Miller SS-64M SWINGARC Owner's Manual

Millerfi
January1993
Form:
OM-1586A
Effective With Serial No. KD342492
OWNERS
MANUAL
SS-64M Boom Mounted
Wire Feeder
Miaoprocessor ConPol led Constant Speed Wire Feeder
For Use With Maxtron 450
Welding
Power Source
GMAW, GMAW-P, And FCAW Welding
For
For .023 To 1/8 Inch (0.6 To 3.2 mm) Wires
Standard Wire Feed
Programmable
SpeedOf 5OTo
780 1PM
(1.3To
19.8
MPM)
Pulse Weld Parameters
Give this manual to the operator.
Read and follow these instructions and all
safety blocks carefully.
Have
only trained
install, operate,
or
and qualified persons
service this unit.
Call your distributor if you do not understand
the directions.
cover
8192
ST-157 388
For
f~)
or:
help, call
your distributor
MILLER ELECTRIC
Mfg. Co.,
1079, Appleton, WI 54912
P.O. Box
414-734-9821
PRINTED IN USA
I
I
J
MILLERS
TRUE BLU ElM LIMITED WARRANTY
(Equipment
This limited warranty
with
Effective January 1, 1992
serial number preface of KC
a
supersedes all previous MILLER warranties and is aaclusive with
below, MILLER Electric
Mfg. Co.. Appleton, Wisconsin, warrants to its original retail purchaser that new
MILLER eouipment sold after the effective date of this limited warranty is tree of de
tects in material and workmanship at the time it is shipped by MILLER. THIS WAR
RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT
Subject
LIMITED WARRANTY
to the tarms and conditions
MILLERS
NESS.
the
or
warrantieo expressed
or
implied
Kits
Replacement Fans
Withis the warranty periods listed below, MILLER wilt repair or replace any war
ranted parts or components that fail due to such detects is material or workmanship
MILLER must be notified in writing within thirty (30) days of such detect or failure, at
on
newer)
othar guarantaes
Accessory
I
which time MILLER will provide instructions
no
or
True
eiuenM
Limited
Warranty
shall not
apply
to.
Items furnished
by MILLER. but manufactured by others, ouch as engines or
trade accessories. These items are covered by the manutacturers warranty, if
any.
2.
Consumable components: such
and
warranty claim procedures lobe
as
contact tips,
cutting nozzles.
contactors
relays
followed.
3.
start on the date that the
and are
I.
as
was
delivered to the
original
Plasma Arc
Cutting
Power Sources
Parts and Labor
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the
engine manufacturer.)
TO THE EXTENT PERMtTTEO BY LAW, THE REMEDIES PROVIDED HEREIN
ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE
LIABLE FOR DIRECt INDIRECT SPECIAL, INCIDENTAL OR CONSEOUENTIAL
DAMAGES (INCLUDING LOSS OF PROFIT). WHETHER BASED ON CON
TRACT, TORT OR ANY OTHER LEGAL THEORY.
Pans and Labor
Motor Driven Guns
Process Controllers
Water Coolant
*
Systems
HF Units
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY tMFLIEO WAR
Grids
Spot
*
RANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL
THEORY WHICH, BUT FOR THIS PROVISION. MIGHT ARISE BY IMFLtCATtON,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING. IN
CLUDING ANY IMFLtEO WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR FURFOSE. WITH RESPECT TO ANY AND ALL EOUIFMENT
Welders
*
Load Banks
*
SDX Transformers
*
Running Gear/Trailers
Field Options
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.
(NOTE: Field options are covered under True BtuenM for
warranty period of the product they are installed in, or for
whichever in greater.)
one year
5.
6 Months
B.
90
Days
warranty claim
covered by this warranty, the esclusive remedies
option: (I) repair: or (2) replacement: or, where authorized in
writing by MILLER in appropriate cases, (3) the reasonable cost of repair or replace
ment at an authorized MILLER service station: or (4) payment of or credit for the pur
chase price (less reaaonabie depreciation based upon actual use) upon return ot the
goods at customers risk and eepsnss. MILLERS option of repair or reptecement
will be FOB.. Factory at Appleton, Wisconsin, or FOB. at a MILLER authorized ser
vice facility as determined by MILLER. Therefore no compensation or reimburse
ment br transportation costs of any kind will be allowed.
Robots
2 Years
Year
not had reasonable
shall be, at MILLERS
Semi-Automatic and Automatic Wire Feeders
I
equipment which has
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER
In the event of a
4.
or
Parts and Labor
3 Yearn
*
industry standards,
CIALIINDUSTRIAL USERS AND PERSONS TRAINED AND EXFERtENCED tN
THE USE AND MAINTENANCE OF WELDING EOUIFMENT
main power rectitisrs
Transformer/Rectifier Power Sources
3.
by any party other than MILLER. or equip
improperly installed, improperly operated or misused
and necessary maintenance, or equipment which has been used for operation
outside of the specifications tor the equipment.
