim
>Sequence
50.
DualSchd
250
1PM
Card
0.0
Sec
3
N
Weld Parameters
Display
Parameter ranges
are as
Trim
0-99
(Arc Length),
follows;
Changes to Trim are also displayed
on front panel display.
Parameter
Wire Feed
Speed,
50-780 Inches
Per Minute, 1PM
Changes
on
1PM
front panel
are
also
displayed
display.
Seconds, 0-25.0 Sec. If value set is
Set Desired Trim
~OrQ~j
Increase!
Decrease
I~_3
Weld
Trim
I
200
1PM
I
0.0
Sec
>50
Trim
be fine tuned
while welding.
can
Set Desired Wire Feed
zero (0), welding will continue until
welding gun trigger is released.
V
Speed
Or~
Increase!
Decrease
1PM can be tine
tuned while welding.
Set DesiredTime,
If Applicable
lncrease/
Decrease
~
Side Panel
Parameter
Select
Proceed to next
Figure
OM-1588
Page
38
8-3.
Setting
Weld
figure.
Sequence Display
Go to
Figure
8-4.
1
Crater Parameters Display
Parameter ranges
are as
Trim
0-99
follows:
_________
Crater
~:0
Z~mk~~~:o TrimH
Side Panel
Parameter
Select
Set Desired
Side Panel
Trim
Parameter
1
Crater
Tr
60
>2QQ
0.00
(Arc Length),
Wire Feed
imi
Speed, 50-780
Inches
Per Minute, 1PM
1PM
Seconds, 0-2.50 Sec. If value set is
zero
(0), there is no Crater
Sec
Set Desired
Wire Feed Speed
sequence.
Select
Go to Figure 8-5.
Side Pan:I
Increase/
Decrease
Increase!
Decrease
>QEat~f
Crater
Trim~(p=~]60
60
150
1PM
0.20
Sec
1
TrimLi
150
1PM
Sec
Side Panel Set Desired Time
Parameter
Select
Increase
Proceed to next figure.
Figure
8-4.
Increase!
Decrease
Setting
Crater
Sequence Display
1
__/
Burnback Parameters
Burnback
__
__
I
I
Bu
r
nback
r n
b
a ~
K
can
be
Display
adjusted from
0-0.25 seconds. If value set is zero
there
is
Burnback
no
(0),
sequence.
Go to
0. 00
Sec
>Q~.OQ
Sec
0.12
Figure
8-6.
Sec
___________
Side Panel
Set Desired Time
Parameter
Select
Side Panel
Parameter
Select
Increase
Proceed to next
Increase!
Decrease
Figure
8-5.
Setting
Burnback
figure.
Sequence Display
1
______/
______
______
Postflow
>Eastflcw
Postflow Parameters
Go to
0.0
Sec
Sec
Side Panel
Parameter
Select
Set Desired Time
Increase!
Decrease
Figure
8-6.
1.2
Display
Postflow can be adjusted from
0-9.9 seconds. If value set is zero
(0), there is no Postflow sequence.
Figure
8-7.
Sec
Side Panel
Parameter
Select
Increase
Proceed to next
figure.
Setting Postflow Sequence Display
OM-1588 Page 39
Preflow Parameters
1
Preflow
Display
be
can
adjusted from 0-9.9
seconds. If value set is zero (0),
there is
Go to
Preflow
>PreflQw
0,0
SecF~
>
Side Panel
Parameter
Select
Sec~
~
8-7.
Preflow
8-8.
Side Panel
Parameter
Select
Set Desired Time
Setting
Preflow sequence.
Sec~
1.2
Increase!
Decrease
Figure
no
Figure
Increase
Proceed to next figure.
Sequence Display
Run-In Parameters
1
Parameter ranges
Di~play
are as
follows:
Trim, 0-99.
Wire Feed
Speed,
50-780 inches
per minute, 1PM
Seconds, 0-2.5 Sec. If value set is
(0), there is no Run-In
zero
sequence.
Run i
Side Panel
Parameter
Select
ri
Set Desired
Wire Feed Speed
I
I
Li
Side Panel
Parameter
Select
Increase!
Decrease
Run in
~
~
Trim
150
L~9~
Side Panel
Parameter
Select
Increase
1PM
Sec
Set Desired Time
Increase!
Decrease
Figure
OM-1588
Page
40
8-8.
Setting
Run-In
Sequence Display
~
TEACHING A PULSE WELDING PROGRAM
SECTION 9
WARNING
a
ELECTRIC SHOCK
can
WELDING WIRE
wounds.
kill.
Do not touch live electrical parts.
Control circuit and feeder
when
using
or
operational power are On
changing the microprocessor
settings.
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
trigger is pressed.
NOTE
See GMAW-P
(Pulsed MIG) Process Guide supplied
with unit for
more
information.
9-1.
Pulse Waveform
Explained
The wire feeder, not the
welding
power source, controls weld output
for pulsed welds.
I
Peak Current Of
ApK
100-565
ApK
Amperes
high pulse
is the
Peak
current.
of
welding
melts the
current
welding wire and forms a droplet.
droplet is forced into the weld
The
puddle.
2
Abt<
Background Current
Of 10-200 Amperes
Abl< is the low weldcurrent. Back.
ground
current
preheats welding
wire and maintains the
background
is
arc
/\
arc.
current is too
unstable
and
When
low, the
hard
to
maintain.
3
Pulses Per Second Of
PPS
20-400
C
Q)
PPS, pulse rate, and frequency
0
0.
E
1
2
4
4
(Hz)
are
PPS
or
used
interchangeably.
pulse rate of
60 pulses of current
each secopd.
C,,
4
PWms
A
60 Hz means
are
produced
Pulse Width Of
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
or fluidity of the molten
puddle is controlled by
stiffness
weld
PWms.
Ret. S-0259
Figure
9-1. Pulse Waveforms And
Explanation Of Terms
OM-1568
Page
41
Teach Points
9-2.
Explained
1PM
780
750
700
650
600
550
Example Of
A
Synergic
Setting
For 425 1PM With
All Teach Points Set At
50 1PM Increments
500
450
400
350
300
250
200
~
ApK
o
AbK
o
pps
150
100
PWms
50
150
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
150
AbK
30
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
teach point, the user can adjustfour parameters: peak amperage (ApK), background
amperage (AbK), pulses per second (PPS).
and pulse width in milliseconds (PWms) to
shape the pulse waveform of the weld
custom
output.
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
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.
speed
of
a
Page
42
Below the wire feed
teach
point, and
4
speed
of the lowermost
above the wire feed
speed
9-2.
Typical
PWms
5
To
ensure a proper arc length reading, elec
trical stick-out must be carefully maintained,
of the uppermost teach point, the unit may
limit wire feed speed settings in pulse MIG to
and the weld must be terminated
maintain all
gun away from the workpiece.
pability
pulse parameters
within the
Ca-
ing the gun trigger,
not
by pulling
by
the
releas
welding
of the unit.
The
Pulse MIG programs made by the manufacturer have pulse waveform information entered for all 15 teach
can
relocate and
points. The operator
modify the setting of one,
or
any number of the 15 teach points if the factory set information is not appropriate for a
specific application.
teach
Figure
OM-1588
3
After the parameters for each teach
point are
established,anarcmustbestruckandmain-
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 mode, the unit does not maintain
length
with variations in elec
trical stick-out. In the
Adaptive Pulse mode,
a
constant arc
the unit
maintain
a
of varia
adjusts pulse frequency to
constant arc length regardless
tions in electrical stick-out.
tamed for at least 5 seconds. This allows the
wire feeder to learn the
Proceed to next
sociated with the
program.
Teach Point
arc voltage length astaught pulse parameters.
Settings
And
figure
to teach a
Resulting Synergic Setting
pulse
M IG
9-3.
A. Pulse
Teaching
Welding Program
READ SAFETY BLOCKS at start of
Section 9 before proceeding.
~A1~ ;l ~ II ~
A.
Selecting And/Or Redefining Teach
Speed
Point Wire Feed
Process
1
point (1PM)
A teach
but the wire feed
and
Display
can
be selected
speed of a
teach
either the side
on
point
can
panel
or
front
panel displays.
only be redefined with the Purge
on the front panel display.
Display
When unit is first turned On, Pro
button
Control knob while 1PM is selected
cess
is the default screen, at other
use mode select button to se
times
lect Process.
2
Teach
2
Display
/
Use parameter select button to
lect Teach.
se
Use increase/decrease buttons to
select On.
1PM
3
You
(Teach Point)
also select
can
a teach point
panel Display Control
cursor on the front panel
with the front
knob if the
display
is
pointing
at 1PM.
To redefine the wire feed
a
teach
4
point, proceed
Front Panel
as
speed of
follows:
Display
Use parameter select buttQn to
lect 1PM (teach point).
se
Press and hold Purge button while
turning Display Control knob to re
define the teach point wire feed
speed. For example, if teach points
reside at 150, 200, and 250
Side Panel
Parameter
Select
the teach
justed
ipm,
at 200 can be ad
to a wire feed
to 249
Selecting
point
speed of
151
pm.
Repeat the procedure for as many
points as desired.
of the 15 teach
A Teach Point
To
set
or
adjust teach point
to Figure 9-4.
parameters, go
Redefining
5 0
450
Tr
im
I
PM
ii
>Prg
P
U
I
A Teach Point
50
S_er~
>4
5 0
Trim
Prg
1PM
1
Pulse
Front Panel
Parameter
Select
~urge~~J
And
50
>4 6 0
Figure
9-3.
T
rim
Prg
1PM
Pu)
Selecting
iL~~
sel
And/Or Redefining A Teach Point
OM-1588
Page
43
B.
Setting Teach Point Parameters On The Side Panel
Increase!
