Miller SS-64M SWINGARC Owner’s Manual

OM-1586
155 318P
June 1998
Miller
The Power ofBlue.
Processes
~
MIG
(GMAW) Welding
Pulsed MIG
Flux Cored
(GMAW-P)
(FCAW) Welding
Description
Wire Feeder
(Use
SS-64M
with
CC/CV Power Sources)
SwingarcTM
12 and 16 Foot
D~
Visit
our
website at
www.MillerWetdz.com
OWNERS
MANUAL
From Miller to You
U
Thank you and
you
can
congratulations on choosing Miller. Nowi
job done and get it done right. We know
get the
I
have time to do it any other way.
you dont
Thats
why
Today,
the
when Niels Miller first started
building arc
welders in 1929, he made sure his products offered
long-lasting value and superior quality. Like you, his
customers couldnt afford anything less. Miller products
had to be more than the best they could be. They had to
be the best you could buy.
people that build and sell Miller products continue the
tradition. Theyre just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
¶~f~Jfl1i1J1fl1~
Working as bard asyoudo
This Owners
Miller
help
Manual is
products.
you
designed
help you get the most out of your
Please take time to read the Safety precautions. They will
protect yourself against potential hazards
on
.
Tram MlltB~ Is
power
backed by the must hassle-tree
to
source
wepranty in the blIsIlIesS:
the worksite. Weve
made installation and
operation quick and easy.
With Miller you can count on years of reliable
service with proper maintenance. And if for
iIh(iUIIIW
REGISTERED
QUALITY SYSTEM
the unit needs
some reason
Miller is the first welding equipment
manufacturer in the U.S.A. to be
registered to the ISO 9001 Quality
System Standard.
repair,
theres
a
Troubleshooting section that will help you
figure out what the problem is. The parts list
will then help you to decide which exact part
you may need to fix the problem. Warranty and
service information for your particular model
are also provided.
Miller offers
a
Manual which
more
Technical
provides
detailed service and
parts information for your
unit
To obtain
a
Technical
Manual, contact your local
distributor Your distributor
can also supply you with
Welding Process Manuals
as SMAW, GTAW.
such
GMAW,
Miller Electric manufactures
of welders and
welding
For information
products,
on
a
full line
~
related
other
equipment.
quality Miller
contact your local Miller distributor
to receive the latest full line
catalog
or
individual
catalog sheets. To locate your nearest
distributor call 1-800-4-A-Miller.
L
and GMAW-P,
TABLE OF CONTENTS
SECTION 1
-
SAFETY PRECAUTIONS
-
READ BEFORE USING
1-4.
Symbol Usage
Arc Welding Hazards
Additional Symbols for Installation, Operation,
Principal Safety Standards
1-5.
EMF Information
1-1.
1 -2.
1-3.
SECTION 1
1-1.
1-2.
1-3.
-
1
1
and Maintenance
CONSIGNES DE SECURITE
-
normes
1-5.
Information
sur
5
5
avec
Iinstallation,
-
les
champs ØlectromagnØtiques
9
9
INSTALLATION
3-6.
3-7.
Control Box Connections
3-8.
14-Pin
3-9.
Motor Start Control
3-10.
Removing Safety
3-2.
3-3.
3-4.
3-5.
Plug
9
10
10
10
11
12
Hoses
13
13
Information
14
Collar And
Adjusting
14
Boom
15
3-11. Gun Recommendation Table
Type, Size, And Feed Speed Capability
Installing And Threading Welding Wire
3-12. Wire
3-13.
SECTION 4
-
Table
15
16
17
OPERATION
17
4-2.
Operational Terms
Pulse Welding Terms
4-3.
Front Panel Controls
18
4-4.
Side And Rear Panel Controls
4-1.
SECTION 5
5-1.
-
17
SETFING SEQUENCE PARAMETERS
Parameters In A
Sequence
Program
SECTION 6- SETFING DUAL SCHEDULE PARAMETERS
Dual Schedule Pair
6-1.
Selecting
6-2.
Dual Schedule Switch
SECTION 7
7-1.
7-2.
7-3.
-
Diagrams
USING THE OPTIONAL DATA CARU
8-1.
9-2.
9-3.
9-4.
9-5.
9-6.
9-7.
9-8.
19
20
20
21
22
22
Installing Data Card
Displays
23
22
Card
System Setup Display
24
Parameters
SECTION 9- STANDARD PULSE WELDING PROGRAMS
9-1.
18
19
Data Card Terms
SECTION 8- SYSTEM SETUP
Program
Program
Program
Program
Program
Program
Program
Program
1
2
3
4
5
6
7
8
-
-
-
-
-
-
-
-
24
25
Steel
25
Steel
25
Steel
25
Steel
25
Stainless
26
Stainless
26
Nickel
26
Alloy
Silicon Bronze
SECTION 10- TEACH POINTS
26
27
10-1. Teach
27
10-2.
28
10-3.
Using 15 Points
Teach Using 4 Points
Redefining Teach Points
SECTION 11
-
MAINTENANCE AND TROUBLESHOOTING
29
31
11-1. Routine Maintenance
31
11-2. Error
32
11-3.
Displays
Troubleshooting
SECTION 12
-
ELECTRICAL DIAGRAM
SECTION 13- PARTS LIST
OPTIONS AND ACCESSORIES
WARRANTY
OM-1 586P
8
9
INTRODUCTION
Installing Swivel Into Pipe Post
Installing Boom And Reel Support
Installing Wire Guide Extension
Adjusting Control Tilt Bracket
Equipment Connection Diagrarrt
Connecting Weld Cables And Gas
3-1.
le fonctionnement
8
de sØcuritØ
Specifications
SECTION 3
5
7
Principales
2-1.
3
LIRE AVANT UTILISATION
et Ia maintenance
1-4.
-
3
4
Signification des symboles
Dangers relatifs au soudage a arc
Dangers supplØmentaires en relation
SECTION 2
1
33
34
.36
SECTION 1
SAFETY PRECAUTIONS
-
READ BEFORE USING
-
nd_5/97
som
Symbol Usage
1-1.
Means
a
A
Arc
1-2
not
safety
possible
are
hazards
are
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary
actions to avoid the hazards.
related.
Hazards
Welding
symbols
shown below
to call attention to and
see
There
special safety message.
Marks a
The
Out!
procedure! The possible
adjoining symbols.
shown in the
lET Means Note~
A
Watch
Warning!
hazards with this
are used throughout this manual
identify possible hazards. When you
the symbol, watch out, and followthe related instructions
safety information given below is
to avoid the hazard. The
summary of the more complete safety information
found in the Safety Standards listed in Section 1 -4. Read and
follow all Safety Standards.
only
A
A
grounding of the workpiece
It earth
with
a
separate cable
do not
-
use
is
required, ground it directly
clamp or work cable.
work
Do not touch electrode if you are in contact with the work,
another electrode from a different machine.
ground,
or
a
Only qualified persons
repair this unit.
should
install, operate, maintain, and
During operation, keep everybody, especially children, away.
only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Use
a
Keep
all
can
kill.
worktable
as near
clamp
Do not connect
electrical parts can cause fatal
shocks or severe burns. The electrode and work
circuit is electrically live whenever the output is on.
The input power circuit and machine internal
circuits are also live when power is on. In semiautomatic or
automatic wire welding, the wire, wire reel, drive roll housing, and all
metal parts touching the welding wire are electrically live. Incorrectly
installed or improperly grounded equipment is a hazard.
Do not touch live electrical
weld
place.
when not connected to
than
more
workpiece to prevent
object.
one
electrode
or
work cable to any
output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
Turn Off
parts.
dry, hole-free insulating gloves
Wear
single
securely
in
good metal-to-metal contact to workpiece
the weld as practical.
contact with any metal
live
Touching
floor level.
working above
covers
cable with
Insulate work
ELECTRIC SHOCK
and
panels
Clamp work
or
harness if
safety
Wear
and
body protection.
yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the
work or ground.
FUMES AND GASES
can
be hazardous
Insulate
Do not
use
there is
a
AC
output in damp
danger
of
output
is
confined,
or
if
required,
required
use
for the
remote
Keep your
welding process.
output
control if
present
on
unit.
input power or stop engine before installing or
equipment. Lockout/tagout input power according
OSHA 29 CFR 191 0.147 (see Safety Standards).
Disconnect
to
Properly
Owners
this
install and
ground
this
equipment according
to its
Manual and national, state, and local codes.
Always verify the supply ground
power cord ground wire is properly
-
in disconnect box
or
grounded receptacle
When
If
that cord
check and be
connected to
plug
-
that
input
ground terminal
a properly
is connected to
attach
proper
grounding
double-check connections.
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
-
-
Turn off all
equipment
when not in
If ventilation is poor,
Read
the
Material
manufacturers
Do not
.
Do not
use worn,
drape cables
over
your
body.
or
exhaust at the
arc
to
use an
approved air-supplied respirator.
Data
Safety
Sheets
(MSDSs)
instructions for metals, consumables,
and
the
coatings,
a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
Do not weld in locations
operations.
form highly
poorly spliced
cables.
near
degreasing, cleaning,
The heat and rays of the arc
toxic and irritating gases.
Do not weld
cadmium
use.
damaged, undersized,
use
cleaners, and degreasers.
on
can
or
spraying
react with vapors to
coated metals, such as galvanized, lead, or
unless the coating is removed from the
plated steel,
weld area, the
.
and/or
area
fumes and gases.
welding
Work in
outlet.
making input connections,
conductor first
sure
head out of the fumes. Do not breathe the fumes.
inside, ventilate the
remove
servicing
fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
Welding produces
-~-~ ~
falling.
Use AC output ONLY if
If AC
areas, if movement is
L_.IIV
area
is well
ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
OM-1586
Page
1
ARC RAYS
burn eyes and skin
can
BUILDUP OF GAS
Shut off
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
can
injure
shielding gas supply when
not in
Always ventilate confined spaces
approved air-supplied respirator.
awelding helmet fitted with a proper shade offilterto protect
or watching (see ANSI 249.1
Z87.1 listed in Safety Standards).
kill
or
use.
or
use
Wear
your face and eyes when welding
and
Wear
approved safety glasses
HOT. PARTS
helmet.
burns.
Do not touch hot parts bare handed.
protective screens or barriers to protect
glare; warn others not to watch the arc.
Use
Wear
can cause severe
with side shields under your
others from flash and
Allow
cooling period before working
on
gun
or
torch.
protective clothing made from durable, flame-resistant
(leather and wool) and foot protection.
material
MAGNETIC FIELDS
WELDING
Welding
on
caUsefireorexplosion.
can
closed
containers, such
Pacemaker
or pipes, can causethem to blow up. Sparks
off from the welding arc. The flying sparks,
hot workpiece, and hot equipment can cause fires
and burns. Accidental contact of electrode to metal objects can
cause sparks, explosion, overheating, or fire. Check and be surethe
area is safe before doing any welding.
Protect
yourself
fly
and others from
Do not weld where
flying sparks
flying sparks
can
possible, tightly
cover
NOISE
Noise from
strike flammable material.
(10.7 m)
them with
of the welding arc.
approved covers.
fire, and keep
that
aware
can cause
fire
Do not weld
on
welding
on
a
fire
closed containers such
as
Wear
Connect work cable to the work
unknown
Do not
prevent welding
paths
use
and
as
tip
equipment
can
approved
ear
protection
if noise level is
CYLINDERS
can
explode if damaged.
causing
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the welding
process, be sure to treat them carefully.
pipes,
(see
welding area as
traveling long, possibly
electric shock and fire hazards.
welder to thaw frozen
when not in
or
to AWS F4.1
or
Protect
cut off
welding
wire at
compressed gas cylinders from excessive heat,
shocks, slag, open flames, sparks, and arcs.
mechanical
Install
pipes.
cylinders in an upright position by securing to a stationary
or cylinder rack to prevent falling or tipping.
support
Keep cylinders away from any welding
use.
Wear oil-free
protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Remove any combustibles, such as a butane
from your person before doing any welding.
lighter or matches,
Never
drape
Never allow
Never weld
a
a
welding
welding
on a
torch
over a
other electrical circuits.
or
gas
cylinder.
electrode to touch any
pressurized cylinder
-
cylinder.
explosion
will result.
Use
FLYING METAL
can
injure eyes.
only correct shielding gas cylinders, regulators, hoses,
fittings designed for the specific application; maintain them
associated parts in good condition.
Turn face away from valve outlet when
Welding, chipping,
.
close to the
current from
Remove stick electrode from holder
contact
or
high.
partition
or
tanks, drums,
they are properly prepared according
Safety Standards).
to
processes
the hidden side.
unless
practical
some
extinguisher nearby.
ceiling, floor, bulkhead,
on a
damage hearing.
If
welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Be
spot
and hot metal.
Be alert that
Watch for
can
or
damage hearing.
Remove all flammables within 35 ft
this is not
keep away.
going near arc welding, gouging,
welding operations.
drums,
can
wearers
affect pacemakers.
Wearers should consult their doctor before
tanks,
as
can
wire
brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side
shields even under your welding helmet.
opening cylinder
and
and
valve.
Keep protective cap in place overvalve except when cylinder is in
use or
connected for
use.
Read and follow instructions
associated
equipment,
compressed gas cylinders,
publication P-i listed in Safety
on
and CGA
Standards.
.
OM-1586 Page 2
1 -3~
Symbols For Installation, Operation,
Additional
And Maintenance
MOVING PARTS
FIRE OR EXPLOSION hazard.
Do not install
place
or
unit on, over,
or near
combustible surfaces.
Do not install unit
away from
Keep
all
doors, panels,
closed and
flammables.
moving parts
securely
in
injury
such
as
covers, and
fans.
guards
place.
building wiring be sure power supply system
properly sized, rated, and protected to handle this unit.
Do not overload
is
near
Keep
can cause
-
FALLiNG UNIT
can cause
injury
HF.
Use
lifting eye
cylinders,
gear, gas
Use equipment of
can
causeinterference.
High-frequency (HF.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
any other accessories.
or
RADIATION
only, NOT running
to lift unit
adequate capacity to
lift and
support unit.
Have
using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
If
responsible
The user is
unit.
only qualified persons familiar with
equipment perform this installation.
electronic
promptly
having a qualified electrician
problem resulting from the
for
correct any interference
installation.
OVERUSE
Allow
can cause
cooling period;
Reduce current
starting
to weld
Do not block
STATIC
Put
or
OVERHEATING
follow rated
reduce
or
on
at once.
duty cycle
Have the installation
before
filter airflow to unit.
grounded
boards
or
wrist
strap
regularly
checked and maintained.
Keep high-frequency source doors and panels tightly shut,
keep spark gaps at correct setting, and use grounding and
shielding to minimize the possibility of interference.
again.
(ESD) can damage PC
handling
by
duty cycle.
interference, stop using the
the FCC about
If notified
equipment
boards
BEFORE
parts.
ARC WELDING can
static-proof bags and
store, move, or ship PC boards.
Use proper
cause
interference
boxes to
Electromagnetic energy can interfere with
electronic equipment such as
computers and computer-driven equipment
sensitive
MOVING PARTS
can cause
such
injury
Keep
away from
Keep away
moving parts.
from
pinch points
as
robots.
all equipment in the welding
electromagnetically compatible.
Be
such
as
To reduce
drive
possible,
rolls.
sure
WELDING WIRE
can cause
injury.
Be
possible interference, keep weld cables as short as
together, and down low, such as on the floor.
welding operation
equipment.
sure
according
Do not press gun
trigger
until instructed to do
welding machine
this
is
and
installed
grounded
to this manual.
such
point gun toward any part of the body,
people, or any metal when threading
Do not
welding
1-4.
100 meters from any sensitive elec
If interference still occurs, the user must take extra measures
as moving the welding machine, using shielded cables,
so.
other
is
close
Locate
tronic
area
line
filters,
or
shielding
the work
area.
wire.
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 Health Standards,
using
American
OSHA 29 CFR 1910, from
dent of Documents, U.S. Government
Superinten
Printing Office, Washington,
D.C. 20402.
Safe
Handling
of
Compressed Gases
in
Cylinders, CGA Pamphlet
P-i, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
Welding and Cutting, CSA Standard Wi 17.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1 R3.
Code for Safety in
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances,
American Welding Society Standard AWS F4.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
Protection, ANSI Standard Z87.1 ,from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Code, NFPA Standard 70, from National Fire
Batterymarch Park, Quincy, MA 02269.