3 Years Labor
5 Years Parts
that has been modified
based upon
retail purchaser,
follows:
Original
2.
equipment
Equipment
ment that has been
MILLER shall honor warranty claims on warranted equipment listed below in the
event of such a failure within the warranty time periods. All warranty time periods
the
a
remaining
Some states in the U.S.A. do not allow limitations of how long an implied warranty
lasts, or the exclusion of incidental. indirect. special or consequential demeges, so
minimum ot
the above limitation or escluaion may not apply to you. This warranty orovidea spe
cific legal rights. and other rights may be aveilable, but may vary from state to stete.
Batteries
In
Parts and Labor
or
MIG Guns/TIG Torches
Cutting
*
Plasma
*
Remote Controls
Canada. legislation
in some
remedies other than
as
provinces provides for certain additional werranties
stated herein, and to the extent that
they may
not be
waived, the limitations and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may be available, but may
Torches
vary from
province
to
province.
a~1-
I
RECEIVING-HANDLING
Before
Unpacking eqUipment, check carton for any damage that may have occurred during shipment. File any claims for )oss or damage
delivering carrier. Assistance for filing or settling claims may be obta)ned from distributor and/or equipment manufacturers
Transportation Department.
with the
When
requesting information about this equipment, always provide Model Designation
Use the
or
following
spaces to record Model
Designation
and Serial
or
and Serial
Style Number of your unit.
or
Style
Number.
The information is located
on
the
rating
label
nameplate.
Model
_________
Serial
or
Style
No.
Date of Purchase
miller 5/92
ERRATA SHEET
January 14,
1993
FORM: OM-1586-A
Use above FORM number when
After this manual
to data
appearing
was
printed, refinements
as
Dia.
**First
...
This sheet Ii sts
exceptions
PARTS LIST
follows:
Part
No.
Mkgs.
77-28
equipment design occurred.
extra manuals.
later in this manual.
AMENDMENT TO SECTION 16
Amend Parts List
in
ordering
PC8O,RC8O
...
digit represents page
158 578
no
Replaced
With
...
159 477
Description
..
CIRCUIT CARD, HF filter (Eff
digits following dash represent item
Quantity
w/KD348472)
no.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
1
ARC WELDING SAFETY PRECAUTIONS
WARNING
a
ARC WELDING
be hazardous.
can
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information that will be found in the
Safety Standards listed on the next page. Read and follow all Safety Standards.
INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
HAVE ALL
QUALIFIED PEOPLE.
ELECTRIC SHOCK
can
kill.
live electrical parts can cause fatal shocks
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.
Properly
6.
When
Touching
or
1.
2.
3.
severe
making input connections,
7.
Turn off all
8.
Do not
cables.
equipment
when not in
Disconnect
input power
equipment.
or
stop engine before installing
or
servicing
ARC RAYS can burn eyes and skIn;
NOISE can damage hearIng.
~
or
poorly spliced
Do not wrap cables around your
body.
10.
Ground the
electrical
11.
Do not touch electrode if in contact with the work
12.
only well-maintained equipment.
damaged parts at once.
13.
Wear
a
Keep
all
9.
14.
this
grounding
use.
damaged, undersized,
worn,
use
workpiece
to
good
a
Do not touch live electrical
parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating
attach proper
conductor first.
mats or covers.
4.
install and ground this equipment according to its
Owners Manual and national, state, and local codes.
5.
(earth) ground.
safety
harness if
and
panels
ground.
replace
or
above floor level.
working
covers
or
Repair
Use
securely
in
place.
ARC RAYS
2.
Wear
helmet fitted with
welding
a
a
proper shade of filter
(see
ANSI Z49. 1 listed in
Arc rays from the welding process produce intense
heat and strong ultraviolet rays that can burn eyes
and skin. Noise from some processes can damage
..
hearing.
3.
4.
Safety Standards) to protect your face and
eyes when welding or watching.
Wear approved safety glasses. Side shields recommended.
protective screens or barriers to protect others from flash
glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
Use
and
NOISE
5.
1.
Use
approved
ear
plugs
or ear
muffs if noise level is
FUMES AND GASES
to your health.
I Welding produces fumes
I
these fumes and gases
health.
can
high.
be hazardous
Work in
6.
Do not weld in locations
and gases. Breathing
be hazardous to your
can
£...~.
your head out of the fumes. Do not breathe the fumes.
area and/or use exhaust at the arc to
1.
Keep
2.
If inside, ventilate the
remove
7.
fumes and gases.
welding
If ventilation is poor, use
4.
Read the Material
an
instruction for metals, consumables,
manufacturers
burns. Accidental contact of electrode or welding
wire to metal objects can cause sparks, overheating,
or fire.
and others from
flying sparks
1.
Protect
2.
Do not weld where
3.
Remove all flammables within 35 ft
yourself
flying sparks
can
Watch for fire, and
6.
Be
aware
that
can cause
unless the
fire
keep
welding
on
a
fire
on a
extinguisher nearby.
7.