Decrease
>P
r
On
Teach
0 C e S S
Sequence
>450
1PM
Dual Schd
340
Apk
70
Abk
Card
Teach
~_Or_-~>343
Teach
On
~ 7,,~,/Abk
Apk
>34~
_________
_________
On
1PM
460
1PM
460
Apk
Abk
70
Side Panel
I
Parameter
Select
Side Panel
Parameter
Select
Increase!
Increase!
Decrease
Decrease
460
1PM
343
Apk
7Q
Abk
1~0
PPS
>
I
1~J
Side Panel
Parameter
Select
Increase!
Decrease
343
Apk
343
Apk
92
Abk
92
Abk
280
PPS
>
PWm
I
_______
>Teach
~
460
1PM
~
Apk
92
Abk
Or
280
_____
/
Side Panel
Parameter
Select
Increase!
Decrease
4
5
I
Progl
C
I Pulse
I 035SteelI
(
Argon-Oxy~
When the Process Teach mode is
On, and
1
ApK Display
2
AbK
Display
3
PPS
Display
~
PWms
custom
of the
following pulse parameters is Selected: ApK, AbK, PPS, or PWms, the front
panel displays the selected pulse parameter
instead of Trim (arc length). When the pulse
one
parameter is selected
value
can
be
or
the side
panel
follows:
Page
44
9-4.
5
Display
When values have been set for
strike and maintain
Repeat procedure
Figure
OM-1588
as
is
complete
(see
Turn Teach mode Off.
on
changed
Display Control knob,
the front panel, the
with the front panel
program
Figure 9-2).
Setting
an arc
a
teach
point,
for five seconds,
at each teach
point until
Custom Pulse Screen
The letter C will appear in the upper
ner of all customized programs.
To set
right cor
Sequence Welding Parameters,
Section 8-2.
Teach Point Parameters On The Side Panel
see
N OlE
1~
Program #__________
Make copies of this chart for future
Wire
use.
Size/Type________________________ Gas_________________________
Program Name____________________________________________ Card #_______________________
Gun Model_____________________________________________ Flowrate
1PM
ApK
AbK
PPS
PWms
CFM
COMMENTS
Preflow:___________________ Sec.
Run-In Trim:_______________ 1PM:____________________________ Sec.:__________________________
Crater Trim:_______________ 1PM:__________________________ Sec.:_________________________
Postflow:___________________ Sec.
OM-1588
Page
45
9-4.
Changing
To
Adaptive
Pulse
Welding
I ~H 4
READ SAFETY BLOCKS at start of
Section 9 before proceeding.
Welding parameters
for both
a
Pulse and
are
the same
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
1
U
Side Panel
Mode Select
shown:
Side Panel
Default
display
Display
when unit is first
turned On, at other times
use
side
panel mode select button to select
Process.
/
>Prg
>Process
1_
Pulse
Sequence
DualSchd
035Steel
Card
ArgonOxy
Side Panel
Parameter
Select
,
>Process
Prg
Sequence
1
>Eu!~~
DualSchd
035Steel
Card
ArgonOxy
lncrease/
U
Decrease
V
>Pr-~ocess
Prg
Sequence
Page
46
>~d~p1EuL.&~
DualSchd
035Steel
Card
ArgonOxy
Figure
OM-1588
1
9-5.
Changing
To
Adaptive
Pulse
Welding
SECTION 10- TEACHING A MIG WELDING PROGRAM
WARNING
a
ELECTRIC SHOCK
can
kill.
WELDING
wounds.
Do not touch live electrical parts.
Control circuit and feeder operational power are On
when using or changing the microprocessor
WIRE
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
settings.
the gun whenever the power switch is On and the gun
trigger
A.
Changing
To MIG
is pressed.
Welding
1
Side Panel
Default
U
display
Display
when unit is first
turned On, at other times
Side Panel
Mode Select
panel
use
side
mode select button to select
Process.
Go to
Figure
10-2.
/
>Process
>Prg
Sequence
1.
Pulse
DualSchd
035Steel
Card
Arg
on
Oxy
Side Panel
Parameter
Select
>P
r
Prg
0 c e 5 5
1
Sequence
Dual Schd
Card
Figure
10-1.
Changing
To MIG In The Process Mode
OM-1588
Page
47
B.
Setting Sequence M1G Welding Parameters On Side
Panel
Display
Side Panel
1
Display
When unit is turned On, Process is
the default mode. Use side panel
mode select button to
select
f
>Process
Sequence.
2
I
>Prg
Side Panel Parameter Select
Button
MIG
Sequence
Use side
Qua lSchd
panel parameter
select
button to select parameters.
Card
3
Weld Parameters
Parameter ranges
(~~)
Display
are as
follows:
Volts, 10.0-38.0 Volts
Side Panel
Mode
Select
Wire Feed Speed, 50-780 Inches
Per Minute, 1PM
.
Seconds, 0-25.0 Sec. If value set is
(0), welding continues until
zero
welding
Process
>W~l d
>Sequence
trigger
is released.
Inductance, 0-99 %
18. OVo I
DualSchd
200
1PM
Card
0.0
Sec
t
Changes to voltage and wire feed
speed (1PM) parameters in the
weld sequence are also
on front panel display.
Go to
Set Desired
gun
Figure
displayed
10-3.
Voltage
3
Increase! Weld
Decrease
can
Sequence
Volts
be fine tuned
while
welding
Side Panel
Parameter
Select
Set Desired Wire Feed
Set Desired Weld Time,
If
lncrease/
Decrease
Increase!
Decrease
Side Panel
Parameter
Select
Weld Sequence 1PM
can be fine tuned
while welding
Set Desired Inductance,
If
Applicable
>Wa I
~
Increase!
Decrease
Side Panel
20.OVoitH
Increase
Proceed to next
Parameter
Select
Figure
OM-1588
Speed
Applicable
Page
48
10-2.
Setting
Weld
Sequence Display
figure.
1
Crater Parameters
Parameter ranges
Display
follows:
are as
Volts. 10.0-38.0 Volts
1
Wire Feed
>~
a
Speed.
50-780 Inches
Per Minute, 1PM
18.QVoI
I PM
2 00
I
Seconds,0-2.5OSec. Ifvaluesetis
(0), there is no Crater
zero
0.OOSec
sequence.
___________________
Go to
I
Figure
10-4.
Side Panel
Parameter
Select
U
4
____________________________
____________________________
I
Crater
I>1~0Volt
I
I
I
Crater
I
24.OVoIt
1PM
1PM
0.OOSec
0.OOSec
250
Crater
24.OVolt
400
I
1PM
__
__
__
Set Desired
Voltage
Side Panel
Parameter
Select
Set Desired
Wire Feed Speed
lncrease/
Side Panel
Parameter
Select
Set Desired Time
Increase,
Decrease
Increasel
Decrease
Decrease
I
I
_________
I
>c
24
I
~
.
400
1.
~
OVo I
1PM
l2Sec
Side Panel
Parameter
Select
Increase
Proceed to next figure.
Figure
10-3.
Setting Crater Sequence Display
1
Burnback Parameters
Parameter ranges
are as
Display
follows:
Volts. 10.0-38.0 Volts
Seconds, 0-0.25 seconds. If value
set is zero
(0), there is
no
Burnback
sequence.
Go to
Burnback
18.0
Vol
0.00
Sec
Q
Vol
0.00
Sec
>1~
Side Panel
Parameter
L
Burnback
tL
Set Desired
Burnback Volts
Select
16
10-4.
Setting
0
Vo I
Sec
Side Panel
Parameter
Select
Burnback
10-5.
~
Set Desired
Burnback Time
Increase,
Decrease
Increase,
Decrease
Figure
.
Figure
I
16. 0
Vo I
0.12
Sec
Side Panel
Parameter
Select
Increase
Proceed to next
figure.
Sequence Display
OM-1588
Page
49
Postflow Parameters
1
______/
______
______
>PQSttIQW
Postflow
Sec~~~>Q~Q Sec~
>P~~tfiow
0.0
Side Panel
Parameter
Select
~1.2 Sec~
~
Increase
Proceed to next
Increase!
Decrease
10-5.
Go to
Setting
Postflow
figure.
Sequence Display
Preflow Parameters
I
______/
______
>~reflo~
Go to
~
Side Panel
Parameter
Select
Sec
adjusted
Figure
(0),
10-7.
Side Panel
Parameter
Select
Increase
Increase!
Decrease
10-6.
can
Display
from 0-9.9
Sec
1.2
Set Desired Time
Figure
be
seconds. If value set is zero
there is no Preflow sequence.
______
Preflow
Sec
0.0
Figure 10-6.
Preflow
>Pr~flow
can
Side Panel
Parameter
Select
Set Desired Time
Figure
Display
be adjusted from
0-9.9 seconds. If value set is zero
(0), there is no Postflow sequence.
Postflow
Proceed to next
Setting
Preflow
figure.
Sequence Display
Run-In Parameters
1
Parameter ranges
I
Display
are as
follows:
Run in
Volts, 10.0-38.0 Volts
20. OVo I
Wire Feed
1PM
Speed.
50-780 inches
per minute, 1PM
0.0
Side Panel
Parameter
Select
Set Desired
Voltage
Side Panel
Parameter
Select
Increase!
420
2.2
20.OVoIt
t
Sec
20.OVoIt
150
1PM
150
1PM
0.5
Sec
>Q~
Sec
Side Panel
Parameter
Select
Increase
sequence.
~I
Runin
lPM~ ~>Rt~nin
20. OVo I
Seconds, 9-2.5 Sec. If value set is
(0), there is no Run-In
zero
~
Increase!
Decrease
Decrease
>W~ I d
Sec
Set Desired
Wire Feed Speed
F
_J
Set Desired Time
Increase!
Decrease
Figure
OM-1 588
Page
50
10-7.
