Miller | KD497659 | Owner Manual | Miller SS-64M SWINGARC User manual

Miller SS-64M SWINGARC User manual
Millerfi
Form:
October 1993
OM-1586D
Effective With Serial No. KD497659
OWNERS
MANUAL
SS-64M (12) And (16) Foot
Boom Mounted Wire Feeder
Microprocessor Controlled Constant Speed Wire
Multi-Power Source
Compatible
For GMAW, GMAW-P, And FCAW
For .023 To 1/8 in
Feeder
(0.6 To
3.2
Welding
mm) Wires
Standard Wire Feed Speed Of 50 To 780 ipm (1.3 To 19.8 mpm)
Programmable
Pulse Weld Parameters
Circuit Breaker Protected
Read and follow these instructions and all
safety
blocks
Have
only
Give this manual to the operator.
carefully.
trained
install, operate,
or
and
qualified persons
For
service this unit.
Call your distributor if you do not understand
the directions.
cover
7/93
ST.157 388
'
1993 MILLER Electric
or:
help, call your distributor
MILLER Electric
Appleton,
Mlg Co.
WI 54912
Mfg. Co., P.O.
Box 1079,
414-734-9821
PRINTED IN USA
LIMITED WARRANTY
TRUE BLUETM
MILLERS
Effective
(Equipment with
a
January 1, 1992
preface of KC
sariai number
previous MILLER werrenties end is exclusive with
This limited werrenty supersedes eli
the terms and conditions below, MILLER Electric
MI g. Co., Appleton. Wisconsin. warrants to its original retell purchaser that new
MILLER aquipmant sold after the effective date of this limited warranty is free of de
LIMITED WARRANTY
other
guarantees
or
werrenties
expressed
or
implied.
Remote Controls
Subject to
fects in material and workmanship at the tima it is shipped
no
newer)
or
*
Accessory
*
Rapiscamant Parts
by MtLLER. TIllS WAR
RANT? IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES. EXPRESS OR
MILLERS
IMPLIED. INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT
True
Kits
BIuaT_
Limited
Warranty
shall not
apply
to:
NESS.
Items furnished
1.
Within the
warranty periods listed below, MtLLER will repair
or
raplaca any
which time MILLER will
provide instructions
on
Plasma Arc
Cutting
Compressors
contactors
Motor Driven Guns
Process Controllers
TRACt TORT OR ANY OTHER LEGAL THEORY.
Syatams
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR
HF Units
RANTY, GUARANTY DR REPRESENTATION AS TO PERFDRMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT DR ANY OTHER LEGAL
THEORY WHICH, BUT FOR THIS PROVISION. MIGHT ARISE BY IMPLICATION.
OPERATIDN DF LAW, CUSTOM DF TRADE DR COURSE OF DEALING, IN
CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE. WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.
Grids
Spot
Welders
Load Banks
SDX Transformers
Running Gear/Trailers
Field Options
*
tips, cutting nozzles.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN
ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE
LIABLE FOR DIRECT, INDIRECt SPECIAL, INCIDENTAL OR CONSEQUENTIAL
DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CDN
Psrts end Labor
Water Coolant
*
as contact
to normal wear.
wsrrsnty claim covered by this warranty, the exclusive remedies
option: )t) repair: or (2) rapiacamant; or. where authorized in
in appropriate cases, 13) the reasonable cost of repair or replacemantel an authorizad MILLER sarvica station: or (4) payment of or credit for tha pur
chase price (lass reasonable dapracistion based upon actual use) upon return ot the
goods at customers risk and aspansa. MILLERS option of repair or replacement
will be FOB.. Factory atApplaton. Wisconsin, or F.O.B. ala MILLER authorized ser
vice facility as determined by MILLER. Therefore no compansstion or reimburse
ment for transportation costs of any kind will be allowed.
Parts and Labor
1 Yasr
*
parts that fail due
shall be. at MILLERS
Driven Welding Ganarstors
(NOTE: Engines era warranted separately by the angina manufacturer.)
*
or
writing by MILLER
Engine
*
relays
In the avant of a
Power Sources
Robots
2 Years
Air
engines or
warranty, if
CIALIINDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAIHTENANCE OF WELDING EQUIPMENT
Semi-Automatic and Automatic Wira Feeders
4.
such as
MILLER PRODUCTS ARE IHTEHDED FOR PURCHASE AND USE BY COMMER
main power rectifiers
Transformar/Ractifiar Powar Sources
*
by others,
the manufacturers
Parts and Labor
3 Years
3.
by
3 Years Labor
5 Yaars Parts
2.
covarad
Equipment that has bean modified by any party other than MILLER, or aquip
mant that has bean improperly installed, improperly oparstad or misused
based upon industry stsndsrds, or equipment which has not had reasonable
end nacasssry mairttansnca, or aquipmant which has baan used tor oparstion
outside of the specifications for the equipment.
3.
on warranted equipment listed below in the
warranty lime pariods. All warranty time periods
delivered to the original retail purchaser, or
the
was
that
start on the data
equipment
one year after the equipment is sant to the distributor.
MILLER shall honor warranty claims
avant of such a failure within the
Original
era
Consumable componants: such
2.
the warranty claim procedures to ba
and
*
but manutacturad
any.
followed.
1.
by MILLER.
trade accessories. These items
war
ranted parts or components that tail due to such detects in malarial or workmanship.
MILLER must be notified in writing within thirty (30) days of such defect or tailura, at
TN
(NOTE: Field options era covarad undar True Blue
warranty period ol tha producl Ihey era installed in,
whichavar is graalar.(
one year
5.
6 Months
B.
g~
Days
for the
or
for
a
Some
remaining
slates in Iha
U.S.A. do
not allow limitations of how
long
an
implied warrsnty
lasts, or tha asclusion of incidantal, indiract, special or consequential damsgas. so
Iha above iimitstion or asciusion may not apply to you. This warranty provides spe
cific lagal rights, and other rights may ba available, but may vary from stats to stats.
minimum of
Batteries
MIG Guns/TIG Torchas
Plasma
In
Csnsds, Iagislslion
or
remedies other than
in soma
provincas provides for certain additional warranties
they may not be
waived, the limitations and exclusions sat out above may nol apply. This Limited
Warranty provides specific legal rights, and other rights may be available, but may
vary hom province to province.
Parts and Labor
Cutting Torches
as
slslad herein. and to the aslanl thaI
U,.
I
RECEIVING-HANDLING
unpacking equipment, check carton for any dama9e that may have occurred during Shipment. File any claims for loss or damage
deiivering carrier. Assistance for filing or settling claims may be obtained from distributor and/or equipment manufacturers
Transportation Department.
Before
with the
When
requesting information about this equipment, always provide Model Designation and Serial
Use the
or
following
spaces to record Model
Designation
and Serial
or
Style
or
Style
Number.
Number of your unit. The information is located
on
the
rating
label
nameplate.
Model
_________
Serial
or
Style
No,
Date of Purchase
miller 5/93s
ERRATA SHEET
After this manual
to data
was
appearing
printed,
refinements in
June 2, 1994
FORM: OM-1586D
Use above FORM number when
ordering
equipment design
occurred. This sheet lists
extra manuals.
exceptions
later in this manual.
CHANGES TO SECTION 3
INSTALLATION
Replace Section 3-11B. Welding Wire Installation: Installation Of Optional Wire Reel And Reel Type Wire
8
5
4
2
1
Retaining Ring
2
Spanner
3
Lock
4
Wire Retainer
5
Wire Reel
6
Hub
7
Hub Pin
8
Reel
Nut
Support
Remove retaining ring. Pull lock
and turn. Remove spanner nut,
wire retainer, and wire reel from
hub.
.1
Lay wire reel assembly on flat sur
face, and install wire as shown.
Tighten spanner nut until lock is in
position over hole in wire retainer.
Pull lock and turn to insert locking
pin into wire retainer.
Slide wire reel assembly onto hub,
and turn assembly until hub pin is
seated in hole in reel. Reinstall re
O
~1T
taining ring.
III~
Wire Installation
ST143 478~A / ST-152 463
Figure
3-14. Installation Of
CHANGES TO SECTION 15
Replace Figure
15-1. Circuit
Replace Figure
15-2.
4 and 5
on
Sheet)
Wire Reel And Reel
Type
Wire
ELECTRICAL DIAGRAMS
Diagram
Wiring Diagram
this Errata
Optional
For Wire Feeder
(see Pages
2 and 3
on
this Errata
Sheet)
For Wire Feeder Effective With Serial No. KD497659 And
Following (see Pages
r
I
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PP~AN SELECT
I
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OM-1 5860
Page
2
15-1. Circuit
Diagram
For Wire Feeder
.1
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OM-1586D Page 3
Figure
15-2.
OM-1586D Page 4
Wiring Diagram
For Wire Feeder Effective With Serial No. KD497659 And
Following
(4 0
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CHANGES TO SECTION 16- PARTS LIST
Change
Parts List
as
follows:
Dia.
**
79-7
.
124 905
79-8
.
81-2
81-10
.
.
.
82-34
82-43
.
82-44
.
.
.
.
.
.
.
.
.
PC1O
PLG1O3
.
...
....
With
...
+168 104
...
164 842
..
154 932
Added
Added
..
.
.
.
.
.
167 698
010291
167700
167 633
159 264
...
.
165 934
.
..
..
155 024
161 781
Deleted
.
.
..
..
..
..
..
..
..
..
83-15
133 603
83-20
83-
154031
Added
167 387
..
165 799
..
8383-
Added
Added
165 798
..
85-1
057 357
.
.
.
.
.
.
.
**First
163 282
010 493
..
..
..
RETAINER, spool support (Eft wIKE621826)
(consisting of)
1
LABEL, caution falling wire reel can cause damage
NUT, spanner retaining (Effw/KE621826)
METER, (qty chg) (used on front meter only)
LENS, clear anti glare (used on side meter only)
1
CIRCUITCARD,processorw/prom
1
Eff w/KE593886
PANEL, front (Eff w/KE623992)
WASHER, flat .625 ID nylafil (Effw/KE623992)
1
..
Page
6
1
1
1
....
KNOB, pointer (Eff w/KE623992)
WASHER, shldr .612 ID (Eff w/KE623992)
RING, rtng ext .625 shaft grv x .045 thk E style
1
(Eff w/KE623992)
1
SPRING, cprsn .573 OD
x
.088 wire
x
1.062
1
lg
(Eff w/KE644333)
SPACER, locating (Eff w/KE552693)
WASHER, flat .257 ID stl (Eff w/KE644333)
SPRING, pressure arm retaining (Eff w/KE644333)
NUT, .250-28 stl (Eff w/KE644333)
BUSHING, snap-in nyl .625 ID x .875mtg hole
label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1 586D
1
...
digit represents page no digits following dash represent item no.
ordering a component originally displaying a precautionary label, the
+When
Quantity
Description
166 594
168 103
164842
164713
135 635
157 113
097 924
82-45
8282-
.
Replaced
124904
164 842
81-2
.
.
Part
No.
Mkgs.
2
2
2
.
2
2
1
ARC WELDING SAFETY PRECAUTIONS
WARNING
a
ARC WELDING
be hazardous.
can
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information that will be found in the
Safety Standards listed on the next page. Read and follow all Safety Standards.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
ELECTRIC SHOCK
can
kill.
5.
live 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.
1.
2.
3.
Wear
dry. hole-free insulating gloves
yourself
Insulate
from work and
and
or
equipment according
making input connections,
When
attach
ground using dry insulating
stop engine before installing
or
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
to its
grounding
proper
7.
Turn off all
8.
Do not
when not in
equipment
use
use.
damaged, undersized,
worn,
or
poorly spliced
cables.
Do not wrap cables around your
body.
10.
Ground the
electrical
11.
Do not touch electrode if in contact with the work
12.
only well-maintained equipment.
damaged parts at once.
13.
Wear
14.
Keep all panels and
9.
workpiece
to
good
a
(earth) ground.
or
body protection.
servicing
~
this
conductor first.
or covers.
Disconnect input power
this equipment.
ground
Manual and national, state, and local codes.
Do not touch live electrical parts.
mats
4.
6.
install and
Properly
Owners
Touching
Repair
Use
a
safety
harness if
replace
above floor level.
working
covers
ground.
or
securely
in
place.
ARC RAYS
2.
Wear
a
helmet fitted with
welding
a
proper shade of filter
(see
ANSI Z49. I listed in
Arc rays from the welding process produce intense
heat and strong ultraviolet rays that can burn eyes
and skin. Noise from some processes can damage
3.
~
hearing.
Safety Standards) to protect your face and
eyes when welding or watching.
Wear approved safety glasses. Side shields recommended.
Use
protective screens or barriers to protect others from flash
glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resiŒtant
material (wool and leather) and foot protection.
and
NOISE
5.
1.
Use
approved
ear
plugs
or ear
muffs if noise level is
FUMES AND GASES
~~:
.~
can
high.
be hazardous
5.
to your health.
~
Weldingproducesfumesandgases. Breathingthese
fumes and gases
be hazardous to your health.
can
6.
Keep
2.
If inside, ventilate the area and/or use exhaust at the arc to
welding
If ventilation is poor, use an
4.
Read
the
Safety Data Sheets (MSDS5)
and the
coatings,
on
area
Watch for fire, and
6.
Be
or
burns. Accidental contact of electrode orwelding wire
to metal objects can cause sparks, overheating, or
1.
Protect
Do not weld where
yourself
and others from
flying sparks
flying sparks
can
Remove all flammables within 35 ft
(10.7 m) of the welding arc.
them with approved covers.
this is not
If
possible, tightly cover
Be alert that welding sparks and hot materials from welding can
through small cracks and openings to adjacent areas
FLYING SPARKS AND HOT METAL
cause
can
cool, they
and
can
grinding
or
spraying
react with vapors to
galvanized, lead,
or
is removed from the
coating
is well ventilated, and if necessary, while
that
fire
keep
welding
on
a
fire
on a
extinguisher nearby.
ceiling, floor, bulkhead,
Do not weld
Connect work cable to the work
9.
Do not
10.
closed containers such
use
as
as
tanks
or
drums.
close to the
welder to thaw frozen
pipes.
Remove stick electrode from holder
tip
when not in
Wear oil-free
or
Wear
cut off
welding
wire at
use.
protective garments such
as
shirt, cuffless trousers, high shoes, and
1.
partition
welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
contact
11.
on
or
the hidden side.
8.
approved face shield
or
leather
a
gloves, heavy
cap.
safety goggles. Side
shields
recommended.
injury.
Chipping
unless the
7.
and hot metal.
strike flammable material.
aware
can cause
fire.
2.
can
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
5.
fire
degreasing, cleaning,
irritating gases.
plated steel,
explosion.
can cause
near
coated metals, such ,as
Sparks and spatter fly off from the welding arc. The
flying sparks and hot metal, weld spatter, hot
workpiece, and hot equipment can cause fires and
WELDING
4.
toxic and
weld area, the
and cleaners,
3.
highly
Do not weld
cadmium
approved air-supplied respirator.
instruction for metals, consumables,
Material
manufacturers
Do not weld in locations
form
7.
fumes and gases.
3.
a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Shielding gases used for
welding can displace air causing injury or death. Be sure the
breathing air is safe.
operations. The heat and rays of the arc
your head out of the fumes. Do not breathe the fumes.
1.
remove
Work in
cause
throw off
flying
metal. As welds
2.
Wear proper
body protection
to
protect skin.
slag.
srI 9/92
CYLINDERS
explode
can
if
damaged.
Keep cylinders
3.
away from any
welding
or
other electrical
circuits.
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.
1.
Protect
compressed
mechanical shocks, and
2.
cylinders
gas
excessive
heat,
6.
welding electrode to touch any cylinder.
shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
7.
Keep protective
Use
5.
arcs.
cylinders in
stationary support
prevent falling or tipping.
Install and
them to
from
Never allow
4.
secure
a
in
an
or
upright position by chaining
equipment cylinder rack to
only
Read and follow instructions
8.
associated
ENGINE
equipment,
valve except when
over
cylinder
is
compressed gas cylinders,
publication P-i listed in Safety
on
and CGA
Standards.
ENGINE EXHAUST GASES
Engines produce
cap in place
connected for use.
use or
WARNING
a
a
correct
ENGINES
can
kill.
1.
Use
2.
If used in
FUEL
can
fire
cause
a
or
explosion.
1.
2.
be hazardous.
outside in open, well-ventilated
equipment
closed area, vent
away fr om any
harmful exhaust gases.
can
building
engine
areas.
exhaust outside and
air intakes.
Stop engine before checking or adding fuel.
Do not add fuel while smoking or if unit is near any sparks
or
open flames.
3.
4
Engine
fuel
is
highly
flammable.
engine to cool before fueling. If possible, check and add
engine before beginning job.
Do not overfill tank
allow room for fuel to expand.
Do not spill fuel. If fuel is spilled, clean up before starting
Allow
fuel to cold
4.
5.
engine.
MOVING PARTS
can cause
injury.
3.
Have
only qualified people remove guards or
troubleshooting as necessary.
covers
for
maintenance and
Moving parts, such as fans, rotors, and belts can
fingers and hands and catch loose clothing,
4.
cut
5.
1.
Keep all doors, panels,
securely in place.
2.
Stop eng
ne
before
covers,
installing
and
guards
closed and
connecting
unit,
.
.
~-
Reinstall
panels
or
guards and close
starting engine.
1.
2.
servicing
is
wear a face s hietd when working on a battery.
Stop engine before disconnecting or connecting battery
cables.
Do not allow tools to
Do not
gases.
5.
Observe correct
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
i.
generate explosive
can
doors when
Always
4.
The coolant in the radiator
under pressure.
/
Keep hands, hair, loose clothing, and toots away from moving
3.
acid and
disconnect
finished and before
SPARKS can cause BATTE RY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin,
Batteries contain
during servicing,
battery.
parts.
6.
or
To prevent accidental starting
negative (.) battery cable from
use
cause
welder to
sparks when working
charge
polarity (+
batteries
and
)
on
or
jump
on a
battery.
start vehicles.
batteries.
Donotremoveradiatorcapwhenengineishot.Allowengine
to cool.
2.
Wear
3.
Allow pressure to escape before
gloves and put a rag
over
cap
area
when
removing
cap.
be very ho t and
completely removing cap.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49.i, from
Welding Society, 550 N.W. Le.Jeune Rd, Miami FL 33126
Safetyand
American
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-i, from Compressed Gas Association, 1235 Jefferson Davis High
way, Suite 501, Arlington, VA 22202.
Health Standards, OSHA29 CFR 1910, from
dent of Documents, U.S. Government
Superinten
Printing Office, Washington,
D.C. 20402.
Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, Ameri
can Welding Society Standard AWS F4.1,from American Welding So
ciety, 550 N.W. LeJeune Rd, Miami, FL 33126
Code for Safety in Welding and Cutting, CSA Standard Wi 17.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou
levard, Rexdale, Ontario, Canada M9W 1 R3.
Recommended Safe Practices for the
National Electrical Code, NFPA Standard 70, from National Fire Pro
tection Association, Batterymarch Park. Quincy, MA 02269.
Sri
9/92
Safe Practices For Occupation And Educational EyeAnd Face Protec
tion, ANSI Standard Z87.i, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting
And
Welding Processes, NFPA Standard 51 B. from National
Batterymarch Park, Quincy, MA 02269.
Fire Protection Association,
PRECAUTIONS
DE
SECURITE
MISE EN GARDE
A LARC
EN SOUDAGE
LE SOUDAGE
A LARC
est
dangereux.
PROTEGEZ-VOUS,
AINSI OUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES
ENFANTS SAPPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QUILS NAIENT CONSULTE UN MEDECIN).
Le soudage, comme Ia plupart des activitØs industrielles, expose a certains risques. Le soudage nest pas dangereux lorsquon prend des
precautions. Les consignes de sØcuritØ suivantes ne font que rØsumer information contenue dans les normes ØnumØrŁes ci-apres. Lisez et
respectez
toutes ces normes.
SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX DINSTALLATION,
DESSAI.
LELECTROCUTION
Une
peut Œtre mortelle.
dØcharge Ølectrique peut
vous
brler gravement. LØlectrode et le circuit de soudage
sont sous tension au demarrage. Le circuit dentrØe et
les circuits internes des matØriels sont aussi sous
tension des
Ia
mise
en
En soudage
dernier, le support de
en
contact avec le fil de
matØriels mal installØs
ou
soudage
mal mis a
a terre
2.
Ne touchez pas a des piŁces sous tension.
Portez des gants et des vØtements isolants, secs et
3.
lsolez-vous de Ia tle a souder et de Ia mise ala terre
1.
petits tapis isolants ou autres.
DØconnectez Ia prise dentrØe des
non
au
trouŁs.
matØriels ou arrŒtez leur
matØriels eta les mettre ala terre selon le
les codes nationaux, provinciaux et
applicables.
7.
Nutilisez pas de cables uses,
calibre trop petits.
8.
Nenroulez
9.
es
matØriels
apres utilisation.
endommagØs, mal ŁpissØs
ou
de
pas de cables autour de votre corps.
Mettez ala terre Ia tle a souder au moyen dune bonne prise de
terre.
11.
Ne touchez pas a IØlectrode Si vous Øtes en contact avec le
circuit de Soudage (terre).
Nutilisez que des matØriels en bon Øtat. RØparez ou remplacez
sur-le-champ
moyen
de
4.
locaux
DENTRETIEN ET
et
ArrŒtez tous
10.
dangereux.
ces
REPARATION,
6.
sont sous tension. Des
sont
Veillez a installer
manuel dutilisation
marche.
ou semi-automatique avec til, ce
roquette, le logement des galets dentraInement et toutes les piŁces
metalliques
5.
tuer ou vous
DE
les
piŁces endommagees.