Do not weld
Connect work cable to the work
practical
possibly
on
closed containers such
prevent welding
to
unknown
paths
and
as
Do not
use
welder to thaw frozen
I
Chipping
and
can
grinding
drums.
electric shock and fire
or
cut off
protective garments such
heavy shirt, cuffless trousers, high shoes,
1.
Wear
approved
face shield
or
as
and
welding
wire at
leather
gloves.
a
safety goggles.
cap.
Side shields
recommended.
injury,
cool, they
or
welding area as
traveling long,
pipes.
Wear oil-free
4
partition
hazards.
9.
11.
FLYING SPARKS AND HOT METAL can
tanks
from
current
causing
possible, tightly cover them with approved covers,
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
cause
as
close to the
Remove stick electrode from holder
contact tip when not in use.
welding
or
the hidden side.
10.
of the
or
is removed from the
ceiling, floor, bulkhead,
arc.
(10.7 m)
galvanized, lead,
as
coating
is well ventilated, and if necessary, while
8.
If this is not
4.
area
5.
and hot metal.
strike flammable material.
coated metals, such
on
plated steel,
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
and cleaners,
can cause fire or explosion.
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
Do not weld
weld area, the
coatings,
WELDING
near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
cadmium
approved air-supplied respirator.
Safety Data Sheets (MSDSs) and the
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.
5.
cause
throw off
flying
metal. As welds
2.
Wear proper
body protection
to
protect skin.
slag.
srI 9/92
~J
~~
CYLINDERS
explode if damaged.
can
Keep cylinders
3.
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.
or
other electrical
a welding electrode to touch any cylinder.
only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application: maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is
5.
from
excessive
heat,
7.
upright position by chaining
equipment cylinder rack to
8.
compressed gas cylinders
mechanical shocks, and
2.
welding
Never allow
4.
Use
6.
Protect
1.
away from any
circuits.
in
arcs.
cylinders in
them to a stationary support
prevent falling or tipping.
Install and secure
an
or
connected for
use or
use.
Read and follow instructions
associated
equipment,
compressed gas cylinders,
publication P-i listed in Safety
on
and CGA
Standards.
A__WARNING
ENGINES
can
be hazardous.
___
ENGINE EXHAUST GASES
Engines produce harmful
ENGINE
FUEL
can
kill.
Use
If used in
closed area, vent engine exhaust outside and
away from any building air intakes.
1.
Stop engine before checking or adding fuel.
Do not add fuel while smoking or if unit is near
exhaust gases.
can
cause
fire
or
explosion.
outside in open, well-ventilated areas.
1.
2.
2.
equipment
a
any sparks
or
open flames.
3.
Engine
fuel is
highly
flammable.
engine to cool before fueling. If possible, check and add
engine before beginning job.
allow room for fuel to expand.
Do not overfill tank
Do not spill fuel. If fuel is spilled, clean up before starting
Allow
fuel to cold
4.
5.
engine.
MOVING PARTS
can cause
3.
injury.
Have
only qualified people
maintenance and
Moving parts, such as fans, rotors, and belts can
fingers and hands and catch loose clothing.
4.
cut
5.
1.
Keep all doors, panels,
securely in place.
2.
Stop engine before installing
covers,
or
and
guards closed and
connecting
AND
COOLANT
can
skrn.
The coolant in the radiator
under pressure.
can
To
loose
clothing,
for
disconnect
prevent accidental starting during servicing,
negative () battery cable from battery.
Keep hands, hair,
covers
and tools away from
moving
1.
Always
servicing
is
wear a face shield when working on a battery.
Stop engine before disconnecting or connecting battery
cables.
explosive
PRESSURIZED HOT
burn face, eyes, and
or
Reinstall panels or guards and close doors when
finished and before starting engine.
2.
gases.
STEAM
guards
necessary.
6.
unit.
and generate
as
parts.
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin,
Batteries contain acid
remove
troubleshooting
.
3.
Do not allow tools to
4.
Do not
5.
Observe correct polarity (+ and )
1.
use
cause
welder to
sparks when working
charge
batteries
Do not remove radiator cap when
on
on a
battery.
jump start vehicles.
or
batteries.
engine
is hot. Allow
engine
to cool.
2.
Wear gloves and put
3.
Allow pressure to escape before
a
rag
over
cap
area
when
removing
cap.
be very hot and
completely removing
cap.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49. 1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and
Health Standards, OSHA 29 CFR 1910. from
dent of Documents, U.S. Government
D.C. 20402.
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.
Superinten
Printing Office, Washington,
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
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 NW. LeJeune Rd, Miami, FL 33126
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 Eye And Face Protec
tion, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes,
Fire Protection Association,
NFPA Standard 51B, from National
MA 02269.
Batterymarch Park, Quincy,
TABLE OF CONTENTS
SAFETY INFORMATION
SECTION 1
1
SECTION 2- SPECIFICATIONS
SECTION 3
1
INSTALLATION
2
3-3.
Installing Swivel Into Pipe Post
Installing Boom And Reel Support
Installing Wire Guide Extension
3-4.
Wire Guide And Drive Roll Installation
3
3-1.
3-2.