Cutting And Welding Processes, NFPA Standard 51 B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
National Electncal
Protection Association,
Safe Practices For
Occupation
And Educational
Eye
And Face
OM-1586
Page
3
EMF Information
1-5
Considerations About Welding And The Effects Of Low
Electric And Magnetic Fields
Frequency
1.
Keep
Welding current, as it flows through welding cables, will cause electro
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: The body of evidence, in the
committees judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.
However, studies are still going forth and evidence continues to be
2.
Arrange
3.
Do not coil
examined. Until the final conclusions of the research
may wish to minimize your exposure to
welding
To
or
reached, you
electromagnetic fields
magnetic
procedures:
Page
or
one
drape
or
taping
side and away from the
cables around your
Keep welding power
practical.
source
Connect work
to
and cables
them.
operator.
body.
as
far away from opera
tor as
5.
clamp
workpiece
as
close to the weld
as
possible.
About Pacemakers:
fields in the
workplace,
use
the
following
Pacemaker
then
4
cables to
together by twisting
when
cutting.
reduce
OM-1586
are
4.
cables close
wearers
following
consult your doctor first, If cleared by your doctor,
procedures is recommended.
the above
SECTION 1
-
CONSIGNES DE SECURITE
UTI LISATION
LIRE AVANT
-
scm
Signification
~1.
A
des
ndfre 5/97
symboles
Signifie Mise en garde! Soyez vigilant! Cette procedure
prØsente des risques de danger! Ceux-ci sont identifies
par des symboles adjacents aux directives.
Identifie
message de sØcuritØ
un
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant lIy a des
risques de danger relies aux CHOCS ELECTRIQUES, aux PIECES EN
particulier.
MOUVEMENTetaux PIECESCHAUDES.
Reportez-vousauxsymboles
mesures a prendre pour
etauxdirectivesci-dessous afin de connaitre les
lET
Signifie
DangersrØlatifs
1-2.
A
nest pas relatif a a
NOTA
Øviter tout
sØcuritØ.
au
soudage
a Iarc
symboles prØsentØs ci-aprŁs sont utilisØs tout au long du
present manuel pour attirer votre attention et identifier les
risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnØes afin dØviter tout
danger. Les consignes de sØcuritØ prØsentØes ci-aprŁs ne font
Les
A
A
Au coursde
qu
autre machine.
a
ce
reparations
qualifiØes.
et les
des personnes
ne
contact avec Ia
piŁce,
Ia
quun materiel en bon Łtat. RØparer ou remplacer sur-le
piŁcesendommagŁes. Entretenir lappareilconformØment
manuel.
Porter
dol
quand on est
provenant dune
es
un
harnais de sŁcuritŁ
Maintenir solidement
lutilisation, lentretien
vent Łtre confiØs
en
Nutiliser
de sØcuritØ.
Linstallation,
Ne pas toucher lŁlectrode
terre ou une electrode
champ
que rØsumer linformation contenue dans les normes de sØcuritØ
ØnumØrØes a Ia section 1-4 Veuillez lire et respecter toutes ces
normes
danger.
quand
place
en
Fixer Ie cable de retour de
avec Ia piŁce a souderou
on
travaille
hauteur.
en
tous les panneaux et
capots.
facon a obtenir un bon contact mŁtal-mØtal
a table detravail, le plus prŁs possible de Ia
soudure.
lutilisation, tenirtoute personne a lØcartet plus par
ticuliŁrement les enfants.
solar Ia
avec
pas mis a Ia
pince de masse quand
objet metallique.
pour Øviter le contact
piŁce
tout
UN CHOC ELECTRIQUE peut tuer
simple contact avec des piŁces Ølectriques peut
provoquer une electrocution ou des blessures graves.
LØlectrode et le circuit de soudage sont sous tension
des que lappareil est sur ON. Le circuit dentrŁe et les
circuits internes de lappareil sont egalement sous
tension a ce moment-l. En soudage semi-automatique ou automatique,
le f ii, le dØvidoir, le logement des galets dentrainement et es piŁces
mØtalliques en contact avec le fil de soudage sont sous tension. Des
matŁriels mal installŁs ou mal mis a Ia terre prŁsentent un danger.
Un
Ne
toucher
jamais
Porter des
gants
es
et des
piŁces Łlectriques
sous
vŒtements de protection
ily
a
DU COU RANT CONTINU IMPORTANT dans les
convertisseurs
tion Ølectrique.
servir de
source
secs ne
procŁdØ
de
source
soudage
Łlectrique
electnque
courant
zones
LES FUMEES ET
Œtredangereux.
Łlectrique
saire,
se
Eloigner
UNIQUEMENT Si le
courant Łlectrique savŁre nØces
servir de Ia fonction de tØlØcommande Si Iappareil en est ŁquipØ.
source
Łlectrique
municipaux.
Toujours verifier Ia terre du cordon datimentation
Verifier et sassu
que le fll de terre du cordon dalimentation est bien raccordŁ a Ia
borne deterre du sectionneur ou que Ia fiche du cordon est raccordØe
a une prise correctement mise a Ia terre.
-
rer
En effectuant les raccordements dentrØe fixer dabord le conducteur
de mise a Ia terre appropriŁ et contre-vØrifier les connexions.
Verifier frequemment le cordon dalimentation pour voir siI nest pas
endommagŁ ou dŁnudŁ remplacer le cordon immŁdiatement sil est
endommage un cable dŁnudØ peut provoquer une electrocution.
-
-
lappareil
peuvent
votre tŒte des fumŁes. Ne pas
respirer
Ies fumŁes.
le demande.
Couperlalimentation ou arrŒter le moteuravantde procŁder linstal
lation, a Ia reparation ou a lentretien de lappareil. DØverrouiller
Ialimentation selon Ia norme OSHA 29 CFR 191 0.147 (voir normes
de sØcuritŁ).
Installeretmettrelaterre correctement cet appareil conformŁment
et aux codes nationaux, provinciaux et
son manuel dutilisation
Mettre
LES GAZ
Le soudage genere des fumŁes et des gaz. Leur
inhalation peut Œtre dangereux pour votre sante.
W
A
Si Iutilisation dune
de Ialimenta
comportant
_____________
Se servir dune
suppression
tension.
courant electrique dans les
humides, dans les endroits confines ou l ou on risque de tomber.
se
Ia
ArrŒter Ies convertisseurs, dŁbrancher le courant electrique, et dŁ
charger les condensateurs dalimentation selon Ies instructions
indiquŁes dons Ia partie entretien avant de toucher Ies piŁces.
pas de trous.
Sisoler de Ia piŁce et de Ia terre au moyen de tapis ou dautres
moyens isolants suffisamment grands pour empŁcher le contact phy
sique Łventuel avec Ia piŁce ou a terre.
Ne pas
aprŁs
hors tension
Ne pas utiliser des cables
sante ou mal ŁpissØs.
quand
on ne
Iutilise
pas.
uses, endommages, de grosseur insuffi
Ne pas enrouler les cables autour du corps.
Si Ia piŁce soudØedoitŒtre mise a laterre, lefairedirectementavec un
cable distinct ne pas utiliser le connecteur de piŁce ou le cable de
IintØrieur, ventiler Ia
zone
et/ou utiliser
un
Łchappement
au
ni
de Iarc pour IØvacuation des fumŁes et des gaz de soudage.
Si Ia ventilation est insuffisante, utiliser un respirateur a alimenta
tion dair homologuŁ.
veau
Ure Iesspecificationsde sŁcuritØ des matØriaux (MSDSs) et les ins
tructions du fabricant concernant Ies mŁtaux, les consommables,
les
revØtements,
les
nettoyants
et les
dØgraisseurs.
espace fermØ seulement siI est bien ventilØ ou
en portant un respirateur a alimentation dair. Demander toujours a
un surveillant dment formØ de se tenir a proximitØ. Des fumØes et
des gaz de soudage peuvent dØplacer lair et abaisser le niveau
doxygene provoquant des blessures ou des accidents mortels.
Travailler dans
Sassurer
un
que lair de
respiration
ne
prØsente
aucun
danger.
Ne pas souder dansdes endroits situØs a proximitØ dopØrations de
degraissage, de nettoyage ou de pulvØnsation. La chaleur et les
rayons de Iarc peuvent rØagir en presence de vapeurs et former
des gaz hautement
toxiques
et irritants.
Ne pas souder des mØtaux munis dun revØtement, tels que lacier
galvanise, plaque en p10mb ou au cadmium a moms que le revŒte
ment nait Łte enlevØ dans Ia zone de soudure, que lendroit soit
et Si nØcessaire, en portant un respirateur a alimenta
Les revØtements et tous les mØtaux renfermant ces Ł!Ø~
ments peuvent dØgager des fumØes toxiques en cas de soudage.
bien
ventilØ,
tion dair.
-
retour.
OM-1586 Page 5
LES RAVONS DE
LARCpeuventpro-.
LES ACCUMU ATIONSDE GAZ ris~
voquer des bri~Iures dans les yeux et
sur Ia P~U
1..
arc du procØdØ de soudage
rayonnement
gØnŁre des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer
des brfilures dans les yeux et sur Ia peau. Des Øtincettes sont projetØes
Le
pendant
mŒme Ia mart.
de
soudage.
le
quent de provoquer des blessures o
Fermer lalimentation
non
Veiller
toujours a
Porter des
protections approuvØs
Utiliser des Øcrans
ou
des barriŁres pour
protØger des tiers de
lØblouissement; demander aux autres personnes de
garder
ne
dair
DES
en
cas
de
ou se
servir dun
respi
homotoguŁ.
PI¨CES
CHAUDES peuvent pro
voquer des:brlures graves.
pour les oreilles si le niveau sondre est
trop ØlevØ.
et de
bien aØrer las espaces confines
rateur dadduction
Porter un casque de soudage muni dun Øcran de filtre appropriØ pour
protØger votre visage et vos yeux pendant te soudage ou pour regar
der (voir ANSI Z49. 1 et Z87. 1 ØnumØrØ dans les normes de sØcuritØ).
du gaz protecteur
utilisation.
IØclair
pas
Ne pas toucher des
re
larc.
chaudes a mains
parties
nues
Porter des vŒtements de
PrŁvoir
une
ble, resistant
dutiliser
le
protection constituØ dans une matiŁre dura
(cuir ou lame) et une protection des pieds.
feu
au
LE SOUDAGE
I
peut provbquer
incendie
ou une
Le
effectuØ
projetees
de larc
et des
de soudure. La
LES CHAMPS
Les
Le contact accidentel de IŁlectrode avec des
des Øtincelles, une explosion, un
un incendie. Avant de commencer le soudage,
que lendroit ne prØsente pas de danger.
personnes de Ia
projection dØtincelles
porteurs dun
cardiaques.
cardiaque,
restez a distance.
stimutateur
cardiaque doivent
dabord consulter leur mØdecin avant de sapprocher
des operations de soudage a larc, de gougeage ou
de soudage par points.
objets mØtalliques peut provoquer
Se protØger et dautres
metal chaud.
MAGNETIQUES peuvent
Porteurs de stimutateur
projection dØtincel
Øquipements chauds peut provoquer des
incendies et des brlures.
surchauffement ou
verifier et sassurer
de refroidissement avant
Ia torche.
affecter les stimulateurs
sur
provo9uerleurØclatement. DesØtincellespeuventŒtre
les, des piŁces chaudes
ou
Un
explosion.
des conteneurs fermØs tels
que des reservoirs, tambours ou des conduites peut
souda~e
pŁriode
pistolet
et de
LE BRUIT peut affecter louIe.
Ne pas souder dans un endroit l o
sur des substances inflammables.
des Øtincelles peuvent tomber
Le bruit des processus et des
IouIe.
DŁplacertoutes les substances inflammables a une distance del 0,7
m de larc de soudage. En cas dimpossibilitØ
es recouvrirsoigneuse
ment avec des protections homologues.
Des Łtincelles et des matØriaux chauds du soudage peuvent facile
ment passer dans dautres
zones en
traversant de
Porter des
Øquipements peut
affecter
protections approuves pour les oreilles si
le niveau sondre est trop ØlevØ.
petites fissures et
des ouvertures.
SurveillertoutdØctenchementdincendieettenirunextincteuraproxi
mite.
Le
effectuŁ sur un plafond, plancher,
peut dØclencher un incendie de lautre ctØ.
soudage
paroi
Si des BOIJTEILLES sont endomma
gØes, elles purront exploser.
separation
Cu
Des bouteilles de gaz protecteur contiennent du gaz
haute pression. Si une bouteille est endomma
gee, ella peutexploser. Du faitque les bouteillesde gaz
font normalement partie du procØdØ de soudage, les
Ne pas effectuer le soudage sur des conteneurs fermØs tels que des
reservoirs, tambours, ou conduites, a moms quils naient ØtØ prØpa
rØs correctement conformØment a AWS F4.1 (voir es normes de
sous
sØcurite).
Brancher le cable sur Ia piŁce le plus prŁs possible de Ia zone de sou
pour Øviter le transport du courant sur une longue distance par
des chemins inconnus Øventuels en provoquant des risques dØlec
trocution et dincendie.
dage
Ne pas utiliser le poste de
lees.
En
cas
de
electrode
soudage
pour
dØgeler
des conduites ge
utilisation, enlever Ia baguette dØlectrode
couper le fil a Ia pointe de contact.
Porter des vŒtements de
protection dØpourvus
dhuile
une chemise en matØriau lourd, des
vers, des chaussures hautes et un couvre chef.
gants en cuir,
du
porte
tels que des
pantalons sans
re
vos
poches
de
projeter
OM-1586
pØriode de refroidissement des soudures,
6
Ne
jamais placer
elles
une
Øcrans latØraux
ou un
torche de
une
soudage
ne
soudage sur une bouteille a ga.z.
jamais entrer en contact avec
dolt
bouteille.
jamais
souder
une
bouteille
pressurisØe
-
risque dexplosion.
risquent
Øcran facial.
en
face de Ia sortie
en
ouvrant Ia soupape de Ia
Maintenir le chapeau de protection sur Ia soupape, sauf
dutilisation ou de branchement de Ia bouteille.
en cas
Ure et suivre les instructions concernant las bouteilles de gaz corn
les Øquipements associØs et les publications P-l CGA Ønu
prime,
mØrØes dans Ies
avec
ØtoignØes des circuits de soudage cu autres cir
Ne pas tenir Ia tŒte
bouteille.
du laitier.
Page
Tenir las bouteilles
cuits Ølectriques.
Utiliser seulement des bouteilles de gaz protecteur, rØgulateurs,
tuyaux et raccords convenables pour cette application specifique;
les maintenir ainsi que les ØlŁments associØs en bon Łtat.
DES PARTJCULES VOLANTES
peuvent blesser les yeux~.:
Porter des lunettes de sØcuritŁ
Placer les bouteilles debout en les fixant dans un support station
ou dans un porte-bouteilles pour las empŒcher de tomber ou
de se renverser.
Ne
Le soudage, lŁcaillement, le passage de Ia piŁce
a Ia brosse en fil de fer, et le meulage gŁnerent
desØtincellesetdes particules mØtalliquesvolan
tes. Pendant Ia
precaution.
ProtØger les bouteilles de gaz comprimØ dune chaleur excessive,
des chocs mecaniques, du laitier, des flammes ouvertes, des Øtin
celles et des arcs.
Une electrode de
Avant de souder, retirer toute substance combustible de
telles quun allumeur au butane ou des allumettes.
~
avec
naire
non
ou
manipuler
normes
de sØcuritØ.
1-3.
Dangers supplØmentairesen
relation
avec
linstatlation, le fonctionnement
et Ia maintenance
Risque DINCENDIE
~
~
DES
ORGANES MOBILES
provoquer des blessures.
OU
DEXPLOSION.
placer lappareil
Ne pas
A
proximitØ
Ne pas installer
sur,
au-dessus
Cu
Rester a lØcart des organes mobiles
a
Maintenir fermØs et fixement
produits inflammables
de
panneaux,
Ne pas surcharger linstallation Ølectrique sassurer que lalimen
tation est correctement dimensionnØ et protØgØ avant de mettre
lappareil en service.
le
recouvrements
en
et
place les portes,
dispositifs de
protection.
-
LA CHUTE DE LAPPAREIL
comme
ventilateur.
de surfaces infllammables.
lappareil a proximitØ
peuvent
HAUTE FRE
QUENCE (H.F.) risque de provoquer
des interferences.
LE
peut
RAYONNEMENT
blesser.