12.
Portez
13.
Fermez solidement tous les panneaux et les capots.
un
harnais de sØcuritØ si
vous
travaillez
en
hauteur.
moteur avant de les installer ou den faire Ientretien.
C~
Le RAYONNEMENT DE LARC
peut
brUler (es yeux et Ia peau; le BRUIT peut
endommager IouIe.
que
2.
vous
observez lexØcution
dune
soudure.
PortezdeslunettesdesØcuritØapprouvØes. Des Øcran~ latØraux
sont recommandees.
3.
Entourez laire de soudage de rideaux
soudage produit une chaleur et des rayons
ultraviolets intenses, susceptibles de brler les yeux et a peau. Le
bruit cause par certains procŁdes peut endommager louIe.
4.
protection contre les coups darc ou lØblouissement; avertissez
les observateurs de ne pas regarder larc.
Portez des vŒtements en tissus ignifuge durable (lame et cuir)
casque de soudeur avec Øcran filtrant de teinte
(consultez Ia norme ANSI Z49 indiquee ci-apres),
5.
Portez un casque antibruit ou des bouchons doreille
si le niveau de bruit est ØlevØ.
5.
Ne travaillez dans un espace confine que siI est bien ventilØ;
sinon, portez un respirateura adduction dair. Les gaz protecteurs
de soudage peuvent dØplacer loxygene de lair et causer des
Larc
1.
Portez
un
de
appropriØe
pour vous protØger le visage et les yeux Iorsque vous soudez ou
I
d
Les VAPEURS ET LES
~
dangereuses pour
U
Le
FUMEES
sont
=9..
et des chaussures de sØcuritØ.
Ia sante.
soudage degage des vapeurs et des fumØes quil
est dangereux de respirer.
1. Ecartez le visage pour Øviter de respirer les
blessures
A
6.
de soudage est bien
assurez-vous que laire
que es fumØes et les vapeurs sont aspirees a arc.
Si Ia ventilation est mauvaise, portez un respirateur a adduction
3.
dair
4.
ou
approuvØ.
Lisez les fiches
relatives
aux
revŒtements et
~ ~
(~ ~
signaletiques
mØtaux,
aux
et les
produits consummables,
produits nettoyants.
Le SOUDAGE peut
ou une
consignes
causer un
7.
explosion.
5.
6.
produit des Øtincelles et des projections. Avec Ia
chaleur intense dØgagee par Ia tle et les matØriels,
elles peuvent causer un incendie et des brlures. Le
contact accidentel de lelectrode
avec un objet
mØtallique peut provoquer des Øtincelles, un Øchauffement ou un
Larc
2.
3.
Protegez-vous,
projections.
8.
Enlevez toutes
es
matiŁres inflammables dans
10,7 metres autour de larc,
des bÆches
4.
ou
couvrez-les
un
rayon de
soigneusement avec
approuvees.
MØfiez-vous des Øtincelles et des Øclats brUlants, susceptibles
de pØnØtrerdans des aires adjacentes parde petites ouvertures
ou fissures.
ou une
paroi peut
Ne soudez pas
tonneau.
un
en
entlammer Iautre
recipient fermØ,
comme un
ctØ.
reservoir
ou un
Connectez le cable de
soudage le plus prŁs possible de Ia tle
empØcher le courant de suivre un parcours
inconnu, et prØvenir ainsi les risques dØlectrocution et
soudage
long
et
pour
dincendie.
9.
peuvent
degraissage, de
MØfiez-vous des incendies et gardez un extincteur a portØe de
Ia main.
Noubliez pas quune soudure sur un plafond, un plancher, une
de
ainsi que les autres, contre les Łtincelles et les
Ne soudez pas dans un endroit o
des Øtincelles
atteindre des matØriaux inflammables.
de
Ne soudez pas de tles galvanisØesou plaquees en p10mb ou
cadmium sans les avoir grattØes a fond, car ces mØtaux, et
cloison
7.
incendie.
1.
proximite dopØrations
tout revŒtement qui en contient, peuvent alors dØgager des
fumees toxiques. Assurez-vous dune bonne ventilation et portez
un respirateur a adduction dair si cest nØcessaire.
aux
incendie
Ne soudez pas a
en
du fabricant
aux
Ia mort. Assurez-vous que lair eSt propre a Ia
nettoyage ou de pulvØrisation. La chaleur et les rayons de larc
peuvent rØagir avec des vapeurs et former des gaz hautement
toxiques et irritants.
lintØrieur,
ventilØe
ou
approuvØs
respiration.
tumØes.
2.
de cloisons de
ou
10.
Ne faites pas degeler des tuyaux avec un chalumeau.
Videz votre carquois porte-electrodes ou coupez le fil au tubecontact
11.
aprŁs
le
soudage.
Portez des vØtements protecteurs non huileux, tels des gants en
cuir, une chemise Øpaisse, un pantalon sans revers, des
chaussures montantes et un casque.
LES ETINCELLES ET LES
PROJECTIONS BRULANTES peuvent
causer des blessures.
Le piquage et le meulage produisent des Øclats de
Les BOUTEILLES
endommagees peuvent
Les bouteilles contiennent des gaz protecteurs
haute pression. Des bouteilles
3.
2.
Portez des vŒtements de protection individuelle
4.
tout contact entre une bouteille et une electrode.
Nutilisez que des bouteilles de gaz protecteur, des dØtendeurs,
des flexibles et des raccords concus pour chaque application
spØcifique; ces matØriels et les piŁces connexes doivent Øtro en
sous
endommagees peuvent
exploser. Comme les bouteilles font normalement
partie du procedØ de soudage, traitez-les avec soin.
1. Les bouteilles doivent Œtre protOgØes contre les sources de
chaleur intense, les chocs et les arcs de soudage.
2.
Portez
5.
exploser.
des gaz
produisent
Ne mettez pas le
louvrant.
1.
plein
en
PIECES
Des
causer
fumant
ou
2.
proche
dune
EN MOUVEMENT
4.
source
peuvent
en
mouvement, telles des ventilateurs,
des rotors et des courroies peuvent couper
et les mains, ou accrocher des vŒtements
doigts
amples.
es
1.
Assurez-vous que es portes, los panneaux, les capots et los
protecteurs sont bien fermØs.
2.
Avant dinstaller
ou
do connecter
un
systeme, arrŒtez-en le
5.
6.
Seules des personnes
Des
qualifiØes doivent dØmonter des
ETINCELLES peuvent FAIRE
Si
vous
utilisez des machines dans
2.
ACCUMULATEUR peut brUter Ia peau et
es
~
VAPEUR
ET
LE
LIQUIDE
loin
dØtincelles ou dune flamme flue.
Si cest possible, laissez le moteur refroidir avant de faire le plein
do carburant ou den verifier le niveau au debut du soudage.
Ne faites pas le plein do carburant a ras bord : prØvoyez do
espace pour son expansion.
Faites attention done pas renverser do carburant. Nettoyez tout
carburant renversØ avant do faire dØmarrer le moteur.
protecteurs ou des capots pour faire lentretien ou le depannage
nŁcessaire.
Pour empŒcher un dØmarrage accidentel dun systŁme pendant
lentretien, dŁbranchez le cable daccumulateur a a borne
negative.
Napprochez
pas los mains ou los cheveux de piŁces en
mouvemont; elles peuvent aussi accrocher des vŒtements
amplos et des outils.
RØinstallez los capots ou los protecteurs et fermez los portes
travaux dentretien
of avant de faire dØmarrer le
un accumulateur.
ArrŒtez le moteur avant de connecter
cables daccumulateur.
ou
de dØconnecter des
et
4.
sur
5.
DE
1.
Ntezpaslebouchonderadiateurtantquelemoteurnapas
Los accumulateurs contiennent de lØlectrolyte
dos vapeurs explosives.
1. Portez toujours un Øcran facial en travaillant
degagent
REFROIDISSEMENT
endroit confine, les
Nutilisoz quo des outils anti-Łtincollos pour travailler sur un
accumulateur.
Nutilisez pas un poste do soudage pou(chargerun accumulateur
ou connecter provisoirement un vŁhicule.
Utilisez Ia polarite correcte (+ et -) de laccumulateur.
yeUX.
La
un
dechappement doivent Œtre envoyØes a lextØrieur,
prises dair du btiment.
moteur.
EXPLOSER
UNACCUMULATEUR;LELECTROLYTEDUN
dangereux.
Utilisez des machines a lextØrieur dans des aires ouvertes et
apres des
moteur.
3.
ci-dessous.
--
5.
des blessures.
piŁces
normes
fumØes
4.
Des
apres utilisation.
bien ventilØes.
3.
explosion.
Ne faites pas le
de bouteille
P-i de Ia CGA, ØnumŁrØes dans les
Le CARBURANT peut causer un incendie ou
Le carburant est hautement inflammable.
~ ArrŒtez le moteur avant de verifier le niveau de
I
carburant ou do faire le plein.
2.
chapeau
Les MOTEURS peuvent Œtre
dØchappement
en
Remettez le
des
une
le robinet de bouteille
Lisez et respectez les consignes relatives aux bouteilles de gaz
comprimØ et aux matØriels connexes, ainsi que Ia publication
nocits.
-r
visage devant
7.
PEUVENT
Les moteurs
EmpŒchez
8.
MISE EN GARDE
DECHAPPEMENT D ES MOTEURS
ETRE MORTELS.
appropriØs.
bon Łtat.
6.
EnchaInez verticalement les bouteilles a un support ou a un
cadre fixe pour les empŒcher de tomber ou dŒtre renversØes.
Eloignez les bouteilles de tout circuit Ølectrique ou de soudage.
Les GAZ
metal. En refroidissant, Ia soudure peut projeter du laitier.
un Øcran facial ou des lunettes a coques approuvØes.
Des Øcrans latØraux sont recommandØs.
1.
BROLANT SOUS
PRESSION peuvent brUler Ia peau et
es
refroidi.
2.
3.
Øux
Mettezdesgantsetposezuntorchonsurlebouchonpourloter.
Laissez Ia pression sØchapper avant doter complŁtement le
bouchon.
liquide do refroidissement dun radiateur peut
brlant et sous pression.
Le
-
etre
.
PRINCIPALES NORMES DE
Safety in Welding and Cutting norme ANSI Z49. 1, American Welding
Society, 550, N.W. LeJeune Rd., Miami FL 33128.
Safety and Health Standards OSHA 29 CFR 1910, Superintendent
of Documents, U.S. Government Printing Office, Washington D.C.
20402.
Recommended Safe Practices For the Preparation For Welding and
Cutting of Containers That Have Held Hazardous Substances norme
AWS F4.1, American Welding Society, 550, N.W. LoJoune Rd.,
SECURITE
Handling of Comoressed Gases in Cylinders document P-i,
Compressed Gas Association, 1235 Jefferson Davis Highway, Suite
501, Arlington, Va 22202.
Safe
Code for Safety in Welding and Cutting norme CSA Wi 17.2, Asso
ciation canadienne de normalisation, Standards Sales, 176 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1 R3.
Miami FL 33128.
Safe Practices for Occupation and Educational Eve and Face Protec
ti~n, norme ANSI Z87. 1 American National Standards Institute, 1430
Broadway, New York, NY 10018.
National Electrical Code norme 70 NFPA, National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269.
Cutting and Welding Processes norme 51B NFPA, National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
srlt 9/91
EMF INFORMATION
Considerations About Welding And The Effects Of Low Frequency Electric And
~
N OTE
Magnetic
Fields
_____________________
following is a quotation from the General Conclusions Section
Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
there is now a very
Government Printing Office, May 1989): .
large volume of scientific findings based on experiments at the
cellular level and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible
risk or to offer clear science-based advice on strategies to minimize
or avoid potential risks.
The
To
of the U.S.
procedures:
.
magnetic
reduce
fields
Keep
Arrange
3.
Do not coil
cables to
the
workplace,
together by twisting
cables close
1.
2.
in
one
or
use
taping
side and away from the
following
the
them.
operator.
.
4.
or
Keep welding
drape cables around the body.
power
source
and cables as far away
as
nractical
5.
Connect work clamp to workpiece
as
close to the weld
as
possible.
About Pacemakers:
The
above
procedures are among those also
pacemaker wearers. Consult your
recommended for
complete
normally
doctor for
information.
modlo I 4/93
TABLE OF CONTENTS
SAFETY INFORMATION
SECTION 1
1
-
SECTION 2
SPECIFICATIONS
SECTION 3
INSTALLATION
3-1.
3-2.
1
Equipment Connection Diagram
Installing Swivel Into Pipe Post
2
3
3
3-4.
Installing Boom And Reel Support
Installing Wire Guide Extension
3-5.
Wire Guide And Drive Roll Installation
4
3-6.
Welding
3-7.
Wire Feed Motor And Gas Control Connections
6
3-8.
Control Connection
6
3-9.
7
3-11.
Shielding Gas And Weld Cable Connections
Removing Safety Collar And Adjusting Boom
Welding Wire Installation
3-12.
Motor Start Control
3-13.
Threading Welding
3-3.
3-10.
SECTION 4
4
Gun Connections
5
8
9
10
Wire
10
GLOSSARY
12
SECTION 5-OPERATION
5-1.
Front Panel Controls
15
5-2.
Side Panel Controls
17
5-3.
Rear Panel Controls
5-4.
Setting
SECTION 6
6-1.
6-2.
Switches On 450 Ampere Inverter Model
17
Welding
Power Source
18
STEPPING THROUGH THE MICROPROCESSOR CONTROLS
Front Panel
Microprocessor Controls
Side Panel Microprocessor Push Buttons
SECTION 7- STANDARD PULSE WELDING PROGRAMS
19
21
24
OM.15860
10/93
SECTION 8
8-1.
8-2.
GETTING STARTED
Welding With Only Front Panel Controls
Setting Sequence Pulse Welding Parameters On Side Panel Display
33
34
SECTION 9- TEACHING A PULSE WELDING PROGRAM
9-1.
9-2.
9-3.
9-4.
Pulse Waveform
38
Teach Points
39
Explained
Explained
Teaching A Pulse Welding Program
Changing To Adaptive Pulse Welding
SECTION 10- TEACHING A MIG WELDING PROGRAM
SECTION 11
SETTING DUAL SCHEDULE PARAMETERS
40
43
44
48
SECTION 12- USING THE OPTIONAL DATA CARD
12-1.
12-2.
Installing Data Card
Using The Data Card
49
49
SECTION 13SETUP
Setup Flow Chart
Using Setup Displays
13-3.
Selecting Process Capability
13-4.
Selecting Welding Power Source Range
13-5.
Selecting Security Lock
13-6.
Selecting Or Changing Access Code
13-7.
Selecting Voltage Correction
13-8.
Selecting Voltage Sensing Method
13-9.
Selecting Regular Or Hot Arc Start
13-10. Selecting Type Of Dual Schedule Switch
13-11. Selecting Trigger Program Select
13-12. Selecting Remote Increase/Decrease Capability
13-13. Resetting Arc Time
13-14. Using Self Test
13-15. Selecting Units For Wire Feed Speed And Motor Type
13-16. Selecting Bench Or Boom Model Type
13-17. Resetting Memory
13-18. Selecting Voltage Error Shutdown
13-19. Selecting Program Name Feature
13-1.
53
13-2.
54
13-20. Software Version Number
54
55
56
57
58
58
59
59
60
61
61
62
63
63
64
64
65
65
SECTION 14- MAINTENANCE & TROUBLESHOOTING
14-1.
Routine Maintenance
14-2.
Replacing
14-3.
Overload Protection
14-4.
Error Displays
Diagnostic Indicator
Troubleshooting
14-5.
14-6.
The Hub
66
Assembly
67
68
LEDs
ELECTRICAL DIAGRAMS
SECTION 16
PARTS LIST
16-1. Main
16-2.
Assembly
Support, Hub &
69
70
SECTION 15
Figure
Figure
Figure
Figure
Figure
67
72
76
Reel
79
16-3. Control Box
80
16-4. Wire Drive
83
16-5. Boom
84
Assembly
Assembly
Table 16-1. Drive Roll & Wire Guide Kits
86
SAFETY IN FORMATION
SECTION 1
modl.l 2/93
1
r~N~
110
~
U
Read all
safety
messages
U
Obey
all
safety
messages to avoid
U
Learn the
meaning
throughout
this manual.
injury.
of WARNING and CAUTION.
2
1
Safety
Alert
2
Signal
Word
2
\
WARNING
or
a WARNING
a CAUTION
3
ELECTRIC SHOCK
can
kill.~
Disconnect
ristalling
or
input
power
CAUTION
MOVING PARTS
Do not touch live electrical parts
I
belore
wIrer
covers
possible death
happen.
means
injury
can
means
possible minor
injury or equipment damage
happen.
injure.
can
Keep away Iron moving parts.
Keep all panels and
servicing
serious
Symbol
closed
3
Statement Of Hazard And
Result
4
Safety
operating
/
can
5
Instructions To Avoid
Hazard
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
6
I
5
Hazard
6
Safety
Read
7H
~
Turn Off switch when
using high frequency.
1-1.
SECTION 2
Safety
blocks for each sym
NOTE
Special instructions
ation
Figure
safety
bol shown.
7
NOTE
Symbol (If Available)
Banner
for best oper
not related to
safety.
Information
SPECIFICATIONS
Table 2-1. Wire Feeder
Specification
Type Of Input
Power From
Welding
Description
Single-Phase
24 Volts AC. 10
Amperes. 50/60
Hertz
Power Source
Maximum Weld Circuit
Welding
Power Source
Wire Feed
Rating
100 Volts. 750 Amperes. 100%
Type
Constant
Voltage (CV) DC.
High Speed:
Low Speed:
Welding
Range
ipm (1.3 To 19.8 mpm)
1pm (2.3 To 36.5 mpm)
To 213 ipm (0.34 To 5.38 mpm)
92 To 1435
13
.023 Thru 1/8 in (0.6 To 3.2 mm)
Process
Gas Metal Arc
Input Power Cord
10 ft
(GMAW), Gas
Height
With 4 ft
Weight
are
17
the wire feed
-
Pulse
(GMAW-P), Flux Cored Arc Welding (FCAW)
(3.7 m) Boom
16 ft
ft (5.2 m)
Net: 160 lb
Vertical Lift Of Boom
*These
(1.2 m) Post
Metal Arc
(3.1 m)
12 ft
Maximum
With Contactor
Standard: 50 To 780
Speed Range*
Wire Diameter
Duty Cycle
21 ft
(73 kg); Ship:
Horizontal To
60
280 lb
(127 kg)
Above Horizontal
speed ranges while GMAW welding. While Pulse welding.
(6.4 m)
Net: 210 lb
(95 kg); Ship: 350 lb (159 kg)
Horizontal To
the wire feed
(4.9 m) Boom
60
Above Horizontal
speed ranges may be
more
limited
(see Section
9).
OM-1 586
Page
1
SECTION 3INSTALLATION
3-1.
Equipment Connection Diagram
WARNING
a
CYLINDERS
can
explode if damaged.
Keep cylinders away
from
welding
and
ELECTRIC SHOCK
other
electrical circuits.
Never touch
cylinder
with
Always secure cylinder
other stationary support
HOT SURFACES
can
Allow gun to cool before
running gear, wall,
burn skin.
kill.
Turn Off wire feeder and welding power source, and
before
disconnect
input
making
power
connections.
welding electrode.
to
can
Do not touch live electrical parts.
or
The welding wire, drive rolls, drive assembly, and all
metal parts touching the welding wire are electrically
live when welding or feeding wire using gun trigger.
touching.
Have
only qualified
persons install this unit.
wfwamg.1 2/93
1
Welding Power Source
2
Positive (+) Weld
Cable
3
Remote 14 Connection
4
Remote 17 Connection
5
Negative ()
Cable
Output
Weld
Output
-
6
Workpiece
7
Voltage Sensing Clamp
B
Weld Control
9
Boom
10
Gun
3
4
11
Swivel
12
Gas Hose
13
Gas
5.
Supply
12
6
11
10
Ret. ST-152 800-A / 5T-152 321
FIgure
OM-1586 Page 2
3-1.
Typical System Connections
3-2.
Into
Installing Swivel
Pipe
Post
WARNING
a
FALLING
RELEASE OF SPRING PRESSURE
WITHOUT BOOM ATTACHED can cause
serious personal injury.
Do not
remove
safety collar until
instructed to do
BOOM can cause
and equipment
serious
personal injury
damage.
Securely mount pipe post to base that can support
weight of unit with boom in horizontal position.
so.
Use proper
into
equipment for lifting swivel
and boom
place.
I
Swingpak
Base
2
Pipe Post
With Base
3
Steel Bolt
Secure
mum
shown
as
CBC Cart
or
using
as a
1/2 in diameter SAE
mini
grade
5
steel bolts.
4
Swivel
Insert
Assembly
into
pipe post.
Lubricate
swivel.
2
/3
5
Collar
Safety
Do not
remove
until instructed to.
-
Tools Needed:
~
3/4in
ST.152 268
Figure
3-3.
Installing
Boom And Reel
3-2. Swivel Installation
Support
READ SAFETY BLOCKS at start of
Section 3-2 before
proceeding.
I
Swivel Plates
2
Yoke
Remove
plates
7
3
hardware
and
swivel
Boom
Set boom into swivel
4
from
yoke.
as
shown.