Setting
Run-In
Sequence Display
Side Panel
Parameter
Select
SETTING DUAL SCHEDULE PARAMETERS
SECTION 11
a
WARNING
ELECTRIC SHOCK
can
WELDING WIRE
wounds.
kill.
Do not touch live electrical parts.
Control circuit and feeder operational power are On
using or changing the microprocessor
when
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
can only be used
consecutive weld pro
grams such as: 1 & 2, or 3 & 4, or
5 & 6, or 7 & 8. Any program type
with
two
MIG, Adaptive Pulse,
or
Pulse
can
be combined in dual schedule. For
example, Prg 1 is MIG, Prg 2 is
Pulse, or Prg I is Adaptive Pulse,
and Prg 2 is Pulse, etc.
1
Side Panel Mode Select
Button
2
Mode
Display
Use mode select button to select
Dual Schedule, then proceed as
2
3
shown:
3
-
Dual Schedule Parameters
Display
Use side panel increase/decrease
buttons, or Display Control knob
(see Figure 11-2)
pairs.
to
select dual
schedule
lncrease/
Decrease
~g ~
Side Panel
Parameter
Select
Display
Control
If the two desired
welding programs
are not in the proper program order (I & 2, or 3 & 4, etc.), the
in the proper order would 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
most
common
method to
get them
card information.
Figure
11-1.
Setting
Dual Schedule Pairs On Side Panel
Display
OM-1588 Page 51
I
Front Panel Parameter Select
Button
2
Front Panel
Display
Press parameter select button to
select program number on front
panel display.
3
Front Panel
Display
Control
Knob
4
Welding Gun Trigger, Or
DSS-Type Switch
The dual schedule programs can
be alternately selected between
active programs A or B by turning
the
Display
clockwise
Display
Welding Gun
Trigger
OR
Control
Knob
Welding Gun
DSS-Type
Switch
>Prg
Dual
2
(1~j1DuaI
B
Ar
one
releasing the
welding gun trigger, or by an exter
nal mounted DSS-type switch
mounted on the welding gun. See
Section 13-10 for specific switchinstructions.The
type
settings
shown on the front panel display
for the active weld program.
When program B is active, turn Dis
play Control knob one click clock
wise to select another
schedule programs.
pair of
Control
Knob
When dual schedule is On, and Process is selected
panel display,
buttons
Figure
OM-1588
Page
11-2.
52
can
then the side
be used to
Selecting
on
the
panel increase/decrease
change program
numbers.
Between Active Dual Schedule
Programs
or
and
Display
side
click
counterclockwise,
by squeezing
are
~>Prg
~
Control knob
or
A And B On Front Panel
Display
dual
SECTION 12
12-1.
Installing
USING THE OPTIONAL DATA CARD
Data Card
1
Label
Peel
from label and
backing
apply
by
to data card with THIS SIDE UP
metal
pins.
Write the
stored
of the programs
the card on the label.
names
on
Write the
name
equipment the
of the piece of
card is used with
on
the label.
2
Data Card
3
Card Slot
Insert card into slot. To format card.
turn On power to the unit. Select
Card from menu. Data card for
mats when unit enters Card mode.
3
Exit Card mode and turn Off power.
ST- 156 266-B / Ret. S- 155 823
Figure
12-2.
Using
12-1.
Installing
Data Card
The Data Card
Use Mode Select button to select
Card.
1
Card
2
Write
Display
Used to transfer program data from
unit to card. The program card can
hold up to 32 programs. When writ
ing to the card, the next available
program number is
automatically
assigned.
3
Read
Used to transfer program data from
card to unit.
4
Delete
Used to delete program data from
card.
3
5
Done
Used to exit card
4
6
Moving
Moving line is
be changed.
Figure
12-2. Card
display.
Line
under value that
can
Displays
OM-1588 Page 53
I
Card
I
Display
Use Mode Select button to select
Card.
2
Moving
Line
Moving line is
be changed.
under value that
can
Process
Name
3
Sequenc
e
Pr
DualSch d
es
If
s
panel
Be low
>Card
Display
is desired, press side
Parameter Select button to
no name
continue the write
procedure.
When
~
2
F
naming a program, the front
panel Display Control knob can be
used to speed selection of charac
Side Panel
Parameter
Select
ters.
#1/ulse
>Write
Read
035Stee I
Delete
ArgonOx
y
Press
Done
Allowable characters include: 0 thru 9, :, ;,
>,?, @,Athru Z, , IJ], ~,,, athru
%,&,, (,),*,+,_,,/,
I
z,
<,
I,, #, $,
3
lncrease/
Decrease
Side Panel
Parameter
Select
V
Name?
Name?
NQ
ArgonOxy
Yes
~
Press
Increase
No
Yes
~35Steel
035Steel
ArgonOxy
~P
r
e 5
S
Side Panel
Parameter
Select
Side Panel
~
Name?
Parameter
Select
~
5007992
~
Frame
Press
Side Panel
Increase
Parameter
Select
Side Panel
Parameter
Select
Figure
OM-1588
Page
54
12-3.
Naming Programs And~ Writing
To Card
Use Mode Select button to select
Card.
1
Card
2
Moving
Display
o c e s s
Seq
uenc e
Dua lSch d
>Car d
Pre
ss
Bel
ow
Moving
changed.
Read
Side Panel
Parameter And
Select Once
\
Writ
~1
e
Display
Select desired card program to
download. Select feeder program
Mode
Select
number where the card program
Once
goes.
I
V
2
can
be
3
~
Line
line is under value that
3
Pulse
035Steel
>Read
Dele te
Arg onOxy
Done
Press
I
Be
Be
Lost
Lose?
Pulse
1
035SteeII
PrglWillI
Prg1Will~
I
No
~
Press
Yes
~
#
Lost
-
Lose?
A
No
r
Press
Increase
go nOx
Press
y
I
Side Panel
Parameter
Select
Side Panel
Parameter
Select
__________________
I
I
I
Side Panel
Parameter
Select
__________________
I
I
sel
Read
Done~
Card
~
to
Prg
I
~
Pu I
1
Argon_Oxy~
I
Press
Press
Figure
12-4.
Reading From Card
1
Wr
>R
i
e a
De I
WARNING:
d
CardEmptyl
e
are no programs on the
card, this series of displays appear.
I
t e
Warniog Display
If there
Press
t e
Below
Done
Side Panel
cJ
Wr
i
t
Parameter
Select Once
De I
e
>Prg
>Process
e
Read
Sequence
g
MIG
DualSchd
t e
Press
>Done
Side Panel
Parameter
Select
Figure
12-5.
L~C
Reading (Or Deleting)
a
r
d
From An
Empty Card
OM-1588
Page
55
Use Mode Select button to select
Card.
1
Card
2
Moving
Display
Line
Moving line is
be changed.
3
Proces S
Sequen
Pr
DualSc hd
ess
Be low
Side Panel
Parameter And
Select Once
I
I
Write
I
I
Read
>Delete
~_Done
#
2
~Pr
~
~
Mode
Select
Twice
MIG
WARN I NG:
ess
Side Panel
Parameter
Select
2
3
De I
e
t e
Lose?~~~
No
Press
Increase
Yes
Side Panel
Parameter
Select
Side Panel
Parameter
Select
#~
MIG
Press
Side Panel
Parameter
Select
Figure
OM-1588
Page
56
12-6.
can
Display
Select program number to be de
leted from card.
ce
>Card
Delete
under value that
Deleting Programs
From Card
SECTION 13SETUP
Setup Flow Chart
13-1.
2
r~e
1~_
P
>Sy s t em
Range
Secu
r
I
a
Display Selections
Features
3
Settings
s
b i
To set up features that customize
operation, use the setup displays.
I
>Pu I se/Mi
t y
1
2
Features that can be customized
follows:
Access
are as
Example Of Setup Display On Side Panel
Settings
Features
Display
H
Section
Process
>System
Features
Display
Section
Settings
Selection
Selection
Capability
Pulse/Mig
Mig Only
Parameter
>Remote
13-3
Off/On
13-12
Increase!
Decrease
Press Mode Select
To Go To Next
Run Hours
>Arc Time
Setup Display
~
09999.99
Hours
0999,999
Cycles
13-13
.
>Range
25.0 V
Volt Mm
o.o
Volt Max
25.0
AmpMin
0-50A
Amp
50
-
-
13-4
No Reset
99.9 V
Reset
I___________
Max
-
999 A
>Self Test
13-14
I___________
>Security
Program
Number
Lock
Oft/On
13-5
1
>Wire Feed
IPM/MPM
Display
Type
Motor
~
Standard
Low
>Access
Code
Off/On
13-6
Voltage
DVC On/Oft
13-7
Speed
High Speed
I
>Mig Type
13-15
+______________________
Model
>Model
Correction
Type
L
Bench
13-16
Boom
+
>Voltage
Control
17-Pin
Feedback
Volt Sense
Arc Start
Standard
13-8
No Reset
>Memory
13-17
Reset
I
>Arc Start
Type
~Shutdown
13-9
Hot Start
I
No Volt Sense
Off/On
~Name
Card
Oft/On
~So~are
Version
I
13-18
I
>Dual Schedule
Switch
Type
Momentary 2-Pole
13-10
Programs
13-19
Maintained 2-Pole
Maintained 1-Pole
Number~
13-20
Trigger
>Trigger
Program
Select
Oft/On
13-11
I
I
Figure
13-1.
Setup
Flow Chart
OM-1588
Page
57
Using Setup Displays
13-2.
Front Panel
1
Front
2
Setup Display
panel display during setup.
Side Panel Mode And Para
meter Select Buttons
3
Power Switch On Rear Panel
Press and hold down both buttons
while
4
turning
On unit.