2
3
Gun Connections
3-5.
Welding
3-6.
Wire Feed Motor, Gas Valve, And Reed
3-7.
Control Connection
6
3-8.
7
3-10.
Shielding Gas And Weld Cable Connections
Removing Safety Collar And Adjusting Boom
Welding Wire Installation
3-11.
Motor Start Control
3-12.
Threading Welding
3-9.
SECTION 4
4
Relay
Connections
5
8
8
10
Wire
11
GLOSSARY
12
SECTION 5OPERATION
5-1.
Front Panel Controls
14
5-2.
Side Panel Controls
16
5-3.
Rear Panel Controls
16
SECTION 6- STEPPING THROUGH THE MICROPROCESSOR CONTROLS
6-1.
Front Panel
6-2.
Side Panel Microprocessor Push Buttons
Microprocessor Controls
18
20
SECTION 7
STANDARD PULSE WELDING PROGRAMS
SECTION 8
GETTING STARTED
8-1.
8-2.
Welding With Only Front Panel Controls
Setting Sequence Pulse Welding Parameters
SECTION 9TEACHING
9-1.
9-2.
9-3.
9-4.
32
On Side Panel
Display
33
A PULSE WELDING PROGRAM
Pulse Waveform
37
Teach Points
38
Explained
Explained
Teaching A Pulse Welding Program
Changing To Adaptive Pulse Welding
39
41
SECTION 10- TEACHING A MIG WELDING PROGRAM
42
SECTION 11
SETTING DUAL SCHEDULE PARAMETERS
46
SECTION 12
USING THE DATA CARD
12-1.
12-2.
12-3.
Installing Data Card
Using The Data Card
Naming Programs
SECTION 13
13-1.
13-2.
13-3.
48
48
50
SECURITY & SETUP
Security/Setup Flow Chart
Using Security/Setup Screens
Selecting Security Lock
52
53
54
OM.1588A
1/93
SECURITY & SETUP
SECTION 13
13-4.
13-5.
13-6.
13-7.
13-8.
13-9.
13-10.
13-11.
13-12.
13-13.
13-14.
13-15.
13-16.
13-17.
(Continued)
Selecting Or Changing Access Code
Selecting Type Of Dual Schedule Switch
Selecting Trigger Program Select
Selecting Remote Increase/Decrease Capability
Using Self Test
Resetting Memory
Selecting Program Name Feature
Selecting Units For Wire Feed Speed And Motor Type
Method
Selecting Voltage Sensing
Selecting Voftage Error Shutdown
Resetting Arc Time
Selecting Bench Or Boom Model Type
Selecting Regular Or Hot Arc Start
Selecting Voltage Correction
13-18. Software Version Number
55
56
57
57
58
59
59
60
60
61
61
61
62
62
62
SECTION 14- MAINTENANCE & TROUBLESHOOTING
14-1.
63
Routine Maintenance
The Hub
63
14-2.
Replacing
14-3.
Overload Protection
64
14-4.
Error Screens
64
Assembly
Indicator LEDs
14-5.
Diagnostic
14-6.
Troubleshooting
66
SECTION 15
ELECTRICAL DIAGRAMS
SECTION 16
PARTS LIST
Figure
Figure
Figure
Figure
Figure
16-1. Main
16-2.
Assembly
Support, Hub &
65
68
72
Reel
75
16-3. Control Box
76
16-4. Wire Drive
79
16-5. Boom
80
Assembly
Assembly
Table 16-1. Drive Roll And Wire Drive Kits
82
MOVING
SAFETY INFORMATION
SECTION 1
modi.1 8~2
safety messages throughout
Read all
U
Obey
all
to avoid
safety messages
Learn the
meaning
this manual.
injury.
of WARNING and CAUTION.
Safety
Alert
Signal
Word
2
2
1
I
2
I
~!1~1~ll~eU
ELECTRIC SHOCK
can
WARN INC means possible death
or serious injury can happen.
~,
a CAUTION
3
klIV
h,etaIilng
or
Input p~&
serv~lng.
CAUTION
PARTS
Keep away
Do not touth lIve electrical pane.
Ola~nnect
4
before
from
Keep all panels
when operating.
can
I
rraMng pane.
and
means possible minor
injury or equipment damage can
happen.
Injure
~era
dosed
I
I
/
3
Statement Of Hazard And
Result
4
Safety Instructions To Avoid
Hazard
5
£~
READ SAFETY BLOCKS at start of
Section 3-1 before proceedIng.
WARNING
6
5
Hazard
6
Safety
NOTE
J
Turn OFFswitch when
using high frequency.
SECTION 2
Symbol (If Available)
Banner
Read safety blocks for each sym
bol shown.