Yoke Pin
4
Install
5
ter
2
5
pin
pin through yoke. Install
and spread ends.
cot
Bolt
Install bolt,
tighten hardware,
back bolt off
one
6
Knob
Locking
Install
locking
and
half turn.
knob
but
do
not
tighten.
7
~
Reel
Support
Install reel
Tools Needed:
support.
3/8, 3/4 in
5T-142596.B
Figure
3-3. Boom Installation
OM-1 586
Page
3
3-4.
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:
~EZ3lJ
3/8 in
ST-152 323
Figure
3-5.
3-4. Wire Guide Extension Installation
Wire Guide And Drive Roll Installation
a
WARNING
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Turn Off wire feeder and
welding
power source. and disconnect
input power before inspecting
or
installing.
wfwarnll 2/93
A.
Wire Guide Installation
When
check
1
changing wire size or type,
guide size (see Table 16-1).
Drive Rolls
Remove drive rolls before
wire
2
installing
guides (see Figure 3-6).
Wire Guide
Loosen wire
Securing
guide
Screws
screws.
3
Inlet Wire Guide
4
Intermediate Wire Guide
Insert
intermediate guide
until
flange on guide rests against cast
ing. and secure with guide screw.
Install drive rolls (see
Figure 3-6).
Tools Needed:
Ref. ST-137 39~-F / ST-142 597A
Figure
OM-1586
Page
4
3-5. Wire Guide Installation
B.
Drive Roll Installation
When
changing
check
drive
wire size
roll
or
size
type.
(see
Table 16-1).
Shaft Carrier
1
Spring
2
Drive Roll Nut
3
Drive Roll Carrier
Turn all nuts one click until lobes of
nut line up with lobes of drive roll
carrier.
4
Drive Roll
Slide drive rolls onto drive roll carri
ers. Turn nut one click.
5
4
2
Assembly Cover
Drive
Close
cover.
3
ST-142 597-A
Figure
3-6.
Welding
a
Gun Connections
WARNING
ELECTRIC SHOCK
~\
3-6. Drive Roll Installation
can
kill.
.
Do not touch live electrical parts.
Turn Off wire feeder and
welding
power
source,
and disconnect
input
power before
inspecting
installing.
or
wfwarnl,1 2/93
Assembly Cover
1
Drive
2
Gun
3
Gun Connector
Securing Knob
Loosen
securing knob. Insert gun
against
assembly. Tighten knob.
connector until it bottoms
drive
4
Gun
Trigger Plug
5
Gun
Trigger Receptacle
Insert
tacle
I
plug into free-hanging recep
and tighten threaded collar.
6
Trigger Cord
7
Trigger Plug
8
Weld Control
Trigger
Receptacle
3
Insert plug into receptacle
tighten threaded collar.
and
4
6
Ref. STI 52 466 / ST-I 52 321 / Ref. ST-I 57 434
Figure
3-7. Gun And
Trigger
Lead Connections
OM-1586
Page
5
Wire Feed Motor And Gas Control Connections
3-7.
Wire Feed Motor And Gas
1
Valve Control
Receptacle
From Boom
2
Plug
3
Cord From Boom
Insert plug from boom cord into re
ceptacle on rear of control, and
tighten threaded collar.
ST-157 433.A / Ref. ST-157 434
Figure
3-8. Boom Connections
Control Connection
3-8~
1
17-Pin
2
Keyway
To connect
Receptacle
interconnecting
cord to
receptacle, align keyway, insert
plug, and tighten threaded collar.
Weld Current Sensor
3
tacle
(For
Only)
tion
Recep
Op
Use With Field
2
0
35 ft (10.6 m)
ing Lead
4
Connect
Voltage Sens
(see
workpiece
to
Figure 3-10).
2
5
Threaded Collar
6
14-Pin
Plug
To connect
plug to matching recep
tacle on welding power source.
align keyway. insert plug, and tight
en
threaded collar.
ST-157 433-A / Ref. S-0512 / S-0003-A / S-0628
Signals
Source
Supplied To Welding
Through 14-Pin Plug:
Power
E
Remote power source voltage com
mand signal from feeder (potentiom
eter
wiper
or
0 to +10 volts
dc).
A
E
Nonfunctional at this time.
By Welding
Power
Source:
Remote
Contactor Control
H
Signals Supplied
24voltsac.
Metering
Actual weld current output
100 amps.
volt dc
signal;
+1
=
B
Contact closure to
the 24 volts
ac
pin
A
completes
Signals
contactor control cir
Source
Supplied To Welding Power
Through 17-Pin Receptacle:
cuit.
G
common
for 24 volts
Remote
ac
circuit.
C
C
D
Control
Command
signal:
Control circuit
Page
volt dc
6
Output Control
CC/CV select;
+
CV, 0 volts dc
=
13 thru +24 volts dc
G
+
I
Signals
H
Voltagefeedbacko-lovoltsdc;
per 100 amperes.
per 10
Arc control/inductance control; 0 to
+10 volts dc.
common.
voltage output signal;
10 volts dc.
Current feedback 0-10 volts dc; 1 volt
=
CC.
=
F
#10 volts do.
Figure
OM-1586
Actual weld
Feedback
Circuit
Voltage
M
The
arc
volts.
remaining pins
3-9. Control Connections With Pin Information
are
not used.
1 volt
3-9.
Shielding Gas
a
And Weld Cable Connections.
WARNING
CYLINDERS
can
explode
from
Keep cylinders away
if
E LECTRIC SHOCK
damaged.
welding
and
other
electrical circuits.
Never touch
cylinder
with
Always secure cylinder
other stationary support.
welding
to
installing.
or
BUILDUP OF SHIELDING GAS
health or kill.
I
A.
Connecting
kill.
Turn Off wire feeder and welding power source, and
disconnect input power before inspecting or
electrode.
running gear, wall,
can
Do not touch live electrical parts.
Shut off
shielding
gas
supply
can
when not in
harm
use.
Weld Cables And Gas Hoses
The weld cable and
hose extend 10 ft
shielding
(3 m) from
gas
the
boom.
Route
weld
through
reed
cable
from
boom
relay.
If the welding power source or gas
supply are further from the boom,
extend cable
or
1
Weld Cable
2
Insulated
Bolt
hose
as
follows:
Sleeving
together
welding power
weld
cables
source
from
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/Bin
ST-152 800A
Figure
3-10.
Shielding
Gas And Weld Cable Connections
OM.1586
Page
7
B.
Shielding
Gas Connections To
Regulator/Flowmeter
Obtain gas
cylinder and chain to
running gear, wall, or other station
ary support so cylinder cannot fall
and break off valve.
I
Cap
2
Cylinder
Valve
Remove cap, stand to side of valve,
2
and open valve
blows dust and
Gas flow
slightly.
dirt from valve.
Close valve.
3
Cylinder
4
Regulator/Flowmeter
3
Install
5
Fitting
OR
Argon
6
Gas
Adjust
flow rate is 20 cTh
(cubic feet
7
CO2 Adapter
8
0-Ring
adapter with 0-ring between
and
Cb2
regulator/flowmeter
cylinder.
CO2 Gas
Figure
3-11.
Removing Safety Collar
Typical Regulator/Flowmeter
And
Adjusting
-
ssb3.1 12/92
ST-158 897-A
Installation
Boom
WARNING
RELEASE OF SPRING PRESSURE
WITHOUT BOOM ATTACHED can cause
serious personal injury.
Do not
right-hand
Install
~5/8,1-1/8in
1+1
5/8-18
per hour). Check wire manufactur
ers recommended flow rate.
L
4~
Flow
Typical
Tools Needed:
3-10.
has
threads. Install gas hose.
2
4
face is vertical.
so
Gas Hose Connection
remove
FALLING
persona
BOOM can cause
in jury and equipment
Adjustment
yoke.
safety collar until instructed to do so.
rod must be threaded
I
fully through
Knob
Locking
Tighten
serious
damage.
knob
to
prevent boom
movement. Loosen knob to allow
boom
movement.
position
to limit
Pull boom down
move
safety
Change
upward
knob
movement.
slightly
and
re
collar. Boom should
balance in any position from hori
zontal to 60 degrees above hon.
zontal. If necessary, adjust boom
0
as
t~
Tools Needed:
~
1-1/8 in
Pages
Threaded Rod
3
Jam Nut
jam nut and turn threaded
rod until boom balances. Tighten
jam nut. Be sure several full
threads are through yoke to pre
vent boom falling.
4
Yoke
Retain saf ety collar fo r
Increasing Spring
Pressure ForA
Heavy Gun
Figure
OM-1586
2
Loosen
Rod~
E
follows:
3-12. Boom
Adjustments
assemblin g
or
moving
use
in dis
boom.
Ret. ST-152 380-A
3-11.
A.
Welding
Wire Installation
Installation Of
Spool-Type
Wire
1
Retaining Ring
2
Wire
3
Hub
Remove
spool
4
Spool
retaining ring
and slide
onto hub.
Hub Pin
Turn
spool until hub pin fits hole
spool. Reinstall retaining ring.
in
3
2
E
5T.152 648.A
Figure
B.
Installation Of
Optional
3-13. Installation Of
Wire Reel And Reel
Type
Wire
Spool-Type
Wire
1
Retaining Ring
2
Spanner
3
Wire Retainer
4
Wire Reel
5
Hub
6
Hub Pin
7
Reel
Nut
Support
Remove retaining ring and wire
reel assembly (wire reel, wire re
tainer, and spanner nut) from hub.
4
8
Wire Installation
Lay
wire reel
assembly
face. and Kistall wire
on
flat
as
shown.
sur
Slide wire reel
and turn
assembly onto hub,
assembly until hub pin is
seated in hole in reel. Reinstall
p
3
2
re
taining ring.
I
I
ST143478/ST.152
Figure
3-14. Installation Of
Optional
Wire Reel And Reel
463
Type Wire
OM-1586
Page
9
C.
Hub Tension
Adjusting
Turn Off unit and
welding
power
source.
2
1
Hex Nut
2
Spool
Grasp spool in one hand and turn
while using a wrench to adjust hex
nut. When a slight force is needed
to turn spool, tension is set.
Tools Needed:
5/8 in
ST-152 649
Figure
3-15.
Adjusting
Hub Tension
3-12. Motor Start Control
a
WARNING
ELECTRIC SHOCK
STATIC ELECTRICITY
circuit boards.
kill.
can
can
damage parts
on
Do not touch live electrical parts.
Turn Off wire feeder and welding power source, and
disconnect input power before inspecting or
Put on
boards
grounded
or
wrist strap BEFORE
handling
parts.
installing.
wtwaml1
To
2)93
change wire feed starting speed
proceed
as
follows:
Turn Off unit and
welding,
power
source.
Remove wrapper.
Front Panel
1
Remove
screw
ner, and open
2
from upper left cor
front panel.
hinged
Motor Board PCi
3
Motor Start Control Poten
tiometer 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-
Tools Needed:
tiometer R70
conductive screwdriver.
Non-Conductive
Close and
cii~~i===n
secure
front panel, and
reinstall wrapper.
1/4 in
ST-l51 480-Al Ref. SB-t46 862
Figure
3-13.
3-16. Motor Start Control On Motor Control Board PCi
Wire
Threading Welding
a
WARNING
CYLINDERS
can
explode
Keep cylinders away
from
if
WELDING
damaged.
welding
and
other
electrical circuits.
Never touch
cylinder
Do not press gun
with
Always secure cylin~.Jr
other stationary suppo~t.
ELECTRIC SHOCK
welding
to
can
Page
10
cause
puncture
trigger
until instructed to do
so.
electrode.
running gear, wall,
Do not
or
kill.
Do not touch live electrical parts.
The welding wire, drive rolls, drive assembly, and all
metal parts touching the welding wire are electrically
live when welding or feeding wire using gun trigger.
OM-1586
WIRE can
wounds.
people,
toward any part of the body, other
any metal when threading welding wire.
point gun
or
HOT SURFACES
can
Allow gun to cool before
burn skin.
touching.
wfwam2.1 / wfwam7.1 9/91
Spool/Reel
1
Wire
2
Wire Tube
3
Pulley
4
Wire Guides
5
Drive Rolls
6
Jog
7
Gun Conduit Cable
8
Pressure Adjustment Knob
9
Drive Roll Pressure Indicator
6
Button
Scale
B
Tools Needed:
Hold wire tightly to keep
it from unraveling.
5-12 for switch
450 Ampere
Inverter model welding
power source. See welding
power source Owners
Manual for other models.
See
Figure
positon of
OFF
-4
Wire Feeder
(see Figure 5-9)
Welding
Power Source
Set switches.
Manually feed
wire thru tube, over
and up to wire inlet guide.
Pull and hold wire; cut off end.
pulley,
JOG
O~O
0
/
-4
Push wire thru guides up to drive rolls;
continue to hold welding wire. Press Jog button
to thread welding wire. Press Jog button until
drive rolls grab wire. Adjust tension until wire
does not slip. Indicator is for reference only.
Figure
Feed wire to check drive roll pressure.
knob enough to prevent slipping.
Cut off wire. Close
cover.
Adjust
Ref. ST-157 432 / Ref. ST-I 50922 / ST-I 53073 / Ref. ST.I 57432
3-17.
Threading Welding
Wire
OM-1588 Page 11
SECTION 4
The
is
following
a
list of terms and their definitions
as
GLOSSARY.
they apply
to this wire feeder:
General Terms
Adaptive
When the
adaptive pulse welding process is selected, the unit will automatically
regulate pulse frequency in order to maintain a constant arc length, regardless of
change in welding wire stickout.
Pulse
The lower of the two current levels in the
Current
Background
In short circuit
Inductance
welding,
an
pulsing
waveform.
increase in inductance will decrease the number of short
circuit metal transfers per second (provided no other changes are made) and in
crease the arc-on time. The increased arc-on time makes the pool more fluid..
Peak Current
The
Pulses Per Second
Number of peak current
(PPS
Or Pulse
Pulse Width
higher of the
two current levels in the
pulses
pulsing waveform.
which occur in
one
second of time.
Frequency)
(Or
Peak
Time)
Trim
Duration of the
peak
current level.
Term used to represent arc
by volts in MIG programs.
Synergic
Synergic
length adjustments
in
pulse programs.
Trim is
replaced
refers to the units
ability to use preprogrammed pulse parameters in order
pulse settings of Peak Amperage, Background Amperage,
Pulse Frequency and Pulse Width at any specific wire feed speed setting.
to determine the actual
Front Panel Terms
Display Control
Knob
Is used for all
adjustable front panel displays.
Digital Display
2-line
Gas
Allows the gas line and gun to be
Purge Control
Parameter Select Button
Trigger
Wire
Hold Control
Jog Control
by 16-character liquid crystal display
Is used to select
a
variety
purged
with built-in LED
without
of parameters that
When selected, allows the system to remain
hold the gun trigger.
Allows the wire to feed without
energizing
can
energizing
be set
on
backlight.
the wire feeder.
the front
panel display.
energized without the operator having to
the
welding
power
source
contactor and
gas valve. The wire jog speed is independent from actual wire feed speed, and is dis
played
on
the front panel.
Side Panel Terms
4-line
Dual Schedule
Allows two weld programs to be linked together when two different
tions, such as hotter and colder, are required on one wire.
Process Mode
Is used to select the type of process to be used,
Mig.
OM-1 586
Page
12
by
20-character
with built-in LED
Digital Display
liquid crystal display
backlight.
welding
condi
including Pulse, Adaptive Pulse,
or
Remote Parameter
When
Increase/Decrease
decrease
a
is
feature
this
turned
on,
the
operator
selected weld parameter with the
use
can
remotely increase
and
of the optional DSS-10 2-pole
momentary-contact switch.
Sequence
Mode
Allows
a
variety of
sequences to be used within
weld program if
a
required. Se
quences include, preflow gas control from 0 to 9.9 seconds, run-in control of voltage
or trim and wire feed speed from 0 to 2.5 seconds, weld time from 0 to 25 seconds,
crater control of voltage or trim and wire feed speed from 0 to 2.5 seconds, burnback
time from 0 to 0.25 seconds, and
Setup
postflow gas
control from 0 to 9.9 seconds.
Screen Terms
Access Mode
A three-letter code can be
programmed
in the
access
mode which restricts unautho
rized personnel from changing any of the security/set-up
optional Data Card is required to activate this feature.
option of
higher
starting amperage for large
Arc Start
Provides the
Arc Time
Allows actual arctime upto 9,999.99 hours and weld
mulated and
Dual Schedule
displayed
a
on
the
arc
screens.
digital display,
and
NOTE: The
wires.
cycles upto 999,999to be accu
be reset to zero as required.
can
Is used to select the type of dual schedule switch that will be used when the dual
schedule feature is selected.
Mig Type
Selects whether voltage correction is used
Model
Allows selection of
boom-type
feeder
or
not.
-
bench mount feeder
or
pulse program
parameters.
Name Feature
When
using the optional Data Card and turning the name feature on, customized pro
can be identified by name, number, job number, etc.
grams written to the card
Program
Reset
By selecting program reset in the memory reset mode, the unit defaults
factory program settings for the program last active.
The wire feeder
Range
source
requires
that the
voltage
and amperage range of the
be entered. Obtain this information from the
welding
power
to
original
welding
source
power
Owners
Manual.
Remote Parameter
Security
When the Remote Parameter Inc/Dec is on,
for
increasing
at
Trim, Volts,
or
or
decreasing
a
dual schedule switch
weld parameters when the front
can
also be used
panel display
cursor
is
1PM.
Is used to limit what the operator
can
control. This includes
accessing the number of
the program, 1 through 8, and also the range of welding parameters within the pro
gram selected. NOTE: The optional Data Card is required to activate this feature.
Software Screen
Selection of this function will
System
This unit
can
display
be used either with
pulse GMAW (Pulse/Mig)
Only) welding only.
and
System
Reset
a
the software version of the unit.
welding power source capable of regular GMAW
welding power source capable of GMAW (Mig
or a
By selecting system reset in the memory reset mode, the unit defaults to original fac
tory settings for all programs and all set up excluding System, Arc Time, and Model
Type.
OM-1586
Page
13
Trigger Program Select
Allows programs to be selected
Self Test Mode
A built-in
diagnostic
tions if
malfunction
a
with the gun
remotely
feature to check
a
trigger.
variety of wire feeder and power
func
source
occurs.
voltage to be monitored at the output terminals by two methods. This can be
through the 1 7-pin cord connection if the welding power source has a 17-pin
receptacle, or through the use of the units optional external voltage sense lead.
Voltage Control
Allows
Feedback
selected
Voltage Sense Shutdown
When this feature is on, the system immediately shuts down if no arc is initiated upon
gun trigger actuation. When this feature is off, the system (wire feeder), when actu
by the gun trigger, feeds wire for approximately three seconds at set welding
speed and then automatically switches to cold wire jog speed for approximately one
minute. The off feature is normally selected to allow threading wire with the gun
ated
trigger.
Allows the selection of inches per minute or meters per minute for wire feed
This mode is also used to select motor type; standard speed, low speed,
Wire Feed Mode
speed. High
and low
motors are available as
speed
speed.
or
high
factory options.
SECTION 5OPERATION
WARNING
a
ELECTRIC SHOCK
can
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
kill.
Do not touch live electrical parts.
Always
wear
Insulate
Keep
all
from work and
panels and
covers
FUMES AND GASES
in
be hazardous
out of the fumes.
or use
Read Material
Safety
manufacturers
instructions for material used.
breathing
~
S
can cause
injury.
Keep away from pinch points such
near
fire
Keep all doors,
and securely in
panels,
place.
covers, and
as
guards
or
(MSDSs)
and
$
explosion.
flammable material.
keep extinguisher nearby.
Do not locate unit
Do not weld
on
Allow work and
over
closed
MAGNETIC FIELDS FROM HIGH CURRENTS can affect pacemaker operation.
Pacemaker
wearers
keep away.
Wearers should consult their doctor before
.
Watch for fire;
drive rolls.
device.
Data Sheets
can cause
Do not weld
MOVING PARTS
~
Ventilate area,
WELDING
body protection.
place
to your health.
Keep your head
helmet with correct shade of filter.
Wear correct eye, ear, and
ground.
securely
can
welding
Wear
dry insulating gloves.
yourself
.:__:..
near
any
going
welding operations.
combustible surfaces.
closed containers.
equipment
to cool before
Safety Precautions at beginning
welding safety information.
See
handling.
sic
of manual for ba
1
Insulating Gloves
2
Safety
~arn3 I 8/92
Glasses With Side
Shields
3
Welding Helmet
Wear
dry insulating gloves, safety
glasses with side shields, and a
welding helmet with a correct
shade of filter (see ANSI Z49. 1).
sb3.l 10/91
Figure
OM-1586
Page
14
5-1.
Safety Equipment
Work
1
Clamp
Connect work clamp to a clean,
paint-free location on workpiece,
as
close to weld
Use wire brush
possible.
area as
sandpaper to
clean metal at weld joint area. Use
chipping hammer to remove slag
after welding.
Tools Needed:
2
or
Voltage Sensing Clamp
Connect to
workpiece,
(see Section 3-8).
Use
slag
if
chipping hammer
welding.
applicable
to remove
after
sb4 12/93
Figure
5-1.
5-2. Work And
Voltage Sensing Clamps
Front Panel Controls
1
______
1
Parameter Select Button
3
Jog
4
Display Control
5
Trigger Hold
cator Light
6
Purge
2
3
6~
Display
2
Button
Knob
Button Arid Indi
Button
See Section 6 for information
using microprocessor controls.
on
0
5
Rel. ST-155 222
Figure
5-3. Front Panel Controls
1
Parameter Select Button
Press button to
move
indicator
on
display.