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
made while in the setup
changes
displays,
setup displays,
and/or to exit the
turn power to the unit off and back
on or press the gun trigger to return
to the Process
display.
4
/
4
Process
>System
Range
Secur ity
Acces
Capabi
13-2.
I
ty
s
Side Panel
Figure
I
>Pulse/Mig
Display
Accessing Setup Displays
Selecting Process Capability
13-3.
~
N OTE
This selection allows the wire feeder to be used with
variety of welding power
Welding Pulse
a
This selection also determines whether Ga s Metal Arc
sources.
(Pulse/Mig) GMA W-P
is available.
1
/__~.
(
Setup
Example Welding Power Sources:
Puise/Mig =450 Ampere Inverter M:del
=
welding power source to produce
either pulse GMAW-P or regular
)
GMAW welds.
~
When in
I
works
I
I
I
~
y
s
e C
Pr
t em
u
r
o ce S
Capabi
i
t y
u
S
/ 1
Ii
58
welding power
produce regular GMAW
ty~
Select the
Increase
Pr
0 ce
S S
Ca pa b I
l ~ ~ t Ml g
Figure
Page
the wire feeder
the
welds.
g
Q
I
0
Access
OM-1588
Mig Only,
with
source to
1
I Range
S
System Display
When Process Capability is Pulse/
Mig, the wire feeder works with the
13-3.
System Display
process the welding
is able to do.
power
source
When
Mig Only
is selected,
of the setup choices
i
t y
I
are
some
automati
callymadeandarenotavailablefor
selection by the operator.
13-4.
Selecting Welding
~
N OTE
Power Source
Range
Welding power source minimum and maximum voltage values
required. Amperage values are required for pulse welding.
1
See
ers
are
always
Range Display
welding
power source Own
voltage and amper
Manual for
age ranges. Set values to match
welding
2
Minimum
Range
3
Press Mode
Select
Voltage Display
is 0 to 25.0 volts.
Maximum
Range
4
power source ranges.
Voltage Display
is 25.0 to 99.9 volts.
Minimum
Amperage Display
(Available When System Set
For Pulse/Mig)
Range
is 0 to 50 amperes.
Maximum
Inverter Model. Do not
Amperage Display
(Available When System Set
if
For
Default values
using
5
for 450 Ampere
change values
450 Ampere lnverter Model.
are
Range
PulselMig)
is 150 to 999 amperes.
2
Increase
3*
4*
5*
565
Amp
*Use side panel Parameter Select
button to select
voltage
or
amperage.
Use Increase/Decrease buttons to
change
value.
Figure
13-4.
Range Display
OM-1588
Page
59
Selecting Security
13-5.
N OTE
~
Lock
Security
lock works only when
a
data card is inserted
(see Section 12-1).
I
Security Display
Use this
weld
can
display
to lock a programs
parameters
not be made
so
that
using
changes
front panel
controls.
2
Program
Number
Choose the program number (1
through 8) to be locked. A program
2
can
be locked
3
Program
on one or
Lock
When lock is off of
Increase
Display
program, the
weld pa
rameters of that program without
restriction. The operator can also
operator
Press Mode
both sides.
can
a
change all
change sides
without restriction.
With lock
program, the opera
Select
on a
change parameters of that
program but the range of change is
restricted, If only one side is
tor can
the
locked,
change sides
If both sides
Prog
2]
Prog
>Prog
rH>~~ ~~~_i:LocI< QH_~_iLo~ 7–J
Increase
~
Side Panel
Parameter
Select
Side Panel
Parameter
Select
are
program number.
locked, the opera
tor can
changes
change
program number.
In the
cannot
operator
or
side~s but cannot
-
example displays in this fig
operator could change the
ure, the
value of trim –10% and wire feed
speed –100 ipm from programmed
values. If the settings are left at 0,
the
operator cannot change values
programmed. If both
sides are locked, they automatical
from those
ly have
the same range of
change.
If dual schedule is on, the paired
programs are locked and unlocked
(Prog
LJLock
1>Trim
Prog
2
onL_iTh_JLock
or ~ 1>Trim
On
0
1PM
together.
21
U
10
L1PM
0
lncrease/
Decrease
Side Panel
Parameter
Select
Side Panel
Parameter
Select
Increase
Figure
OM-1588
Page
60
13-5.
Security Display
13-6.
r
Selecting Or Changing
N OTE
~
Access Code
Access code works
only
when
data card is inserted
a
(see Section
1
~t~sp~
Code
12-
1)
Display
With code off, access to the setup
displays is not restricted.
With code on, the operator must
know and enter the access code to
/
i
access or
change
any of the setup
displays.
Code
Range
Secur
>A
c c e s
Mig
2
i
ty
Access
>Of f
With
Type
Press Mode
Display
code set, this
display ap
pears when power is turned on
while holding the side panel Mode
s
I
a
and Parameter Select buttons.
Select
Press side panel Parameter Select
button to enter access code. When
the correct letter is entered, the
automatically moves to the
Increase
cursor
next character. When the final ac
cess
Code
>Q
code letter is entered, the dis
play automatically changes
initial setup display.
to the
0
AAA
Side Panel
Parameter
Select
Co d
e
On
>A A A
e S
r
)...
Increase/Decrease
To Set Code
(~
Co d
S
Parameter Select
To Move Cursor
e
On
>Z W X
r
e
S
S
Turn Power Off And Back On
And Access Security Display
I
2
/
I
Enter
Ac
>Cod
AAA
e
c e s s
Code
~P
Figure
r
e S
13-6. Access Code
S
Display
OM-1588
Page
61
Selecting Voltage
13-7.
Correction
1
Mig Type Display
With DVC
the unit
Voltage Correction On,
closed-loop feedback
17-pin cord or voltage
uses
from the
sensing
leads to maintain set volt
age parameters.
With DVC
Voltage
Correction Off,
feedback from the arc is not used
for closed-loop feedback to main
tain voltage parameters. Feedback
from the arc is still used for other
functions.
Be
voltage sensing leads are
or voltage feedback is
available from
welding power
source through the 17-pin recep
sure
connected
tacle.
Figure
Selecting Voltage Sensing
13-8.
N OTE
~
13-7.
Mig Type Display
Method
Voltage sensing feedback
setting is Mig Only.
is
automatically
set for V. Sense when the
1
Voltage
Feedback
System
Display
When
Press
Mode Select
Setup
~
\..Disp~ispIa~,,J
~
I A
I Mi
I >v
c c e $ S
g
I
Type
o I t a g e
ArcStart
Co
n
t
r
~
1
using the 17 Pin setting,
voltage feedback is through
/
welding power source, and
feedback signal is sent through
17-pin cord to the feeder.
~
If the 17 Pin setting is used, it is rec
ommendedthatthevoltagesens
ing terminals on the welding power
I
Feed back
I
P
>1 Z
I
source
be used to monitor
Con t
Fe
e
r
d b
weld cable used.
Hj
01
a c
k
Us
Figure
OM-1588
Page
62
13-8.
Voltage Feedback Display
the
the
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
~
the
age at the workpiece.
When
Increase
arc
arc
13-9.
Selecting Regular
N OTE
~
Or Hot Arc Start
Arc Start selection is not available when the
Do not
use
the Hot Start
setting
for 035 in
System setting
(9 mm)
1
Vol
Setup
~
Type
I>ArcStart
high initial weld curnecessary to start large
diameter welding wires. When in
Hot Start, the 450 Ampere Inverter
Model starts the arc in the CV mode
and switches to CC once the arc is
ArcStar71
>Standard
DualSchd j
Display
Model when
rent
Type
tage
Arc Start
Use the Hot Start mode for pulse
welding with 450 Ampere Inverter
I
Mi g
Mig Only.
smaller wire.
1
/
Press
ModeSelect
or
is
is
Do
not
using
450
started.
unless
use
Hot
Start
Ampere Inverter
Model.
Increase
I
+
lArcStart
I
Type
~>~ot $tart~
Figure
13-10.
Selecting Type
13-9. Arc Start
Display
Of Dual Schedule Switch
Dual Schedule
1
Choose
type
schedule switch
ger
as
of
Display
external
or use
dual
of the
trig
the dual schedule switch.
1
I
I
I
I
I
~
~
Increase
I
~
I
I
Increase
Increase
Figure
13-10. Dual Schedule
Increase
Displays
OM-1588
Page
63
Momen 2P (Momentary
Contact 2-Pole Switch Or
DSS-1 0)
1
(DSS-9M)
(DSS-10)
1
1
~
>,
-~
.
2
2
>
>
Maint 2P
(Maintained-Contact
DSS-9M)
2-Pole Switch Or
2
2
2
Maint I P Or
3
Trigger (Maintai
ned-Contact 1-Pole Switch Or
DSS-9 Or DSS-8)
A
3
2
1
p
C
A
3
B
4
p
B
4
p
p
3
1
(DSS-9)
1
1
Adapter
~
2
2
>~
A
2
2
2
3
4
Figure
3
3
A~
13-11. Dual Schedule Switch
Selecting Trigger Program
3
>
BO
4
2
>
_______
3
>
2
TR
>
13-il.
~
>
BO
Adapter
1
>
>
3
(DSS-8)
1
4
>
Diagrams
Select
1
Trigger Display
When
Program
trigger
can
tween
programs that have at least
0.2 seconds of
Press
Mode Select
Select is On, the
be used to switch be
preflow
time.
Briefly pressing
releasing
trigger switches programs.
and
gun
the
For
example: if programs 1, 2, and 6
have preflow time of at least 0.2 se
conds, pressing the trigger will
switch from program 1 to 2, 2 to 6,
and6tol.
Pr
o
Se I
g
r
e C
am
t
>0 ~
Figure 13-12. Trigger Display
OM-1588
Page
64
13-12.