7
7~I
Symbol
NOTE
Special instructions for best
ation
not related to safety.
oper
SPECIFICATIONS
Table 2-1. WIre Feeder
SpecIfIcation
Of Input Power From
Power Source
Type
Maximum Weld Circuit
DescriptIon
Welding
Rating
Single-Phase
100
24 Volts AC, 10 Amperes, 50/60 Hertz
Volts, 750 Amperes, 100% Duty Cycle
Welding Power Source Type
Constant
Wire Feed
Standard: 50 To 780 upm (1.3 To 19.8 mpm)
High Speed: 92 To 1435 ipm (2.3 To 36.5 mpm)
Low Speed: 13 To 213 ipm (0.34 To 5.38 mpm)
Speed Range
Wire Diameter
Range
Voltage (CV) DC,
.023 Thru 1/8 in.
Welding Process
Gas Metal Arc
Input Power Cord
10 ft.
(0.6 To 3.2 mm)
(GMAW), Gas
Height With
Weight
4 ft
(1.2 m)
17 ft.
Vertical Uft Of Boom
-
Pulse
(GMAW-P),
flux Cored Arc
(3.7 m) Boom
(5.2 m)
280 lbs.
16 ft.
21 ft.
Net: 160 lbs. (73
Ship:
Metal Arc
Welding (FCAW)
(3.1 m)
12 ft.
Maximum
Post
With Contactor
kg)
(127 kg)
Horizontal To 60
Above Horizontal
(4.9 m) Boom
(6.4m)
Net: 210 lbs. (95
kg)
Ship: 350 lbs. (159 kg)
Horizontal To 60
Above Horizontal
OM-1586
Page
1
SECTION 3INSTALLATION
3-1.
Installing Swivel
PIpe
Post
WARNING
a
I,
Into
FALLING
OF SPRING PRESSURE
RELEASE
WITHOUT BOOM ATTACHED can cause
serious personal Injury.
Do not
remove
safety collar until
instructed to do
BOOM
serIous
cause
can
personal Injury and equIpment damage.
Securely mount pipe post to base that can support
weight of unit with boom in horizontal position.
Use proper equipment for lifting swivel and boom
into place.
so.
Swingpak Base
1
or
CBC Cart
5
4
Post With Base
2
Pipe
3
Steel Bolt
Secure as shown using as a mini
mum 1/2 in. diameter SAE grade 5
steel bolts.
Swivel
4
Insert into
swivel.
Safety
5
Do not
3
Assembly
pipe post. Lubricate
Collar
remove
until instructed to.
Tools Needed:
3/4in.
ST-i 52 268
FIgure
3-2.
4~
Installing
Boom And Reel
WARNING
3-1. SwIvel InstallatIon
Support
RELEASE OF SPRING PRESSURE A ND FALLING BOOM HAZARDS. Read
begInnIng of Section 3-1 before proceedIng.
safety Infor
mation at
3
1
SwivelPiates
2
Yoke
Remove
hardware
from
swivel
plates and yoke.
3
Boom
Set boom into swivel
4
as
shown.
Yoke Pin
Install
pin through yoke. Install cot
spread ends.
ter pin and
2
5
Bolt
Install bolt tighten hardware, and
backboltoffone half turn.
6
Locking Knob
Install
locking
knob but do not
tighten.
7
3/4in.,3/8in.
ST-142 596-B
FIgure
OM-1586
Page
2
ReelSupport
Install reel support.
Tools Needed:
3-2. Boom installation
3-3.
Installing
Wire Guide Extension
Fitting
1
Wire Guide
2
Bolt
3
MonocoilLiner
4
Wire Guide Extension
4
flghten bolt to secure liner in wire
guide fitting. Do not overtighten
belt and crush liner.
Tools Needed:
C~J=O
3/8 in.
ST-152 323
Figure
3-4.
3-3. 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.
wfwaznl.1 W91
A.
Wire Guide instailatlon
Figure 3-4. Wire Guide
instailation
OM-1586
Page
3
B.
Drive Roil Installation
When changing wire size or type,
check
roll
size
drive
(see
Table 16-1).
1
Spnng
Shaft Carrier
Close spring shaft carrier.
2
Drive RoU Nut
3
Drive Roll Carrier
Turn all nuts one click until lobes of
nut line up with lobes of drive roll
carner.
Open spring shaft carrier.
4
Drive Roll
Slide drive rolls onto drive roll cam
ers. Close spring shaft carrier. Turn
nut one click.
4
2
3
5
Drive
Close
Figure
3-5.
Assembly
Cover
cover.
ST.142 597.A
3-5. Drive Roll installation
WeldIng Gun Connections
WARNING
A~
___
ELECTRIC SHOCK
can kill.
Do not touch live electrical parts.
Turn OFF wire feeder and
welding
power source, and disconnect
input
power before
inspecting
or
installing.
I
Drive
2
Gun
3
Gun Connector
Loosen
Assembly
Securing
securing
Cover
Knob
knob. Insert gun
connector until it bottoms
drive
4
assembly. Tighten
Gun Trigger Plug
5
Gun
against
knob.
Trigger Receptade
Insert plug into free-hanging recep
tacle and tighten threaded collar.
6
Trigger
7
Trigger Plug
8
Weld Con~ol
Cord
Trigger
Receptadie
3
Insert
tighten
into receptacle and
threaded collar.
plug
R&.ST-152460/ST.152321 /Rd.ST-157434
Figure
OM-1586 Page 4
3-6. Gun And
Thgger
Lead Connections
3-6.