Utiliser lanneau
lever
de
lappareil, NON PAS
les de gaz
ou
les chariot, les bouteil
de sØcuritØ et les ordinateurs.
tout autre accessoire.
engin dune capacitØ appropriØe pour
lappareil.
En utilisant des fourches de levage pour dØplacer lunitØ, sassurer
que lestourches sont suflisamment tongues pour dØpasser du ctØ
oppose de lappareil.
Utiliser
Le rayonnement haute frequence peut provoquer
des interferences avec les Øquipements de ra
dio-navigation etde communication, les services
levage uniquement pour sou
un
soulever
LEMPLOI EXCESSIF peut
SURCHAUFFER LEQUIPEMENT.
Demander seulement a des personnes qualifiØes familiarisØes
avec des Øquipements Ølectroniques de faire fonctionner linstalla
tion.
Lutilisateur est tenu de faire corriger rapidement par
es interferences resultant de linstallation.
un
Ølectricien
qualifiŁ
Si le FCC
reil.
signale des interferences, arrŒter immØdiatement lappa
Effectuer
reguliŁrement
le contrle
et lentretien
de linstallation.
Maintenir soigneusement fermØs les portes et les panneaux des
sources de haute frequence, maintenir les Øclateurs a une distance
correcte et utiliser une terre et et un blindage pour rØduire les inter
PrØvoir
une pØriode de ref roidissement, respec
cycle opØratoire nominal.
RØduire le courantou le cycle opØratoire avantde
recommancer le soudage.
fØrences Øventuelles.
ter le
Ne pas obstruer les passages dair du
LES CHARGES
SOUDAGE A LARC
risque de
provoquer des interferences.
LE
poste.
peuvent endommager
risque
ØlectromagnØtique
LØnergie
ELECTROSTATIQUES
de
provoquer des interferences pour lØquipement
Ølectronique sensible tel que es ordinateurs et
lØquipement commandØ par ordinateur tel que
tes circuits im
primes.
les robots.
Etablir
Ia connexion avec Ia barrette de terre
avant de manipuler des cartes Cu des piŁces.
Utiliser des
pochettes
et des boItes
pour stocker, dØplacer
circuits imprimes.
ou
antistatiques
expØdier des cartes de
lØquipement de Ia zone de soudage soit com
patible ØlectromagnØtiquement.
Pour rŁduire Ia possibilitØ dinterfØrence, maintenir les cables de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
Veiller ace que tout
Veiller a souder a une distance de 100 metres de tout
Łlectronique sensible.
DES
ORGANES
MOBILES
peuvent
provoquer des blessures.
Ne pas
sapprocher
des organes mobiles.
Ne pas sapprocher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent pro
voquer des blessures.
Veitler a ce que ce poste de soudage soit
conformØment a ce mode demploi.
Me pas
diriger
pistolet
vers
avant den
avoir
soi, dautres per
toute piŁce mØcanique
soudage.
sonnes ou
le fil de
le
gachette
en
engageant
et mis
a Ia terre
En cas dinterfØrences aprŁs avoir pris les mesures prØcØdentes, ii
incombe a lutilisateur de prendre des mesures supplØmentaires
telles que le dØplacement du poste, lutilisation de cØbles blindØs,
lutilisation de filtres de ligne ou Ia pose de protecteurs dans Ia zone
de travail.
LES CHAMPS MAGNETIQUES peuvent
affecter les stimulateurs cardiaques.
Porteurs de stimulateur
Ne pas appuyer sur Ia
recu linstruction.
pose
equipement
cardiaque,
restez a dis
tance.
Les porteurs dun stimulateur cardiaque doivent
dabord consulter leur mØdecin avant de sappro
cher des operations de soudage a larc, de gou
geage
Cu
de
soudage
par
points.
OM-1586
Page
7
1-4
Principales
normes
de securitØ
Safetyin Welding and Cutting, norme ANSI Z49. 1, de lAmerican
ding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safetyand Health Sandards,
OSHA 29 CFR 1910, du
of Documents, U.S. Government
20402.
Superintendent
Printing Office, Washington, D.C.
Welding and Cut
of Containers That Have Held Hazardous
AWS F4. 1, de lAmerican
mi FL 33126
Welding Society,
550
Substances, norme
N.W. Lejeune Rd, Mia
Information
sur
les
sur le soudage Ølectrique et sur les effets,
champs magnØtiques basse frØquence
Le cournt
RŁgles de sØcuritØ en soudage,
coupage et procØdds connexes, norCSA Wi 17.2, de lAssociation canadienne de normalisation, vente
de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W
1R3.
Safe Practices ForOccupationAndEducationalEyeAnd Face Protec
tion, norme ANSI Z87.i, de lAmerican National Standards Institute,
pour
lorganisme,
Afin de rØduire
de
soudage, pendant son passage dans les cables de sou
dage, causera des champs Ølectromagnetiques. II y a eu et il y a
encore un certain souci a propos de tels champs. Cependant, aprŁs
avoir examine plus de 500 etudes qui ont ØtØ faites pendant une pe
node de recherche de 17 ans, un comitØ special ruban bleu du
National Research Council
a
Broadway,
New
York, NY 10018.
Cutting and Welding Processes, norme NFPA 51 B, de Ia National
Protection Association, Batterymarch Park, Quincy, MA 02269.
Fire
conclu: Laccumulation
champs ØlectromagnØtiques dans
Garder les cables ensembles en les torsadant
attachant avec du ruban adhØsif.
2
Mettre tous les cables du ctØ
3
Ne pas courber pas et
votre corps.
4
de preuves, sui
comitØ, na pas dØmontrØ que lexposition aux
jugement
champs magnØtiques et champs Ølectriques a haute frequence reprØ
sente un risque a Ia sante humaine.
Toutefois, des etudes sont
es
lenvironnement
travail, respecter les consignes suivantes
1
de
vant le
de Ia
champs ØlectromagnØtiqes
DonnØes
des
Handling of Compressed Gases in Cylinders, CGA Pamphlet
Compressed Gas Association, 1235 Jefferson Davis High
way, Suite 501, Arlington, VA 22202.
P-i,
1430
Code, NFPA Standard 70, de Ia National Fire Pro
tection Association, Batterymarch Park, Quincy, MA 02269.
National Electrical
1-5.
Safe
me
Recommended Safe Practice for the Preparation for
ting
Wel
Garder le poste de
de
ne
oppose
de
ou en
les
lopØrateur.
pas entourer pas les cables autour de
soudage
et les cables le
plus
loin
possible
vous.
du
toujours
5
Relier Ia
pince
de
masse
le
plus prŁs possible
de Ia
zone
de
soudure.
Consignes
relatives
aux
stimulateurs
cardiaques
en cours et les preuves continuent a Œtre examinØes. En at
tendant que les conclusions finales de Ia recherche soient Øtablies, ii
vous serait souhaitable de rØduire votre exposition aux champs Ølec
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur docteur. Si vous Œtes dØclarØ apte par votre docteur, il
tromagnØtiques pendant
est alors recommandØ de
OM-1586
Page
8
le
soudage
ou
le coupage.
respecter les consignes ci-dessus.
.
SECTION 2- INTRODUCTION
Specifications
2-1.
Type
of
Input
24 Volts AC
Single-Phase
10 Amperes
50/60 Hertz
Wire Feed
Speed
Range
Power
Welding
Source
Power.
Type
Constant Voltage (CV)
DC For GMAW Or
Constant Voltage (CV) /
Constant Current (CC) DC
For GMAW-P
All Need 14-Pin And
Standard: 50 To 780
1pm (1.3
To 19.8
mpm)
Optional High Speed:
ipm (2.3 To
36.5 mpm)
92 To 1435
Wire Diameter
Range
.023 To 1/8 in (0.6
To 3.2 mm)
Max
Welding Circuit
Rating
100
Weight
12 ft
Volts,
750
(3.7 m):
(73 kg)
160 lb
Amperes,
100% Duty Cycle
16 ft
Spool Weight:
(27 kg)
(4.9 m):
(95 kg)
210 lb
60 lb
Contactor Control
12 ft
Maximum
Height
With 4 ft
(1.2 m)
(3.7 m)
17 ft
Post
Vertical Lift Of Boom
Horizontal to 60
16 ft
Boom
21 ft
(5.2 m)
Above Horizontal
(4.9 m)
Horizontal to 60
Boom
(6.4 m)
Above Horizontal
SECTION 3- INSTALLATION
3-1.
Installing Swivel
Into
Pipe Post
1
Swingpak
2
Pipe
3
Steel Bolt
5
4
Secure
mum
Base
or
CBC Cart
Post With Base
shown
as
using
as a
mini
1/2 in diameter SAE grade 5
steel bolts.
4
Swivel
Insert
Assembly
into
pipe post.
Lubricate
swivel.
2
3
5
Safety
A
Do
Collar
not
until
remove
instructed to.
Tools Needed:
~
ST-152 268
OM-1586
Page
9
1
Swivel Plates
2
Yoke
Remove
plates
3
from
hardware
and
Boom
Set boom into swivel
4
ter
5
5
2
6
as
shown.
Yoke Pin
Install
4
swivel
yoke.
pin
pin through yoke. Install
and spread ends.
cot
Bolt
Install bolt, tighten hardware, and
back bolt off one half turn.
6
Locking
Install
Knob
locking
knob
but do not
tighten.
7
Reel
Support
Install reel
support.
Tools Needed:
~ 3/8, 3/4 in
ST-142 596-C
3-3.
Installing
Wire Guide Extension
1
Wire Guide
2
Bolt
Fitting
3
Monocoil Liner
4
Wire Guide Extension
Tighten bolt to secure liner in wire
guide fitting. Do not overtighten
bolt and crush liner.
Tools Needed:
cIII~J~==iJ
3/8 in
ST-i 52 323
3-4.
Adjusting Control
Tilt Bracket
1
Tilt Bracket
2
Rear Pivot Screw
3
Front Screw
Loosen rear pivot screw. Remove
front screw. Pivot control down
ward to desired
viewing angle. Re
tighten front screw.
Tighten pivot screw.
place
and
3
5T-801 279
OM-1 586
Page
10
.
3-5.
ri~ł~ ~
1
300/400 Ampere Model
CC/CV Inverter Welding
Power Source
U? Use settings shown for both
pulse MIG welding and MIG
welding.
2
450 Ampere Model DC
Inverter Welding Power
Source
3
14-Pin Cord
4
Positive
5
Negative (-)
Be
sure
Weld Cable
(+)
weld
Weld Cable
cables
are
sized
properly for peak amperage if
pulse welding (see welding power
source Owners
Manual).
0
6
Workpiece
7
Voltage Sensing
(Optional Use)
8
Wire Feeder
PANEL
0
For connections
9
Section 3-7.
Gun
gun is rated for peak am
perage if pulse welding. Install ac
cording to its Owners Manual.
Be
REMOTE
INDUCTANCE/DIG
see
Lead
V/A CONTROL
sure
~
.
Equipment Connection Diagram
6
10
Gas Hose From Boom
11
Shielding
Gas
Supply
10
ST-aol 805/Ref ST.175086/Ref ST.180311-B
OM-1 586
Page
11
Connecting
3-6.
Weld Cables And Gas Hoses
The weld cable and
hose extend 10 ft
shielding gas
(3 m) from the
boom.
Route
weld
through
reed
from
cable
relay,
If the
if
boom
applicable.
welding power
supply are further from
source or
extend cable
or
1
Weld Cable
2
Insulated
Bolt
together
gas
the boom,
hose as follows:
Sleeving
weld
cables from
welding
power source and boom.
Use electrical tape and insulated
sleeving
3
to cover connection.
Shielding
Gas Hose
Connect hose to gas supply or ex
tension hose. The hose from the
boom
has
5/8-18
right-hand
threads.
Tools Needed:
~ 5/8
in
Ref. ST-aol 8051 Ref. ST-152 800-A
OM-1586
Page
12
.
3-7.
Control Box Connections
Optional
1
Reed
Relay
Connection
2
Wire Feed Motor And Gas
Valve Control
3
Receptacle
Wire Feed Motor And Gas
Valve Control
Plug
From
Boom
4
14-Pin Cord
5
Volt Sense Lead
(Optional
Use)
6
Gun
Trigger Plug
From Boom
======
4
ST-157 433-B / Ref. ST-157 434
3-8.
14-Pin
Plug Information
REMOTE 14
*The
remaining pins
are
Pin Information
~jfl*
24 volts
B
Contact closure to A
G
Circuit
C
+10 volts dc
D
Remote control circuit
common.
E
0 to +10 volts dc
command
H
Voltage feedback;
F
Current feedback; Oto +10 volts dc, 1 volt per 100 amperes.
M
CC/CV Select (+24 V
N
Inductance
ac
with
to socket G.
A
common
respect
completes
24 volts
ac
contactor control circuit.
for 24 volts AC circuit.
output
to remote control with
input
0 to +10 volts
=
signal
dc,
respect
to socket D.
from remote control with
1 volt per 10
arc
respect
to socket D.
volts.
CV)
(0-10 V)
not used.
OM-1 586
Page
13
Motor Start Control
3-9.
To
change wire feed starting speed
proceed
as
follows:
Turn Off unit and
welding
power
source.
Remove wrapper.
1
Front Panel
Remove
screw
ner, and open
from upper left cor
front panel.
hinged
2
Motor Board PCi
3
Motor Start Control
Potentiometer R70
Rotate
potentiometer clockwise to
increase time it takes the motor to
ramp up to speed. Remove protec
tive white rubber cap before
making adjustment. Adjust poten
using a small non-
tiometer R70
conductive screwdriver.
Close and secure front
reinstall wrapper.
panel,
and
Tools Needed:
Non-Conductive
c:I:::::z:J=::::=fLJ
1/4 in
ST-i 57480-A / Ref. SA-183 121-B
1
Locking
Tighten
Knob
knob
to
prevent
boom
movement. Loosen knob to allow
boom
movement.
position
to limit
Change
upward
knob
movement.
Pull boom down
move
safety
slightly and re
collar. Boom should
balance in any
zontal to 60
position from
degrees
zontal. If necessary,
as follows:
2
Threaded Rod
3
Jam Nut
hori
above hori
adjust
boom
Loosen jam nut and turn threaded
rod until boom baJances. Tighten
jam nut. Be sure several full
threads are through yoke to pre
vent boom falling.
2
4
Yoke
4
Retain
safety collar for use in disas
sembling or moving boom.
Rod
E
Tools Needed:
~-~-~r 1-1/8
3
2
Increasing Spring
Decreasing Spring
Pressure For A
Heavy Gun
Pressure For A
Ught Gun
in
Ref. ST-152 380-A
OM-i 586
Page
14
.
3-11. Gun Recommendation Table
Gun
Process
GMAW-P
GMAW
FCAW
3-12. Wire
Motor
Speed
-
-
-
Hard
Hard
or
or
GW-500 Or GW-600
Cored Wires
M25, M40, Or GA-50C
Cored Wires
Self-Shielding
Type, Size,
Wire
GA-4OGL Or GA-5OGL
Wires
Type
And Feed
Speed Capability
Table
Feed
Wire Size
.023 To 5/64 in
Standard
All
Standard
All
3/32 To 7/64 in (2.4 To 2.8 mm)
Standard
All
1/8 in (3.2 mm)
Optional High
All
.023 To 5/64 in
(0.6
To 2
mm)
(0.6102 mm)
Speed Capability
50 To 780
ipm (1.3
To 19.8
mpm)
50 To 700
ipm (1.3
To 17.8
mpm)
50 To 300 pm
92 To 1440
(1.3
ipm (2.3
To 7.6
mpm)
To 35.6
mpm)
OM-1 586
Page
15
3-13.
Installing
And
Threading Welding Wire
Tools Needed:
~~
Install
wire
is
wire feed
taut
~=z~ 15/16,3/8
in
spool.
Adjust tension
wire
3/16,5/641n
nut so
when
stops.
4,
Install wire
guide.
4-
-~
g? Be
sure that outlet cable has proper
size liner for the welding wire size.
When installing gun, position liner
extending from outlet wire guide as
close as possible to drive rolls without
OJ~ Forsoft wire orsmall diameterstainless
steel
to drive
Jog
rolls; continue to hold wire. Press
button to feed wire out gun.
use
2 drive rolls and set drive
roll pressure from 0 to a maximum of 4
on the pressure indicator scale (so that
only
the inner spring is compressed).
setting will generally give the best
performance for these types of wires.
touching.