Selecting
Remote Increase/Decrease
Capability
1
Remote
Display
When Parameter IncjDec is On,
the
dual
momentary-contact
schedule switch can be used for
I,
changing
as
for
weld parameters as well
between
switching
programs.
Press
de Select
Setup
Display
Dua lSchd
Par amet
Tr
Inc IDec
gger
>Remo t
Arc
e
eT~
For example: when the
panel display is
the front
cursor on
on
Trim
Volts, the dual schedule switch
>Qf f
be used to
Time
remotely change
value. When the front
I
eter
select
is
on
or
can
the
panel param
Prg,
the
dual
schedule switch can be used to
the program number. A
DSS-1O dual schedule switch is
recommended for this purpose.
change
Increase
Pa
r
a m e
t e
r
Inc /Dec
>0
Figure
13-13.
Resetting
n
Display
13-13. Remote
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 using this display.
1
/
Press
Mode Select
Trigger
0
Remote
.O0~
OCyc
I
-~
Arc
Sel
Time
>r~o
B~~t
fTes t
I
Increase
0. OOH
r
OCyc
$
I
>as
Press
Figure
13-14. Arc Time
Display
OM-1 588
Page
65
13-14.
Using Self Test
1
only Factory Authorized persons
perform tests or replace parts.
Have
Switch A
This checks the
crease
2
gun switch in
position.
Switch B
This checks the gun switch de
crease
3
position.
Trigger
This checks the gun
4
trigger.
Wire Feed
This checks the wire feed motor.
1
5
Gas
This checks the gas valve.
Gun Increase
Switch
6
Contactor
This checks the
source
7
welding power
contactor.
CV/CC
This tests the
pin at the 17-pin re
ceptacle that controls whether the
unit is in CC (constant current) or
CV (constant voltage).
3
>1
r
I g g
~
T~gugner
/
>G~ S
Increase
On
Off
Li
Press
I
Press
Side Panel
~
Parameter
Select
Increase
--
-
The welding wire and all metal parts in contact with
it carry weld output when the welding power source
contactor is energized.
o
p
7
Figure
OM-1588
Page
66
13-15. Self Test Procedure
r
e s s
n
13-15.
Selecting
Units For Wire Feed
And Motor
Speed
Type
Wirefeed
1
Display
The
displayed unit of wire speed
can be changed along with the wire
feed motor type.
~1
Increase
Di sp
Display
I
PM
Motor
lay
I>MPM
T Motor
YPeH~_
Type
d
a n
r
d
Parameter Decrease
Increase
Increase
a
Select
13-16. Wirefeed
Figure
13-16.
Selecting
Bench Or Boom Model
NOTE ~
Display
Type
is
System setting
This selection is not available when the
I
Mig Only.
Model
Type Display
1
The unit
I
Press
Mode Select
(
Setup
-~
-~
I
I
I
S
I
w
e
I
fT
r
e
f
S
t
e e
d
e
I
I>Model
M
em o
r
properly
set to
feeders
model
factory
the
Bench for bench
or
Boom
for
Swingarc model feeders. The settingloadstheproperpulseparam
I
Mode
I
is.shipped from
eters into memory for the model
used.
T y p e
>B~nh
This selection does not
~
when
a
change
memory reset is done.
I
Increase
I
Model
I
Type
]
Figure
13-17. Model
Type Display
OM-1588
Page
67
Reset
13-17.
Resetting Memory
I
No Reset
Memory
/
/
~
Access
cannot be reset.
1
Press
Mode Select
2
\
Program
Reset
Press Parameter Select button to
Setup
Display
reset last active program to
factory
program
settings.
original
All other
program and setup information
mains the same.
3
Increase!
Decrease
System
re
Reset
Press Parameter Select button to
reset programs and setup to origi
nal factory settings. System, Arc
>ErQgr~rn
1
4
Time, and Model Type settings are
not affected by the system reset.
4
Reset
I
Voltage Shutdown Display
(Default) Displays
Press
>Process
Sequence
>Prg
Pu I
I
I
Side Panel
Parameter
Select
1
se
I
DualSchd
035 St
ee
Card
Argon
Oxy
Increase!
Decrease
Reset
Press
Side Panel
Parameter
Select
Figure
13-18.
Selecting Voltage
13-18.
Resetting Memory
Error Shutdown
With Arc
Siart/Volt
Sense on, the
unit shuts down when no arc volt
age is sensed. If the unit shuts
Press
Mode Select
down,
an error
message appears
(see Section 14-4).
With Arc Start/Volt Sense off, the
unit continues to feed wire even
there is no arc voltage
sensed.
when
Increase
Arc
Volt
Start I
Sense
>Q~
Figure
OM-1588
Page
68
13-19.
Voltage
Shutdown
Display
13-19.
Selecting Program
Name Feature
Name
1
When
Display
program card is used, the
programs written from the unit to
the card can be named.
a
/
Press
Mode Select
Access
Setup
Display
Memory
Card
Shutdown
Programs
>Name
>Qn
Sof tware
Increase
Ca
r
d
Pr
o
g
r
ams
>011
Figure
13-20.
13-20.
Naming Card Programs
Software Version Number
1
/1
/
Press
Mode Select
(
Setup
\~~~lay
Memory
Version
Shutdown
#123456Z
Example
Display
When
talking
Version Number
with service person
nel, this number may be required.
(Check actual unit display for num
ber.)The factory keeps this number
on
file with the serial number of the
unit.
Name
~o
f t
w a
Figure
r
e
13-21. Version Number
Display
OM-1588
Page
69
MAINTENANCE & TROUBLESHOOTING
SECTION 14
a
WARNING
ELECTRIC SHOCK
can
HOT PARTS
kill.
Do not touch live electrical parts.
TurnOffwirefeederandweldingpowersource,
disconnect
maintaining,
input
or
before
inspecting.
servicing.
MOVING PARTS
Keep
power
and
can cause
S
Maintenance
such
as
drive rolls.
14-1. Routine Maintenance
Off all power before main
a Turn
taming.
Figure
OM-1 588
Page
70
can cause severe
burns.
cooling period before servicing gun
or
unit.
injury.
away from moving parts.
Keep away from pinch points
Allow
14-1. Maintenance
persons.
to
be
performed only by qualified
wfwarri4.t 8/92
14-2.
Replacing
The Hub
Assembly
READ SAFETY BLOCKS at start of
Section 14 before proceeding.
Turn
Off wire feeder and welding
source. Retract wire onto reel
power
and
remove.
Take
hub
apart
as
shown.
Retaining Ring
1
2
Hex Nut
3
Washer
4
Spring
5
Keyed
6
FiberWasher
7
Brake Washer
8
Hub
9
Hub
Washer
Support Shaft
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
6
force is
welding
(see Section 3-12).
7
7
6
5
4
Tools Needed:
3
2
~
15/l6in
ST~142 709
Figure
14-2. Hub
Assembly
14-3. Overload Protection
i~H
READ SAFETY BLOCKS at start of
Section 14 before proceeding.
Turn Off wire feeder and
power
1
I
welding
source.
Circuit Breaker CBI
CBI protects the wire feeder motor
from overload. If CB1 trips, the wire
feeder shuts down. Check for
jammed wire, binding drive gear, or
misaligned drive rolls. Correct
problem.
Allow
cooling period
and
manually
reset breaker.
Ref. ST~9DO 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
sensing connections. CheckS con
nections at 17-position plugs/recep
tacles at the unit and welding power
arc
source.
Turn unit off and back
after
on
cor
recting problem.
Re
T
ease
r
gge
r
I
If this
2
3
N
Volt
No
Se
n
s
e
d
~ror~
3
Memo
r
y
Prg
occur
when
Error
M emory
Prg
Memory CRC Error Display
Perform
p
4
Go
00
-~-----
N
system
reset.
Error
Display
through pulse parameters
make
sure
No Tach Sensed Error
1
The
tach
motor
reaching
ror
to
they do notexceed set
tings of the Range display (see Sec
tion 13-4 and Section 7) or perform a
system reset.
5
Er
a
Memory Range
The data in the program indicated is
out of usable range.
1
CRC
Range
continues to
The data in the program indicated is
not the same data that was saved.
4
I
error
pulse welding, it may help to select
Hot Start (see Section 13-9).
Display
feedback
the control. Check
is
not
connec
tions.
5
Press front panel Parameter Select
to clear error.
Tach
No
6
Se
n
s
e
d
Er
Arc Start Error
Display
This appears when pulse welding
and current is detected but the arc
ror
6
cannot be started. Check and correct
pulse parameters
program
Arc
age
settings.
Check
and volt
voltage sensing
connections.
Start
Er
ror
Press front
7
panel Parameter Select
to clear error.
7
Arc
Stop Error Display
Arc
Stop
Er
This appears when pulse welding
and the motor does not stop at the
end of the weld. If there is high fre
ror
being used in the area, turn
it oft. A motor brake circuit problem
quency
can
also
cause
Press front
this
error.
panel Parameter Select
to clear error.
Ref ST-155 222
Figure
OM-1588
Page
72
14-4. Error
Displays
14-5.
Diagnostic
Indicator LEDs
WARNING
a
___
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Turn Off wireleeder and
welding power
source,
and disconnect
input power before inspecting
or
maintaining.
Turn Off wire feeder and
power
source.
There
are
welding
Remove wrapper.
nine LEDs
Interface
on
Board PC5O. These LEDs
can
be
used to check certain functions dur
ing troubleshooting.
LEDs 1
through
when power is
feeder.
I
5 should all be
applied
on
to the wire
LED1
Indicates +15 VDC with respect to
PS common on the board.
2
LED2
Indicates 15
PS common
3
VDC with respect to
on
the board.
LED3
Indicates +15 VDC with
circuit board
4
to
LED4
Indicates 15
circuit board
5
respect
common.