Ref
Figure
5T-153 976
5-4. Parameter Select Button
OM-1586
Page
15
Display Control
I
knob
Turn
to
Knob
value
change
selected.
Spin
knob to
quickly change pa
slowly by
rameters or move knob
clicks to fine tune parameters.
Figure
5-5.
Display
Control Knob
1
Jog
Push Button
Push to
PURGE
JOG
cuit
0?
I
momentarily feed welding
energizing welding cir
shielding gas valve.
wire without
or
Jog speed is varied using the Dis
play Control knob while Jog button
is pressed. Default setting is 200
ipm.
When
Jog button is released, unit
displays preset wire feedspeed,
and previously selected parameter
21
is active.
Jog does not work when gun trigger
is
2
Jog
pressed.
Purge Push
Button
Push to
15.
OV
momentarily energize gas
purging of air
from gun shielding gas line, and ad
justing shielding gas re9ulator
without energizing the welding
Prg
valve. This allows
-~
>200
Jog
I
PM
Jog
circuit.
>1
5
.
260
OV
I
Prg
PM
Front panel controls, side panel
controls, and gun trigger do not
work when Jog or Purge button is
MIG
pressed.
Figure
5-6.
Jog
And
Purge
Buttons
Hold Button
1
Trigger
2
Indicator
Light
To weld without
0~~2
holding gun trigger
cycle, press and
weld
throughout
release button to turn
on
indicator
light.
To start weld
cycle, and feed weld
ing wire, press and release gun
trigger within the first three sec
HOLD
onds after
an arc
has been struck.
It gun trigger is not released within
the first three seconds after arc ini
tiation, trigger hold stops, but is still
active for next weld
weld
cycle,
trigger.
Trigger
hold
while gun
Figure
OM-1586
Page
16
5-7.
Trigger
Hold Button
cycle.
To end
press and release gun
cannot
trigger
is
be
started
pressed.
5-2.
Side Panel Controls
1
Parameter Increase Button
2
Parameter Decrease Button
3
Parameter Select Button
4
Mode Select Button
5
Mode
6
Parameter
Display
Display
See Section 6 for information
using microprocessor
on
controls.
2
5
3
4
6
Pet ST.155 223
Figure
5-3.
5-8. Side Panel Controls
Rear Panel Controls
2
1
Power Switch
Use power switch to turn unit On
and Off.
2
00
Circuit Breaker
(See Section
14-3)
o~o
ST-157 433-A
Figure
a
WARNING
BUILDUP OF SHIELDING GAS
Shut off
5-9. Power Switch
shielding gas supply
can
when not in
harm health
or
kill.
use.
warnl.I 9/91
1
Shielding
2
Valve
3
Gun
Gas
Cylinder
Trigger
cylinder just before
Open valve
welding.
on
Gun
turns weld
trigger
gas flow
on
output and
and off.
3
Close valve
ished
on
cylinder
when fin.
welding.
sb5 1 6/92S-0621-C
Figure
5-10.
Shielding Gas
OM-1586
Page
17
CAUTION
a
damage this
HIGH FREQUENCY will
Turn off
high frequency
using
Install &
Install
source
when
Put
Welding
Connect
) )
System
Wire Feeder~,/J(See Figure
unit.
this unit.
disconnect this unit from power
Completely
J
when
) )
3-1)JJ
using high frequency.
O~~\\
~Turn
Safety ) )
Equipment 7,1
Personal
Turn On
Wire Feeder And ) )
Power Source JJ
Shielding~\\
On
Gas
)
)
Set All
Controls
(IfApplicable)7J (See Figure
5-12
Begin
Welding
)
ssb61
Figure
5-11.
Sequence
Of Gas Metal Arc
Welding (GMAW), Gas Metal
Welding (FCAW)
Arc
Inverter Model
Welding
Power Source
Always
settings
-
Pulse
9/92
(GMAW-P),
And Flux Cored Arc
5-4.
Setting
Switches On 450
Ampere
use
switch
shown with this wire feeder.
A/V
o
PANEL
~J14
ON
G~OUTPtJT (~NTfrCTOR1
o
PANEL
ARC FORCE /INDUCTAN~E
AND CC/CV
Ret. ST-I 50 171-B / Ret. Sc-145 332O
Figure 5-12. Setting Switches On
OM-1 586
Page
18
450
Ampere Inverter Model Welding Power Source
SECTION 6 STEPPING THROUGH THE
MICROPROCESSOR CONTROLS
a
WARNING
__
E LECTRIC SHOCK
can
WELDING WIRE
kill.
can
puncture
cause
wounds.
Do not touch live electrical parts.
Control circuit and feeder operational power are On
when using or changing the microprocessor
Do not
point gun towards any part of the body, other
people, or any metal when programming.
The welding wire is electrically live and moves out of
settings.
the gun whenever the power switch is On and the gun
trigger is pressed.
N OT E
eight (8) pulse welding programs (see Section 7).
This unit is equipped with
When
the unit is turned On for the first time program 1 comes up, therefore, program 1 is
illustrated throughout this manual. Instructions are given later in this manual on
how to select
6-1.
Front Panel
or
change
a
program.
Controls
Microprocessor
Turn On
welding power source and
wire feeder. Follow along with the
controls as shown.
-
I
Front Panel
2
Parameter Select Button
Display
Press parameter select button to
move indicator.
The indicator points to parameters
that are selected for change.
0
0
Parameter select button
indicator between Trim
0
and 1PM while
0
0
Go to
50
Trim
1PM
20 0
>50
Tr
rn
I
PM
Tr
rn
I
PM
200
50
>200
Figure
can move
(arc length)
welding.
6-2.
>Prg
Pulse
Prg
1
Pulse
Prg
Put
1
se
Ref. ST-155 222
Figure
6-1. Front Panel Parameter Select Button
OM-1586
Page
19
1
I
Front Panel
Display
Select parameter to be
~
2
o
Display Control
Turning
following changes
ting:
Trim
by
2
~Y_~
~
to selected set
length)
(arc
creases
o
o
Knob
knob one click causes the
0
o
changed
(see Figure 6-1).
increases/de
one.
The trim (arc
changed also
panel
length) value being
changes on the side
parameter display (see
Figure 8-3).
Wire feed
decreases
>
5 0
1
r
I
2 0 0
I
m
P M
P
r
g
u
I
s
P
1
speed (1PM) increases/
by one inch per minute.
The wire feed speed value being
changed also changes on the side
I
panel
parameter
Program
number
ses/decreases
The
Display
by
5 5
200
T
r
i
1PM
P
r
g
1
I
F55
(see
ceptionofDualScheduleMode
(see Section 11).
Pulse
_________________
Display Control knob can ~e used
Jog speed when Jog button
is pressed (see Figure 5-6).
to set
Select
Trim
1PM
display
The program number cannot be
changed while welding, with ex
Front Panel
rJTh Parameter
11J
increa
_______________
m
_____________________
(Prg #)
one.
number
program
being
also changes on the side
panel parameter
Figure 6-5).
__________________
(see
changed
Control
>
display
Figure 8-3).
e
Go to
Pig
Figure
6-3.
ii
Pulse
Display
Control
55
>300
Trim
1PM
Prg
ii
Pulse
0 Front Panel
r1l Parameter
Select
55
300
Trim
1PM
~>Prg
ii
Pulse
Display
Control
+
__________________________
Tim
1PM
1>Prg
21
Pulse
Ret. ST.1 55222
Figure
OM-1586
Page
20
6-2. Front Panel
Display Control
Knob
6-2.
Side Panel
Microprocessor
I
Push Buttons
~!
1
Mode
2
Mode Select Button
Display
Press Mode button to
tor in left window
Go to
Figure
move
indica
display.
6-4.
Side Panel
Process
>S
e
q
u
e n c e
Dual Schd
Ca
r
d
Process
Sequence
>D
u a
I S C h d
Card
P
r
0 C e S S
Sequence
Dual Schd
>C
a
r
d
Ret, ST-154 109
Figure
6-3. Side Panel Mode Select Button
OM-1586
Page
21
1
2
Parameter
Moving
Moving line is
be changed.
3
Display
Line
under value that
can
Side Panel Parameter Select
Button
Press side
button to
window
panel parameter
move
select
indicator in
right
display.
Side Panel
Ref. 5T-154 109
Figure
OM-1586
Page
22
6-4. Side Panel Parameter Select Button
Use side
panel mode select button
changed (see
Figure 6-3).
to select mode to be
Use side panel parameter select
button to selec~ parameter to be
changed (see Figure 6-4).
1
Increase Button
Press button to increase value that
is underlined
2
by
the
moving
line.
Decrease Button
Press button to decrease value
that is underlined
line.
by
the
moving
Side Panel
2
R&. ST-154 109
Figure
6-5. Side Panel Parameter Increase And Decrease Buttons
OM-1586
Page
23
STANDARD PULSE WELDING PROGRAMS
SECTION 7
following eight (8) pulse welding programs are in the memory of the wire feeder. Use this information if it is neces
sary to change a standard program, or as a basis to build your own custom program. If at any time while changing a
standard program, or while building your own custom program, you want to revert back to the standard program in the
wire feeder memory, see Section 13-17, Resetting Memory.
The
Program
Wire
Program
# 1
Program
Name: .035
Size/Type:
Steel, Argon
-
.035
1
Gas: 98 Ar
S-3
-
2
Oxy
or
95Ar
-
5
Oxy
Card #________________________
Oxy
Flowrate: 40 CFM
Gun Model: MILLER GW
1PM
ApK
AbK
PPS
PWms
750
490
105
200
2.0
700
480
100
190
1.9
650
470
95
185
1.9
600
465
93
180
1.9
550
460
90
175
1.8
500
450
85
170
1.8
450
430
80
160
1.8
400
410
75
150
1.7
350
390
70
140
1.7
300
370
65
130
1.6
250
350
50
120
1.6
200
330
47
110
1.6
150
315
45
90
1.5
100
300
45
40
1.5
80
290
40
35
1.5
COMMENTS
Preflow: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:__________________________
Crater Trim: 50
1PM: 200
Sec.:___________________________
Postflow:
OM-1586
Page
0
24
Sec.
Program
Program
Wire
# 2
Size/Type:
Program Name: .045 Steel, Argon
-
2
Gas: 9BAr
S-3
.045
-
2
Oxy
or
95 Ar
-
5
Oxy
Card #_________________________
Oxy
Flowrate: 40 CFM
Gun Model: MILLER GW
1PM
ApK
AbK
PPS
PWms
750
540
110
220
3.2
700
530
110
210
3.2
650
520
110
200
3.2
600
510
110
190
3.2
550
500
110
180
3.1
500
490
105
170
3.0
450
470
105
160
2.9
400
450
100
150
2.8
350
440
100
140
2.7
300
430
95
130
2.6
250
420
90
120
2.5
200
400
80
100
2.5
150
380
70
80
2.4
345
50
60
2.4
310
30
38
2.2
COMMENTS
.
.
100
-
80
Preflow: 0 Sec.
Run-In Trim: 50
1PM: 200
Crater Trim: 50
1PM: 200
Sec.:___________________________
-
Sec.:___________________________
Postflow: 0 Sec.
OM.1586
Page
25
Program
Wire
Program
# 3
Program
Name: .052
Size/Type:
Steel, Argon
-
.052
3
S-3
Gas: 98Ar
-
2
Oxy
or
95 Ar- 5
Oxy
Card #________________________
Oxy
Gun Model: MILLER GW
Flowrate: 40 CFM
1PM
ApK
AbK
PPS
PWms
750
565
145
260
3.1
700
565
140
260
3.1
650
560
135
260
3.1
600
560
130
255
3.1
550
560
125
240
3.1
500
550
120
225
3.0
450
540
115
210
2.9
400
530
110
195
2.8
350
520
105
170
2.7
300
510
100
155
2.7
250
500
90
140
2.6
200
480
80
120
2.6
150
460
70
100
2.5
100
420
50
80
2.4
50
350
32
50
2.2
COMMENTS
.
Preflow: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:___________________________
CraterTrim:50
1PM: 200
Sec.:_____________________
Postflow:
OM-1586
Page
0 Sec.
26
Program
Program
Wire
# 4
Program Name: .035
Size/Type:
309, Argon
-
.035
4
Gas: 98 Ar
309
-
2
CO2
or
95Ar
-
5
CO2
Card #________________________
CO2
Flowrate: 40 CFM
Gun Model: MILLER GW
1PM
ApK
AbK
PPS
PWms
750
390
95
210
2.2
700
380
95
200
2.1
650
370
90
190
2.0
600
360
85
180
1.9
550
350
80
170
1.9
500
340
75
160
1.9
450
330
70
150
1.8
400
320
65
140
1.8
350
310
60
130
1.7
300
300
55
120
1.6
250
290
50
100
1.6
200
280
45
80
1.6
150
270
40
60
1.6
100
270
36
40
1.5
80
260
30
30
1.5
COMMENTS
.
.
Preflow: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:___________________________
Crater Trim: 50
1PM: 200
Sec.:___________________________
Postllow: 0 Sec.
OM-1586 Page 27
Program
Wire
Program
# 5
Program
Name: .045
Size/Type:
Steel, 309, Argon
.045
-
5
Gas: 98 Ar
309
-
2
CO2
or
95Ar
-
5
CO2
Card #________________________
CO2
Gun Model: MILLER GW
Flowrate: 40 CFM
1PM
ApK
AbK
PPS
PWms
750
490
115
290
2.3
700
480
115
280
2.3
650
450
115
270
2.1
600
435
112
260
2.0
550
430
110
240
2.0
500
425
105
230
1.9
450
420
105
220
1.9
400
415
105
200
1.8
350
410
100
180
1.8
300
400
95
160
1.7
250
380
88
140
1.7
200
360
85
115
1.7
150
340
68
88
1.6
100
320
50
70
1.6
80
310
45
60
1.5
COMMENTS
.
Preflow: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:__________________________
Crater Trim: 50
1PM: 200
Sec.:___________________________
Postftow: 0 Sec.
OM-1586
Page
28
Program
Program
Wire
# 6
Program Name: 3/64
Size/Type: 3/64
6
Gas:
4043
Argon
Card #________________________
4043, Argon
Flowrate: 40 CFM
Gun Model: MILLER GW
1PM
ApK
AbK
PPS
PWms
750
510
150
190
3.5
700
485
150
180
3.4
650
485
150
180
3.4
600
470
145
180
3.3
550
445
140
170
3.1
500
420
135
160
2.9
450
400
130
150
2.8
400
360
120
140
2.7
350
340
115
130
2.6
300
310
100
120
2.5
250
277
87
110
2.4
200
250
68
100
2.3
150
215
50
90
2.1
100
190
30
80
2.0
80
190
27
45
2.0
COMMENTS
Preflow: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:__________________________
Crater Trim: 50
1PM: 200
Sec.:___________________________
Posthow: 0 Sec.
OM-1586
Page
29
Program
Wire
Program
# 7
Program
Name: 3/64
Size/Type: 3/64
7
Gas:
5356
Argon
Card #________________________
5356, Argon
Gun Model: MILLER GW
Flowrate: 40 CFM
1PM
ApK
AbK
PPS
PWms
750
515
130
190
2.8
700
510
120
190
2.8
650
490
120
180
2.7
600
470
115
170
2.7
550
450
110
160
2.6
500
430
100
150
2.5
450
410
90
140
2.5
400
390
80
130
2.4
350
370
65
112
2.4
300
340
52
103
2.3
250
325
47
90
2.3
200
300
40
80
2.2
150
277
35
53
2.2
100
260
24
40
2.2
50
230
20
35
2.0
COMMENTS
Preflow: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:__________________________
Crater Trim: 50
1PM: 200
Sec.:___________________________
Postflow: 0 Sec.
OM-1586
Page
30
Program
Program
Wire
# 8
Program Name: .035
Size/Type:
Nickl, Argon
-
.035
8
Gas: 75 Ar
Nickl
-
25 He
Card #_________________________
He
Flowrate: 40 CFM
Gun Model: MILLER GW
1PM
ApK
AbK
PPS
PWms
750
390
110
130
3.5
700
380
105
130
3.5
650
370
100
125
3.4
600
360
90
120
3.4
550
350
85
115
3.3
500
345
80
110
3.3
450
340
75
105
3.3
400
335
65
90
3.2
350
332
60
75
3.1
300
320
55
65
3.0
250
310
50
58
3.0
200
297
44
52
2.9
150
282
37
42
2.9
100
262
29
33
2.8
50
225
23
30
2.7
COMMENTS
Preflow: 0 Sec.
Run-In Trim: 50
1PM: 200
Sec.:__________________________
Crater Trim: 50
1PM: 200
Sec.:___________________________
Postflow: 0 Sec.
OM.1586
Page
31
SECTION 8
GETTING STARTED
WARNING
a
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Always
wear
Insulate
dry insulating gloves.
yourself
Keep all panels
from work and
and covers
FUMES AND GASES
to your health.
Keep your
ground.
securely
in
use
welding
MOVING PARTS
Keep away
breathing
helmet with correct shade of filter.
body protection.
from
can cause
pinch points
Keep all doors, panels.
and securely in place.
device.
injury.
such
covers, and
as
drive rolls.
guards
closed
Safety
Read Material
manufacturers
Data Sheets (MSDSs) and
instructions for material used.
can cause
Do not weld
Wear
place
be hazardous
can
4
Wear correct eye, ear, and
head out of the fumes.
Ventilate area, or
WELDING
~
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
near
fire
or
explosion.
MAGNETIC FIELDS FROM HIGH CUR
RENTS can affect pacemaker operation.
Pacemaker
wearers
keep away.
flammable material.
Wearers should consult their doctor before
Watch for fire;
keep extinguisher nearby.
Do not locate unit
Do not weld
on
Allow work and
N OTE
~
over
Page
32
combustible surfaces.
welding, gouging,
or
going
spot welding opera
tions.
closed containers.
equipment
to cool before
handling.
See Safety Precautions at beginning of manual for ba
sic welding safety information.
wlwarri6
1
6/92
Set up equipment according to Figure 5-11. Find the standard pulse welding
program in Section 7 that is closest to your application (by wire size and type and
gas
OM-1566
near arc
type)
when
setting up.
8-1.
Welding
With
Only
Front Panel Controls
Turn On
welding power
wire feeder, and gas.
1
/
Trim
50
I
2 0 0
P
u
Display
is the default program
Program
the first time the unit is turned on.
1
I
atothertimesthelastprogram
number selected is displayed. Use
1
>Prg
P M
Front Panel
source,
s
the front
e
panel parameter select
button to select the
Prg
#.
I
2
__i_.
(.11
Select
Display
~J
Prg3
Control
closest to
/
/
2 0 0
r
I
I
m
P M
>
P
r
g
P
u
I
3
s
weld
program from
which is
wire and
through 8)
your needs (by
gas).
Strike
T
5 0
the
Section 7 (1
2
3
an arc
Trim
and
try
a
sample weld.
(Arc Length)
If necessary, select Trim, and adjust to achieve the best arc.
e
4
1PM
If necessary, select 1PM, and adjust to achieve the best arc.
Front Panel
Mode Select
Go to Section 8-2.
Trim
>50
200
1PM
Prg
3
Pulse
-~
Display
Control
I
Trim
>55
200
1PM
Prg
3
Pulse
(~\
Front Panel
Mode Select
Trim
55
>200
1PM
Prg
3
Pulse
Display
Control
Trim
55
>250
1PM
Prg
3
Pulse
7
Figure
8-1.
Welding
With
Only
Front Panel Controls
OM-1586
Page
33
8-2.
Setting Sequence Pulse Welding
a
Parameters On Side Panel
WARNING
ELECTRIC SHOCK
can
kill.
WELDING
wounds.
Do not touch live electrical parts.
-
Display
WIRE
can
cause
puncture
Do not point gun towards any part of the body, other
people, or any metal when programming.
Control circuit and feeder operational power are On
using or changing the microprocessor
when
settings.
The
welding
wire is
electrically
live and moves out of
the gun whenever the power switch is On and the gun
trigger is pressed.
NOTE ~
Figure
8-2 is
a
through Fig ure
graphic layout of a weld cycle. Follow examples in Figure 8-3
adjust sequence welding parameters to fit your needs.
8-8 to
Weld Time 0-25 Sec.
Crater Time
0-2.5 Sec.
A
/
~
Trigger
Trigger
Burnback Time
0-0.25 Sec.
Time
Released
Pressed
Re ~. S-0271
Figure
OM-1 586
Page
34
8-2. Weld
Cycle
I
Side Panel Mode Select
Button
When unit is turned On. Process is
the default mode, at other times.
side
use
to select
2
panel mode
Sequence.
select button
Side Panel Parameter Select
Button
Use side
panel parameter
select
button to select parameters.
3
Weld Parameters
Parameter ranges
Trim
V
S
>W~l~
/
50.
Trim
Dual Schd
250
PM
Card
0.0
Sec
>Sequen
ce
are
follows:
(Arc Length), 0-99
Changes
Proces
Display
are as
also
to Weld
displayed
Sequence Trim
on front panel
display.
-H
Wire Feed
Speed,
50-780 Inches
Per Minute, 1PM
Changes
are
also
Sequence
to Weld
displayed
on
front
1PM
panel
display.
Seconds, 0-25.0 Sec. If value set is
zero (0), welding will continue until
welding gun trigger is released.
Set Desired Weld
Sequence Voltage
Go to
~ Or~
Increase!