Install gun. Lay gun cable out straight. Cut
off end of wire. Push wire through guides up
wire,
This
To
adjust
drive roll pressure, hold nozzle
about 2 in (51 mm) from nonconductive
surface and press gun trigger to feed wire
against surface. Tighten knob so wire does
not slip. Do not overtighten. If contact tip is
completely blocked, wire should slip at the
feeder (see pressure adjustment above).
Cut wire off. Close
Repeat
cover.
for other side.
5T-152 648.A/ Ref. 5T-157 432/ Ref. 51-137 391-A/ ST-142 597-Al Ref. S-0627-A/ Ref. ST-150 922
OM-1586
Page
16
SECTION 4- OPERATION
4-1.
Operational
Note ~
The
following
is
a
Terms
See Menu Guide for detailed
list of terms and their definitions
as
programming steps.
they apply
to this wire feeder:
General Terms:
Adaptive
Pulse
The wire feeder
Welding
less of
Cold Wire
change
automatically regulates pulse frequency
welding wire stickout.
to maintain
constant arc
a
length, regard
in
When weld amperage is not present, wire feeds for about three seconds at set wire feed speed.
Then the welding power source contactor deenergizes and wire continues to feed at the wire jog
Jog
speed.
Inductance
As inductance increases,
Trim
Arc
arc on
time increases, and the weld
length adjustment in pulse welding. Increasing
placed by volts in MIG programs.
The
Synergic
the
puddle
becomes
trim increases the actual
operator programs pulse parameters for a specific wire feed speed.
pulse parameters between these wire feed speed increments.
more
fluid.
length.
arc
Trim is
re
The wire feeder determines
Side Panel Terms:
Process Mode
Sequence
Is used to select the
Mode
type
of process to be used,
including Pulse, Adaptive Pulse,
or
Mig.
weld, crater, burnback, postflow,
Is used to select and program the weld sequences which include
and run-in.
preflow,
Dual Schedule Mode
Is used to select
a
Card Mode
Is used to select
use
Mode
Security
Only
functions with
rameter
4-2.
Pulse
Welding
pair
a
of programs that
of the
optional
can
be used
data card
data card. Allows
using
together.
storage
and retrieval
the lock feature for
capabilities.
restricting range
of program pa
changing.
Terms
1
Apk
Peak
=
Increasing Apk
Amperage
increases
penetra
tion.
Vpk
Peak
=
Voltage
voltage during peak current
phase of the pulse waveform. This
determines
arc
length during
adaptive pulse welding.
Arc
3
/\
2
Abk
3
PPS
Background Amperage
=
Maintains
arc
=
Increasing
speed.
Amps
4
PWms
between
pulses.
Pulses Per Second
PPS increases travel
=
Pulse Width In
Milliseconds
1
Increasing
2
PWms
increases
bead
width.
Time
/
OM-1586
Page
17
Front Panel Controls
4-3.
EIIm~
I
2
6~
>0
3
5
0
4
Ref. ST-155 222
1
Display
crease/decrease by
2
Parameter Select Button
The program number cannot be changed
while welding, with exception of Dual Sched
Press button to
3
move > on
display.
Display Control
Turn control to
change value pointed to by>.
Turning control one click causes Trim (arc
length) to increase/decrease by one or Volt
to increase/decrease by 0.1.
ule Mode
(see Section 6).
Pulse is
default
4
Trigger
Hold Button And Indicator
crease/decrease by
turning control one
speed (1PM) to in
one.
can
be set
clicks
causes
crease
When
click
by
Prg
0.1.
# is
selected, turning control
program number
(Prg #)
one
to in-
Jog speed is varied using the Display Con
Jog button is pressed. Default set
ting is 200 1PM.
trol while
Light
light
per program ba
on for programs
comes
where this feature is active.
Purge
Button
Push to
without
momentarily energize gas valve
energizing the welding circuit.
To weld without
holding gun trigger through
cycle, press and release button to
feature on (indicator light turns on).
turn
To start weld
trigger within
causes
4-4.
selected, turning control three
wire feed speed (MPM) to in
out
on a
out weld
When MPM is
momentarily feed welding wire with
energizing welding circuit or shielding
6
Trigger Hold
sis. Indicator
When 1PM is selected,
click causes wire feed
Push to
gas valve.
setting. To change type of
process (Pulse, Adaptive Pulse, or MIG) use
side panel controls (see Section 4-4).
a
Button
Jog
5
one.
cycle, press and release gun
three seconds after an arc has
been struck. To end weld
release gun
trigger.
cycle,
press and
lET
Jog
and
Purge only
work
on
the active
side of the feeder.
Holding the Jog and Purge buttons at the
time displays pulse parameters on
the side panel display and voltage on
front panel display.
same
Side And Rear Panel Controls
Display
1
Mode
2
Mode Select Button
Press button to
move >
3
Parameter
Display
4
Parameter Select Button
Press button to
5
5
move >
in
in
display.
display.
Parameter Increase Button
6
Parameter Decrease Button
7
Power Switch
8
Circuit Breaker CB1
6
CB1 protects the wire feeder from
overload.
Ref. ST-157 433-B! Ref. ST-155 223
OM-1 586
Page
18
SECTION 5- SETTING SEQUENCE PARAMETERS
OM-1586
Page
19
SECTION 6- SETTING DUAL SCHEDULE PARAMETERS
6-1.
Selecting
Dual Schedule Pair
Dual Schedule is used with two
r
consecutive weld programs 1 & 2,
3&4,5&6,or7&8.Anyprogram
_____________________
type (MIG, Adaptive Pulse, or
Pulse) can be combined in dual
schedule.
Side Panel
1
Use side
1
See
panel
Menu
Display
to turn feature
Guide
for
on.
detailed
programming steps.
2
Front Panel
Display
Press front panel parameter select
button to select program number.
3
Front Panel
4
Dual Schedule Switch
Section
0T Switch
Display Control
(See
6-2)
type
is set in
System
Setup.
5
Welding
Gun
Trigger
Selecting dual schedule program A
or B is done by using Display Con
trol, dual schedule switch,
trigger
setup).
(depending
on
or
gun
system
When program B is active, turn
Display Control one click clock
wise to select another pair of dual
schedule programs.
~
Programs
can
be
in desired order
rearranged
using the data
card. See Section 7.
24.0V
250
1PM
>Prg
1
Dual
A
__~D~ay
>Prg
2
Dual
B
Display
Control
OM-1 586
Page
20
>Prg
3
Dual
A
6-2.
Dual Schedule Switch
Diagrams
1
Momen2P
(Momentary-Contact
2-Pole
Switch)
2
>
>
2
2
3
2
Maint 1 P
1-Pole
2
>
4
(Maintained-Contact
Switch)
Maint 2P
2-Pole
(Maintained-Contact
Switch)
Trigger
scheduling after estab
welding arc.
Allows dual
lishing
A
3
2
1
>
0
a
A
3
B
4
UT If trigger is used for dual
schedule switch, Trigger Hold
is disabled.
>
0
4
p
4
3
1
1
Adapter
ii
1
_
>
2
TR
___________
I
3
>
3
>
A\~~>
>
2
2
>
TR
3
>
4
>
OM-1 586
Page
21
SECTION 7- USING THE OPTIONAL DATA CARD
7-1.
.
Data Card Terms
CARD SCREEN TERMS
WRITE
READ
Programs
Programs
To Card
From Card
PULSE MIG TERMS
PPS
Amperage
k
(Pulses Per
Second)
I
PWms
t~
-r
Apk (Peak
Amperage)
(Pulse Width In
Milliseconds)
JU~-rv
Abk
Time
(Background
Amperage)
5A-1 58435
7-2.
Installing
Data Card
1
Label
Apply
label to data card. Write pro
gram information on label.
2
Data Card
3
Card Slot
For Blank Data Card:
Insert card into slot. To format card,
turn On power. Select Card from
menu. Data card formats when unit
enters Card mode.
For Power Source Data Card:
Insert card into slot. Turn On pow
Push Parameter Select button
er.
within 3 seconds and the 8 pro
grams and setup information are
read into the wire feeder memory.
Unit is
Wait
front
ready
to
use
when Please
message disappears from
panel display.
ST-156 266-B
OM-1586
Page
22
7-3.
Card
Displays
lE~ See Menu Guide for detailed
programming steps. Security
mode only functions with a
data card.
Display
1
Card
2
Moving
Line
line is under value that
Moving
be changed.
Sequence
3
can
Write
DualSchd
>Card
Security
Pr
Transfers program data from unit
to card. The program card can hold
up to 32 programs. When writing to
ess
Be low
the card, the next available pro
gram number is automatically as
signed.
Side Panel
Parameter
Select Once
4
Read
Transfers program data from card
to unit.
5
Delete
Deletes program data from card.
6
Done
4
Exits card
display.
5
OM-1 586
Page
23
SECTION 8- SYSTEM SETUP
8-1.
System Setup Display
Note ~
DISPLAY SETFING
*
>System
>Range
Parameters
See Menu Guide for detailed
NOTES
Select the process the
*
programming steps.
welding
power
source
is able to do.
Welding power source minimum and maximum voltage values are always needed. Amperage
for pulse welding. Set values to match welding power source ranges.
of setup
>Access
When on, restricts
>Mig Type
Default is Off. Set to On
>Voltage
Default is
use
only
14-pin receptacle.
values
are
required
screens.
for older CV
welding power
Use V. Sense when
more
source
without
than 50 ft
(1 5m)
voltage
feedback at 14-socket
of weld cable is used
receptacle.
(including gun
cable
length).
>Arc Start~
Use Hot Start
only
with Inverter Model
welding
power
source
and
large
diameter wires. The
arc
starts in CV and
switches to CC.
>Dual Schedule
See Section 6-2.
>Trigger
When on,
trigger
be used to switch between programs that have at least 0.2 seconds of
can
preflow
time pro
grammed.
>Remote
When on,
a
dual schedule switch
panel display>
can
be used to
change
Volts
or
Trim, 1PM,
or
Prg depending
where the front
>Arc Time
Displays
>Wire Feed
Choose to
>Memory
Program Reset: unit defaults to original factory setting for the last active program. Setup information
change. If setup card is in card slot, program will be loaded from card.
accumulated
display
arc
time and
cycles.
inches per minute
or
meters per minute and motor
type,
but installed motor must match selection.
Reset: unit defaults to original factory settings for all programs and setup
card is in card slot, program will be loaded from card.
System
setup
Total Reset: unit defaults to
setup card is in
*
on
is.
card
When on, the system
age is sensed.
>Teach
Default is 15
>Gas Flow
Setting
>Software
Know this when
Automatically
Can be used
-~
immediately
but
can
must be Meter Off if
talking
shuts down if
be set to 4
option
no arc
points.
is not installed.
with service
personnel.
set if power source data card is used.
only when optional data card is inserted.
Selection does not appear on display when MIG Only is System choice.
Must remain set to Meter Off if option is not installed to prevent system
OM-1586
Page
for all programs and
24
setup including System
and Arc Time. If
and Arc Time. If
slot, program will be loaded from card.
>Shutdown
points,
original factory settings
excluding System
does not
error.
voltage
is sensed. When
off, wire feeds
even
if
no arc
volt
.
SECTION 9- STANDARD PULSE WELDING PROGRAMS
.
Note ~
Apk
Peak
=
Amperage, Vpk
=
Peak
Voltage,
Abk
=
Background Amperage,
Pulses Per Second, PWms Pulse Width (milliseconds). Four teach points were use d for
factory set programs. If selection is set for fifteen teach points, the remaining points are
PPS
=
=
interpolations from
9-1.
Wire
Program
Size/Type:
1
-
the 4
taught points.
Steel
Gas: Ar
.035
-
CO2
or
Ar
-
Oxy /
40 CFH
(19 Urn)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
700/17.8
440
36.7
160
180
2.9
400/10.2
385
32.4
108
126
2.3
200/5.1
335
28.7
61
81
2.0
100/2.5
328
27.4
37
47
1.7
9-2.
Wire
Program
Size/Type:
2
-
Steel
Gas: Ar
.045
1PM / MPM
Apk
700/17.8
-
CO2
or
Ar
.
Oxy /
40 CFH
(19 Urn)
Vpk
Abk
PPS
PWms
518
35.0
195
205
3.6
400/ 10.2
466
31.3
147
158
2.9
200/5.1
412
28.5
93
106
2.4
100/2.5
375
26.5
50
66
2.2
9-3.
Wire
Program
Size/Type:
3
-
.052
Gas: Ar
-
CO2
or
Ar
-
Oxy /
40 CFH
(19 U/rn)
Apk
Vpk
Abk
PPS
PWms
625 / 15.9
560
39.3
200
229
3.6
400/10.2
525
36.2
148
189
3.5
200/5.1
475
31.7
102
131
2.7
100/2.5
445
29.6
50
80
2.4
Wire
Program
Size/Type:
4
-
Gas: Ar
Apk
400 /10.2
COMMENTS
Steel
.062
1PM / MPM
COMMENTS
Steel
1PM / MPM
9-4.
COMMENTS
-
CO2
or
Ar
-
Oxy /
40 CFH
(19 L/rn)
Vpk
Abk
PPS
PWrns
550
36.8
200
195
4.1
300/7.6
510
36.3
145
175
3.8
200/5.1
480
31.6
110
155
3.2
460
28.7
COMMENTS
OM-1 586
Page
25
9-5.
Program
Wire
Size/Type: .035
5
-
Stainless
Gas: Ar
-
He
-
C02/40
CFH
(19 Urn)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
700/17.8
403
33.9
132
191
2.8
400/10.2
318
31.6
87
146
2.4
200/5.1
295
28.5
53
94
1.9
100/2.5
280
26.0
32
45
1.8
9-6.
Wire
6
Program
-
Stainless
Size/Type: .045
Gas: Ar
-
He
-
CO2 /
40 CFH
(19 L/m)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
700 / 17.8
480
39.0
200
227
3.2
400/10.2
425
32.4
155
185
2.5
200/5.1
360
28.0
100
115
2.0
100/2.5
350
26.2
40
70
2.0
9-7.
Program
Wire
Size/Type: .035
7
-
Nickel
Nickel
Gas: Ar
Alloy
-
He / 40 CFH
(19 U/rn)
Apk
Vpk
Abk
PPS
PWrns
700/17.8
350
34.5
130
144
3.7
400/10.2
310
30.0
80
105
3.3
200/5.1
280
27.5
48
55
2.9
100/2.5
260
25.1
28
36
2.5
Program
Wire
Size/Type: .035
8
-
SiBr
Gas:
Argon /
40 CFH
Vpk
Abk
PPS
PWrns
510/13.0
340
30.7
100
125
3.7
400 / 10.2
310
29.8
83
97
3.4
200 / 5.1
277
26.6
48
55
3.0
120/3.1
242
25.2
31
31
3.0
26
.
(19 Urn)
Apk
Page
COMMENTS
Silicon Bronze
1PM / MPM
OM-1 586
COMMENTS
Alloy
1PM / MPM
9-8.
COMMENTS
COMMENTS
SECTION 10- TEACH POINTS
10-1. Teach
Using
15 Points
~.
L~
Apk
=
Peak
Amperage
A
Vpk
=
Peak
Voltage
o
Abk
=
Background Amperage
O
PPS
1PM / MPM
Pulses Per Second
=
PWms
=
Pulse Width
(Milliseconds)
780/ 19.8
750/19.1
700/17.8
650/16.5
600/15.2
550/14.0
500/12.7
450/11.4
Example Of A Synergic
Setting For 425 1PM With
400/10.2
All Teach Points Set At 50
1PM
(1.3 MPM)
Increments
350/8.9
300/7.6
250
/ 6.4
200/5.1
150/3.8
100/2.5
50/1.3
300
330
360
370
420
27
30
33
36
37
42
Abk
10
20
30
40
50
60
70
80
90
100
110
120
130
PPS
20
55
80
105
130
160
185
210
235
260
290
315
340
selection for 15 teach
points gives a more
defined curve for a specific range. At each
teach point, the user can adjust five param
eters to shape the pulse waveform of the
weld output. The six parameters are: 1PM
(MPM), Apk, Vpk, Abk, PPS, and PWms.