A.
Wire Feed Motor, Gas Valve, And Reed
Wire Feed Motor, Gas Valve, And Reed
Relay
Relay Connections
Connections
1
3
Wire Feed Motor And Gas
Valve Control Receptacle
2
Plug From Boom
3
Cord From Boom
Insert plug from boom cord into re
ceptacle on rear of control, and
tighten threaded collar.
4
Relay Receptacle
Reed
Insert
plug from reed relay
mounted on swivel into receptacle,
and tighten threaded collar.
Ref. ST-ISO 931-Al Ref. ST-157 434
Figure 3-7. Boom Connections
B.
Shielding Gas Connections
To
Regulator/Fiowmeter
Obtain gas cylinder and chain to
running gear, wall, or other station
ary support so cylinder cannot fall
and break off valve.
1
Cap
2
Cylinder
Valve
2
Remove cap, stand to side of
valve, and open valve slightly. Gas
flow blows dust and cart from valve.
Close valve.
8
3
3
Cylinder
4
CO2
5
Regulator
Washer
Install onto gas
face is vertical.
CO2 Fiowmeter/Regulator
cylinder
6
Gas Hose Connection
7
Flowmeter
so
that
has
5~-18
right-hand
Obtain gas hose with
fittings, and install between flowmeter and welding power source.
Fitting
threads.
8
Flow
Adjust
2
Typical
flow rate is 20 cfh
feet per
hour).
(cubic
3
Tools Needed:
1-lI8in.5/8in.
Argon
Or Mixed Gas
Fiowmeter/Regulator
Figure
3-8. Gas
ub3l 2/92SB-lOg
492-A
OM-1586
Page
Supply Connections
5
3-7.
Control Connection
1
17-Pin Receptacle
2
Keyway
interconnecting cord to
receptacle, align keyway, insert
plug, and tighten threaded collar.
To connect
3
Reed Relay
Section 3-6)
4
35 ft. (10.6
ing Lead
Connect
Receptacle (See
m) Voltage Sens
workpieco
to
(see
Figure 3-10).
5
Threaded Collar
6
14-Pin
Plug
To connect plug to matching recep
tade on welding power source,
align keyway, insert plug, and tight
en threaded collar.
To
Signals Supplied
14-PIn Plug:
WeldIng
Power Source
Through
Contactor Control
A
24 volts
B
Contact closure to pin A
tactor control circuit
G
Circuit
ac.
common
completes the 24 volts ac con
for 24 volts
ac
circuit.
Voltage Control
+10 volts dc.
C
Command
D
Control circuit
E
Remote power source voltage command signal from
feeder (potentiometer wiper or 0 to +10 volts dc).
H
Nonfunctional at this time.
signal;
common.
6
5
The
remaining pins
are not
Signals Supplied
17-Pin Receptacle:
Remote
To
used.
Welding
Power Source
Output Control
C
CC/CV select; +l3thru +24 volts dc
CC.
G
Arc controldinductance
Signals Supplied By Welding
Remote
Through
control; 0
=
CV, Ovoltsdc
=
to +10 volts dc.
Power Source:
Metering
E
Actual weld current output
amps.
M
Actualweldvoltageoutputsignal;+1
signal;
+1 volt dc
=
100
voltdc= lOvolts
do.
The remaining pins
are
not used.
Ref. ST-158 931A/
Figure
OM-1 586
Page
6
3-9. Control Connections With Pin Information
Ref. S-0612/ S-0003-AI S~O628
3-8.
ShIelding Gas
AA
And Weld Cable Connections
WARNING
CYLINDERS
can
explode
from
Keep cylinders away
If
ELECTRIC SHOCK
damaged.
welding
and
other
electrical circuits.
Never touch
Turn OFF wire feeder and welding power source.
and disconnect input power before inspecting or
cylinder with welding electrode.
Always secure cylinder
other stationary support.
to
kill.
can
Do not touch live electrical parts.
installing.
running gear, wall,
BUILDUP OF SHIELDING GAS can harm
health or kill.
Shut off
shielding gas supply
when not in
use.
warn4.r 9/91
The weld cable and shielding gas
hose extend 10 ft. (3 m) from the
boom.
Route
through
weld
reed
cable
from
boom
relay.
If the welding power source or gas
supply are further from the boom,
extend cable
tI~I~2
or
1
Weld Cable
2
Insulated
hose
as
follows:
Sleeving
together weld cables from
welding power source and boom.
Bolt
Use electrical tape and insulated
sleeving to cover connection.
3
Shielding Gas
Hose
Connect hose to gas supply or ex
tension hose. The hose from the
has
boom
5/8-18
right-hand
threads.
Tools Needed:
~ 5/8in.
ST-i 52 800-A
Figure
3-10.
Shielding
Gas And Weld Cable Connections
OM-1586
Page
7
Removing Safety
3-9.