Decrease
Figure
8-4.
Weld
Trim
>50
Trim
can be fine tuned
while welding.
see Figure 6-2
200
1PM
0.0
Sec
~
~
Set Desired Weld Sequence
Wire Feed Speed
Side Panel
Parameter
Select
We I d
Increase!
Decrease
Trim
60
Or~j
>200
1PM
0.0
Sec
PM can be fine
tuned while welding.
see
Figure
6-2.
Side Panel
Parameter
Select
Set Desired Weld Sequence
Weld Time. If Applicable
V
We I d
Trim
60
Increase!
Decrease
300
1PM
1>0.0
Sec
Side Panel
Parameter
Select
Proceed to next
figure.
We I
60
d
Trim
300
1PM
>3.5
Sec
Increase
Figure 8-3. Setting Weld Sequence Display
OM-1586
Page
35
1
Crater Parameters
Display
Parameter ranges
are as
Trim
0-99
(Arc Length),
Wire Feed
Speed,
follows:
50-780 Inches
Per Minute, 1PM
~~1
Seconds, 0-2.50 Sec. If value set is
zero
(0), there is no Crater
Side Panel
Parameter
Select
Side Panel
Parameter
Select
Set Desired
Trim
Set Desired
Wire Feed Speed
Go to
Increase!
Decrease
60
1
1PM
Sec
0.20
Figure
8-5.
Side Panel
Parameter
Select
Crater
Trim
150
~
Increase!
Decrease
>crater
60
sequence.
Side Panel
Parameter
Trimj
150
1PM
>
Sec
Set Desired Time
Select
Increase!
Decrease
Increase
Proceed to next figure.
Figure
8-4.
Setting
Crater
Sequence Display
Burnback Parameters
______/
Burnback
______
______
Bu rriback
>~u~nbacb
Display
be adjusted from
0-0.25 seconds, If value set is zero
can
there
(0),
is
no
Burnback
sequence.
Go to
0.00
Sec
>Q~QQ
Side Panel
Parameter
Select
Sec
Set Desired Time
0.12
Setting
8-5.
Increase
Proceed to next
Burnback
figure.
Sequence Display
1
0.0
Sec_F ~
Side Panel
Parameter
Select
Postflow
Go to
Sec
Set Desired Time
1.2
Select
Figure
Page
36
Sec
Side Panel
Parameter
Increase!
Decrease
OM-1586
Postflow Parameters
8-6.
Setting
Disptay
Postflow can be adjusted from
0-9.9 seconds. If value set is zero
(0), there is no Postflow sequence.
/
>~Q~f!Q~
8-6.
Side Panel
Parameter
Select
Increase!
Decrease
Figure
Figure
Sec
Increase
Proceed to next figure.
Postflow
Sequence Display
Figure
8-7.
Preflow Parameters
1
P reflow can be
Display
adjusted from
0-9.9
seconds, If value set is zero
there is
Go to
>E
~ ~
1.2
Side Panel
Parameter
Select
8-7.
Set Desired Time
Setting
(0),
Preflow sequence.
Figure
8-8.
f
Sec
Side Panel
Parameter
Select
Increase
Proceed to next figure.
Increase/
Decrease
Figure
no
Preflow
Sequence Display
1
Run-In Parameters
Parameter ranges
Display
are as
follows:
Trim, 0-99.
Wire Feed
Speed, 50-780
inches
per minute. 1PM
Seconds. 0-2.5 Sec. If value set is
zero
(0),
there
is
no
Run-In
sequence.
Set Desired
Parameter
Wire Feed
Select
Speed
Side Panel
Parameter
Select
Increase!
Decrease
>WeId
>Runin
Trim
Runin
I
TrimHss_TrmH
Side Panel
Parameter
Select
Increase
Set Desired Time
lncrease/
Decrease
Figure
8-8.
Setting
Run-In
Sequence Display
OM-1586
Page
37
TEACHING A PULSE WELDING PROGRAM
SECTION 9
a
WARNING
ELECTRIC SHOCK
can
WELDING WIRE
wounds.
kill.
Do not touch live electrical parts.
can
cause
puncture
Do not point gun towards any part of the body, other
people, or any metal when programming.
The welding wire is electrically live and moves out of
ControlcircuitandfeederoperationalpowerareOn
when using or changing the microprocessor
settings.
the gun whenever the power switch is On and the gun
trigger is pressed.
~
N OTE
See GMAW-P (Pulsed MIG) Process Guide supplied with unit for
more
information.
9-1.
Pulse Waveform
Explained
The wire feeder, not the
welding
power source, controls weld output
for pulsed welds.
1
Peak Current Of
ApK
100-565
Amperes
ApK is the high pulse of welding
Peak
current.
current
melts
the
welding wire and forms a droplet.
The droplet is forced into the weld
puddle.
2
AbK
Background Current
Of 10-200
Amperes
Abt< is the low weld current. Back
ground
current
preheats welding
wire and maintains the arc. When
background
arc
/
low, the
tain.
N
11\
C
Q)
0
a.
E
current is too
is unstable and hard to main
1
3
PPS
Pulses Per Second Of
20-400
1~
PPS.
pulse rate, and frequency
(Hz)
are
PPS
or
used
interchangeabty.
A
,
pulse rate of 60 Hz means
60 pulses of current are produced
2
each second.
*
Time
/
4
PWms
Pulse Width Of
1.0-5.0 Milliseconds
PWms is the time spent at peak
current (1.2 ms is .0012 seconds).
This time must be long enough to
form
a
droplet of welding wire. The
stiffness
weld
or
fluidity
puddle
is
of the molten
controlled
by
PWms.
R&. S-0259
Figure
OM-1586
Page
38
9-1. Pulse Waveforms And
Explanation Of Terms
Teach Points
9-2.
Explained
PM
780
750
700
650
600
550
Example Of A Synergic
Setting For 425 1PM With
All Teach Points Set At
50 1PM Increments
500
450
400
350
300
250
ApK
200
E
AbK
o
pps
150
100
PWms
50
150
180
210
240
270
300
330
360
370
420
450
480
510
540
565
ApK
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
AbK
30
55
80
105
130
160
185
210
235
260
290
315
340
365
400
PPS
3
2
The teach mode allows the user to create
custom pulse MIG welding programs. The
teach mode has 15 teach
points. At each
point, the user can adjust four parame
ters: peak amperage (ApK), background
amperage (AbK), pulses per second (PPS),
and pulse width in milliseconds (PWms) to
shape the pulse waveform of the weld
output.
teach
Wire feed speed teach points can range from
the minimum to the maximum wire feed
speed of the feeder. When using a standard
speed motor, wire feed speed teach points
typically range from 50 to 750 ipm. The wire
feed speed of a teach point can be redefined
to any wire speed setting between adjacent
teach points (see Section 9-3). The feeder
uses pulse parameters at teach points to es
tablish the pulse parameters at any wire feed
speed setting.
Figure
9-2.
Typical
PWms
5
4
Below the wire feed speed of the lowermost
point, and above the wire feed speed
To
of the uppermost teach point, the unit may
limit wire feed speed settings in pulse MIG to
and the weld must be terminated
teach
maintain all
pability
pulse parameters
within the
ca
ensure a proper arc length reading, elec
trical stick-out must be carefully maintained,
by releas
welding
the gun trigger, not by pulling the
gun away from the workpiece.
ing
of the unit.
taught arc length represents a Trim (arc
length) setting of 50. Increasing the value of
Trim, increases the actual arc length. Like
wise. decreasing the value of Trim will de
crease actual arc length.
The
Pulse MIG programs made by the manufac
turer have pulse waveform information en
points. The operator
modify the setting of one, or
any number of the 15 teach points if the fac
tory set information is not appropriate for a
specific application.
tered for all 15 teach
can
relocate and
In the Pulse
a
mode, the unit does not maintain
constant arc
length
with variations in elec
trical stick-out. In the
Adaptive Pulse mode,
adjusts pulse frequency to maintain
constant arc length regardless of varia
the unit
After the parameters for each teach point are
established, an arc must be struck and main
a
tions in electrical stick-out.
tained for at least 5 seconds. This allows the
wire feeder to learn the arc
Proceed to next
sociated with the
program.
Teach Point
voltage length as
taught pulse parameters.
Settings
And
figure
to teach a
pulse MIG
Resulting Synergic Setting
OM-1586
Page
39
Teaching
9-3.
~! ~AL1
A.
A Pulse
Welding Program
READ SAFETY BLOCKS at start of
Section 9 before proceeding.
;1 ~ II ~ 1e
Selecting And/Or Redefining
Teach Point Wire Feed
Speed
Process
1
A teach
point (1PM)
can
be selected
but the wire feed speed of
and
Display
a
teach
either the side panel
on
point
can
only
Control knob while 1PM is selected
or
front
panel displays,
be redefined with the
the front
on
Purge
Display
When unit is first turned On. Pro
cess is the default screen, at other
times use mode select button to se
lect Process.
button
panel display.
2
Teach
Display
Use parameter select button to
lect Teach.
se
Use increase/decrease buttons to
select On.
3
1PM
You
(Teach Point)
also select
can
a teach point
panel Display Control
cursor on the front panel
with the front
Side Panel
Mode Select
knob if the
display
is
pointing
at 1PM.
To redefine the wire feed
3
Decrease
_______
>4~O
On
PM
340
ApK
70
AbK
r~Teach
~j
l>40Q
1PM
340
Apk
70
Abk
-Or--j
Qo
>Teach
I
400
1PM
~
340
Apk
....
70
Press and hold
Purge
Control knob to
point
to a wire feed
to 249
ipm.
the
set
or
adjust
parameters, go
rim
>Prg
A Teach Point
1
50
Trim
Prg
1
~
4
1PM
50
Pulse
1PM
>450
Pu
I
Front Panel
Parameter
Select
Purge?~
And
I
Figure
OM-1586
Page
40
~ 0
>460
9-3.
T
r
m
1PM
Selecting
]
And/Or
i~
r
g
Pul
Redefining
button while
re
1L1
sej
A Teach Point
se
speed of 151
procedure
points
of the 15 teach
A Teach Point
To
1
se
at 200 can be ad
justed
Repeat
50
Display
turning Display
the teach
Parameter
Select
Redefining
follows:
define the teach point wire feed
speed. Forexample, if teach points
reside at 150. 200, and 250 ipm,
Side Panel
Selecting
speed of
as
Use parameter select buttqn to
lect 1PM (teach point).
______
On
point, proceed
Front Panel
4
a
_______
Teach
teach
a
to
for
as
as
desired.
many
teach
Figure
9-4.
point
Setting
B.
Teach Point Parameters On The Side Panel
lncrease/
Decrease
>P
r
a
c e S
On
Teach
S
Sequence
>4~Q
1PM
Dual Schd
340
Apk
70
Abk
Card
Teach
J
On
1PM
460
Apk
L_0r_-_>~4~
Teach
On
1PM
460
7,,~,,,/Abk ~
Apk
70
Abk
I
I_____________
___
Side Panel
Parameter
Select
I
~
lncrease/
Decrease
Increasef
Decrease
343
Apk
92
Abk
>~80
PPS
1.9
Side Panel
Parameter
Select
~l
Or
460
1PM
~
Apk
ZO
Abk
160
PPS
>
PWms
rea~e~
Pulse
035Steell
-1
Ar~on-Oxyj
>
Side Panel
Parameter
Select
Qf
~1
lncrease/
Decrease
4
r
I
L_J
Side Panel
Parameter
Select
5
1/
Progl
C~
Pulse
I 035Steel!
Argon-Oxy~
When the Process Teach mode is On, and
one
of the
following pulse parameters
is
lected: ApK. AbK. PPS, or PWms. the front
panel displays the selected pulse parameter
instead of Trim (arc length). When the pulse
parameter is selected on the front panel, the
value can be changed with the front panel
Display Control knob, or on the side panel as
follows:
1
2
AbK
Display
3
PPS
Display
4
PWms
5
ApK Display
strike and maintain
~epeat procedure
Figure
9-4.
Setting
Custom Pulse Screen
Display
When values have been set for
custom
Figure
Turn Teach mode Off.
se
program
9-2).
an arc
a teach point.
for five seconds.
at each teach
is
point until
(see
complete
The letter C will appear in the upper
ner of all customized programs.
To set Sequence
Section 8-2.
right cor
Welding Parameters,
see
Teach Point Parameters On The Side Panel
OM-1586
Page
41
N OTE
~
Make copies of this chart for future
use.
Program #___________ Wire Size/Type_________________________ Gas___________________________
Program Name____________________________________________ Card #________________________
Gun Model_____________________________________________ Flowrate
1PM
ApK
AbK
PPS
PWms
CFM
COMMENTS
Preflow:_____________________ Sec.
Run-In Trim:______________ 1PM:_________________________ Sec.:________________________
Crater Trim:______________ 1PM:________________________ Sec.:_______________________
Postflow:___________________ Sec.
OM-1586
Page
42
9-4.
Changing
To
Pulse
Adaptive
Welding
READ SAFETY BLOCKS at start of
Section 9 before proceeding.
Welding parameters
are
the same
for both a Pulse and an Adaptive
Pulse welding program. While
welding adaptively, the unit uses
feedback to attempt to maintain a
constant arc length. To change to
Adaptive Pulse welding, proceed
as shown:
1
Side Panel
Mode Select
Side Panel
Default
display
Display
when unit is first
turned On, at other times
use
panel mode select button
to select
side
Process,
2
V
>Process
>Prg
Sequence
1_
Pulse
DualSchd
035Steel
Card
ArgonOxy
>Process
Prg
Sequence
1
>Eu!~~
DualSchd
035Steel
Card
ArgonOxy
>Process~
Sequence
Prg
1
>~daptPulse
DualSchd
035Steel
Card
ArgonOxy
Figure
9-5.
Changing
To
Adaptive
Pulse
Welding
OM-1586
Page
43
SECTION 10- TEACHING A MIG WELDING PROGRAM
a
WARNING
ELECTRIC SHOCK
can
WELDING WIRE
wounds.
kill.
Do not touch live electrical parts,
Control circuit and feeder operational power are On
when using or changing the microprocessor
settings.
can
cause
puncture
Do not point gun towards any part of the body, other
people, or any metal when programming.
The welding wire is electrically live and moves out of
I
the gun whenever the power switch is On and the gun
trigger is pressed.
A.
Changing
To MIG
Welding
I
Side Panel
Default
U
Side Panel
Mode Select
O
V
Prg
1
>~uls5
DualSchd
035Steel
Card
Argon Oxy
>Process
Prg
1
>Ml~
Sequence
Dual Schd
Ca
r
d
Figure
OM-1586
Page
44
10-1.
when unit is first
use
panel mode select button
to select
Process.
Side Panel
Parameter
Select
Sequence
Display
turned On, at other times
Go to
>Process
display
Changing
To MIG In The Process Mode
Figure
10-2.
side
B.
Setting Sequence M1G Welding
Parameters On Side Panel
Display
Side Panel
Display
When unit is turned On, Process is
the default mode. Use side panel
mode
select
button
to
select
Sequence.
2
>Prg
>Process
1
Side Panel Parameter Select
Button
MIG
Sequence
Use side
Dual Schd
Ca
panel parameter select
button to select parameters.
r
d
3
Weld Parameters
Parameter ranges
Display
are as
follows:
Volts, 10.0-38.0 Volts
Side Panel
Wire Feed Speed, 50-780 Inches
Per Minute. 1PM
Seconds, 0-25.0 Sec. If value set is
(0), welding continues until
zero
welding
Process
18. OVo I
>Sequence
DualSchd
200
1PM
Card
0.0
Sec
I
is released.
to voltage and wire feed
(1PM) parameters in the
weld sequence are also displayed
on front panel display.
speed
Figure
10-3.
Voltage
>19
Increase! Weld Sequence Volts
Decrease
can be fine tuned
while
Œ
Side Panel
Parameter
Select
We I d
1.
>~
9Vo I
3
18.OVolt
200
1PM
200
1PM
0.0
Sec
0.0
Sec
welding
Side Panel
Parameter
Select
I
Set Desired Wire Feed
Set Desired Weld Time,
If
trigger
Changes
Go to
Set Desired
gun
Inductance, 0-99%
Applicable
Weld
I 420
1PM
Sec
~
nduc
20. OVo I
~~~j>2QQ
0.0
1PM
Sec
Increase! Weld Sequence 1PM
Decrease
can be fine tuned
while welding
Increase!
Side Panel
Parameter
Select
Decrease
Side Panel
Parameter
Select
Speed
I
Weld
Set Desired Inductance,
If
Applicable
Weld
Increase!
>Weld
420
1PM
2.2
Sec
20.OV0I
>~Q~I nduc
Decrease
Side Panel
420
1PM
2.2
Sec
ts
Increase
Proceed to next
figure.
Parameter
Select
Figure
10-2.
Setting
Weld
Sequence Display
OM-1586
Page
45
1
Crater Parameters
Parameter ranges
Display
are as
follows:
Volts, 100-38.0 Volts
>Gratet
1 8
~,_,_-i
Wire Feed Speed, 50-780 Inches
Per Minute, 1PM
OVo I
.
200
1PM
Seconds, 0-2.50 Sec. If value set is
0. OOSec
~
(0),
zero
there
is
Crater
no
sequence.
Side Panel
Parameter
Select
Go to
Crater
Crater
>18~QVoIt
I
I
24.OVoIt
j
Crater
I
24.OVolt
Figure
10-4.
~
250
1PM
1PM
>~~Q
0.OOSec
Set Desired
Side Panel
Voltage
Parameter
Select
Set Desired
Wire Feed Speed
Increase!
Decrease
1PM
400
~QQSec
0.OOSec
Side Panel
Parameter
Select
Set Desired Time
Increase!
Decrease
Increase!
Decrease
>G
r ~
t e
I
24. OVo I
I
400
1.
1PM
l2Sec
Side Panel
Parameter
Select
Increase
Proceed to next figure.
Figure
10-3.
Setting Crater Sequence Display
1
Burnback Parameters
Parameter ranges
are as
Display
follows:
Volts, 10.0-38.0 Volts
Seconds, 0-0.25 seconds. If value
set is zero
(0),
there is
no
Burnback
sequence.
Go to
I>BULfl~a~~~
I
18.0
Volt
0.00
Sec
___________
0.00
Volt
16.0
Sec
>Q~12
Set Desired
Burnback Volts
Select
Side Panel
Parameter
Select
Figure
46
16.0
Volt~
Sec
0.12
Sec
10-4.
Setting
Set Desired Time
Increase!
Increase!
Decrease
Page
Volt
___________
Side Panel
Parameter
OM-1586
10-5.
Burnback
Burnback
>1~Q
Figure
Decrease
Burnback
Sequence Display
Side Panel
Parameter
Select
Increase
Proceed to next
figure
1
______
______
Postflow
>EQ~tt!Q~
Go to
Sec_r
0.0
~
Side Panel
Parameter
Select
>
Sec
0
Figure
10-6.
Sec
.2
1
Display
Postflow can be adjusted from
0-9.9 seconds. If value set is zero
(0), there is no Postflow sequence.
______/
>~Q~tfio~
Postflow Parameters
Side Panel
Parameter
Select
Set Desired Time
Increase
Increase!
Proceed to next
Decrease
Figure
Setting
10-5.
Postflow
figure.
Sequence Display
1
Preflow Parameters
Preflow
I
>P E ~
Pr e f
f I
I
>Er
ow
f
e
Sec
Sec
>
adjusted
Display
from 0-9.9
seconds. If value set is zero
there is no Preflow sequence.
ow
Go to
0.0
be
can
Figure
(0),
10-7.
Sec
1.2
__________
Side Panel
Parameter
Select
Side Panel
Parameter
Select
Set Desired Time
Increase
Proceed to next
Increase!
Decrease
Figure
10-6.
Setting
Preftow
figure.
Sequence Display
1
Run-In Parameters
Parameter ranges
I
>~L!0
Runin
10
18.OVoI
>18. QV0
1
I
200
1PM
200
1PM
0.0
Sec
0.0
Sec
20.
Wire Feed
OVo I
>2QQ
1PM
Lo.o
Sec
Set Desired
Voltage
Side Panel
Parameter
Select
follows:
Speed,
50-780 inches
per minute, 1PM
Seconds, 0-2.5 Sec. If value set is
zero
Side Panel
Parameter
Select
are as
Volts, 10.0-38.0 Volts
Runin
~
t
Display
Set Desired
Wire Feed Speed
(0),
there
is
no
Run-In
sequence.
I
Increase!
Decrease
Increase!
Decrease
420
1PM
2.2
Sec
20.OVolt
150
1PM
0.
Sec
5
20.OVolt
150
>Q
Side Panel
Parameter
Select
Increase
Side Panel
Parameter
Select
Runin
___________F ~Buojo
20.OVolt
~
~
1PM
Sec
Set Desired Time
Increase!
Decrease
Figure
10-7.
Setting
Run-In
Sequence Display
OM-1586
Page
47
SETTING DUAL SCHEDULE PARAMETERS
SECTION 11
WARNING
a
___
E LECTRIC SHOCK
,4
kill.
can
5~
Do not touch live electrical parts.
I
WELDING WIRE can
wounds.
Control circuit and feeder operational power are On
when using or changing the microprocessor
~I I
puncture
Do not point gun towards any part of the body, other
people, or any metal when programming.
The welding wire is electrically live and moves out of
I
settings.
cause
the gun whenever the power switch is On and the gun
trigger is pressed.