Abk
400
PPS
54
270
24
The teach mode allows the user to create
custom pulse programs. The teach mode
200
540
51
240
21
3
2
140
365
510
48
210
18
PWms
Apk
Vpk
480
45
180
10
Apk, Vpk, Abk, PPS, and PWms acting
together provide the energy necessary to
burn off welding wire at a set wire feed
speed. The graph below shows that as wire
feed speed increases, energy increases
(Apk, Vpk, Abk, PPS, and PWms acting
PWms
5
4
Under
565
56
450
100
Apk
Vpk
some
its wire feed
conditions, the wire feeder lim
speed
rameters within the
to maintain all
pulse pa
capability of the system.
synergically).
OM-1 586
Page
27
10-2. Teach
Using
4 Points
.
L~
Apk
=
Peak
Amperage
A
Vpk
=
Peak
Voltage
0
Abk
=
Background Amperage
0
PPS
=
Pulses Per Second
1PM / MPM
PWms
Pulse Width
=
(Milliseconds)
780/19.8
750/19.1
700/17.8
650/16.5
600/15.2
550/14.0
500/12.7
450
/ 11.4
Example Of A Synergic
Setting For 425 1PM With
400/10.2
Teach Points Set At
350/8.9
Intervals Of 100
200
(5.1),
700
400
1PM
300 / 7.6
(2.5),
(10.2), And
(17.8 MPM)
Increments
250 / 6.4
200/5.1
150/3.8
100/2.5
50/1.3
Apk
Vpk
100
180
210
240
270
300
330
360
370
420
10
18
21
24
27
30
33
36
37
42
Abk
10
20
30
40
50
60
70
80
90
100
110
120
130
PPS
20
55
80
105
130
160
185
210
235
260
290
315
340
PWms
1
The teach mode allows the
2
user
to create
pulse programs. The teach mode
selection for 4 teach points gives the whole
welding range quickly. At each teach point,
the user can adjust five parameters to
shape the pulse waveform of the weld
output. The six parameters are: 1PM (MPM),
Apk, Vpk, Abk, PPS, and PWms.
custom
OM-1586
Page
28
3
450
480
510
540
45
48
51
54
4
its wire feed
burn off
rameters within the
feed
wire at
a
set wire feed
below shows that
as
wire
speed increases, energy increases
(Apk, Vpk, Abk, PPS, and PWms acting
synergically).
56
Apk
Vpk
140
200
Abk
365
400
PPS
5
Apk, Vpk, Abk, PPS, and PWms acting
together provide the energy necessary to
welding
speed. The graph
565
PWms
Undersomeconditions,thewirefeederlim
speed to maintain all pulse pacapability of the system.
10-3.
Redefining
Teach Points
*4
1
position
OT
Redefining
1PM
1PM determines the weld metal de
1PM Teach Point
rate.
Redefining 1PM is not normally
required unless special wire or
is
unusual
joint design
needed.
Use front
button to
panel parameter
move>
Display Control
point value.
Trim
50
Purge
~
Ar~d
1
Prg
2
Apk
3
Abk
1PM
Peak
-
Pulse
power
4
Amperage
Background Amperage
-
Peak and
depend
>460
select teach
Press and hold Purge button while
turning Display Control to redefine
the ipm teach point. For example:
there are teach points at 150, 200,
and 250 1pm; the teach point at 200
can be adjusted to a wire feed
speed of 151 to 249 1pm.
Pulse
Trim
50
to
1
Prg
1PM
>450
select
to select 1PM. Use
on
background amperage
welding
the range of the
source.
PPS
-
Pulses Per Second Of
20-400
5
PWms
-
Pulse Width Of
1.0-5.0 Milliseconds
Use side
pulse
Redefining
panel
controls to
change
See
Menu
parameters.
Guide for detailed
Pulse Parameters
programming
steps.
After values
maintain
are
an arc
set, strike and
for five seconds.
Do this for each teach
point.
by releasing gun trigger,
not by pulling gun out of weld. Re
peat for each custom teach point.
End weld
The
Trim
2
taught arc length represents
(arc length) setting of 50.
a
points are set, the
parameters be
points synergically.
Once the teach
wirefeeder adjusts
tween teach
4
3
I
400
1PM
I
340
>70
I
160
340
Apk
Apk
70
Abk
Abk
>160
PPS
PPS
1.4
PWms
___i,5
I
I
I
340
Apk
70
Abk
160
PPS
I>i
.9
Ref. 5-0259 / Ret. ST-i 54 109
OM-1 586
Page
29
Date___________________ Program Number_____
Wire
SizelType_________________________________
Flowrate
Equipment
Wire
Used
-
Power Source
CFH(L/min)
Serial Number.
Feeder______________________
Serial Number___________________________
_________
Gun
Model_____________________ Weld Cable
Wire
Manufacturer_________________
________________
1PM / MPM
Apk
Abk
-
Positive
Negative
Mt g. Date
PPS
PWms
Vpk
COMMENTS
.
Preflow
Seconds:_________
Run-In Trim/Volts:________ 1PM / MPM:___________________________________ Seconds:___________________________
Crater
Volts:____________________ 1PM / MPM:____________________________ Seconds:___________________________
Postflow
Seconds:_______
.
OM-1586
Page
30
SECTION 11
-
MAINTENANCE AND TROUBLESHOOTING
11-1. Routine Maintenance
A
Disconnect power before
maintaining.
OM-1 586
Page
31
11-2. Error
Displays
IIIIEI
R
e
eas
e
I
r
gge
r
I
2
00
No
S
Volt
ens
e
d
1Error
3
1
N
Memory
Prg
CRC
Er
1
ror
Release
Error
Trigger
Display
This appears if the trigger is closed
when the unit power is turned on, or
if the trigger is stuck or defective.
2
No Volt Sensed Error
The
arc
Display
Press
front
7
Arc
Stop
Parameter
panel
Select to clear
error.
Error
Display
This appears when pulse welding
and the motor does not stop at the
end of the weld. If there is
4
N
Memo
Rang
r
Prg
y
Er
e
1
ror
voltage sense circuit is not
receiving feedback. Check voltage
connections.
Check
sensing
connections at 14-position plugs!
receptacles at the unit and welding
source.
power
Turn unit off and
5
back
after
on
correcting problem.
N
Tach
o
S ensed
6
Arc
Start
Arc
Stop
8
Mi
nCFHxx
Ga
9
s
F
I
o w
ror
\
Ma
10
x
C F H
x
x
GasF
low
Gas
Out
of
11
Range
Coolant
Flow
12
\
I
Unlocked
r
o
g
r
am
ror
continues
error
pulse welding,
to
occur
it may
help to
select Hot Start.
Press
front
Select to clear
8
CRC Error
Memory
Display
The data in the program indicated
is not the same data that was
saved.
Perform
4
a
system
reset.
Memory Range
Error
Minimum Gas Flow Error
it above set value.
The data in the program indicated
is out of usable range.
Go
through pulse parameters to
sure they do not exceed
settings of the Range display or
perform a system reset.
make
5
front
9
No Tach Sensed Error
Maximum Gas Flow Error
The motor tach feedback is not
reaching the control. Check
connections.
Press
front
Select to clear
Select to clear
panel
Parameter
10
Gas Out Of
Display
Error
below 100 CFH.
Coolant Flow Error
This appears only when coolant
flow switch option is installed.
coolant
recirculating
system.
started.
Check
Unlocked
Program
Error
Display
This appears when pulse welding
and current is detected but the arc
be
Range
error.
Arc Start Error
cannot
Parameter
panel
error.
the internal sensor, the unit shuts
down until the gas flow can be
12
6
bring
This appears when gas flow is
greater than 100 CFH. To protect
Check
front
flow to
it below set value.
11
Press
error.
This appears when gas flow is
above the maximum CFH set (xx in
adjusted
Display
Parameter
panel
Select to clear
example). Adjust gas
Display
Parameter
panel
error.
This appears when gas flow falls
below the minimum CFH set (xx in
example). Adjust gas flow to bring
Press
3
ror
7
1
1Error
1Er
1Error ~
1Er
1Error ~
1Er
1Error ~
1Er
If this
when
high
used in the area,
turn it off. A motor brake circuit
problem can also cause this error.
frequency being
and
This appears when attempting to
run an unlocked program while
other programs are locked. Either
lock the unlocked program or
correct program
and
voltage
pulse parameters
settings. Check
select
voltage sensing
connections.
locked.
a
different program that is
ror
R&. ST-1~~
OM-1 586
Page
32
11-3.
Troubleshooting
Disconnect power before
A
S
Remedy
Trouble
feeds, shielding gas flows,
Wire
electrode wire is not
but
energized.
Wire feeder is on, meter(s) do not light
up, motor does not run, gas valve and
welding
pull in.
power
source
Check interconnecting cord connections. If secure, check cord for
Sections 3-5 and 3-7).
Check and reset CB1
or
feeds
Check gun
trigger. See gun Owners
Clean
or
to correct size drive roll
replace dirty
Replace
contact
tip
Wire does notfeed until
trigger is pulled,
trigger is re-
but continues to feed after
leased, and trigger hold is
Gas valve in feeder is
guides.
liner. See gun Owners
foreign
Authorized Service
or
Manual.
matter from around nozzle
Have
Check for
13-1).
drive roll.
spatter
Factory
Table
(see Section 3-13).
Agency
opening.
check drive motor
or
motor control board PCi.
input voltage.
a
short between
welding
trigger
leads and weld cable.
Repair
short
or
replace welding
a
short between
welding gun trigger
leads and weld cable.
Repair
short
or
replace welding
gun
gun.
not on.
rattling loudly
erratic
or
wire
(see
Remove weld
Check for correct
slowly.
does not
or worn
or worn
Manual.
Manual.
hub tension and drive roll pressure
Incorrect size
Unit
4-4).
connection. See gun Owners
trigger
Change
along with possible
feed speed.
Section
Check gun
Readjust
runs
(see
continuity and repair or replace (see
contactor do not
Electrode wire feeding stops
erratically during welding.
Motor
troubleshooting
or
slow wire
switch out of Run-In
Check for
gun.
Install, reconnect,
or
replace voltage sensing
lead.
Speed.
Wire feeder power is on, displays
up, but unit is inoperative.
light
Check
welding gun trigger
leads for
continuity,
and
repair
leads
or
replace gun.
OM-1586
Page
33
SECTION 12- ELECTRICAL DIAGRAM
.
II
IIr~
L~
-
FCV
~m1~5
E
L
WITH ~
o~ ~e~r ~TD~
2<~-~
~
1~1~2>-~
~ ~
3E-~-<~3 >~
a-~
WIlT
2
l4~4~4~
-
S
Figure
OM-1586
Page
34
12-1. Circuit
Diagram
______
I
FLilfi ~
I
I
I
o
F~S-8
(~i~t~i)
i
~ I ~
~HH~
F~ I~CTE
~E.Dt~TftETD~)
I
CIA
-
I
I
I
I
I
I
I
I
I
I
___
~-e
~
V~V
V~V~V~V~V_V
1I~I~J8I~I~U
RCW-1>.I
~00-3> I
rcuj-e>~
r~W-2>
i/o
~
I
V
____
I
~
IFI~~II
vvvvvvv~
L~ I
_~J ~ L L~! 1
FluB
V
I
2~TOOOO0OO0O
0
i_ 34~
-
~
11~ ~1O4 10 ~ LED.
By IT~.F. 04 P4
~ 140-I FLT04 ~
I
I
L__~_~t~
I
_______
I
17 PlC ~4~4
l~41
>
I
a~,tv (-24~.c~)
<<~4
~
p~Q
I
n-lop ~
I
.
F~4-7>>
1flCTN~ (D-U~)
>>~~
~4-6 >>-~
4a~t4~ ~0C
(w~4)
~,0~0
>)-~< II
>>~< 41
I I
ii
(
LEFE~~~1D~) I
I
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____________
P4TEWAII ~PJIJ
00
~
.~,-
Ic~1
>>-~~
~4T ~
<<~2-3
~
4
________
~fl8>>
~11-1>>
~t15>>
R~2-2>>
K
~fl-2>>
~3~4
~itv (.2c4C4)
-
~
~
~
~-2:
~
~53-.3:
~
42
~<Ft;82-e
14
-
)l
>
___________________
~
~444~0
14 P14 ~M1)I
~1-1
>
~I3
>~
0~?
I
V
v-v-v-v-,
___________________________________________________________
T
T
I~
I2~
:~
PS. ~4
_
~
I0
_
anna
p
~?I~4-1
pci
icroy ~3Ag)
I
c
~-6
~
I
PS. DSCTICI04
>~C
C~7/M~G1
~5-1
>>
::~~
>
_____________
-x~--~--o~
I
~
1O~IPl
I
I
_
24V10 aiD
RR
-
4(0
SD-i 83 495-A
OM-1 586
Page
35
SECTION 13- PARTS LIST
Q7 Hardware is
common
and
.
not available unless listed.
Os
CO
CO
C)
LI~
CO
LU
CO
(fl
C)
LI~
CO~
CM
0-i
C~J
CO
C)
U-
Ci
CM
CO
Ci
CO
/
S
ST-i 57 507-6
Figure
OM-1 586
Page
36
13-1. Main
Assembly
Quantity
Item
No.
Dia.
Model
Part
No.
Mkgs.
Description
Figure
1
149 251
1
149 252
PLG23
079 878
...
079 531
605 156
PLG28
080 328
...
See Note
2
3
164 475
3
164 474
PLG37,38
047 636
.
..
..
..
....
....
163 519
....
139 600
..
139 599
..
....
010 606
....
603 106
....
056 112
....
5
600 324
..
6
149 884
..
6
080 947
..
7
602 243
..
8
602 213
..
9
601 872
10
080 157
..
11
132 053
..
..
..
13
149
838
..
13
149
839
..
13
078
264
..
13
079
216
..
14
075
078
14
079
217
Fig
RC37
17
PLG33
18... PLG7
16...
...
...
...
..
..
13-5
..
047 637..
135 409
....
..
115 092..
605 227
..
125 785
..
21
139 265
..
22
156 243
..
23
159 360
..
24
145 639
..
25
167 774
..
19
20
.
.
.-.
GS1
....
25
167
776
..
..26
157295
..
27
604 612
..
28
082 050
..
29
159 646
..
30
159 647
..
180 146
180 118
180 277
180 276
Note: When
ordering
17ft
1
.
.
1
1
....
....
..
....
....
2
21ft
1
1
1
1
2
CONNECTOR & PINS
CONNECTOR, circ clamp str rlf sz 1 7-?0 Amp 206322-2
CABLE, port No. 18/14 8/c (order by ft)
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)
BRACKET, spring retaining
BRACKET, spring retaining
WASHER, fIat stl std .375
WASHER, lock stl split .375
NUT, stl hex full .375-16
FITTING, grease 1/8NPT
SCREW, cap stl hexhd .375-16 x 1.500 Ig
SUPPORT, hub & reel
PIPE POST, 4ff w/base or
PIPE POST, 6ff w/base
PIPE POST, 4ff w/base or
PIPE POST, 6ff w/base
PIPE POST, 4ff w/o base or
PIPE POST, 6ftw/o base
010 603
13-3
2
....
4
15
CONNECTOR, circ clamp str rlf sz 11 Amp 206358-2
CABLE, port No. 184/c (order by ft)
CONNECTOR w/SOCKETS, free hanging
CONTROL BOX, (Fig 13-2)
CABLE, interconnecting (consisting of)
CABLE, interconnecting (consisting of)
079 739
Fig
1
CONNECTOR & PINS
....
..
16
1
....
..
I
Assembly
CABLE, trigger (consisting of)
CABLE, trigger (consisting of)
....
4
12
13-1. Main
12
2
....
....
17ft
2
2
21ft
1
1
2
2
2
2
26ft
30ff
2
2
26ff
30ff
1
1
8
8
4
4
4
4
1
1
4
4
1
1
1
1
1
1
1
1
1
1
BOOM ASSEMBLY
1
1
CONNECTOR & SOCKETS
CONNECTOR & PINS
CONNECTOR & SOCKETS
1
1
1
1
1
1
NUT, nyl hex jam .75ONPST
VALVE, 24VAC 2 way custom port 1/8 orf
COVER, motor & components
CLAMP, motor top
INSULATOR, screw machine
STRIP, buna N compressed sheet .062 x 4.000sq
DRIVE ASSEMBLY, wire (Fig 13-4)
DRIVE ASSEMBLY, wire (high speed) (Fig 13-4)
GUIDE, monocoil
SCREW, set sti sch 8-32 x .125 cup point
LINER, monocoil inlet wire
CLAMP, motor base
INSULATOR, motor clamp
KIT, trigger isolation (consisting of)
1
1
1
1
1
1
....
....
....