Collar And
Adjusting
Boom
WARNING
A~
FALLING
RELEASE OF SPRING PRESSURE
WITHOUT BOOM ATTACHED can cause
serious personal Injury.
Do not remove
BOOM
can
cause
serious
personal Injury and equIpment damage.
Adjustment
yoke.
safety collar until instructed to do so.
rod must be threaded
Locking
1
fully through
Knob
knob to prevent boom
movement. Loosen knob to allow
boom movement Change knob
position to limit upward movement.
Tighten
3
Pull boom down slightly and re
safety collar. Boom should
balance in any position from hori
zontal to 60 degrees above hori
zontal. If necessary, adjust boom
as follows:
move
2
Threaded Rod
3
Jam Nut
Loosen jam nut and turn threaded
rod until boom balances. Tighten
jam nut Be sure several full
threads are through yoke to pre
vent boom falling.
Tools Needed:
~
-,~
1-1/8 in.
4
E
safety collar for use in
assembling or moving boom.
FIgure
3-10.
A.
WeldIng
Yoke
Retain
Increasing Spring
Decreasing Spring
Pressure ForA
Heavy Gun
Pressure For A
Light Gun
3-11. Boom
dis
Ref. ST-I 52380
Adjustments
Wire Installation
installation Of
Spool-Type
Wire
1
Retaining Ring
2
WureSpool
3
Hub
Remove
spool
4
retaining ring
and slide
onto hub.
Hub Pin
Turn
spool until hub pin fits hole in
spool. Reinstall retaining ring.
2
E
ST.152
FIgure
OM-1586
Page
8
3.12. InstallatIon Of
Spool-Type Wire
B.
installation Of
Optional
Wire Reel And Reel
Type
Wire
6
7
1
Retaining Ring
2
Spanner Nut
3
Wire Retainer
4
WireReel
5
Hub
6
Hub Pin
7
Reel
Support
Remove retaining ring and wire
reel assembly (wire reel, wire re
tainer, and spanner nut) from hub.
8
Wire Installation
4
Lay wire reel assembly
on
face, and install wire
as
flat sur
shown.
Slide wire reel assembly onto hub,
and turn assembly until hub pin is
seated in hole in reel. Reinstall re
taining ring.
3
2
/Da fflj ac~
ST.143 478/ ST.152 483
Figure 3-13. Installation Of Optlonai
C.
Adjusting
Wire Reel And Reel
Type Wire
Hub Tension
Turn OFF unit and
welding
power
source.
1
Hex Nut
2
Spool
Grasp spool in one hand and turn
while using a wrenth to adjust hex
nut. When a slight force is needed
to turn spool, tension is set.
2
E
Tools Needed:
5/8 in.
ST.152 649
Figure 3-14. AdjustIng
Hub Tension
OM-1 586
Page
9
3-11. Motor Start Control
WARNING
a
ELECTRIC SHOCK
can
kill.
Do not touch live electiical parts.
Turn OFF wire feeder and welding power source,
and disconnect input power before inspecting or
STATIC ELECTRICITY
circuit boards.
can
damage parts
on
Put on
boards
grounded wrist sUap BEFORE handling
or
parts.
installing.
wfwaml.V ~91
To change wire feed starting speed
proceed as follows:
Turn OFF unit and
welding
power
source.
Remove wrapper.
1
Front Panel
Remove screw from upper left cor
ner, and open hinged front panel.
2
MotorBoard PCi
3
Motor Start Control Poten
tionieter R70
Rotate potentiometer clockwise to
increase time it takes the motor to
ramp up to speed. Remove protec
tive white rubber cap before
2
making adjustment. Adjust poten
tiometer R70 using a small
conductive screwdriver.
Close and se~ire front
reinstall wrapper.
panel,
non-
and
Tools Needed:
1/4 in.
ST-1574~O/ R&. SB-148 862
Figure
OM-1586
Page
10
3-15. Motor Start Control On Motor Control Board PCi
3-12.
Threading Welding
A~
Wire
WARNING
CYLINDERS
can
explode
Keep cylinders away
from
If
WELDING WIRE
wounds.
damaged.
welding and other
can
cause
puncture
electrical circuits.
Do not press gun
cylinder with welding electrode.
Always secure cylinder to running gear, wall,
other stationary support.
point gun toward any part of the body, other
people, or any metal when threading welding wire.
Never touch
ELECTRIC SHOCK
can
trigger until instructed
to do so.
Do not
or
kill.
HOT SURFACES can burn skIn.
Do not touch live electrical parts.
Allow gun to cool before
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 Uigger.
touching.
wfwarn2.l Fwfwam7.~ 9f9i
1
Wire
Spool/Reel
Loosen wire from spooVreel, cut off
bent wire, and pull 6 in. (150 mm)
of wire off spooVreel.
2
Wire Tube
Manually feed wire through tube,
over pulley and into monocoil liner
at wire inlet guide.
3
Wire Guides
4
Drive Rolls
Manually feed wire through wire
guide(s), up to drive rolls.
Turn wire feeder and welding pow
er source ON (see Figure 5-9), and
OUTPUT/CONTACTOR
place
switch on welding power source in
REMOTE position, if applicable.