Dual Schedule can only be used
two consecutive weld pro
grams such as: 1 & 2, or 3 & 4. or
5 & 6, or 7 & 8. Any program type
with
MIG, Adaptive Pulse, or Pulse can
be combined in dual schedule. For
example, Prg
Pulse, or Prg
1
is MIG,
I is
Prg
2 is
Adaptive Pulse,
2 is Pulse. etc.
and
Prg
1
Side Panel Mode Select
Button
2
Mode
Display
Use mode select button to select
Dual Schedule, then proceed as
shown:
~>~g ~
3
Dual Schedule Parameters
Display
-
Use side
panel increase/decrease
buttons,
or
Display Control
(see Figure 11-2)
schedule pairs.
to
knob
select dual
Control
Display
if the two desired
welding programs are not in the proper program order (1 & 2, or 3 & 4 etc.), the most
method to get them in the proper order would be to write one program to a data card, and then
read the program from the card into the desired program number, see Section 12 for data card inform ation.
common
Figure
Setting
11-1.
Dual Schedule Pairs On Side Panel
1
Parameter
1
2
~tPanelP1 :
Display
2
0 V
~
I
5 0
P M
>
P
r
D
u
a
/
g
1
I
A
Front Panel
Display
Press parameter select button to
select proqram number on front
panel display.
I
\~S&ec~/
Front Panel Parameter Select
Button
J
3
Front Panel
Display Control
Knob
3
4
Display
Welding Gun
Trigger
Control
Knob
Welding Gun
DSS-Type
OR
Switch
I
P
g
3
Dual
A
>
r
~
>
P
r
g
Dual
BI
are
Display
When dual schedule is
Figure
OM-1586
Page
11-2.
48
Selecting
can
be used to
for the active weld program.
When program B is active, turn Dis
play Control knob one click clack
On, and Process is selected on the side panel display, then
the side panel increase/decrease buttons
The dual schedule programs can
be alternately selected between
active programs A or B by turning
the Display Control knob one click
clockwise or counterclockwise, or
by squeezing and releasing the
welding gun trigger, or by an exter
nal mounted OSS-type switch
mounted on the welding gun. See
Section 13-10 for specific switchtype instructions. The settings
shown on the front panel display
2 I
Control Knob
1Th~
Welding Gun Trigger, Or
DSS-Type Switch
change program numbers.
Between Active Dual Schedule
Programs
wise to select another
pair of
schedule programs.
A And B On Front Panel
Display
dual
SECTION 12- USING THE OPTIONAL DATA CARD
12-1.
Data Card
Installing
1
-J
~O
C)
(C
(,(
~.)
Label
Peel
backing
from label and
apply
by
to data card with THIS SIDE UP
metal
pins.
Write the
stored
names
of the programs
the card
on
Write the
on
the label.
of the piece of
the card is used with on
name
equipment
the label.
2
Data Card
3
Card Slot
Insert card into slot. To format card.
On power to the unit. Select
turn
Card from
p1B3 e~ea vi-og
menu.
Data card for
mats when unit enters Card mode.
Exit Card mode and turn Off power.
b
ST.156 266-B / P&. S-155 823
Figure
12-2.
Using
12-1.
Installing
Data Card
The Data Card
Use Mode Select button to select
Card.
Proces
S
Sequen
ce
I
DualSc hd
>Card
Pie
ss
Bel
ow
1
Card
2
Write
Display
Used to transfer program data from
unit to card. The program card can
hold up to 32 programs. When writ
ing to the card, the next available
program number is
automatically
assigned.
(C.
:N~>~,
Side Panel
Parameter
Select Once
V
i
t
#
1
De I
e
Delete
Used to delete program data from
card.
PuIse~
5
Done
t e
Used to exit card
4_~] ~Done
6
/
5
Read
Used to transfer program data from
card to unit.
4
Read
~
3
Moving
Moving line is
be changed.
/
6
Figure
12-2. Card
display.
Line
under value that
can
Displays
OM-1 586
Page
49
1
Card
Display
Use Mode Select button to select
Card.
2
Moving
Line
line is under value that
Moving
changed.
Se quenc
e
3
Pre
Du atSch d
Name
Bel
>Ca rd
Display
ss
If no
ow
~
2
name
is desired, press side
panel Parameter Select button
continue the write procedure.
-
~1
When
Side Panel
Parameter
Select
naming
a
program, the front
ters.
1
t e
Read
035
Dele te
Arg
P
Done
St
ee
I
on
Ox y
res
s
Allowable characters include: 0 thru 9, :, ;, <,
.?.@,AthruZ,,W],~,athruz,I.,,#$,
%.&.,(j,*,+,_,..I,
\_r~
Increase!
Decrease
Side Panel
Parameter
Select
____
I
~Name? No
035Steel~
Argon_Oxyes
Press
Name?
I~
035Steel
~
-..I
I
ArgonOxy
Press
Increase
No
Side Panel
Parameter
Select
I
(
O
Side Panel
Parameter
Select
Name?
~r:~
5007992
T
Frame
Press
~ Side Panel
Parameter
Select
~
#1
Increase
Side Panel
Parameter
Select
Pulse
5007992
Fr ame
Press
Figure
OM-1586
Page
50
12-3.
Naming Programs
And
to
panel Display Control knob can be
used to speed selection of charac
J
>Wr
can
be
Pr oces S
Writing To Card
Use Mode Select button to select
Card.
Pro
cess
Seq
uenc e
Pres
Dua lSch d
s
Card
Moving
Read
3
Side Panel
Parameter And
Select Once
~
Writ e
>Read
Dele te
Mode
Select
Once
~1
Argo
Ox y
n
Pres
Be
s
wrr~1
Pr
No
Y~
Lose?
Side Panel
Parameter
Select
Side Panel
Parameter
Select
I
Done~
Prgl
1
Prg
to
!~4Q
Increase
__________________
Card
II
Press
(~~)
Read
I
Lost
~
Yes
Side Panel
Parameter
Select
Wi
gi
Be
Lost
Press
__________________
I
,~
~
1
Figure
12-4.
Pulsel
O35Steel~
ArgonOxyl
Press
Press
Reading
From Card
Warning Display
1
>R
e
I
a
d
De I
e
e
WA R N I N
Car
program to
I
Lose?
i
card
e~1
Pu Is
Prgl
Wr
Display
goes.
ee
I
can
3
035St
Done
under value that
download. Select feeder program
number where the card program
I
~
\
Line
Select desired
(r~
2
Display
Moving line is
be changed.
Below
>Car d
1
2
j~
GT1
dEmp
1
If there
are
no
programs
card, this series of
on
the
displays appear.
t y
Press
t e
Below
Done
(.
))
Side Panel
Parameter
Select Once
V
Wr
i
t
>Proc
e
Read
De I
e
es
>Prg
S
Sequence
t e
2
MIG
Dual Sc hd
Press
>Done
Card
Side Panel
Parameter
Select
Figure
12-5.
Reading (Or Deleting)
From An
Empty Card
OM-1586
Page
51
Use Mode Select button to select
Card.
~~O
Seq
1
Card
2
Moving
Display
Line
Moving line is
be changed.
cess
3
Delete
Dua lSchd
Display
L
Select program number to be de
Pre
ss
Bel
ow
leted from card.
Side Panel
Parameter And
Select Once
Mode
Select
Twice
WARN I NG
Side Panel
Parameter
Select
2
3
#2
Delete
Card
Lose?
No
Increase
Yes
Press
Side Panel
Parameter
Select
Side Panel
Parameter
Select
Card
Prg2~
MIG
Deleted
Press
r
~
Press
Side Panel
Parameter
Select
Figure
52
12-6.
MIG
Prg2~
Press]
Page
can
uence
>Car d
OM-1586
under value that
Deleting Programs
From Card
SECTION 13SETUP
Setup Flow Chart
13-1.
2
//
P~7o
Th_
>s y
s
t em
c
Ac
r
I
>P
t y
I
u
s
e
.
I
Features
3
Settings
I
M
I
Tosetupfeaturesthatcustomize
operation, use the setup displays.
ty
Features that can be customized
follows:
C e S $
Example Of Setup Display On Side
Display Selections
~
Ca pa b I
Range
Secu
e
1
2
are as
Panel
I
Features
Display
Section
Settings
~
Selection
Process
>System
Display
I
Capability
Settings
Section
Selection
>Remote
13-3
Pulse/Mig
Mig Only
Features
Parameter
Off/On
13-12
lncrease/
I
Decrease
Press Mode Select
To Go To Next
>Arc Time
Setup Display
>Range
>Security
Volt Mm
0.0 -25.0 V
Volt Max
25.0.- 99.9 V
~
AmpMin
0-50A
~
AmpMax
50-999A
~
Program
Number
Lock
Oft/On
13-4
13-5
Run Hours
09999.99
Hours
0999,999
Cycles
No Reset
Reset
>Self Test
>Wire Feed
13-14
IPM/MPM
Display
Type
Motor
Code
Off/On
13-6
>Mig Type
Voltage
DVC On/Oft
13-7
Speed
High Speed
>Model
Model
Correction
>Voltage
13-15
Standard
Low
>Access
13-13
Type
Bench
13-16
Boom
Control
17-Pin
1
Feedback
Volt Sense
L
+__________________________
13-8
>Memory
No Reset
13-17
Reset
I
>Arc Start
Arc Start
Type
Standard
13-9
>Shutdown
No Volt Sense
Off/On
13-18
>Name
Card
Oft/On
13-19
>Software
Version
Hot Start
I
+______________________
>Dual Schedule
Switch
Type
Momentary
2-Pole
13-10
Programs
Maintained 2-Pole
Maintained 1-Pole
Number~
13-20
Trigger
>Trigger
Program Select
Oft/On
13-11
I
Figure
13-1.
Setup Flow Chart
OM-1586
Page
53
13-2.
Using Setup Displays
Front Panel
1
Setup Display
2
Front
panel display during setup.
2
Side Panel Mode And Para
meter Select Buttons
3
Power Switch On Rear Panel
3
Press and hold down both buttons
H~,:
while
4
turning On
Side Panel
unit.
Setup Display
Follow this
procedure any time ac
cess is required. Once in the setup
displays. use the Mode Select but
ton to select a particular display.
To
save any or all of the
made while in the setup
and/or to exit the
changes
displays,
setup displays.
turn power to the unit off and back
on or press the gun trigger to return
to the Process
display.
4
/
Security
Front Panel
Display
Acc
>Pulse/Mig
ess
Side Panel
Figure
13-3.
Process
Selecting
~
N OTE
13-2.
Display
Accessing Setup Displays
Capability
This selection allows the
sources.
wire
feeder to be used wit h
(Pulse/Mig) GMA W-P
1
\~
Pulse/Mig
Mig Only
Access
\
Setup
Display
,/
a n
g
e
Sec
u
r
A
e s s
c c
GMAW welds.
When in
1
54
Mig Only,
works
with
source
to
the
the wire feeder
welding
power
produce regular GMAW
welds.
/
Select
power
Process
Cap
t y
a
b i
I
s ~
Increase
I
t y
M
g
Figure
Page
Capability is Pulse/
Mig. the wire feeder works with the
welding power source to produce
either pulse GMAW-P or regular
~-H-~
>System
OM-1586
When Process
450 Ampere Inverter Model
450 Ampere Non-Inverter Model
=
=
System Display
Power Sources:
)
I
I
I
I
+
R
welding power
Welding Pulse
is available.
Example Welding
/
of
variety
a
This selection also determines whether Ga s Metal Arc
13-3.
Process
~
Cap
~
>Pyj~ g
a
b i
I
Qn
System Display
the
process the welding
is able to do.
source
WhenMigOnlyisselected,some
i
t ~
of the setup choices
are
automati
callyrnadeandarenotavailablefor
selection by the operator.
13-4.
Selecting Welding
~
N OTE
Power Source
Range
Welding power source minimum and maximum voltage
required. Amperage values are required for pulse welding.
values
are
always
1
Range Display
See
welding power source Own
Manual tor voltage and amper
ers
age ranges. Set values to match
welding
2
Minimum
Range
3
Press Mode
Select
are for 450 Ampere Inverter Model.
Do not change values if using 450 Ampere
Inverter Model.
Voltage Display
is 25.0 to 99.9 volts.
Minimum
Amperage Display
(Available When System Set
For Pulse/Mig)
Range
5
Default values
Voltage Display
is 0 to 25.0 volts.
Maximum
Range
4
power source ranges.
is 0 to 50 amperes.
Maximum
Amperage Display
(Available When System Set
For Pulse/Mig)
Range
is 150 to 999 amperes.
2
3*
-
*Use side panel Parameter Select
button to select
voltage
or
amperage.
Use Increase/Decrease buttons to
change
value.
4*
Figure
13-4.
Range Display
OM-1556 Page 55
Lock
Selecting Security
13-5.
N OTE
~
Security
lock works
when
only
data card is inserted
a
(see Section 12-1).
1
Security Display
Use this
display
to lock
weld parameters
can not be made
programs
changes
using front panel
so
a
that
controls.
2
2
1~
/
System
>Prog
1
Lock
Off
Range
>Secu
r
i
Program
Number
Choose the program number (1
through 8) to be locked.
3
Program
Lock
When lock is off of
operator
can
Display
a
change
program, the
all weld pa
rameters of that program without
t y
restriction.
Access
Increase
With lock
Press Mode
on a
program, the opera
change parameters of that
program but the range of change is
tor can
Select
restricted.
In the
example displays in this fig
operator could change the
ure, the
value of trim –10% and wire feed
speed –100 ipm from programmed
settings are left at 0,
the operator cannot change values
values. If the
from those
programmed.
If dual schedule is on, the
programs
together.
6
~
Side Panel
Parameter
Select
I
Prog
I~
Lock
I>Tr
im
Oi
2
Frog
2~
Lock
Ont
0b~f~i>Tr
0~
1PM
~
U
im
1PM
21
Frog
~
On~
Lock
Trim
0
Increase!
Decrease
r
Side Panel
Parameter
Select
>1
101
PM
I
I
Increase!
Decrease
Side Panel
Parameter
Select
Increase
Figure
OM-1586
Page
56
13-5.
Security Display
are
paired
locked and unlocked
13-6.
Selecting Or Changing
NOTE
~
Access Code
Access code works
only
when
data card is inserted
a
(see Section 12-1).
1
Code
Display
With code off,
displays
I;
access
to the
setup
is not restricted.
With code
on.
the operator must
access code to
know and enter the
I
access or
change
any of the setup
displays.
Cod
Range
Securi
e
2
ty
With
>A C C e S S
Mig
Access
>Q.f f
a
Display
code set, this
pears when
Type
while
Press Mode
I
holding
display ap
power is turned on
the side panel Mode
and Parameter Select buttons.
Select
Press side panel Parameter Select
button to enter
increase
cursor
1-I
access
code. When
the correct letter is entered, the
automatically
moves to
the
next character. When the final ac
cess
code letter is entered, the dis
to the
play automatically changes
initial setup display.
Side Panel
Parameter
Select
Co d
e
On
>AAA
~Press
,J~
Increase/Decrease
To Set Code
(Th
Parameter Select
To Move Cursor
Co d
e
On
>zWx
~P
r
S
e
S
Turn Power Off And Back On
And Access Security Display
I
;
Enter
>Code
AAA
Access
Code
~P
Figure
r
e s
13-6. Access Code
S
Display
OM-1586
Page
57
13-7.
Selecting Voltage
Correction
Mig Type Display
With DVC
Correction On.
Voltage
the unit uses
from
closed-loop feedback
17-pin cord or voltage
the
sensing leads to maintain set volt
age parameters.
With DVC
Voltage Correction Oft.
feedback from the
is not used
arc
for closed-loop feedback to main
tain voltage parameters. Feedback
from the
is still used for other
arc
functions.
Be
voltage sensing leads are
or voltage feedback is
available from the welding power
source through the 17-pin recep
sure
connected
tacle.
Voltage
Co
r
r
e c
>QY~
Figure
13-8.
Selecting Voltage Sensing
N OTE
~
13-7.
0
t
n
Qff
Mig Type Display
Method
Voltage sensing feedback
setting is Mig Only.
is
automatically
set for V. Sense when the
1
Voltage
System
Feedback
Display
the 17 Pin
When
using
setting.
voltage feedback is through
welding power source, and
arc
feedback
the
17-pin
signal
is sent
the
cord to the feeder.
If the 17 Pin
setting
is used, it is rec
ommended that the
ing
through
the
terminals
source
on
the
voltage sens
welding power
be used to monitor arc volt
age at the workpiece.
using the V. Sense setting.
voltage feedback is through the
voltage sense leads connected to
the feeder. Use this setting when
When
arc
there is
more
than 50 ft
weld cable used.
Figure
OM-1586
Page
58
13-8.
Voltage Feedback Display
(15 m) of
13-9.
Selecting Regular
N OTE
~
Or Hot Arc Start
Arc Start selection is not available when the
Do not
use
the Hot Start
setting for
.035 in
System setting
(9 mm)
or
is
Mig Only.
smaller wire.
1
Arc Start
Display
Use the Hot Start mode for
welding
Ampere
with 450
Model when
pulse
Inverter
initial weld
high
cur
rent is necessary to start large di
ameter welding wires. When in Hot
Start, the 450 Ampere Inverter
Model starts the
arc
in the CV mode
and switches to CC once the arc is
started. Do not use Hot Start un
less
1
using
450
Ampere Inverter
Model.
/
Mode Select
M
I
g
Ty
p
e
~
Figure
13-10.
Selecting Type
Ar
c
S t
a
r
t
Increase
Ar
c
S t
a
r
~ --~-~_~~
13-9. Arc Start
Display
Of Dual Schedule Switch
1
Dual Schedule
Choose
type
schedule switch
ger
as
of
Display
external
or use
dual
of the
trig
the dual schedule switch.
~1
~tncrease
~
L~
Increase
Figure
13-10. Dual Schedule
Displays
OM-1586
Page
59
Momen 2P
1
(DSS-9M)
(DSS-1 0)
>
DSS-1O)
>
Maint 2P
2
2
(Momentary-
Contact 2-Pole Switch Or
2
2
(Maintained-Contact
DSS-9M)
2-Pole Switch Or
2
Maint 1 P Or
3
Trigger (Maintai
ned-Contact 1-Pole Switch Or
DSS-9 Or DSS-8)
A
3
1
2
C
A
C
C
C
B
B
4
4
p
3
1
(DSS-9)
1
Adapter
1
(DSS-8)
1
~
Adapter
1
1
~
2
2
2
2
2
TR
>
3
2
H
3
2
>
________
3
>
3
3
4
4
3
BC
BC
1~
4
Figure
13-11.
13-11. Dual Schedule Switch
Selecting Trigger Program
Diagrams
Select
1
Trigger Display
When
Program
trigger
can
Select is On, the
be used to Switch be
tween programs that have at least
0.2 seconds of
preflow time.
Briefly pressing and releasing
gun trigger switches programs.
the
For
example: if programs 1, 2, and 6
have preflow time of at least 0.2 se
conds.
pressing
the
trigger
will
switch from program 1 to 2. 2 to 6.
and 6 to 1.
/
/
Press
Mode Select
Setup
Display
ArcSta rt
Prog
DualSc hd
Sele ct
>Tr
igge
Remo t
r
ram
I
>Qf
e
Increase
Figure
OM-1 586
Page
60
13-12.
Trigger Display
Program
Select
13-12.
Selecting
Remote Increase/Decrease
Capability
1
Remote
Display
When Parameter Inc/Dec is On,
the
be used for
can
weld parameters as well
between
switching
changing
as
dual
momentary-contact
schedule switch
for
programs.
For example: when the
panel display is
the front
cursor on
on
Trim
Volts, the dual schedule switch
be used to
or
can
remotely change the
panel param
is on Prg, the dual
value. When the front
eter
select
schedule switch
be used to
can
program number. A
the
change
DSS-10 dual schedule switch is
recommended for this purpose.
4
Press
Mode Select
\~
Setup
Display
I
DualSchd
Parameter
Tr
InciDec
igger
>Remo I
/1
Arc
e
Time
Pa
r
ame
t e
r
c/Dec
>Of
~____________
Increase
Figure
13-13.
Resetting
13-13. Remote
Display
Arc Time
1
Arc Time
Display
The unit accumulates
arc hours up
to 9999.99 hours or 999999 weld
cycles
before
(0). The
ing
this
arc
rolling
timer
can
over
to zero
be reset
us
display.
I,
Press
Mode Select
( Setup
\~lay
Tn
0.
gger
Remote
>Arc
Time
Sel
fTest
Figure
O0~
OCyci
>No
O.OOHrs
Increase
OCycl
P eset
~___________
13-14. Arc Time
Press
Display
OM-1586
Page
61
Self Test
Using
13-14.
1
only Factory Authorized persons
perform tests or replace parts.
Have
a
Switch A
This checks the gun switch increase
2
Press
Mode
Select
position.
Switch B
Access
This checks the gun switch de
Setup
Display
crease
3
position.
Trigger
This checks the gun
4
trigger.
Wire Feed
This checks the wire feed motor.
/
5
Rem
o
>S
e
Wi
t e
It~.p_
>
T ime
Arc
I
f I
r
ef eed
Off
e 5
Gas
Gun Increase
Switch
This checks the gas valve.
--c?_
This checks
6
Contactor
source
7
the
welding
power
contactor.