VDC with respect to
common.
LED5
Indicates +5 VDC with respect to cir
cuit board common.
6
LED6
On when the contactor is not
ener
gized.
7
LED7
On when the CV mode is used.
8
LED8
On when the gas valve is not
ener
gized.
9
LED9
On when the wire feed motor is not
running.
Tools Needed:
~
1/4
fl
Ret. 5T-162 132 / ST157
Figure
363
14-5. Indicator LEDs
OM-1588
Page
73
Troubleshooting
14-6.
WARNING
a
__
ELECTRIC SHOCK
can
Do not touch live electrical
HOT PARTS
kill.
Allow
parts.
TurnOffwirefi~derandweldingpowersource.
disconnect
input
maintaining,
or
from
can cause
Wire feeder is on, meter(s) do not light
up, motor does not run, gas valve and
injury.
shooting
to be
performed only by qualified
such
as
drive rolls.
wfwam4.1 8/92
Troubleshooting
-~
Check
Remedy
Section
cord connections.
-.
Check and reset CBI.
-.
Check gun
trigger
Check gun
tri~ger.
interconnecting
3-9
or
feeds
Readjust drive roll
Readjust
Change
Clean
or
Replace
connection.
*
-~
pressure.
to correct size drive roll.
replace dirty
or worn
contact
3-7
-~
hub tension.
Incorrect size
14-3
-.~
contactor do not
Electrode wire feeding stops
erratically during welding.
tip
or worn
wire
-~
3-14
-~
--
drive roll.
guides.
liner.
or
Remove weld spatter
or
3-68
-S
-S
3-6B
-S
3.6A
-S
foreign
matter from
around nozzle
*
*
-S
opening.
Have
Factory
Authorized
check drive motor
Motor
runs
slowly.
Wire does not feed until trigger is pulled,
but continues to feed after trigger is re
leased, and trigger hold is not
or motor
-S
Check for correct input
-~
Check for
cable.
a
Service Station/Service Distributor
Repair
or
1H
voltage.
short between
short
--S
--
control board PCi.
welding gun trigger
replace welding gun.
leads and weld
~
-
-~
*
on.
Gas valve in feeder is rattling loudly
along with possible erratic or slow wire
feed
*
Check for a short between welding gun trigger leads and weld
cable. Repair short or replace welding gun.
-S
speed.
Unit does
not
switch
out
of Run-In
~
Speed.
Wire feeder power is on, displays
up, but unit is inoperative,
OM-1588
Install, reconnect,
or
replace voltage sensing
3.9
lead.
L
*See gun Owners
Page
74
Manual.
unit.
inspecting,
Trouble
Wire feeds, shielding gas flows, but
electrode wire is not energized.
source
or
and
Table 14-1.
power
burns.
servicing gun
moving parts.
Keep away from pinch points
welding
pull in.
before
servicing.
MOVING PARTS
Keep away
before
power
can cause severe
cooling period
light
-~
Check welding gun trigger leads for continuity, and repair leads
replace gun.
or
-~
*
NOTES
OM-1588
Page
75
ELECTRICAL DIAGRAMS
SECTION 15
OPTIOPAL CLST~R
CORECTION FOP REF~TE
PROGRAM SELECT
SEE
SIDE
DSPL2
FIELD
D
C
IRDTRECTIOP)
9
I
GOTO
COP
6
6
I
6
6
6
23456
DSPLI
FRONT DISPLAY
DATA
~I ~I H
RCSI
F
~~~iflh!lliuuhi___
~1 ~
CARD
)
goioo-i>>
~
9C100-2>>
FILTER BOARD
RCIG0-3>)~-
RCIOO/PLGIOO
ROIGI/PLOIOP
PC100-6>>-
w
~
INCREMENT
DECREMENT
PC6O
___________
~
I
~
I
,vvvvv
P942
9943
PBA4
-~-
RD
00-5>>
CARD
9C41/PLGAI
PARAMETER
SELECT
~
R061/OATA
PC4O
N
I_____________
SELECT
vvV
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PRO
-~-
vv~
RC6O/PLG6O
~
P911
SELECT
9030
A
DISPLAY
v_v_v_v_v
~
~
RD
d
~
;I ~I ~I ~I i
16
LEFT/RIGHT
SELECT
34
CGNDUCTOR
CABLE
o
0
P925
JOG
o
PC 0
PLRGE
o
0
9922
o
992
MICROPROCESSOP BOARD
SC IS
RC24
RC)0/PLGIO
RIGHT
TRIGGER
HOLD
LEFT
II
TRIGGER
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L
I
C~OJCTOP
CABLE
o
~
~
d,s~IME.9C
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I
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7
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r
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SELECT
LED
LEO
PC 11-3
I
/7
TRIGGER
DECREMENT
/8
TRIGGER
INCREMENT
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LEFT
,~
oTrth,T
RC2S-330--
9021
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-
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,
RC2l/PLG2ARCD~T>
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USED WITH SWITGARC
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OM-1588
Page
76
(
I
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L
15-1. Circuit
I
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2<1 4.4__L..< ~ >_L<14 (
6
Figure
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____________
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>1,1>
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(OPTIOPAL)
PLO9I
P1.0931
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7
3
3,>
___________
RC)6/PLOI6
RC26>>
RIGHT RC27>
TRIGGER
HOLD
RC23 TPIQGER
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~
RCI2/PLGI2
RCIS/PLGIS
o
P923
LED
I
PCI l/PLGI
o
Diagram For Wire Feeder
.1
6
-
WTEPE;
I
PPS-8
(OPTION)
I
PCio
I
I
~p
-
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SWITCH BOARD
I
RCIIO/PLSIIS
I
SHIELD
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I
i
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I
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OR DETACI-WI ENT ~TIDW
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I
0
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IT
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PC I
MOTOR
BOARD
2IVAC~&D
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PCI /PLDI
5C2/PLD2
5C3/PLD3
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PC6/PLOH
SO-T64 541-A
QM-1 588
Page
77
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I
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SD-164 540-A
OM-1588
Page
79
SECTION 16
PARTS LIST
0
0
0
I
C,
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4
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OM-1588
Page
80
Quantity
Model
Part
No.
Dia.
Item
No.
Mkgs.
Description
Figure
149-251
149 252
PLG21,23
079 531
602 156
PLG28,29
080 328
079 534
.2
See Note
.3
164 475
164 474
.3
16
Assembly
CABLE, trigger (consisting of)
CABLE, trigger (consisting of)
2
2
CONNECTOR & PINS,
(consisting of)
pin push-in 14-l8ga Amp
079 878
079 535
16-1. Main
I
12
1
1
66359-6
CONNECTOR, circ
CONNECTOR, circ clamp str nt szll Amp 206358-2
CABLE, port No. 18 4/c (order by ft)
CONNECTOR w/SOCKETS, (consisting of)
CONNECTOR, circ skt push-in 14-l8ga Amp 66358-6
CONTROL BOX, (Fig 16-3)
CABLE, interconnecting (consisting of)
CABLE, interconnecting (consisting of)
4
.
.
4
.
2
2
17ft
2lft
1
4
1
.
.
4
.
1
1
2
2
PLG27,28,
37,38
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
047 636
079 535
079 739
163 519
159 297
.4
010 604
044 858
073 432
056 108
134 834
010606
056 851
139 600
..5.
139 599
..5.
010 603
010 606
603 106
056 112
.6..
600 324
602 243
.8..
602 213
9
601 872
10..
080 947
10..
151 626
11
132 053
12..
Fig
16-2
13
149
838
13
149
839
13
079
264
13
4079216
14
075
078
079
217
Fig
16-5
14
15
16
17.
605 227
RC27,37
047 637
079 534
18
PLG11,17
048 144
115 092
113 746
19
PLG33,34
135 409
114 656
20
139 813
..21..GS1,2.... 125 785
22
139 816
23
159 647
CABLE, port No. 18/14 8/c (order by ft)
HOSE ASSEMBLY, gas (consisting of)
FITTING, hose brs bushing 1/4NPT x .625-18RH
FITTING, pipe brs Y short 1/8NPT ml x 1/4NPT
FITTING, brs barbed M 3/l6tbg x 1/8NPT
FITTING, hose brs ferrule .425 ID x .718 Ig
HOSE, SAE .187 ID x .410 OD (order by ft)
FITTING, hose brs nut .625-18RH
FITTING, hose brs barbed nipple 3/l6tbg
HOSE, gas (consisting of)
HOSE, gas (consisting of)
FITTING, hose brs barbed nipple 1/4tbg
FITTING, hose brs nut .625-18RH
HOSE, nprn brd No. 1 x .250 ID (order by ft)
FITTING, hose brs ferrule .475 ID x .718 Ig
CABLE, weld cop strd No. 4/0 (order by ft)
WASHER, flat stl std 375
WASHER, lock stl split .375
NUT, stl hex full .375-16
BRACKET, spring retaining
BRACKET, spring retaining
SCREW, cap sti hexhd .375-16 x 1.500 Ig
SUPPORT, hub & reel
PIPE POST, 4ft w/base or
PIPE POST, 6ft w/base
PIPE POST, 4ft w/base or
PIPE POST, 6ft w/base
PIPE POST, 4ft w/o base
PIPE POST, 6ft w/o base
...
2
.
.
.
.
....
14.
2
.
....
l7ft
1
2
1
1
2
..
....
....
..
.
.
...
lft...
1
1
...
2
21ft
....
.
2
14
.
1
2
1
1
2
ift
.
.
...
.
.
.
.
.
..
.
1
1
2
2
2
2
26ft
2
26ft
8
4
4
2
30ft
..
....
2
3Oft
..
....
...
2
.
..
8
4
4
1
1
4
1
.
....
4
i
1
1
1
1
1
1
...
1
1
....