CIRCUIT CARD,
assembly trigger
PLUG, assembly
PLUG/LEADS
Control Box contact
factory
service
department
1
1
4
4
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
for proper number.
OPTIONAL
To maintain the
Replacement
factory original performance of your equipment, use only Manufacturers Suggested
required when ordering parts from your local distributor.
Parts. Model and serial number
OM-1586
Page
37
c~)
UJ~ Hardware is
common
and
not available unless listed.
.
cj
)
/
/
/
0
/
0
C-)
0.
cJ
A
c0
CD
/
/
0J
Q
0)
a,
a~
0)
0)
C)
Sf157 508-D
Figure
OM-1 586
Page
38
13-2. Control Box
Item
No.
Dia.
Mkgs.
Part
No.
Figure
147139
155024
3
144844
PC4O
158160
PLG16,41
155023
PC6O
i56623
PLG6O
153501
RC7O
048 282
4
5
...
6
7
10
11
12
..
..
2)
TAPE, adh acrylic double sided .010 x .500 x 3.000
LENS, clear anti glare
STAND-OFF, No. 6-32 x .875 Ig
CIRCUIT CARD, schd side
CABLE, ribbon 24posn 6.000 in (RC16) (RC14)
CIRCUIT CARD, cyber card
CONNECTOR & SOCKETS
CONNECTOR w/SOCKETS
158719
131 204
148439
115092
191 504
115092
153501
115093
162382
170980
PLG1O,24
PLG12,50... 155629
13
126689
14
097132
15
138044
16
600 399
17
176089
18
601 222
19
151 187
20
134464
21
+154 927
22
155261
4
1
14
1
1
1
(RC6O)
1
1
CONNECTOR & SOCKETS
154938
....
13-1 Item
158720
079531
PC5O
PLG51
PLG52
PLG53
PLG54
PLG55
PC1O
PLG11
PLG15
PLG17
PLG18
(Fig
163917
079 535
9
13-2. Control Box
CONNECTOR, circ 4 pin Amp 211882-1
CONNECTOR, circ pin push-in 18-l4ga Amp 66359-6
CONNECTOR, circ clamp str rlf Amp 206358-2
STRIP, mtg PC card
CIRCUIT CARD, interlace
079 532
8
Quantity
Description
1
1
(RC51)
CONNECTOR & SOCKETS (RC52)
CONNECTOR & SOCKETS (RC53)
CONNECTOR & SOCKETS (RC54)
CONNECTOR & SOCKETS (RC55)
CIRCUIT CARD, processor w/proms
CONNECTOR & SOCKETS (RC11)
CONNECTOR & SOCKETS (RC15)
CONNECTOR & SOCKETS (RC17)
CONNECTOR & SOCKETS (RC18)
CABLE, ribbon 34posn 12.000 in (RC1O) (RC24)
CABLE, ribbon l4posn 3.000 in (RC12) (RC5O)
STAND-OFF, 6-32 x 1.500 Ig
STAND-OFF, 6-32 x .375 Ig
1
1
1
1
1
1
1
1
1
1
1
1
4
4
BUSHING, strain relief .120/.150 ID x .500mtg hole
WIRE, strd l4ga blk 600V 105C (order by ft)
TUBING, plstc PVC .250 ID x .370 OD x 9.000
CLAMP, univ 50A
LATCH, slide flush
LABEL, warning general precautionary
1
35ft
1
1
1
1
WRAPPER
1
1
182299
PANEL, side lower
RECTIFIER, integ 40A 800V
CIRCUIT BREAKER, man reset 1P 1OA 250V
SWITCH, rocker SPST 1OA 25OVAC
BLANK, snap-in nyl .875mtg hole
STAND-OFF, 6-32 x .625 Ig
CIRCUIT CARD, HF filter
115093
CONNECTOR&SOCKETS
158720
CONNECTOR & SOCKETS
115092
CONNECTOR & SOCKETS
131 054
CONNECTOR & SOCKETS
29
010290
30
163520
BUSHING, strain relief 1.030 ID
CABLE, port No. 18/14 11/c (order by if)
CONNECTOR & PINS, (consisting of)
CONNECTOR, circ clamp str rlf sz 17 & 20
..23....SR1
..24....CB1
Si
..25
035 704
083 432
111 997
26
000527
27
073 756
28
31
....
....
PC8O
PLG81
PLG82
PLG83
PLG89
PLG9
33
141 162
079 739
32
....
RC4O
047637
048144
34
35
36
134201
pci
183120
PLG1
115092
PLG2
115093
PLG3
PLG4
115094
PLG6
136810
115091
181 499
CONNECTOR & SOCKETS
CONNECTOR, circ pin plug
1
1
1
1
2
1
1
(RC82)
(RC83)
(RC89)
1
1
1
1
l7ft
1
1
i
keying
in sockets
2
STAND-OFF SUPPORT, PC card .312/.375
CIRCUIT CARD, motor control
8
CONNECTOR &SOCKETS(RC1)
CONNECTOR & SOCKETS (RC2)
CONNECTOR & SOCKETS (RC3)
CONNECTOR & SOCKETS (RC4)
CONNECTOR & SOCKETS (RC6)
CASE SECTION, bottom/rear
1
1
1
1
1
1
1
OM-1 586
Page
39
179201
153169
Item
No.
Dia.
Part
No.
Mkgs.
Description
Figure
37
38
..
13-2. Control Box
(Fig
13-1 Item
Quantity
2) (Continued)
145 948
BRACKET, mtg control box
1
PC2O,30
169 502
1
PLG25
164 899
CIRCUIT CARD, display front
CONNECTOR & SOCKETS (RC25)
1
39
159 264
40
167 633
41
167 698
42
010 291
43
167 700
1
47
164842
48
030170
49
154933
50
154 109
RING, retaining ext .625 shaft grv x .O45thk E style
WASHER, shldr .612 ID
PANEL, front
WASHER, flat .625 ID nylafil
KNOB, pointer
ACTUATOR, switch
LENS, LED 4345 green
NAMEPLATE, (order by model and serial number)
METER LENS, w/gasket
BUSHING, snap-in nyl .750 ID x 1.000mtg hole
PANEL, inner control
PLATE, ident inner control
PLG39
115 092
CONNECTOR & SOCKETS
1
RC7
135 409
CONNECTOR&SOCKETS
1
44
45
46
+When
ordering
a
component originally displaying
a
precautionary label, the label should also
.
1
1
1
1
8
1
1
1
1
1
1
be ordered.
To maintain the
factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
S
OM-1 586
Page
40
Item
No.
Part
No.
Figure
.
1
2
3
4
.
.
.
.
.
.
5
.
7
..
.
058 628
..
.
058428
..
108
9
10
+168 104
.
.
166 594
.
.
168 103
14
lET Hardware is
Support,
Hub & Reel
(Fig
13-1 Item
12)
SUPPORT,reel.
WASHER, fbr .656 IDxl.5000Dx.l25thk
WASHER, brake sti
HUB, spool
REEL, wire 60 lb (consisting of)
SUPPORT, reel spool
RETAINER, spool support (consisting of)
LABEL, caution falling wire reel can cause damage
NUT, spanner retaining
WASHER, flat stl keyed 1.500diax .l25thk
SPRING, cprsn .970 OD x .120 wire x 1.250
WASHER, flat stl .640 ID x 1.000 OD x l4gathk
NUT, stl slflkg hex reg .625-11 w/nylon insert
RING, retaining spool
1
2
2
1
1
1
1
....
1
1
....
..
.
.
010 233
..
.
.
605 941
..
.
.
136 684
.
.
058 427
common
13-3.
....
.
.
13
..
057 971
11
12
008
124 900
.
.
8
..
010191
.
6
142399
Quantity
Description
.
.
..
1
1
1
1
1
and
not available unless listed.
2
3
5
2
11
13
14
*Includes Item 8
8
ST-146 339-B
Figure
13-3.
Support,
Hub & Reel
OPTIONAL
+When
ordering
a
component originally displaying
a
precautionary label, the label should also be ordered.
factory original performance of your equipment, use only Manufacturers Suggested
Parts. Model and serial number required when ordering parts from your local distributor.
To maintain the
Replacement
OM-1 586
Page
41
U~ Hardware is
common
and
not available unless listed.
.
SeeTabIel3-1 For
Drive Roll & Wire Guide Kits
18
19
20
22
23
16
7
6
10
12
26
27
28
36
32
31
ST~8O1 456-A
Figure
OM-1 586
Page
42
13-4. Drive
Assembly,
Wire
Item
No.
Dia.
Part
No.
Mkgs.
Figure
...
...
..
..
1
010 668
..
2
172 075
..
3
149 962
4
..
149 486
..
163282
..
...
5
..
6
165 798
..
7
165799
..
..
...
..
8
132 750
..
9
150 520
..
..
10
133 493
..
11
133350
..
156 354
..
...
..
..
12
12
Ml ,2
M1,2
.
156
...
353
153 491
..
*153 493
13
155 098
..
14
..
182 414
..
15
182415
..
..
16
137 248
..
17
129 351
..
..
18
602 200
..
..
19
604 772
..
..
20
182 156
..
..
21
182 155
..
22
132 746
..
23
181 522
..
24
132 747
..
..
..
...
25
..
26
..
27
PC51
PLG57
PLG58
.
.
.
.
.
.
.
.
..
.
.
133739
183 330
153 631
131 204
604 311
131 203
..
..
..
..
..
132 611
..
29
149 959
..
30
179 265
..
..
31
108 940
..
32
33
604 538
..
..
151 437
..
..
34
128 237
..
..
35
+179 263
..
..
..
36
601 872
..
37
602 213
..
..
38
602 243
..
..
39
601 966
..
..
40
167 387
..
41
168 825
42
133 308
..
25)
SCREW, cap stl sch .250-20 x 1.500
CARRIER, drive roll w/components 24 pitch
SPACER, carrier drive roll
PIN, rotation arm rocker
NUT, .250-28st1
SPRING, pressure arm retaining
4
WASHER, flat
2
4
4
2
2
2
.257 ID stl
2
ARM, pressure
SPACER,
RING, retaining
rotation
2
pin
ext .250 shaft
x
.O25thk
2
PIN, hinge
1
MOTOR, gear 1/8hp 24VDC 272RPM (consisting of)
MOTOR, gear 1/8hp 24VDC 500RPM (consisting of)
KIT, brush replacement (consisting of)
CAP, brush
BRUSH, carbon
KIT, cover motor gearbox (consisting of)
COVER, motor gearbox (consisting of)
GASKET, cover
SCREW, cover
1
1
1
2
2
1
1
1
5
SPACER, locating
RING, rtngext.25oshaftgrvx.O25thk
KIT, brush holder
WASHER, flat
PIN, cotterhair
SPRING, indicator
SCREW, hexwhd-slt stl slffmg 8-32 x .500
2
WASHER, lock stl split No. 8
WASHER, flat stl SAE No. 8
SPRING, cprsn
SPRING, cprsn
BUSHING, spring
SHAFT, spring
1
1
1
1
1
1
1
1
2
1
2
1
CARRIER, shaft
WASHER,flat.375lDx.625ODx.062
KNOB, extension
CIRCUIT CARD, digital tach (consisting of)
1
CONNECTOR & SOCKETS
GROMMET, rbr .250 ID x .375mtg hole
CONNECTOR & PINS
OPTICAL ENCODER DISC
FITTING, brs barbed M 3/l6tbg x .312-24
1
1
1
1
1
1
1
1
ADAPTER, gun/feeder LH
SCREW, cap stl hexwhd .250-20 x .750
WASHER, flat stl SAE .312
KNOB, plstc T 1.125 Ig x .312-18 x 1.500 bar
SCREW, hexwhd-slt stl slffmg 10-32 x .500
COVER, drive roll (consisting of)
LABEL, warning electric shock and pinch
NUT, stl hex full .375-16
WASHER, lock stl split .375
1
4
1
1
2
1
1
....
..
..
13-1 Item
....
28
178 937
(Fig
....
..
..
Wire
....
...
..
Assembly,
....
153 550
155 099
155 100
154 031
133493
184 136
13-4. Drive
....
153 492
..
Quantity
Description
..
..
..
1
1
WASHER, flat stl .375
SCREW, cap stl hexhd .375-16 x 1.250
SPACER, locating
DRIVE, pinion 40T 24P .376 bore
RING, retaining
ext .375 shaft
x
1
1
2
1
.O25thk
1
Part of 132 129 Optional High Speed Motor
*Recommended Spare Parts.
+When ordering a component originally displaying
a precautionary label, the label should also be ordered.
factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
To maintain the
OM-1 586
Page
43
S
L()
(0
N.
co
~
\
\
c~)
Co
C
~ Hardware is
common
and
not available unless listed.
ST-142 601-F
Figure
OM-1 586
Page
44
13-5. Boom
Assembly
Quantity
Item
No.
Model
Part
No.
Figure
.2..
1
1
139 336
GUARD, motor protector
CLAMP, hose .405 .485c1p
1
1
2
2
.5..
139633
.6..
073 742
073 741
079 029
075 462
602 250
079 020
...12..
149858
...12..
080 723
...13..
150258
...14..
024 605
...15..
075101
...16..
079 030
17..
+174 754
080157
174688
142804
134 327
073 666
047 224
602 246
079 667
080 812
079 632
602 243
079 622
149 322
-i-When
1
PULLEY,Vsglgrv
080811
079 664
...18..
15)
079 621
159989
.4..
11
13-1 Item
010 313
159991
079 665
...10..
Assembly (Fig
13-5. Boom
BUSHING, snap-in nyl .625 ID x .875mtg hole
BOOM, single
BOOM, single
GUIDE, wire
GUIDE, wire
GUIDE, wire inlet
LINER, monocoil 3/32-1/8 wire x 15.687
PIN, clevis .750 OD x 2.156 Ig
CLEVIS, .812 yoke 6.062 Ig .750-l6thd
NUT, stl hex full fnsh .750-16
SHAFT, boom counterbalance
WASHER, flatstl SAE .750
NUT, stl hex elastic stop .750-16
SPRING, cprsn 3.750 OD x .625 wire x 36.000
SPRING, cprsn 3.750 OD x .687 wire x 33.750
RETAINER, spring
BEARING, ball thr sgl row .750 x 1.625 x .625
NUT, stl hex special .750-16 x 1.250
WASHER, lock stl ext tooth .750
BASE, swivel boom (consisting of)
FITTING, grease 1/8NPT
BRACKET, mtg control tilt
LABEL, Swingarc caution heavy spring
LABEL, warning general precautionary
BOLT, mach stl hexhd .750-16 x 2.750
KNOB, T-bar .500-13 thd
WASHER, flat stl std .500
PIPE, plstc .500 x 133.750
PIPE, plstc .500x 181 .750
BOLT, U stl .250-20 x .875 wide x 1.375 deep
WASHER, flat stl std .375
WASHER, shldr .381 ID x .750 OD
PIN, cotter hair .072x1.437
010493
.2..
12116
Description
ordering
a
-
component originally displaying
a
....
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
5
3
3
2
2
2
2
1
precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1 586
Page
45
Table 13-1. Drive Roll and Wire Guide Kits
C,
~
Wire Size
E5
-C,
V-GROOVE
U-GROOVE
UC-GROOVE
VK-GROOVE
E~
~C~
.
.
4 RoIl
Drive
4 RoIl
Drive
4 RoIl
Drive
4 RoIl
Drive
Kit
Roll
Kit
Roll
Kit
Roll
Kit
Roll
149 518
151 024
087 130
150993
149518
151 025
053695
mm
150993
149518
151 026
053700
151 036
072000
151 052
132958
mm
150993
149518
161 189
053696
£
Fraction
Metric
.023-025 in
0.6mm
150 993
.030 in.
0.8
mm
.035 in.
0.9
.040 in.
1.0
.
.045 in.
1.1/1.2mn
150994
149519
151 027
053697
151 037
053701
151 053
132957
151 070
083489
.052 in.
1.3/1.4mr
150994
149519
151 028
053698
151 038
053702
151 054
132956
151 071
083490
151 029
053699
151 039
053706
151 055
132955
151 072
053708
151 056
132959
1.6
mm
150995
149520
1.8
mm
150995
149520
(.079 in.)
2.0
mm
150995
149520
151 040
053704
151 057
132960
151 073
053710
(.094 in.)
2.4
mm
150996
149521
151 041
053703
151 058
132961
151 074
053709
2.8
mm
150996
149521
151 042
053705
151 059
132962
151 075
053711
3.2
mm
150997
149522
151 043
053707
151 060
132963
151 076
053712
.068-072 in
5/64 in.