CV/CC
This tests the
at the
pin
17-pin
re
that controls whether the
ceptacle
unit is in CC (constant current)
CV (constant voltage).
or
>Ic I gg~t
Off
4
5
O~
_________________
>W
Increase
I
r
-
~
e
f
e
-
~
Side Panel
Parameter
Select
I
_________________
J
>Wi
_:
r
~ f ~
-
-
I
Pres
Press
~
Increase
~
~
Of
Pre
f~
ss
_____________
___
_____________
___
~
>QQnt~~1Q~L
The welding wire and all metal parts in contact with
It carry weld output when the welding power source
contactor is energized.
OffI
p
r
e ~
lncrease~>~aa
p
Side Panel
Parameter
Select
6
__On~
>G
Q fl
t ~ ~ t Q
r
7
I
I
Increase
-
Side Panel
Parameter
Select
Press
__
Figure
OM-1586
Page
62
13-15. Self Test Procedure
Side Panel
Parameter
Select
]
On
r
e s s
Speed And
Units For Wire Feed
Selecting
13-15.
Motor
Type
1
Wirefeed
The
displayed unit of wire speed
be changed along with the wire
can
feed motor
Display
type.
Increase
Display
Display
1PM
PM
Motor
Type~
Motor
Type~
Figure
13-16.
Selecting
N OTE
~
Parameter Decrease
Select
Increase
Increase
13-16. Wirefeed
Bench Or Boom Model
Display
Type
This selection is not available when the
is
System setting
1
Mig Only.
Model
The unit is
properly
model
Type Display
shipped from
the factory
set to Bench for bench
feeders
or
Boom
for
Swingarc model feeders. The set
ting loads the proper pulse param
eters into
memory for the model
used.
This selection does
not
change
when a memory reset is done.
Model
Type
>~
Figure
13-17. Model
Q Q rn
Type Display
OM-1586
Page
63
Resetting Memory
13-17.
1
No Reset
Memory
1
Press
Mode Select
(
Setup
~D~ay~lay
2
cannot be reset.
Program Reset
Press Parameter Select button to
reset last active program to
~
original
factory
program settings. All other
program and setup information re
mains the same.
3
System
Reset
Press Parameter Select button to
reset programs and setup to origi
nal factory settings. System, Arc
Time, and Model Type settings are
not affected by the system reset.
4\
>Process
Sequence
4
Reset
1
VoItag~
(Default) Displays
r
2
>Prg
Pul
Side Panel
Parameter
Select
1
se
DualSchd
035 Stee
Card
Argon
I
Oxy
I
~ffl3
Re:
I
~
Side Panel
Parameter
Select
Figure
13-18.
Selecting Voltage
13-18.
Resetting Memory
Error Shutdown
Shutdown
Display
With Arc StartNolt Sense on, the
unit shuts down when no arc volt
age is sensed. It the unit shuts
down, an error message appears
(see Section 14-4).
With Arc StartNolt Sense off, the
unit continues to feed wire even
when
there
is
no
arc
sensed.
Increase
-~-~VoI
~
Figure
OM-1586
Page
64
13-19.
Voltage Shutdown Display
Ar
S t
c
t
~>Qff
a
r
t
/
Sense
voltage
13-19.
Selecting Program
Name Feature
1
Name
When
Display
program card is used, the
programs written from the unit to
a
the card
can
be named.
~~Programs
Ca
r
d
Increase
Figure
13-20.
13-20.
Naming
Card
Programs
Software Version Number
1
Example Version
Number
Display
When
talking with service person
nel. this number may be required.
(Check actual unit display for num
ber.) The factory keeps this
ber
on
num
file with the serial number of
the unit.
Figure
13-21. Version Number
Display
OM-1 586
Page
65
MAINTENANCE & TROUBLESHOOTING
SECTION 14
a
WARNING
ELECTRIC SHOCK
can
HOT PARTS
kill.
Do not touch live electrical parts.
Turn Off wire feeder and
disconnect
maintaining,
welding
Allow
power
before
input
power
servicing.
source,
can cause severe
cooling period
before
burns.
servicing gun
or
unit.
and
inspecting.
or
MOVING PARTS
Keep
away from
Keep
away from
can cause
injury.
Maintenance
moving parts
to
be
performed
only by qualified
persons.
pinch points
such
as
drive rolls.
wfwarn4.1 8/92
14-1. Routine Maintenance
6 Months
3 Months
Off all power before
a Turn
taining.
main
Tape Or
Blow Out
Or
Vacuum
Cable
--
Clean
Drive
Rolls
Replace
Cracked
Parts
14-P~i Cord
a,
&
Gas Hose
Figure
OM-1586
Page
66
Inside
Gun Cable
14-1. Maintenance Schedule
14-2.
Replacing The
Hub
Assembly
READ SAFETY BLOCKS at start of
Section 14 before proceeding.
Turn Off wire feeder and welding
power source. Retract wire onto
Spool and
as
1
Retaining Ring
2
Nut
3
Flat Washer
4
Spring
5
Keyed
9
6
65
remove.
Take hub apart
shown.
Washer
6
Fiber Washer
7
Brake Washer
8
Hub
9
Hub
3
2
Support Shaft
Replace
slide
worn or
parts
broken parts, and
shaft in order
onto
Shown.
Tools Needed:
Tighten
hex nut until
a
slight force
is needed to turn hub, Install weld
ing wire (see Section 3-11).
15/l6in
ST-142 709
Figure
14-2. Hub
Assembly
14-3. Overload Protection
READ SAFETY BLOCKS at start of
Section 14 before proceeding.
Turn Off wire feeder and welding
power source.
1
Circuit Breaker CB1
CB1 protects the wire feeder motor
from overload. If CB1 trips, the wire
feeder shuts down. Check for
jammed wire, binding drive gear.
misaligned
drive
or
rolls.
Correct
and
manually
probtem.
Allow
cooling period
reset breaker.
Ref 5T.157 433A
Figure
14-3. Circuit Breaker CB1
OM-1586
Page
67
14-4. Error
Displays
Release
1
Trigger
Error
Display
This appears if the trigger is closed
when the unit power is turned on, or
if the
R
e
I
T
r
i
trigger
is stuck
or
defective.
2
No Volt Sensed Error
The
arc
Display
eas
e
voltage sense circuit is not
receiving feedback. Check voltage
sensing connections. Check con
nections at 17-position plugs/re
ceptacles at the unit and welding
gge
r
Turn unit off and back
power
source.
on
after
cor
recting problem.
2
If
this
error
continues
to
occur
when
No
S
pulse welding, it may help to
select Hot Start (see Section 13-9).
Volt
ens
ed
Er
3
ror
Memory
CRC Error
Display
The data in the program indicated
is not the same data that was
3
saved.
Memory
CRC
Prg
Perform
Error
4
a
system
reset.
Memory Range
Error
Display
The data in the program indicated
is out of usable range.
4
N
Go
Memo
r
y
Range
through pulse parameters to
sure they do not exceed set
tings of the Range display (see
Prg
Er
make
0
r
r
Section 13-4 and Section 7)
form
5
5
N
S
o
ed
system
or
per
reset.
No Tach Sensed Error
Display
Tach
ens
a
Er
The motor tach feedback is not
reaching the control. Check con
ror
nections.
6
\\
Press
front
Select to clear
Arc
6
Start
Er
ror
panel
Parameter
error.
Arc Start Error
Display
This appears when pulse welding
and current is detected but the arc
7
cannot be started. Check and cor
Arc
Stop
program pulse parameters
voltage settings. Check volt
age sensing connections.
rect
~Error
and
Press
froht
panel
Select to clear error.
7
Arc
Parameter
Stop Error Display
This appears when pulse welding
and the motor does not stop at the
end of the weld. If there is high fre
quency being used in the area, turn
it off. A motor brake circuit problem
can
also
Press
cause
front
Select to clear
this
error.
panel
Parameter
error.
Ret 5T.155 222
Figure
OM-1586
Page
68
14-4. Error
Displays
14-5.
Diagnostic
a
Indicator LEDs
WARNING
___
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Turn Off wire feeder and
welding
power
source, and
disconnect input power before
inspecting
maintaining.
or
Turn Off wire feeder and
power
source.
There
are
welding
Remove wrapper.
nine LEDs
on
Interface
Board PC5O. These LEDs
used
check
to
certain
can
be
functions
during troubleshooting.
LEDs 1
through 5 should all be on
applied to the wire
when power is
feeder.
1
LED1
Indicates +15 VDC with respect to
PS common on the board.
2
LED2
Indicates 15
PS common
3
LED3
Indicates
+
15 VDC with respect to
circuit board
4
VDC with respect to
the board.
on
common.
LED4
Indicates 15
VDC with respect to
circuit board common.
5
LED5
Indicates +5 VDC with respect to
circuit board
6
common.
LED6
On when the contactor is not
ener
gized.
7
LED7
On when the CV mode is used.
8
LED8
On when the gas valve is not
ener
gized.
9
LED9
On when the wire feed motor is not
running.
N
Tools Needed:
cIII:II:::~J=:==1J
1/4 in
STi 57 480A / ST.l 57363
Figure
14-5. Indicator LEDs
OM-1586
Page
69
14-6.
Troubleshooting
A~
WARNING
ELECTRIC SHOCK
can
Do not touch live electrical
HOT PARTS
kill.
Allow
parts.
can cause severe
cooling period
before
burns.
servicing gun
or
unit.
Turn Off wire feeder and welding power source, and
disconnect
input power before inspecting,
maintaining,
or
servicing.
MOVING PARTS
can cause
Injury.
shooting
Keep away from moving parts.
to be
performed only by qualified
~.
Keep away from pinch points such
as
drive rolls.
Table 14-1.
wfwarn4. 1 8/92
Troubleshooting
Section
Remedy
Trouble
Wire feeds, shielding gas flows, but
electrode wire is not energized.
~-s~
]
Checkinterconnectingcordconnections.lfsecure,checkcordfor
continuity and repair or replace.
~-.
I
3-8
_____________
Wire feeder is on, meter(s) do not light
up, motor does not run, gas valve and
welding power
pull in.
source contactor
Electrode wire feeding stops
erratically during welding.
or
J.
Check and reset CB1.
do not
feeds
I
-~
Check gun trigger connection.
-~
Check gun trigger.
-
-S
-
-S
3-13
-
-S
3-11 C
3-6
I
Readjust drive
roll pressure.
Readjust hub tension.
Change
Clean
or
to correct size drive roll.
replace dirty
Incorrect size
Replace
or worn
contact
tip
or worn
wire
or
*
3-5B
--S
drive roll.
guides.
-
-S
3-5B
-
-ł
3-5A
*
liner.
Remove weld spatter
or
foreign
matter from
around nozzle
*
--S
opening.
Have Factory Authorized Service Station/Service Distributor
check drive motor or motor control board PCi.
runs
j
slowly.
Wiredoesnotfeeduntiltriggerispulled,
but continues to feed after trigger is released, and trigger hold is not on.
Gas valve in feeder is rattling
along with possible
feed speed.
erratic
or
loudly
-~
j-s..
J.
Unit does not switch out of Run-In
~
i
}
voltage
Check for a short between welding gun trigger leads and weld
cable. Repair short or replace welding gun.
-~
slow wire
Speed.
Check for correct input
-0
Check for a short between welding gun trigger leads and weld
cable. Repair short or replace welding gun.
Install, reconnect,
or
-S
-
I
1-S
1
I
replace voltage sensing lead.
-
.-ł
-ł
3-8
I
____________
Wire feeder power is on, displays
up, but unit is inoperative.
light
i
]
-0
Check
welding gun trigger leads for continuity,
replace gun.
and
repair leads or
~
-ł
I
_____________
*See gun Owners
OM-1586
Page
70
Manual.
NOTES
OM-1586
Page
71
SECTION 15
ELECTRICAL DIAGRAMS
I
CONNECTION
FOP
PP~12RAM
SEE
DSPL2
DISPLAT
FIELD
0
C
REMOTE
SELECT
INNTPL~TI12A)
B
A
CON
6
6
5
6
SIDE
I
iooso
I
DATA
CAPO
)
6
6
6
2
3
4
PCIOO-I~
PCIOO
PC
PPS-B
BOARD
INCREMENT
I
DECREMENT
00-2
FILTER
PC1003>)
RCIOO/PLOIOO
PCIOI/PLOIOI
PCIOO-6
-~____________________________
________________
I~&~
AA~AR~
PARAMETER
SELECT
V~V~V~V
PC3N
.~.e____~9,.>
0
PC3N
VVVVVV.~f~
PARAMETER
MODE
SELECT
0
PB3I
SELECT
_______
BC36
~
RC3N
.~> PC3N
LI
_______________
a
__________________
RC36
PC36
AOLD
PURSE
~
IC
PC36
UT
RC33
PC36
5C36
PC
30
RC29
0
0
PB23
0
0
P522
PC3I
9~> PC36
COMM0N,~
________
IS
~
RC2O
.100
CABLE
RC37
RC2A
~
~
P821
) RC37
PC32
RC22
C~OJCTOP
J
~COOLANT
..ID(TACAACPT
IPLOBI
M~.
IA>
eu
k~i
FLOW
1
SWITCk
~L
PLOB3
ocw
I
~
3>_____?.I I3>PA~O
PC23
1>
PC2O
4
PC24/Pt024
SC
_________
MICROPROCESSOR BOARD
0
PCIS/RLOIO
PCII PLO
~D)I3>3
RC2S/PLO2S
>>~
PCI
II
API)
PCI
PCI 5/PLO IS
PCI I
RCI6/PLOI6
PC II
PCI 7/PLO 17
PCI1
5C27>
PC2I>
~
I
&K
)
___________________
Pt023
I
1
I
I>_I
________
_vv
L
~~II~I~I
U
PTCSEP
2 ~II~ -~I ~I
vv_
DECREMENT
______
I>I~II~I
I... 101.11
1>1
I~I
r
1
USED
I
O.E.i
OPTICAL
ENCODER
OP
In
~In
I
o
AtTN SWII10ARC
DETAC~MAENT
OPTION
-~
no
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:
I
(
~
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o
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d2~~-(2E-~-?.2>~-<I2(
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I
I
I
_______
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ANT
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I
3
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C
U
OM-1586
Page
72
2
I
~
15-1. Circuit
/0
70
BL~II~I~I
9
~
&M
a
I
PLGS7/PLO5B
Figure
I
PCI
>2>2
~
PLG2B
-
BCI1
II
Al.
i-8~
RCI2/Pt.O12
______________________________
2>
I
RC26
0
-
,
rr~
SWDCARC
L~
CI~
PC
LED
d
:2S~
_________
CABLE
I~o~
11131920
~&&&&
34
CONDUCTOR
CABLE
CABLE
RC3b
U.
II
5
.~
I
0
L~2
~AAAAAAAAAAA~
TPIGGER
5C36
D.C
d~.
~
PC36
0.
-UT
Diagram
For Wire Feeder
IA
C~~~TOR
CABLE
/
~~1
RE NSTE
PENOANT
I
RPS-8
(OPTION)
~ciio
I
595-8
SWITCH BOARD
I
901 IO/PLGIIO
I
I
1SHIELO
PE~0
I
S
z<PcIIo-4
I
I
~
95(10-3
~
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I
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I
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I
I
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I
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DV
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CURPENT
FEEDBACK
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I
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(IV/IOV)
>
F
>
c
>
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IM>~
>
CCEPCT
TO POWEP
SOURCE
M
-
~
124VCV1
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rUGED
RC5A/PLDSA
8C65/PLGS5
.
PCS2-
~
SENSE
<<9562-7
8C84
<<RC82-8
PCB3
RC69-
(0 5056-7
Dr.fl_)
0
A)
~_~__.
(<9C62-K
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a
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A)
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A)
A)
A)
A)
A)
)
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>8
>~8~)~
ONIVE ASS?
PICK-UP
I
SENSE
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I
PC8O
SI
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-
K)
OPTION
c
COIM.AAND
FlUTES
A)
Ic
960
RCS3-2>~
A)
SWINOSPC
C
SENSE
PCD3-3
K)
WITH
DETACI+ENT
10~~
RCS.3/PLGS3
<~ RCDS-2
I
(OPTIONAL)
FIELD INSTAUGTIONS)
<<RC8O-pO
8052/Pt.G02
Pd
(SEE
<<9582-3
< ~
~<<5C55-6
CURRENT
PCS I/PIGS I
pCS5-8
~
SENSE
SENSON
(
I
I/IOV
CURRENT
WELD CURRENT
PIG7O
L
INTERFACE
RCDO/PL 000
A)
(24V-CVI
RC8I-G>
PC5O
/1
IS
>
CC/CV
<<RCB2-
15V
__
PIN
~PENI FEE~A~
< 5C55-4
~
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COI~A
PIN
r
CC/C
/0
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7
50
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GHD
17
.3:5
2
-
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BOARD
RCS2PL082
6C89/PL075
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o
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BCBO>HF
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I
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r
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I
9109
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TRIGGER
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4
COI4~N
059
E
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H
P.S.
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RC6-I
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MOTOR
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I
BOARD
I
CCE$SCT
POWER
SOLURCE
BCI/PLGI
TO
B02/PLD2
7
<< RCA-K
(< RCA-A
Pt3/PLG3
PCI /PLG4
PC5/PLGS
P06/PICA
I
I
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1~~~I
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I
L
<< 503-4
<< 9C3-2
SD-I64 705A
OM-1586
Page
73
I
I
I
I
II
I
PC2O
FRONT DISPLAY
PC
MOTOR BOARD
Figure
OM-1586
Page
74
15-2.
Wiring Diagram
For Wire Feeder
I
00 >> ~4 0>
en
10
C,
~,
0
-
F.
I1~
_ ~ i_V
~ 0 0 (801? -10
-
0 P1
6C41/PLI
cJ~
_
IOG(PCB- 6C851
I
_
63A(PL&0- 62(PLGO- 61(PLGO-I 2~BB~
1111
00 rn0- -
RCIO/PLG
18 ID 0 2
I
0~
180 ni_I (-U
0 10 A,
-4 0
(l4A(PLC5-2)I16(PLG5-3j~IOE(PLCS5-4
_-
0
U)
I
I
l~~1
-AC
IC(SRI
26
PC87 RC84
D0
RI
RCB3 ~ ~_.
~88
,~J I
~
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(EXIT)
(RC7-8)
418
LEAD
SCI SE
BLAO<1P69-)
-AC)
0
-~
IJAE(PLG9-D BLIE(PG9-) PLG9-C)
P1 <)
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;tj
00 en0- :
2
662
0
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L148PG5-6L158P6 -7(
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-7
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(_ I4BPLGI
I
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C,
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(A
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n (A 0
LjDBPGI-71(
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SECTION 16
PARTS LIST
C
U,
0~
Os
7
/
c~4
(0
C,
Li~
LU
.0
E
0
CO
C,
Ll~
CO
4
C
Co
(0
t-
C
0,
0
a)
04
04
0
Cd
C,
(0
C,
U-
04
E
CE)
C)
U,
C,
Cd
U,
a)
U
C
C)
EL,
C)
to
C,
C
C)
/8
Er,
C)
0,
C,
4
(0
C,
U-
OM-1586
Page
76
Quantity
Item
No.
Model
Part
No.
Dia.
Mkgs.
Description
Figure
1
149 251
1
149 252
079 878
PLG23
.
.
..
.
PLG28
.
.
.
CONNECTOR & PINS, (consisting of)
CONNECTOR. circ pin push-in 18-l4ga Amp 66359-6
CONNECTOR. circ clamp str rlf sz 11 Amp 206358-2
CABLE, port No. 184/c (order by if)
CONNECTOR w,SOCKETS. free hanging (consisting of)
CONNECTOR. circ skt push-in 24-l8ga Amp 66358-6
CONTROL BOX. (Fig 16-3)
2
3
PLG37,38
.
079 531
.
.
.
605 156
.
.
.
.
.
.
080 328
079 534
See Note
164 475
164 474
047 636
079 535
079 739
163519
139 600
4
4
6
7
.
.
.
.
.
.
.
.
.
.
.
.
.
.
010 606
.
.
.
243
.
.
.
.
.
.
.
.
.
.
.
.
.
9
601 872
.
.
10
080 157
.
.
11
132 053
12
Fig
16-2
13
149
838
..
13
149
839
..
13
078
264
..
13
079
216
..
14
075
078
..
14
079217
Fig 16-5
047 637
17
.
PLG33
.
135 409
114 656
18... PLG7
19
GS1
20...
..
.
.
115 092
..
113 746
.
.
605 227
.
.
125 785
.
.
..
24
145 639
..
156 354
.
156 353
..
Ml
Ml
.
.
.
.
4
153 491
153 492
153 493
155 098
153 550
155 099
155 100
154031
133493
.
..
..
.
.
.
..
.
.
14
.2.
.2
l7ft
.
2lft
.
1
.2
.2
.
26ft
.
2
3Oft
.
26ft
.
.
.
.
.
.
.
2
30ft
..
1
-
.1
.8
.4
.4
.1
x
1.500
.4
Ig
.1
1
or
1
1
or
PIPE POST, 4ft w/o base
..
159 360
.
.2
14.
PIPE POST, 6ft w/base
..
156243
...
.2.
2
PIPE POST, 4ft w/base
23
.
.4
2
PIPE POST, 6ft w/base
22
.
4
.
PIPE POST, Mt w/base
139 265
25
21ft
1
SUPPORT, hub & reel
..
.
.2
.
SCREW, cap stl hexhd .375-16
..
.
2
l7ft
NUT, stl hex full .375-16
FITTING, grease 1/8NPT
21
25.
.
..
.
079 534
.
CABLE, weld cop strd No. 4/0 (order by if)
BRACKET, spring retaining
BRACKET, spring retaining
WASHER, fIat stl std .375
WASHER, lock stl split .375
602 213
16... RC37
.