BOOM ASSEMBLY
1
NUT, nyl hex jam .75ONPST
CONNECTOR & SOCKETS, (consisting of)
2
CONNECTOR, circ skt push-in 14-l8ga Amp 66358-6
CONNECTOR, circ pin plug keying Amp 200821 -1
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & PINS, (consisting of)
CONNECTOR, rect pin 24-1 8ga Molex 39-00-0040
COVER, protector motor
VALVE, 24VAC 2 way custom port 1/8 orf
PANEL, end cover
INSULATOR, motor clamp
14...
14
2
2
2
2
....
....
....
....
....
8
....
2
....
8
...
1
2
1
2
....
....
....
....
1
2
2
2
8
2
8
1
2
1
2
OM-1588 Page 81
134834
132611
604311
113746
Quantity
No.
Model
Part
No.
Dia.
Item
Mkgs.
Description
Figure
24
25
156-243
PLG51,57
..
131 203
114 656
26
159360
27
159 646
28..
145 639
29.. TK1,2
153 631
30.. PLG57
131 204
.
16-1. Main
12
Assembly (Continued)
CLAMP, motor top
2
CONNECTOR & PINS, (consisting of)
CONNECTOR, rect pin 24-lBga Molex 39-00-0040
3
INSULATOR, screw machine
CLAMP, motor base
STRIP, buna N compressed sheet .062 x 4.000sq
CIRCUIT CARD, digital tach (consisting of)
CONNECTOR & SOCKETS,
32.
33.
33.
M1,2
M1,2
....
.
156354
156353
153 491
153 492
153 493
155 098
153 550
155 099
155 100
154 031
133 493
16-6
34
Fig
35
157 295
36
604 612
37
082 050
164 969
2
8
2
2
..2....2
(consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
GROMMET, rbr .250 ID x .375mtg hole
31
OPTICAL ENCODER DISC
HOSE, SAE .187 ID x .410 OD (order by ft)
MOTOR, gear 1/Bhp 24VDC 272RPM (consisting of)
MOTOR, gear 1/8hp 24VDC 500RPM (consisting of)
KIT, brush replacement (consisting of)
CAP, brush
BRUSH, carbon
KIT, cover motor gearbox (consisting of)
COVER, motor gearbox (consisting of)
GASKET~ cover
SCREW, cover
SPACER, locating
RING, rtng ext .250 shaft grv x .O25thk
3.... 3
2
3ft
of 132 129
..2....2
....2
.2
Page
82
....2
2
1
WIRE DRIVE ASSEMBLY
2
....2
GUIDE, monocoil
SCREW, set stl sch 8-32 x .125 cup point
LINER, monocoil inlet wire
BUS BAR, connecting weld current
2
....2
4
2
Optional High Speed Motor S/R.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1588
3ft
2 ....2
NOTE: When ordering Control Box contact Factory Service Department for proper number.
OPTIONAL
Part
16
....2
Part
No.
Item
No.
Description
Figure
1
2
.
3
4
5
...058427
....
.
..605941
....
.
.
6
010233
.058628
8
....
9
.
058428
108008
....
Hub & Reel
(Fig
16-1 Item
12)
RING, retaining spool
NUT, sti slflkg hex reg .625-11 wlnyl insert
WASHER, flat stl .640 ID x 1.000 OD x 1 4ga thk
SPRING, cprsn .970 OD x .120 wire x 1.250
2
2
2
2
4
2
SUPPORT, reel
REEL, wire 60 lb (consisting of)
SUPPORT, reel spool
RETAINER, spool support
NUT, spanner spool support
.080393
10..
Support,
WASHER, flat sti keyed 1 .500dia x .1 25thk
WASHER, fbr .656 ID x 1.500 OD x .l25thk
WASHER, brakesti
HUB, spool
..057971
.010191
7
11
.
136684
16-2.
Quantity
124900
12.... 124905
13.... 124904
2
1
1
1
2
3
8
7
6
9
10
SC.081 760
Figure
16-2.
Support,
Hub & Reel
OPTIONAL
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1588 Page 83
273
ST80
17
24
10
23
2
9
26
~25
Box
8
Control
31
4
16-3.
Figure
3
2
-
~
16-432
Fig
33
16-7
Fig
34
38
36
35
Part
No.
Dia.
Item
No.
Mkgs.
Description
Figure
1
162253..
2
RC3O,40 ...047637..
...
079534..
048144..
134201..
3
PCi
PLG1
4
155114..
115092..
113746..
115093..
PLG2
113746..
PLG4
115091
113746..
PLG6
....
5
6
7
8
..
CB1
Si
PC8O, RC81
PLG75....
..
136810..
114066..
161706..
083432..
111997..
163 921
131204..
113746..
PLG82
...
.
PLG9O....
9
158720..
147995..
153501
147995..
073756..
11
151187..
+162364..
12
010325..
13
134464..
14
163519..
10
15
PLG9
141 162..
134731
16
079739..
17
18
601222..
603106..
19
600399..
20
138044..
107983..
048 282..
079534..
000527..
21
22
RC7O
23
24.... PLG1O3
...
135635..
114656..
25....
PLG19
158719..
147995..
26....
CR101
....
072817..
27....
RC7,8
....
135 409..
114656..
28
SRi
035704..
030170..
29
30... PLG29,39....115092..
113746..
145948..
..31
32
33 PLG12,50
34
35
36
PC5O
Figi6-4..
155629..
154938..
097132..
163917..
16-3. Control Box
Quantity
(Fig
16-1 Item
2)
PANEL, side lower
CONNECTOR & SOCKETS,
1
(consisting of)
CONNECTOR, circ skt push-in 14-1 8ga Amp 66358-6
CONNECTOR, circ pin plug keying in sockets Amp 200821-1
2
14
4
STAND-OFF SUPPORT, PC card .312/.375
CIRCUIT CARD, motor control
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-1 Bga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
10
CONNECTOR, rect skt 20-1 4ga Amp 350536-1
CASE SECTION, bottom/rear
CIRCUIT BREAKER, man reset 1P 1OA 250V
SWITCH, rocker SPST 1OA 25OVAC
CIRCUIT CARD, HF filter dual
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-1 8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-l8ga Amp 770904-3
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-1 8ga Amp 770904-3
STAND-OFF, 6-32 x .625 Ig
LATCH, slide flush mtg hole 1 .000 wide x 1.500 Ig
4
1
1
8
1
6
1
10
1
1
1
1
1
1
3
1
12
1
6
2
1
WRAPPER
1
BUSHING, strain relief .840 ID x .875mtg hole
LABEL, warning general precautionary
CABLE, port No. 18/14 8/c (order by ft)
CONNECTOR & PINS, (consisting of)
CONNECTOR, circ pin push-in 14-l8gaAmp 213603-1
CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2
CLAMP, univ 50A
HOSE, nprn brd No. 1 x .250 ID (order by ft)
WIRE, strd l4ga blk 600V 105c (order by ft)
BUSHING, strain relief .120/.150 ID x .500mtg hole
BLANK, snap-in nyl .500mtg hole
CONNECTOR w/SOCKETS, (consisting of)
CONNECTOR, circ skt push-in 14-i8ga Amp 66358-6
BLANK, snap-in nyl .875mtg hole
CONNECTOR & PINS, (consisting of)
CONNECTOR, rect pin 24-1 8ga Molex 39-00-0040
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-1 8ga Amp 770904-3
RELAY, end 24VAC DPDT
CONNECTOR & PINS, (consisting of)
CONNECTOR, rect pin 24-l8ga Molex 39-00-0040
RECTIFIER, integ 40A 800V
BUSHING, snap-in nyl .750 ID x 1 .000mtg hole
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-1 Bga Molex 39-00-0038
BRACKET, mtg control box
PANEL, front w/components
CABLE, ribbon l4posn
STRIP, mtg PC card
STAND-OFF, 6-32 x .375 Ig
CIRCUIT CARD, interface
1
1
1 2ft
1
14
1
1
ift
35ft
1
1
1
.
4
1
1
2
1
2
1
2
8
1
3
2
8
1
1
1
1
4
1
OM-1 588
Page
85
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure
PLG51
158 720
158 719..
147 995
PLG53
148 439
147 995
PLG55
.
.
.
.
115 092
..
113 746
.
.
126 689
..
161 781
..
PLG11
115 092
..
113 746
.
PLG15
153 501
..
147 995
..
PLG17
.
115 093
113 746
.
.
155 022
..
155 023
..
41
Fig
16-7
..
097 868
.
.
.
.
..
.
39... PLG1O,24
40... PLG16,41
158 373
.
..
PC1O
37
38
.
131 204..
113 746
PLG54
.
.
097 866
059 712
.
010 145
+When
ordering
a
1
rect skt
12
1
2
.
3
.
10
.
8
1
1
1
4
1
1
.
8
.
6
1
1
6
.
.
.
.
.
.
.
.
.
.
.
.
2) (Continued)
.
.
.
CONNECTOR,
CABLE,
CABLE,
PANEL,
CABLE,
.
..
16-1 Item
22-l8ga Amp 770904-3
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-l8ga Amp 770904-3
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-lBga Amp 770904-3
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
STAND-OFF, 6-32 x 1 .500 Ig
CIRCUIT CARD, processor w/proms
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-l8ga Amp 770904-3
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
116 964
600 343
(Fig
CONNECTOR & SOCKETS, (consisting of)
..
147995....
PLG52
16-3. Control Box
Quantity
.
ribbon 34posn
ribbon 24posn
1
side w/components
1
1
interconnecting pwr (consisting of)
.-.
CONNECTOR, circ l7skt plug Amphenol MS-3106A-20-29S
CONNECTOR, circ clamp slf sz 20-22 Amphenol MS-3057-1012
CABLE, port No. 16 5/c (order by ft)
CONNECTOR, circ l7pin plug Amphenol MS-3106A-20-29P
.