(15)
Each Kit Contains An Inlet
Guide,
Intermediate
Guide, And 045 233 Antiwear Guide With 604612 Setscrew 8-32
x
.125, Along
With 4 Drive Rolls.
2 Kits
Required
For Dual Models.
S-O~9-D
S
OM-1586 Page 46
Index No. M/2.4
Issued October 1997
GOM Series
Single and Dual, Bench and Boom Mounted,
Programmable, Constant Speed Wire Feeders
IKII1!IsIsIr
The 60M Series of semiautomatic wire
The dual 60M models
F~~1
feeders offers the ultimate in versatility,
required,
simplicity, programmability and
performance. Designed primarily for the pulsed MIG
welding process, all 60M models are equipped with
eight synergic pulse programs for use with the
V
Invision456, Phoenix~456,
as
well
as
other inverter
style and conventional-type CV and CC/CV welding
power sources.
specific welding requirements, the
factory set programs can be easily modified using the
teach mode. In addition to pulsed MIG capabilities,
To meet your
the 60M offers features
MIG welding
D-60M, Dual Wire Feeder
~1~Jfl~11flJ1fl~
L~
Processes
not
found
on
or
ideal when a standby gun is
are
for applications that require
two
different
can
perform
wire sizes and/or types. The dual models
the same process
on
both sides,
or one can
be used for
conventional MIG and the other used for pulsed MIG
welding. Only one gun can be operated at a time. The
Swingarc~ boom models are ideal when welding on
large weidments requiring long reach and maneuver
abllity~ Swingarc models are available in single and dual
models with 12 ft (3.6 m) and 16 ft (4.9 m) boom lengths.
coupled with a Mifier CV or CC/CV
complete, precise system for
optimum welding performance.
A6OM wire feeder
power source offers a
conventional
systems.
Features
Benefits
Microprocessor based with
digital motor speed control and
conventional
Otters
precise control and regulation of the welding
systems.
arc
not found in
motor tachometer feedback
a wide variety of applications to fill virtually any semiautomatic wire
requirement, increasing productivity while decreasing overhead.
Accommodates
Available in single or dual,
bench or boom models
feed
Operator-friendly front panel
One control for setting weld parameters.
Two, back-lit liquid crystal
Easy-to-set and view all welding parameters and selectable features.
displays
Pulsed MIG
(GMAW-P)
~ Welding
-
Eight, built-in synergic pulse
Quick and easy selection of the
nght pulse program based
on
your wire and gas.
programs
MIG
(GMAW)
~ Welding
Teach mode for
pulse programs
Full-feature, adjustable weld
sequence control
Allows field modification of
pulse programs
to meet your
specific application.
-
Flux Cored
(Gas and
(FCAW) Welding
Self-shielded)
Description
Consistent results are possible by programming limits to the range of parameter
adjustments. Eliminates inadvertent changes of preset parameters that could affect
weld quality.
Dual schedule
Allows two
capabilities
Arc time totalizer and
counter
Power Sources
Electronic
Miller Electric
Mfg. Co.
1635 West Spencer Street
WI 54914 USA
International
HeadquartersUSA
Phone: 920-734-9821
USA and Canada FAX: 920-735-4134
International FAX: 920-735-4125
welding conditions, such
as
hot and cold, to be
programmed
for
one
wire.
Handy feature for conducting job studies and maintenance schedules.
cycle
trigger hold control
Allows the
operator to make long extended welds without holding gun trigger.
Gas purge and wire jog control
Purge gas line and feed wire without energizing system.
Quick-change drive rolls and
quick connect for Miller guns
No tools
Rotatable wire drive
Eliminates sharp bends in the gun cable, thus improving wire feed performance and
extending the service life of the gun liner. (Bench models only.)
assembly
Company
Appleton,
-
Programmable, security system
Use with CC/CV and CV
An Illinois Tool Works
run-in,
You can select and adjust any parameter within the weld sequencepreflow,
weld time, crater, burnback and postflow, as required.
Covered drive roll
Protects drive roll and gears tram dust, dirt and other
assembly
Sealed ball bearing,
driven system
all-gear
Easy loading and threading
welding wire
required. Easy attachment.
of
atmospheric contaminants.
Smooth, positive and accurate wire feed offers long, uninterrupted service life.
Wire threads
through drive system without having
to release the drive roll pressure arm.
European HeadquartersUnited Kingdom
Phone: 44
FAX: 44
(0)1625-525556
(0)1625-537553
Ordering Information
-.
Web Site www.MillerWelds.com
Miller
Swingarc Boom Models
Bench Models
Notes:
Drive Rolls must be ordered
S-60M Single Wire
#131 794*
SS-60M Single Wire
D-60M Dual Wire
#131 796~
12 ft (3.7 m) boom
~
16 ft (4.9 m) boom
#131 798*
31 797~
Refer to
separately.
Mounting Equipment section
When
pulsing using
Miller inve rter power
sources, international-s lyle connectors for
DS-60M Dual Wire
4/0 weld cable must be ordered
The Power ~fBlue.
to
order boom mounts.
12 ft (3.7 m) boom
#131799
16 ft (4.9 m) boom
#131800
*~fi Certified by Canadian Standards Association to both Canadian and U.S. Standards.
(#138 181.
iwo
required).
Pulse MIG
Welding Process
When Pulse MIG welding, the power source
rapidly switches the output from high peak
current to low background current in precisely
regulated intervals. The peak current pinches
off a spray-transfer droplet while the low
background current cools the puddle and
maintains the arc with little
or no
S
w
metal
Lu
transfer. With proper adjustment of the pulse
parameters, the Pulse MIG welding process can
a
produce high -quality welds when using a broad
range of material types, thicknesses, and joint
configurations.
L
Advantages of Pulse MIG Process over
conventional MIG Welding:
~ Equal or faster travel speeds
~ Can use larger, more economical wire
TIME
PULSE MIG WAVE FORM
diameters
Reduces
or
eliminates spatter
Lower heat
input; therefore, reduced distortion
Better out-of-position puddle control
Optimum bead shape and penetration
Potential reduction in fume particulate
emission
60M
Design Features
Available in
single or dual wire,
Swingarc boom style.
Programming
bench
or
provide:
Swingarc
360 degree turning radius
power source:
Counterbalanced boom
shielding gas
In-boom cable
(1) .035 in (0.9 mm)
(2) .045 in (1.2 mm)
(3) .052 in (1.3mm)
(4) .062 in (1.6mm)
models
12
or
16 ft (3.6
routing
or
4.9 m) boom
length
Can be used with
a
variety of Miller
power sources:
use
welding
the 60M with the Invision456,
Phoenix
456,
or
the XMTfi304 CC/CS!
inverter power source (with an optional
Power Source Data Card
see page 5)
For conventional MIG
60M
or
can
also be used with the Deltaweldfi
Dimension
50780
welding only, the
Series power source.
1PM (1.319.8 m/ntirL) wire feed
speed range
Accommodates .023-1/8 in (0.6-32 mm)
diameter welding wire
Microprocessor-based control
Low voltageoperates
24VDC
off 24 VAC
high-torque, permanent magnet
motor
Four-drive-roll Posifeed
wire drive system
provides easy threading of welding wire
Millers True
BlueaWarranty
3 yearsparts
and labor
Operating Features:
length (in Adaptive Pulse mode)
can be regulated at the power
source output studs or at the welding gun
Gun trigger can be used to make program
arc
Arc voltage
selection
(5) .035 in (0.9 mm)
(6)
sensed after 3 seconds
Feeder will compensate for variations in
tip-to-work distance and provide a constant
309 stainless steel wire with Argon/CO2
.045 in
is present when the gun trigger is pressed
Drops out contactor and gas valve if arc is
Selectable
shielding gas
For pulse MIG/conventional MIG
Automatic shutdown if no wire feed speed
not
Mild steel wire with Argon/Oxygen
lOft (3m) 4/0 weld power cable and
gas hose
2
Features
Eight Synergic Pulse MIG Programs factoryset for use with the Invision456
welding
Arc time counter accumulates and
(1.2 mm)
Nickel alloy wire with Argon/Helium
shielding gas
actual
time
Counter can be reset toO (zero)
(7) .035 in (0.9mm)
displays
(up to 9,999.99 hours)
and weld cycles (up to 999,999 cycles).
arc
as
required.
Ideal for job time studies, shift output,
Silicon bronze wire with Argon
maintenance,
etc.
shielding gas
(8) .035 in (0.9mm)
Note: For XMT 304 Power Source Oats Card,
and Accessones.
On-Board
see
Options
Programming and Diagnostics:
factory-set synergic pulse programs can
be modified to meet specific welding
applications
Feeder can be manually programmed for
the voltage and/or amperage range of the
power source being used
Automatic shutdown if arc voltage is not
detected when gun trigger is depressed
All
Security Capabilities:
Feeder can be programmed to limit the
range of parameter control, the number of
programs available, and the selectable
parameters that are available to the operator
A
to
three-digit code can be programmed
restrict unauthorized
set-up screen
access
to
the
Control Panels
Sequence Chart
Wire Feed
Sequence
Time
-5
Preflow
09.9
sec.
not active
not active
Run-in
02.5
sec.
adjustable
adjustable
Weld
025
adjustable
adjustable
adjustable
adjustable
not active
adjustable
(voltage only)
not active
not active
-6
r~r~
Crater
02.5
Burnback
0025
Postf low
09.9
Speed
sec.
sec.
sec.
sec.
Arc
adjustable in the MIG process mode
Miller CV inverter power source.
Note: Inductance is
6DM Series Side Panel
1. Mode
Voltage or
Length
-4
only
Displays.
when
using
a
2. Mode Select Button. Provides thoice of four modes:
Process Mode. Pulse, adaptive pulse,
MIG. Also
or
used to teach customized
pulse programs.
Sequence Mode. Allows variety of sequences in weld
program. (Refer to Sequence Chart.)
Dual Schedule Mode. Links two weld programs
when two different welding conditions are required
for
one
wire.
Card Mode. Writes programs to optional Data Card
or reads programs from the Data Card.
3. Parameter Select Button. Selects parameter to
be changed.
6DM Series Front Panel
4. Parameter
voltage or arc length, wire
speed, and program number.
2. Purge Button. Purges gas line and gun without
energizing feeder.
3. Gun Trigger Receptacle. Prewired for single- and
dual-schedule operation. Receptacle will accommodate
a variety of dual schedule switches.
4. Trigger Hold Button and Light System remains energized
when operator releases gun triggerideal when making
1. Parameter Select Selects
feed
Display
5. Parameter Increase Button
6. Parameter Decrease Button
extended welds.
5.
6.
Digital Display
Jog Button. Feeds wire without energizing the power
source contactor
7.
and gas valve.
Display Control. Single-knob control for setting all
adjustable, displayed parameters.
Typical
Installations
All 60M feeders are supplied with alOft (3m),
Pulse MIG
or
Conventional MIG Welding
14-pin control cord.
lnvision
iVote: To connect the 60M feeder to
450 power
source use
an
existing Maxtron
adapter cord #043 661.
456,
Phoenix
14-Pin Control Cord
and XMl 304 power
source
(MIG
or
Pulse)
Gas Hose
with
Swingarc)
lOft
(3 m)
lOft
(3 m) 4/0 Weld Cable (supplied with Swingarc)
(supplied
6DM
(3m) 14-Pin Control Cord
(supplied with Swingarc)
lOft
Conventional MIG Welding
Miller
electronically
controlled CV
or
power
with
source
N
CC/CV
14-Pin Control Cord
14-pin receptacle
(MIG only)
Miller
lOft
(3m) Gas
lOft
(3 m) 4/0
Hose
(supplied with Swingarc)
Weld Cable
(supplied
with
Swingarc)
6DM
electronically
CC/CV
controlled CV
or
power
with
source
(3m) 14-Pin Control Cord
(supplied with Swingare)
lOft
14-pin receptacle
(MIG only)
OMuler.
3
(Use with
Specifications
(Subject to change without notice.)
Industrial
Input
Electrode Wire
Single Wire Models
Power
Diameter
S-60M Bench
24 VAC
.0231/8 in
50780
50/60 Hz
(0.63.2 mm)
(1.319.8
rn/mm.)
12 ft
Capacity
Peak Current
Speed
Background
Current Range
Pulses per
Second*
0200
20400
PPS
CCICVPower
Sources.)
Pulse
Width
Dimensions
Net
1.05.0
H: 14 in
58 lb
SS-60M, Swingarc~
12 ft
(3.6 m) Boom
160 lb
(73 kg)
280 lb
(127 kg)
Swingarc~
16 ft
(4.9 m) Boom
210 lb
(95 kg)
350 lb
(159 kg)
16 ft SS-60M,
Wire
~
1PM
Range
100600
A
A
(356 mm)
Milliseconds W: 14 in (356 mm)
D: 26-1/2 in (673 mm)
Weight
Ship Weight
(26 kg)
62 lb
(28 kg)
Dual Wire Models
D-60M, Bench
24 VAC
T.o231/8
50/60 Hz
1(0.63.2mm)
in
I
1PM
50780
100600
A
0200
(1.319.8
rn/mm)
A
20400
PPS
1.05.0
H: 14-3/4 in
Milliseconds W: 18 in
D: 32 in
(375 mm)
(457 mm)
(813 mm)
82 lb
(37 kg)
90 lb
(41 kg)
12ff DS-60M,
Swingarc~
~
12 ft
(3.6 m) Boom
207 lb
(94 kg)
318 lb
(144 kg)
16ff DS-60M,
Swingarc~
J~
16ff
(4.9 m)
280 lb
(127 kg)
411 lb
(186 kg)
Applies ony
when 6CM feeders
Drive Roll Kits
are
used with the lnvision~456 and Phoenix456 power sources.
Select drive roll kits from chart below according to type and ~ size being used. Drive roll kits include necessa,y guides and feature
:~
~
V
groove
for hard wire
Wire size
(0.6 mm)
(
.~
~
.023/.025 in
Boom
U
groove for
soft wire or
soft-shelled
cored wires
V
knurled
for hard-shelled
cored wires
#151 036
#151 052
~
an
anti-wear sleeve for the inlet guide.
U
cogged for
extremely soft
wire orsoft
shelled cored
wires (i.e., hard
lacing types)
#151 024
.030 in
(0.8 mm)
#151 025
.035 in
(0.9 mm)
#151 026
.040 in
(1.0 mm)
#161 190
.045 in
(1 .1/1 .2 men)
#151 027
#151 037
#151 053
#151 070
(1.3/1.4 mm)
#151 028
#151 038
#151 054
#151 071
#151029
#151039
#151055
#151072
.052 in
1/l6in(1.6mm)
.068/072 in
(1.8 mm)
#151 065
5/64 in
(2.0 mm)
#151 040
#151 057
#151 073
3/32 in
(2.4 mm)
#151 041
#151 058
#151 074
7/64 in
(2.8 mm)
#151 042
#151 059
#151 075
#151 043
#151 060
#151 076
1/8 in
(3.2 mm)
Nylon
Wire Guides for
Wire Size
.047 in
(1.2 mm)
lIl6in(1.6mm)
3,32 in (2.4 mm)
4
I
Feeding Aluminum
Inlet Guide
#151 203
#151 205
#151 207
I
Wire
Intermediate Guide
#151 204
#151 206
#151 208
I
Note: ~U groove drive rolls
recommended when
are
feeding aluminum
wire.
~
.
Options
and Accessories
Skill Level Index
The box
A
following the
stock number of field-installed
options contains a letter and number. The letter indicates
required to install the option. The number
indicates the approximate time required for installation (see
legend).
the skill level
Weld Current Sensor #160 963
This
B
Easy. No previous experience needed.
Average. Requires removal of service panels.
Mechanical ability is helpful,
CDifficult.
splicing
May require
the
use
of electrical wires.
component pails is
more
of
an
Repair
D
ohmmeter and/or
or
May require the use of an ohmmeter and the
ability to read a circuit diagram. Repair or replacement
of component parts is complex.
Technical.
Example:
replacement of
18:301 Skill Level: B, Time: 30 minutes
difficult
1 A: 051
option is required when using M feeders
with older style Miller CV power sources:
Deltaweldfi prior to serial no. KG14 1349 and
Dimensiontm
prior to serial no.
KC 253517.
Power Source Data Card forXMT 304 CC/CV
#043390
Simply insert the Data Card in the 60M
control and with the push of a button the
eight synergic pulse programs for the XMT
304 are loaded in memory and ready to use.