.
884
947
CONNECTOR & PINS. (consisting of)
CONNECTOR. circ pin push-in 18-1 4ga Amp 66359-6
CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2
CABLE, port No. 18/148/c (order by if)
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
.
.
324
1
4
CABLE, interconnecting (consisting of)
CABLE, interconnecting (consisting of)
.
.
8
15
.
139 599
600
149
080
602
6
.
010 603
603 106
056 112
5
.
..
.
1
.
.
079 535
16
Assembly
CABLE, trigger (consisting of)
CABLE, trigger (consisting of)
..
.
16-1. Main
I
12
.1
1
.1
PIPEPOST,6ftw/obase
1
.1
BOOM ASSEMBLY
CONNECTOR & SOCKETS.
1
.1
1
.1
or
(consisting of)
CONNECTOR, circ skt 14-l8ga Amp 66358-6
CONNECTOR & PINS, (consisting of)
CONNECTOR, rect pin 24-l8ga Molex 39-00-0040
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
NUT, nyl hex jam .75ONPST
.
14.
1
.
.8
.
.8
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
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
.
.
14
....
1
....1
...1
.4
.4
...1
....1
1
1
1
1
1
2
2
KIT, cover motor gear box (consisting of)
COVER, motor gear box (consisting of)
1
GASKET, cover motor gear box
SCREW, cover motor gear box
SPACER, locating
RING, rtngext .25oshaftgrvx.O25thk
1
1
1
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
2
2
1
1
1
5
.
2
.
1
OM-1586
5
2
1
Page
77
Quantity
Model
Part
No.
Dia.
Item
No.
Mkgs.
Description
Figure
153 631
27..
PLG57...
131 204
113 746
28
132 611
29
Fig
30
157 295
604 612
31
32
33..
PLG58...
16-4
082 050
131 203
114 656
159 646
159 647
34
35
Note: When
ordering Control
16-1. Main
12
Assembly (Continued)
CIRCUIT CARD, digital tach (consisting of)
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-1 8ga Molex 39-00-0038
OPTICAL ENCODER DISC
WIRE DRIVE ASSEMBLY
GUIDE, monocoil
SCREW, set stl sch 8-32 x .125 cup point
LINER, monocoil inlet wire
CONNECTOR & PINS, (consisting of)
CONNECTOR, rect pin 24-l8ga Molex 39-00-0040
CLAMP, motor base
INSULATOR, motor clamp
Box contact
factory
service
.3.3
department for proper number.
OPTIONAL
Part
of Option 132 129
High Speed
Motor SIR.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1586
Page
78
16
Part
No.
Descnption
Quantity
-
Item
No.
Figure
1
...
.
3
....
.
.
.
.
4
.
.
.
010 191
.
058 628
..
058 428
.
.
.
.
108
008
Support.
SUPPORT, reel
WASHER. fbr .656 ID
WASHER. brake stl
142 399..
.
2
16-2.
.
Hub & Reel
(Fig
16-1 Item
12)
1
x
1.500 OD
x
.l25thk
2
2
HUB, spool
1
REEL, wire 60 lb (consisting of)
SUPPORT, reel spool
RETAINER, spool support
NUT, spanner spooi support
WASHER, flat stl keyed 1.500dia
1
5
.
.
.
6
.
.
..
124 900
....
1
....
124 905
....
1
124 904
.
.
.
.
7
8
9
.
.
.
.
.
.
.
.
057 971
.
10....
010233..
SPRING,cprsn .9700Dx
11
605 941
WASHER, flat stl .640 ID
12
13
.
...
.
.
.
.
.
.
.
.
..
136684
.
.
058 427
.
.
1
.
x
.l25thk
1
.l2Owirex 1.250
1
x 1.000 OD x l4ga thk
NUT, stl slflkg hex reg .625-11 w/nylon insert
RING, retaining spool
1
1
1
2
3
5
9
10
11
12
13
SC.146 339
Figure
16-2.
Support,
Hub & Reel
OPTIONAL
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1586 Page 79
0
0
to
(0
cJ
N.
cJ
x
0
0
I
0
C-)
cJ
0
I
U,
U-
0
C.,
U,
(0
OM-1586
Page
80
Dia.
Item
No.
Mkgs.
Part
No.
Description
Figure
.2...
.3...
PC4O....
.4...
PLG16,41
.5...
PC6O....
PLG6O
.6...
.8...
.9...
10
PLG17
11
12
...
...
PLG1O,24
PLG12,50
14
15
16
17
18
19
.20
.21
.22
SRi
CB1
Si
.23
.24
.25
26
27
28
..
PC8O, RC81
R80....
PLG75
PLG82
29
30
31
32
PLG9....
2)
TAPE, adh acrylic double sided .010
METER LENS, w/gasket
STAND-OFF, No. 6-32 x .875 Ig
CIRCUIT CARD, schd side
CABLE, ribbon 24posn 6.000 in
CIRCUIT CARD, cyber card
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-l8ga Amp 770904-3
CONNECTOR w/SOCKETS, (consisting of)
155 023..
156 623..
153501
147 995..
113746..
153501
147995..
.115093..
113746..
155 022..
155 629..
126 689..
097132..
138 044..
600 399..
13
16-1 Item
164 842..
144 844..
158160..
048 282..
079 534..
079 532..
079 535..
079531
154938..
163917..
PC5O...
PLG51
158720..
147995..
PLG52
158719..
147995..
PLG53
131204..
.i13746..
PLG54
148439..
147995..
PLG55
115092..
113746..
PCi0...
164713..
PLG11
115092..
PLG15
(Fig
147 139..
RC7O....
.7...
16-3. Control Box
Quantity
603106..
601 222..
151 187..
134 464..
+154927..
155261
035704..
083 432..
x
.500
x
3.000
4
2
14
1
1
1
1
6
1
CONNECTOR, circ skt push-in 24-i Bga Amp 66358-6
CONNECTOR, circ 4 pin Amp 211882-i
CONNECTOR, circ pin push-in 18-1 4ga Amp 66359-6
CONNECTOR, circ clamp str rlf Amp 206358-2
STRIP, mtg PC card
CIRCUITCARD, interface
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-1 Bga Amp 770904-3
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-1 8ga Amp 770904-3
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-1 8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-1 8ga Amp 770904-3
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-i 8ga Molex 39-00-0038
CIRCUIT CARD, processor w/proms
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-i 8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-l8ga Amp 770904-3
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CABLE, ribbon 34posn 12.000 in
CABLE, ribbon i4posn 3.000 in
STAND-OFF, No. 6-32 x 1.500 Ig
STAND-OFF, No. 6-32 x .375 Ig
BUSHING, strain relief .120/.150 ID x .500mtg hole
WIRE, strd l4ga bik 600V iO5C (order by ft)
HOSE, nprn brd No. 1 x .250 ID (order by ft)
CLAMP, univ 50A
LATCH, slide flush mtg hole 1.000 wide x 1.500 lg
LABEL, warning general precautionary
4
1
1
1
12
1
2
1
3
1
10
1
8
1
1
8
1
6
1
6
1
1
4
4
1
35ff
1ff
1
1
1
WRAPPER
PANEL, side lower
1
1
RECTIFIER, integ 40A 800V
CIRCUIT BREAKER, man reset 1P 1OA 250V
111 997.. SWITCH, rocker SPST 1 OA 25OVAC
000 527.. BLANK, snap-in nyl .875mtg hole
073 756.. STAND-OFF, No. 6-32 x .625 Ig
164 709.. CIRCUIT CARD, HF filter (consisting of)
164 708..
RESISTOR, w/terminals
131 204.. CONNECTOR & SOCKETS, (consisting of)
113746..
CONNECTOR, rect skt 24-i 8ga Molex 39-00-0038
158 720.. CONNECTOR & SOCKETS, (consisting of)
147995..
CONNECTOR, rect skt 22-l8ga Amp 770904-3
010325.. BUSHING, strain relief .840 ID x .875mtg hole
163519.. CABLE, port No. 18/14 8/c (order by ft)
141 162.. CONNECTOR & PINS, (consisting of)
134731
CONNECTOR, circ pin push-in 18-l4ga Amp 213603-1
079739.... CONNECTOR, circ clamp str rlf sz 17 & 20 Amp 206322-2
1
1
1
1
4
1
1
1
12
1
l2ft
1
14
OM-1586
Page
81
Item
No.
Part
No.
Dia.
Mkgs.
Description
Figure
33
PLG19
PLG1O3..
135635
.
35
RC4O...
079 534
048144
37
134201
...PC1...
155114
PLG1...
115092
113746
PLG2...
16-1 Item
2) (Continued)
CONNECTOR, rect pin 24-l8ga Molex 39-00-0040
CONNECTOR & SOCKETS, (consisting of)
114656
047 637
36
(Fig
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR. rect skt 22-l8ga Amp 770904-3
CONNECTOR & PINS, (consisting of)
158719
147995
34
16-3. Control Box
Quantity
115093
1
2
1
2
1
CONNECTOR, circ skt push-in 24-l8ga Amp 66358-6
CONNECTOR, circ pin plug keying in sockets Amp 200821 -1
STAND-OFF SUPPORT, PC card .312/.375
CIRCUIT CARD, motor control
CONNECTOR & SOCKETS. (consisting of)
14
CONNECTOR. rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
8
6
2
8
1
I
1
40
158702
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS. (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS. (consisting of)
CONNECTOR. rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR. rect skt 20-l4ga Amp 350536-1
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR. rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR. rect pin 24-1 8ga Molex 39-00-0040
CASE SECTION, bottom/rear
41
145948
BRACKET, mtg control box
1
PC2O,30
158104
CIRCUIT CARD. schd front
1
PLG25
164899
CONNECTOR & SOCKETS,
147995
CONNECTOR, rect skt 22-l8ga Amp 770904-3
PANEL, front
WASHER, shldr delrin .257 ID x .500 OD x .343 x .187 shldr
KNOB, pointer
ACTUATOR, switch
LENS, LED 4341 red
NAMEPLATE, (order by model and serial number)
BUSHING, snap-in nyl .750 ID x 1 .000mtg hole
PANEL, inner control
PLATE, ident inner control
CLIP, component .437dia mtg adh back
4
CABLE, interconnecting (consisting of)
CONNECTOR, circ l7skt Amphenol MS-3106A-20-29S
CONNECTOR. circ clamp str rlf sz 20-22 Amphenol MS-3057-1012
CABLE, port No. 16 5/c (order by ft)
CONNECTOR, circ 17 pin Amphenol MS-3106A-20-29P
1
113 746
PLG3...
.115094
.
PLG4...
113746
115091
113746
PLG6...
136810
.114066
38
PLG39
115092
113746
39
...RC7...
135409
114656
42
43
154932
44
.157113
45
097 924
46
153169
47
089 032
48
.
49
030170
50
154933
51
154109
059712
158373
097 868
116964
600 343
097 866
+When
ordering
a
component originally displaying
a
(consisting of)
precautionary label,
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1586
Page
82
1
4
1
10
1
4
1
8
1
8
1
1
1
1
1
8
1
1
1
1
1
2
1
2
lOft
1
Part
No.
Description
Figure
16-4. Wire Drive
Assembly (Fig
16-1 Item
-
~
-
-
Quantity
-
Item
No.
29)
1 .500
....
010668..
SCREW, cap stl sch .250-20
2
150147..
3
....
149962..
CARRIER. drive roll w/components
SPACER, carrier drive roll
4
....
149486..
....
132750..
PIN, rotation arm rocker
ARM, pressure
SPACER, rotation pin
RING, retaining ext .250 shaft x .O25thk
PIN, hinge
KNOB, w/extension
WASHER, flat buna .375 ID x .625 OD x .O62thk
SHAFT, spring
2
....
PIN, spring cs .093 x .625
CARRIER, shaft
BUSHING, spring
SPRING, cprsn .724 OD x .082 wire x 1 .000
SPRING, indicator
WASHER, flat sti SAE No. 8
WASHER, lock stl split No. 8
SCREW, mach stl rdh 8-32 x .500
SPACER, locating
DRIVE, pinion
RING, retaining ext .375 shaft x .025 thk
HOSE, SAE .187 ID x .410 OD (order by ft)
FITTING, brs barbed M 3/l6tbg x .312-24
1
1
4
5
6
7
....
150520..
....
133493..
.
133350..
152241
10....
133739..
11....
132824..
12....
010837..
132747..
8
....
9
.
.
.
13....
16....
132746..
133603..
137248..
17....
604772..
18....
602200..
19....
602082..
154031..
133530..
133308..
134834..
149959..
149746..
108940..
604538..
151437..
14....
15....
20....
21....
22....
23....
24....
.25....
26....
27....
28....
29....
30....
.31....
32....
33....
34....
35....
See Table 16-1,
151290..
149527..
601872..
602213..
602243..
149964..
601966..
Page
x
4
4
2
2
2
1
1
1
2
2
1
1
1
1
.2
2ft
ADAPTER, gun/feeder LH
SCREW, cap stl hexhd .250-20 x .750
WASHER, flat stl SAE .312
KNOB, plstcT 1.125 lg x .312-18 x 1.500
SCREW, mach stl hexwhd 10-32
COVER, drive roll
x
.500
NUT, stl hex full fnsh .375-16
WASHER, lock stl split .375
WASHER, flat stl std .375
PIN, groove type H .25Odia x .500 Ig
SCREW, cap stl hexhd .375-16 x 1.250
.
9
82
For Drive Roll &
Wire Drive Kits
7
8
13
17
18
19
6
34
27
2
SC-137 222O
Figure
16-4. Wire Drive
Assembly
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1586
Page
83
0
0
0)
(0
~
0)0
>
a,
E
w
Cl)
4
0
(d
E
U,
cJ
a
0
\\
cJ
w
C)
(0
c.J
(\1
,~-~-~--- ~j
/
/
OM-1586
Page
84
LL
Quantity
Model
Part
No.
Item
No.
Description
Figure
1
.057357..
2...
159991..
2.159989..
3.079665..
.3.080811..
4.079664..
5.139633..
6.073742..
.7.073741..
8...
079029..
9...
075462..
10...
11
...
16-5. Boom
Assembly (Fig
.
149858..
150258..
14...
024605..
15...
075101
16...
079030..
+139831
080157
18...
142804..
19...
134327..
20...
602246..
21
047224
...
22...
073666..
23...
079667..
23...
080812..
24...
079632..
25...
602243..
26...
139590..
27...
010313..
.28...
139336..
+When
ordering
a
1... .1
1
.1
1
1
...1
1
1
2
.2
1
1
x
.625 wire
x
36.000
x
.687 wire
x
33.750
x
1
.625
.1
precautionary label,
1
.1
1
.1
1
.1
1
.1
1
.1
.1
SCREW, mach stl hexhd .750-16 x 2.750
PIPE, plstc .500 x 133.750
PIPE, plstc .500 x 181.750
BOLT, U stl .250-20 x .875 wide x 1 .375 deep
WASHER, flat stl std .375
PULLEY, V sgl grv 8.875dia x 8.000P x .375 bore
PIN, cotter hair .072 x 1.437
GUARD, motor protector
a
....1
2
RETAINER, spring
BEARING, ball thr sgl row .750 x 1 .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
LABEL, Swingarc caution heavy spring
LABEL, warning general precautionary
WASHER, flat sti std .500
KNOB, T-bar .500-13 thd
component originally displaying
16
15)
602250.. WASHER, flat stl SAE .750
079020
NUT, stl hex elastic stop .750-16
13...
17..
16-1 Item
BUSHING, snap-in nyl .93710 x 1.l25mtg 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
SPRING, cprsn 3.750 OD
12... 080723.. SPRING, cprsn 3.750 OD
12...
12
1
.1
1
.1
1
.1
1
.1
1
.1
1
.1
.4... .5
4
.4
1
2
1
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1586 Page 85
Table 16-1. Drive Roll & Wire Guide Kits
G,
~
Wire Size
E~
~
V-GROOVE
~
VK-GROOVE
UC-GROOVE
4 Roll
4 Roll
Drive
4 Roll
Kit
Roll
Kit
Drive
Roll
053700
151 036
072000
151 052
132958
151 027
053697
151 037
053701
151 053
149519
151 028
053698
151 038
053702
150995
149520
151 029
053699
151 039
053706
150995
149520
4 RoIl
Kit
Drive
Roll
149518
151024
087130
150993
149518
151025
053695
0.9mm
150993
149518
151 026
.045in.
1.1mm
150994
149519
.052in.
1.3mm
150994
1.6mm
1.8mm
~
Fraction
Metric
.023-.025in
0.6mm
150993
.030in.
0.8mm
.035in.
.066-.072in
U-GROOVE
E~
Kit
Drive
Roll
132957
151 070
083489
151 054
132956
151 071
083490
151 055
132955
151 072
053708
151056
132959
.
5/64 in.
(.079in.)
2.0mm
150995
149520
151 040
053704
151 057
132960
151 073
053710
2.4mm
150996
149521
151 041
053703
151 058
132961
151 074
053709
2.8mm
150996
149521
151042
053705
151059
132962
151075
053711
3.2mm
150997
149522
151 043
053707
151 060
132963
151 076
053712
3/32 in.
(.094in.)
(ibm.)
1/8 in.
(.1253n.)
S-0549-C
Each Kit Contains An Inlet Guide, Intermediate Guide, And 045 233 Antiwear Guide With 604612 Setscrew 8-32
With 4 Drive Rolls.
2 Kits
Required For Dual Models.
OM-1586
Page
86
x
.125, Along
OPTIONS AND ACCESSORIES
EXTENSION CORDS
WATER HOSE KITS
decrease feature available in the
(Optional)
For
60M control. The
Note: For
systems and Miller
exceed
optimum performance, do not
60 ft. (18 m) between the power
GWwatercooled
source
and 60M control.
with Miller coolant
use
used with
optional
EXTENSION CORDS
14PIN
(7.6 m)
50 ft. (15 m)
guns. Can be
water flow
WIRE REEL ASSEMBLY
safety
(#108 008)
switch.
For SS64M
For 60 lb. (27
(12) model
(#159 288)
(7 m)
Can be added to the standard 10
25 ft.
(#042 120)
(16)
Designed for use with 6 ft. (1 .8 m)
pipe post only. Replaces the
standard spool assembly, allowing
the spools or coils of wire to be
positioned lower for easier loading
and unloading. Not recommended
(#159 289)
(8.2 m)
Can be added to the standard 10
ft. (3 m) cord. Two 25 ft. cords can
be used
(15 m)
together
to make a 50 ft.
extension.
DUAL SCHEDULE
SWITCHES
For
use
with
Swingarc
system mounted
on
feeder
CBC cart.
feature in the 60M control
LOW- AND HIGHSPEED
DSS8
MOTORS
Factory
for
with dual schedule
use
only)
model
27 ft.
(7.6 m)
075 Field
(#096
For SS64M
EXTENSION CORDS
coil of wire
kg)
ADJUSTABLE SPOOL CARRIER
23 ft.
ft. (3 m) cord.
trigger operates
trigger.
standard gun
without the
or
25 ft.
(#122 973)
(#122 974)
17PIN
as a
only
(#156 725) Lowspeed
The lowspeed motor has a wire
feed speed range of 15 to 210 1PM
(0.4 to 5.3 rn/mm). Not
recommended for wire smaller
than 5/64 in.
(2.0 mm)
diameter.
(#132 129) Highspeed
highspeed motor has a wire
feed speed range of 90 to 1400
1PM (2.3 to 35.6 m/min.). Not
The
recommended for wire sizes
than 5/64 in.
larger
(2.0 mm).
Note: The
factory preprogrammed
synergic pulse GMAW programs are
designed for use with the standard
speed range motor.
WATER COOLANT
(#079 691)
installed
SYSTEMS
For 10 ft. (3 m) gun
(#079 693)
For 15 ft.
A
For
(4.6 m) gun
twoposition trigger switch that
easily
attaches to the
welding gun
and is used in
place of the
standard trigger for dual
scheduling.
Note:
Adapter
cord
to use the DSS8
use
with watercooled
RadiatorlA
(#157 364)
is
guns.
115VAC
(#042 492)
Radiator 1A
115 VAC, 100 Hz
(#042 494)
Radiator 2A
230 VAC
(#042 493)
required
1A
115 VAC
Watermate~ 2A
230 VAC
WatermateT
with the 60M control.
(#042 495)
OS S9 M
(#041 792)
For loft. (3 m) gun
(#04 1 793)
For 15 ft. (4.6 m) gun
(#042 496)
CooImate~ 4
115 VAC
(#042 288)
CooImate~ 4
230 VAC
A
twoposition slide switch that
easily attaches to the welding gun
and is used to select the desired
WATER FLOW SAFETY SWITCH
welding
condition for dual schedule
purposes. The trigger operates
a standard gun trigger.
(#157 835 Factory)
(#157 836 Field)
as
(#042 289)
Refer to Literature Index No.
AY/7.2 for additional coolant
system information.
60M DATA CARD
Protects
a
watercooled
gun from
overheating by interrupting the
circuit and shutting down the
system if water is not present or
water stops flowing to the gun.
Note:
Requires
a
water hose kit.
DSS10 REMOTE INC/DEC
SWITCH
(#042 749)
two-position springloaded
momentary contact switch that
easily attaches to the welding gun
to fine tune parameters remotely
while welding. Used with the
A
remote
(#155 910) Blank card
A userinsertable
memory device
that will hold up to 32 complete
weld programs. It is ideal for
saving custom programs and
transferring programs to other
60M
controls.
parameter increase!
I ~JQ~
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