.
.
CLIP, component .437dia mtg adh back
CLAMP nyl .500 clamp dia
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 86
.
.
1
.
.
1
2
1 Oft
.
1
2
1
Dia.
Item
No.
Part
No.
Mkgs.
Description
Figure
2
3
161 714
T47139..
4
164842..
5
144844..
6
...
PC2O,30
PLG25
...
.
.
.
.
160 804
PLG24
089032..
9
153169..
NAMEPLATE, (order by model and serial number)
PANEL, front
1
TAPE, adh acrylic double sided .010
METER LENS, w/gasket
2
LENS, LED 4341 red panel mtg
ACTUATOR, switch
157113.. WASHER, shldr .257 ID x .500 OD
097924.. KNOB, pointer
10
11
x
.500
x
1
3.000..
1
9
1
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-l8ga Amp 770904-3
See Figure 16-3 Item 39
165484..
8
Panel, Front w/Components (Fig 16-3 Item 32)
STAND-OFF, 6-32 x .875 lg
CIRCUIT CARD, schd front
147995..
7....
16-4.
Quantity
1
8
4
6
x
.l87thk
x
.390 OD
x
.l56thk
..
1
1
I
7
11
9
8
ST-BOO 112-B
Figure
16-4. Panel, Front
w/Components
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1588
Page
87
306-0
ST-142
10
)
11
12
13
14
15
-J
8
Ilustraed)
7
6
Model
24
ft
(16
0~
Asembly
Bo m
16-5.
Figure
5
4
28
29
Quantity
Model
Part
No.
Item
No.
Description
Figure
1
010313T.
2
010910..
3
139 590
.
.
4
079 667
.
.
4
080812
.
.
5
079 632
6
079 665
080811
1
12
.
2
.
.
2
15
079 020
..
16
155 335
..
17
149 858
..
17
151 625
..
..
18
150 258
..
...
19
024 605
..
20
075 101
..
079 030
..
22
....
+139 831
080 157
..
..
..
..
..
...
...
23
.
.
.
.
142 804
..
24
134 327
..
25
602 246
..
26
047 224
27
073 666
..
28
057 357
..
29
139 818
..
+When
1
.
2
1
2
..
21
ordering
a
10
.
1
1
..
14
.
I
..
13
.
..
.
.
..
.
2
..
..
..
2
2
11
.
.375 bore
8
10
..
8
x
BOLT, U stl .250-20 x .875 wide x 1.375 deep
GUIDE, wire
GUIDE, wire
079 664
GUIDE, wire inlet
139 633
LINER, monocoil 3/32-1/8 wire x 15.687
159999.. BOOM, dual
160513.. BOOM, dual
073 742
PIN, clevis .750 OD x 2.156 Ig
073 741
CLEVIS, .812 yoke 6.062 Ig .750-l6thd
079 029
NU1~ stl hex full fnsh .750-16
075 462
SHAFT, boom counterbalance
602 250
WASHER, flat stl SAE .750
9
..
4
.
9
..
PIN, cotterhair .072x1.437
WASHER, flatstl SAE .375
PULLEY, V sgl grv 8.875dia x 8.000P
PiPE, plstc .500 x 133.750
PIPE, plstc .500x 181 .750
16
15)
.
8
..
16-1 Item
.
7
..
Assembly (Fig
.
6
..
16-5. Boom
I
12
..
NUT, stl hex elastic stop .750-16
PIPE, blk 3.000 x .875
SPRING, cprsn 3.750 OD
SPRING, cprsn 3.750 OD
.625 wire
x
36.000
.
x
.640 wire
x
36.000
.
x
.
a
.
.
.
....
....
1
1
2
1
....
2
....
1
I
1
1
.625
precautionary label,
1
1
1
1
1
1
.
.
.
.
.
.
.
...
.
1
.
.
1
.
.
..
.
.
.
.
1
1
1
....
1
....
1
.
.
.
.
1
.
.
.
.
.
..
.
.
..
.
.
.
.
1
1
2
1
1
.
1
1
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 .937 ID x 1 .l25mtg hole
GUARD, motor protector
component originally displaying
.
I
x
RETAINER, spring
BEARING, ball thr sgl row .750 x 1.625
NUT, stl hex special .750-16 x 1.250
.
....
.
1
1
2
1
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1588
Page
89
SeeTable 16-1 For
Drive Roll & Wire Guide Kits
~
10
11
12
13
14
6
ST-152 711-B
Figure
OM-1588
Page
90
16-6. Wire Drive
Assembly
Item
No.
Part
No.
Description
Figure
16-6. Wire Drive
Quantity
16-1 Item
Assembly (Fig
34)
-
010 668
.
.
150 147
.
.
.
.
.
.
2
.
.
2
3
4
5
6
7
8
9
..
10
11
...
..
12
13
14
..
..
15
..
16
..
...
..
...
..
..
..
..
17
18
19
20
21
21
22
23
.
24
..
25
..
..
SCREW, cap sti sch .250-20 x 1 .500
CARRIER, drive roll w/components
149 962;-.
SPACER, carrier drive roll
149 486
PIN, rotation arm rocker
132750.. ARM, pressure
150 520
SPACER, rotation pin
133 493
RING, retaining ext .250 shaft x .O25thk
133350.. PIN, hinge
010 837
PIN, spring CS .093 x .625
129 351
SCREW, hexwhd-slt stl slffmg 8-32 x .500
602 200
WASHER, lock stl split No. 8
604 772
WASHER, flat stl SAE No. 8
137 248
SPRING, indicator
133 603
SPRING, cprsn .724 OD x .082 wire x 1.125
132 746
BUSHING, spring
132 824
SHAFT, spring
132 747
CARRIER, shaft
133739.. WASHER,flat.375IDx.625ODx.062
152 241
KNOB, extension
149 959
FITTING, brs barbed M 3/l6tbg x .312-24
149 746
ADAPTER, gun/feeder LH
149 745
ADAPTER, gun/feeder RH
108 940
SCREW, cap stl hexwhd .250-20 x .750
604 538
WASHER, flat stl SAE .312
151 437
KNOB, plstcT 1.125 Ig x .312-18 x 1.500 bar
128 237
SCREW, hexwhd-slt stl slffmg 10-32 x .500
149 527
COVER, drive roll
601 872
NUT, stl hex full .375-16
602 213
WASHER, lock stl split .375
602 243
WASHER, flat stl .375
149964
PIN, groove .25odiax.500lg
601 966
SCREW, cap stl hexhd .375-16 x 1 .250
154031
SPACER, locating
133 530
DRIVE, pinion
133 308
RING, retaining ext .375 shaft x .O25thk
1
2
26
27
...
28
...
29
...
30
..
31
..
32
..
33
..
34
.
.
.
.
4
4
.
4
2
2
1
1
.
1
..
.
1
..
1
.
1
..
..
2
..
2
1
..
1
..
1
.
..
1
..
1
1
..
1
..
4
..
1
..
1
..
2
..
1
..
.
1
..
1
.
1
..
2
..
1
..
..
2
..
1
..
1
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1588
Page
91
Dia.
Item
No.
Part
No.
Mkqs.
Description
Figure
1
147139..
2
_164842..
3
154933..
PC6O
4
PLG6O
....
156623..
153501
147995..
5....PLG41
PC4O
6
158160..
7
144844..
8
154109..
9
153169..
16-7.
Quantity
Panel, Side w/Components (Fig 16-3 Item 41)
TAPE, adh acrylic double sided .010
METER LENS, w/gasket
PANEL, inner control
CIRCUIT CARD, data card
CONNECTOR & SOCKETS,
x
.500
x
3.000
2
(consisting of)
CONNECTOR, rect skt 22-1 8ga Amp 770904-3
See Figure 16-3, Item 40
CIRCUIT CARD, side display
STAND-OFF, 6-32 x .875 Ig
PLATE, ~dent inner control
ACTUATOR, switch
4
6
1
4
1
4
6
3
9
8
ST-800 Ii 3-B
Figure
16-7. Panel, Side
wlComponents
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1588
Page
92
Table 16-1. Drive Roll And Wire Guide Kits
w
~
Wire Size
V-GROOVE
U-GROOVE
VK-GROOVE
UC-GROOVE
E~
~
4 Roll
Drive
Roll
4 Roll
Kit
Kit
Drive
Roll
053700
151036
072000
151052
132958
151 027
053697
151 037
053701
151 053
149519
151028
053698
151038
053702
150995
149520
151 029
053699
151 039
053706
1.8mm
150995
149520
2.0mm
150995
149520
151040
2.4mm
150996
149521
2.8mm
150996
3.2mm
150997
Kit
Drive
Roll
149518
151024
087130
150993
149518
151025
053695
0.9mm
150993
149518
151026
.045in.
1.1mm
150994
149519
.0521n.
13mm
150994
1.6
mm
Metric
.023-.025in
0.6mm
150993
.O3Oin.
0.8mm
.035in.
.068-.072in
4 Roll
4 Roll
Kit
Drive
Roll
132957
151 070
083489
151054
132956
151071
083490
151 055
132955
151 072
053708
151056
132959
053704
151057
132960
151073
053710
151 041
053703
151 058
132961
151 074
053709
149521
151042
053705
151059
132962
151075
053711
149522
151 043
053707
151 060
132963
151 076
053712
~
Fraction
5/64 in.
(.079in.)
3/32 in.
(.094in.)
1/8 in.
(.125in.)
S-0549-C
Each Kit Contains An Inlet Guide, Intermediate Guide, And 045 233 Antiwear Guide With 604612 Setscrew 8-32
With 4 Drive Rolls.
2 Kits
Required
x
.125, Along
For Dual Models.
OM-1588
Page
93