The
eight XMT programs are for
.030 in steelwirewithArgon/CO2
.035 in steel wire with
Remote Pmgram Selectors
RPS-8 #160977 Field
(B: 201
Wire Straightener
For .035.045 in (0.91.1 mm) wire
#141580
A:051
Fight-position rotary switch used to
remotely select weld programs. Includes
For 1/161/8 in (1.63.2 mm) wire
33 ft (10 m) cord to connect feeder.
#141581
IA:051
Improves wire feeding
performance and increases life of gun liner
and contact tip.
Reduces cast in wire.
Argon/CO2
.045 in steel wire with Argon/CO2
.030 in SS wire with Pulse ui-mix
.035 in SS wire with Pulse ui-mix
.045 in SS wire with Pulse ui-mix
High-Speed Motor
For single and right side of dual models.
#132 129 Factory only
.035 in SiB wire with Argon
.035 in Nickel wire with Ar/He
For left side of dual wire models.
For S-60M Model
Provides wire
#13493610ft.(3m)
#134937
8:551
25ft(7.6m)
18:551
For D-60M Model
#134935
25ft(7.6m)
#155910
Blank Card. Stores up to 32 complete weld
programs. Ideal for saving custom programs
and
only. Field-installed
only. Separates the feeder control module
from the wire drive assembly and base. Ideal
when using Automation Upgrade Module.
transferring programs to other 60M
Automation Upgrade Module #172886
in the 60M, but will
use
factory programs
require the factory set
voltage and current range to be reset.
This module consists of an I/O board and
software upgrade that enables the 60M
control to better communicate with other
peripheral equipment and improves
performance in an automatic welding cell.
Features: two
remote
arc
1PM
wire sizes larger than 5/64 in (2.0mm).
speed motor must be used on each side
Factory-written
synergic Pulse MIG programs will not
operate with high-speed motor.
of the dual wire models.
Water Hose Kit
#09674610ft(3m)
feeders.
The Maxtrontm 450 can
speed range of 901400
(2.335.6 rn/mm). Not recommended for
Same
18:551
For 60M bench models
60MDataCard
Factory only
Control Detachment Kit
#132130
programmable outputs,
A:10J
bench-stylefeeders. Use with Miller
coolant systems and water-cooled welding
guns. Can be used with or without optional
water flow safety switch.
For
If water kit is to be used
dual wire feeder,
a
on
both sides of a
kit must be ordered for
each side of the feeder.
start/stop, remote program select,
voltage monitor, arc error monitor and
wire stick check.
Water Flow Shutdown Switch
#180390
(A:15l
For use with the water hose kits. Protects
water-cooled gun from overheating by
shutting down system if water does not flow.
If required
on
both sides of a dual model,
water flow shutdown
~lle~
two
switches must be ordered.
5
Options and Accessories
Dual Schedule Switches
For use with Dual Schedule Control in 60M feeder.
DSS-8
#079693
IA: 051
Requires adapter cord #157 364. Two-position
trigger switch that easily attaches to the
welding gun. Use in place of the standard
trigger for dual scheduling.
Wire ReelAssembly #108008
Accommodates 60 lb (27 kg) coil of wire.
FeederCart #142382
(A:20]
Low-profile, creeper cart Shipped disassembled.
Reel Covers
Accommodates 60 lb (27 kg) coil of wire.
#058256
For S-60M
single wire model and left side of
D-60M dual wire modeL
#091668
For
right side of D-60M dual wire model.
Protects wire from contaminants.
DSS-9M #041 793
(A: 051
Two-position slide switch that attaches to the
welding gun. Selects welding condition when
utilizing the dual schedule feature. Gun trigger
operates as standard trigger.
HangingBail
#058435
A:151
Electrically isolated. Suspends feeder over
work area.
Spool Covers
Fits
a
12 in
(304 mm) spool of wire.
#057607
A:051
DSS-10 Remote Increase/Decrease Switch
For S-60M
single wire model and left side of
#042749
D-60M dual wire modeL
1A051
Two-position, momentary contact switch that
attaches to the welding gun. Use with the
#090389
TumtableAssembly
IA:051
For right side of D-60M dual wire modeL
Allows feeder to
#146236
rotate as
(B: 201
operator changes
Remote Parameter Increase/Decrease feature
work position. Reduces strain and
fine tune parameters at the welding gun
while welding. Gun trigger operates as
gun cable.
standard
Adjustable Spool Carrier #096075 (A: 201
For use only with Swingarc models with 6 ft
(1.8 m) pipe post mounted on Swingpak base.
to
trigger.
bending of
Replaces standard spool assembly. Positions
welding wire lower for easier loading and
unloading.
Extension Cords
For optimum
perfonnance, do not extend 60M
feeder more than 60 ft (18 m) from power source.
14-Pin Extension Cord
#043690
Carryingcart
#056301
(A:301
Carries wire feeder and miscellaneous welding
supplies. Height 34 in (863mm). Lower tray
height 9 in (228mm). Shipped disassembled.
#043691
25ft(7.6m)
50ft(15m)
Water Coolant Systems
Refer to Water Coolant Systems literature,
Index No. AY/7.2.
6
Mounting Equipment for Swingarc~M Booms
One of the
following is required for mounting
Swingarc~ booms:
the SS-60M and DS-60M
Swingpakm Basepipe post with base plate
CBC Cart (for use with 12 ft 3.7 ml model
only)the 6 ft (1.8 m) pipe post without base
plate (ordered separately)
Pipe Post
The
Swingpak~ Bases
Order a
Swingpak-12 base to mount a 12 ft
(3.7 m) boom. The Swingpak-16 base is for use
with a 16 ft (4.9 m) boom.
Each base accommodates
a
power source,
Swingarc feeder system, water coolant system,
and gas cylinder. The base plate is solid to
help better organize components and cables.
Base includes a three-compartment storage
locker. The entire unit can be moved with
a
forklift irucic
Order pipe post with base for Swingpak base.
Specifications
CBC Cart
For
use
with
12ft (3. 7m) boom only.
Cart accommodates
a
The CBC
power source, 12 ft (3.7 m)
Swingarc feeder, and two gas cylinders. Designed
to provide mobility and a neat, orderly
arrangement of welding equipment.
Order 6 ft (1.8 m)
CBC cart.
pipe post with no base for
and
Ordering Information
Model
Stock No.
Length
Width
Swingpak-12
#085 276
65 in
(1.7 m)
50-718 in
Swingpak-16
#085 934
79 in
(2.0 m)
66-7/8 in
CBC Cart
#152 637
70 in
(1.8 m)
34 in
Net
(1.3 m)
(1.7 m)
(864 mm)
For 12 ft Boom (3.7 m)
(18 in (457 mml Base Plate)
(24
4 ft
(1.2 m)
no
#075 078
#015 078
4 ft
(1.2 m)
with base
#149 838
#078 264
6ft
(1.8 m)
no
#079 217
#079 217
6 ft
(1.8 m)
with base
#149 839
#019 216
Note: The 4 ft
with
(1.2 m) pipe post is not recommended for use
the CBC Cart. The 16 ft (4.9 m) Swingarc feeder cannot
be used.
base
CBC Cart Features
2000 lb
(907 kg) load capacity
Multi-position boom
Swing-out outriggers
Wide front-wheel stance and automotive-
type steering
12 in
(305mm) diameter by 3 in (76mm)
wide wheels
Mounting facilities for most Miller CV
power sources
Compartment in base of cart to add ballast
weight when using lightweight power sources.
Minimum ballast weight of 300 lb (136 kg)
required
Fold-up gas bottle loading ramp
QM111e~
Ship Weight
(187 kg)
418 lb
504 lb
(229 kg)
510 lb
(231 kg)
328 lb
(149 kg)
510 lb
(231 kg)
For 16 ft (4.9 m) Boom
in 1610 mml Base Plate)
Pipe Post Model
base
Weight
412 lb
(190 kg)
System Checklist and Quotation Sheet
Equipment
and
Options
6DM Bench Models
Stock No.
Description
#131 794
S-60M, single
D-60M, dual
#131 796
6DM Swingarc Models
#131 797
#131 798
#131 799
;
Power SourceMIG
or
#131 800
Single,
Single,
Oty.
12 ft Boom
16 ft Boom
Dual, 12 ft Boom
Dual, 16ft Boom
Pulse MIG
Invisionfi 456
See Lit Index. No. DC/20
XMTfi304 CC/CV
See Lit Index No. DC/i 8.8
Phoenix 456
See Lit Index. No. DC/21
Power SourceMIG
only
Deltaweldfi
See Lit Index No. DC/i 6.2
Dimension
See Lit Index No. DC/i 9.2
Options
for any 60M Model
Weld Current Sensor
#160 963
For
Data Card for XMTfi304
#043390
8 programs for XMTfi304
Blank Data Card
#155 910
Store up to 32 programs
High-Speed
#132 129
For single, or right side of dual
For left side of dual
Motors
#132 130
Options
Automation
#134 936
Upgrade_Module
Water Hose Kit
Straighteners
Wire Reel
#134 937
For S-60M, lOft
For S-60M, 25 ft
#134 935
For D-60M, 25 ft
#172 886
Ideal for automatic
Assembly
#180 390
Use with #096 745
#141 580
.035045
#141 581
1/161/8
in wire
in wire
#108 008
Reel Covers
#091 668
For single, or left side of dual
For right side of dual
#057 607
For
#090389
For
single, or left side of dual
right side of dual
See
Options & Accessories
#058 256
~
covers
Carrying Cart
applications
#096745
Water Flow Shutdown Switch
Spool
older-style Miller power sources (pg. 5)
for Bench Models
Control Detachment Kit
Wire
Price
-
.
#056 301
Feeder Cart
#142 382
Hanging Bail
#058 435
TumtableAssembly
#145236
Options for_Swingarc_Models
Adjustable Spool Carrier
#096 075
Mounting Equipment
Miscellaneous
Drive Roll Kit
See Drive Roll Kit table
Extension Cords
See
& Accessories
See
& Accessories
Dual Schedule Switches
Options
Options
See Options
Water Coolant
See Ut Index No. AYI7.2
Remote
Program Controls
Systems
Welding Gun
See Lit Index No. M/1O.O
Primary Power Cable
Secondary Weld Cable
lrrternabonat-Style Connector
& Accessories
Supplied with Swingart? models only
4/0 recommended for Pulsed MIG
#138 181
For 4/0 weld cable
(see
page
4)
Ground Cable with Work Clamp
Gas
Supply
RegulatorlFlowmeter
Gas Hose(s) with Fittings
Welding Wire
Supplied
with
Swingarc
models
only
Spare Consumables
Helmet
Welding Gloves
Date:
Distributed
Miller
The Power ofBlue.
Lithoin USA
Total Ouotsd Price:
br
.
.
Elf ective January 1, ieee
(Equipment
Warranty
Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you
LIMITED WARRANTY
below,
Miller
warrants
equipment sold
the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions
Contact your distributor.
The expertise of the
distributor and Miller is
there to
step of
Kits
Accessory
shipped by Miller. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
INCLUDING
THE
WARRANTtES
OF
IMPLIED,
Replacement
such defects in material
Spoolmate
1.
Items furnished
such
or
Parts
as
covered
2.
engines or
by the manutacturers warranty,
Consumable components; such
Equipment
3.
periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser,
or one year after the equipment is sent to a North American
distributor or eighteen months affer the equipment is sent to
to:
it any.
5 Years Parts
Original
*
Inverters
contact
tips, cutting
or parts
wear.
that has been moditied
by
any
party other
Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has
been
specitications tor
*
as
than
International distributor.
the way
apply
nozzles, contactors, brushes, slip rings, relays
time
1.
shall not
but manufactured by others,
trade accessories. These items are
that tail due to normal
help you every
Warranty
by Miller,
within
Miller shall honor warranty claims on warranted equipment
listed below in the event ot such a failure within the warranty
an
(No labor)
185
True Bluefi Limited
Millers
workmanship. Miller must be
writing
thirty 130) days ot such detect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
notified in
other
Remote Controls
after the effective date of this limited warranty
workmanship at the time it is
MERCHANTABILITY AND FITNESS.
no
Torches
*
is free of detects in material and
warranty periods listed below, Miller will repair or
replace any warranted parts or components Ihat tail due to
always get
newer)
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
*
Subject to the terms and conditions
Mtg. Co., Appleton, Wisconsin,
original retail purchaser that new Miller
-
Electric
its
to
or
warranty supersedes all previous Miller warranties and is exclusive with
guarantees or warranties expressed or implied.
Within the
Service
You
This limited
with a serial numher preface of KJ
operation outside
equipment.
used for
the
ot the
3 Years Labor
-
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
main power rectitiers
(input
output rectitiers only)
and
AND MAINTENANCE OF WELDING EOUIPMENT.
2.
3 Years
Parts and Labor
In the event ot
*
3.
Transtormer/Rectitier Power Sources
*
Plasma Arc
*
Semi-Automatic and Automatic Wire Feeders
*
Inverter Power
*
Intellitig
*
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
engine manutacturer.)
1 Year
Power Sources
Cuffing
Supplies
the
Parts and Labor
*
Motor Driven Guns
*
Process Controllers
a
warranty claim
covered
by this warranty, the
exclusive remedies shall be, at Millers option: (1) repair; or
(2) replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost ot repair or
replacement at an authorized Miller service station; or (4)
payment ot or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return ot the
goods at customers risk and expense. Millers option of
repair or replacement will be FOB., Factory at Appleton,
Wisconsin, or FOB. at a Miller authorized service facility as
determined by Miller. Theretore no compensation or
reimbursement for transportation costs of any kind will be
allowed.
(w/exception
*
Positioners and Controllers
*
Automatic Motion Devices
*
Robots
*
IHPS Power Sources
*
Wafer Coolant
of
Spoolmate 185)
TO THE EXTENT PERMITtED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE
FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEOUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY
*
Systems
AND
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
HF Units
Grids
4
Spot
MIGHT
ARISE
BY
IMPLICATION,
PROVISION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEAUNG, INCLUDING 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,
Welders
Load Banks
SDX Transtormers
Miller
Cyclomatic Equipment
Running Gear/Trailers
Plasma
Cutting Torches (except APT,
Models)
ZIPCUT &
PLAZCUT
*
Deutz
*
Field
Engines (outside
North
installed
whichever is
in,
or
tor
a
America)
greater.)
minimum ot
one
Some states in the U.S.A. do not allow limitaiions ot how long
implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
an
Options
(NOTE: Field options are covered under True Bluefi
for the remaining warranty period ot the product they
are
EXPRESS WARRANTY NOT PROVIDED HEREIN
OR
GUARANTY
ANY
IMPLIED WARRANTY,
year
available, but may vary from
In
Canada, legislation in
additional warranties
herein, and
4.
6 Months
5.
90
Batteries
state to state.
some
or
provinces provides for certain
remedies
to the extent that
other than
they may
limitations and exclusions set out above
as
stated
waived, the
may not apply. This
not be
Warranty provides specific legal rights, and other
rights may be available, but may vary from province to
province.
Umited
*
Days
Parts and Labor
MIG Guns/TIG Torches
miiier_wsrr 1/98
Owners Record
44
1,
Please complete aNd retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment
was
detivered to
original customer.)
Distributor
Address
City
Slate
lip
Resources Available
Always provide Model Name and Serial/Style Number.
Coulact your Distributor for:
To locate distributor nearest you call
1 -800-4-A-Miller.
Welding Supplies
Options
and Consumables
and Accessories
Personal
Safety Equipment
Service and Repair
Replacement
Miller Electnc
1635 West
Appleton,
Training (Schools, Videos, Books)
Circuit
(Servicing
Information
Spencer Street
Headquarters-USA
Phone: 920-735-4505
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Diagrams
Welding
Co
Company
WI 54914 USA
kiternational
Technical Manuals
and Parts)
Mfg
An ll!wtots Tool Works
Parts
European Headquarters
-
Kingdom
Phone: 44 (0)1204-593493
FAX: 44 (0)1204-598066
United
Process Handbooks
www.MjlleiWalds.com
Csilact the Doliveriug Carrier fur:
File
a
claim for loss
or
damage during
shipment.
For assistance in
filing
or
settling claims,
equipment
Department.
contact your distributor and/or
manutacturer s Transportation
~7/i Miller
~
PRINTED IN USA
'
1998 Miller EIe~iic
Mfg. Co. 5/98
z~r~fB&