2
5
Jog Button
6
Gun Condeit Cable
Lay gun condeit cable
out
straight.
Press JOG button to feed welding
wire. Apply enough hand pressure
to wire to allow drive rolls to grab
3
wire to start jogging. Release
switch when approximately 1 in.
(25 mm) of wire extends out end of
4
gun.
6
7
Knob
7
Pressure
8
Drive Roll Pressure Indicator
Scale
9
Adjusting Pressure
A~ustment
Check drive roll pressure by feed
ing wire against a wood board or
concrete surface; wire should feed
steadily without slipping. Increase
drive roll pressure by turning pres
sure ac~ustment knob clodwise.
The drive roll pressure indicator
scale is for reference only.
Tools Needed:
ST-157432/ST-153o73/ R~. S.0627-AI Re4. SC-150 922
Figure
3-16.
ThreadIng Welding
Wire
OM-1586
Page
11
SECTION 4
The
following
is
a
list of terms and their definitions
as
GLOSSARY
they apply
to this wire feeder:
General Terms
Adaptive Pulse
When the adaptive pulse welding process is selected, the unit will automatically ad
just pulse frequency in order to maintain a constant arc length, regardless of change
in welding wire stickout.
Background Current
Typically
Is the electrical influence exerted
Inductance
field,
on
adjacent
Pulses Per Second
Number of peak current
Pulse Width
in
a
of the two current levels in the
Typically
(PPS
the
by current flow
conductor, through
a
magnetic
conductors.
Peak Current
Or Pulse
pulsing waveform.
the lower of the two current levels in the
higher
pulses which
pulsing waveform.
in one second of time.
occur
Frequency)
(Or
Peak
Time)
Duration of the peak current level.
Term used to represent arc
Trim
length
in
pulse programs. Trim is replaced by volts in MIG
programs.
Synergic
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.
Synergic
to determine the actual
Front Panel Terms
Display
Control Knob
Digital Display
Gas
Purge Control
Parameter Select Button
Trigger
Wire
Hold Control
Jog Control
Is used for all
2-line
adjustable front panel displays.
by 16-character liquid crystal display
Allows the gas line and gun to be
Is used to select
a
variety
purged
with built-in LED
without
of parameters that
When selected, allows the system to remain
to hold the gun trigger.
can
energizing
be set
on
backlight.
the wire feeder.
the front panel
display.
energized without the operator having
Allows the wire to feed without
gas valve. The wire
on the front panel.
energizing the welding power source contactor and
jog is independent from actual wire feed speed, and is displayed
Side Panel Terms
Digital Display
4-line
Dual Schedule
Allows two weld programs to be linked together when two different
tions (i.e. hotter and colder) are required on one wire.
Process Mode
Is used to select the type of process to be used,
Mig.
OM-1586
Page
12
by 20-character liquid crystal display
with built-in LED
backlight.
welding
condi
including Pulse, Adaptive Pulse,
or
Remote Parameter
When
Increase/Decrease
decrease
Sequence
Allows
this
feature
is
turned
on,
Mode
operator
use
can
of the
remotely increase and
optional DSS-10 2-pole
a variety of sequences to be used within a weld program if required. Se
quences include, preflow gas control from 0 to 9.9 seconds, run-in control of voltage
or trim and wire feed speed from 0 to 2.5 seconds, weld time from 0 to 25 seconds,
crater control of
voltage
or
trim and wire feed
time from 0 to 0.25 seconds, and
Security/Set-Up
the
selected weld parameter with the
momentary-contact switch.
a
speed from 0 to 2.5 seconds, burnback
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 will restrict
unau
thorized personnel from changing any of the security/set-up screens. NOTE: The
optional Data Card is required to activate this feature.
Arc Time
Dual Schedule
Allows actual
arc
mulated and
displayed
time up to 9,999.99 hours and weld cycles up to 999,999 to be accu
on the digital display, and can be reset to zero as required.
Is used to select the type of dual schedule switch that will be used when the dual
schedule feature is selected.
Memory Reset
By selecting yes in the memory reset mode, the unit will default to original factory pro
gram settings.
Name Feature
When
using
the
optional Data Card
programs written to the card
Security
can
and
turning
be identified
by
the name feature on, customized
name,
number, job number, etc.
Is used to limit what the operator can control. This includes the number of programs
1 through 8, and also the range of welding parameters. NOTE: The option
available,
al Data Card is
required
to activate this feature.
Software Screen
Selection of this function will
Trigger Program Select
Allows programs to be selected
Self Test Mode
A built-in
diagnostic feature to check a variety of wire feeder and power source func
tions if
a
malfunction
Allows
a
choice of two methods of
display
the software version of the unit.
remotely
with the gun
trigger.
occurs.
Voltage Control
Feedback
lected
sensing voltage
for
regulation. This
can
be
se
the
through
17-pin cord connection to the Maxtron 450 which monitors voltage
at the output terminals, or the selection of an external voltage sense lead.
Voltage
Sense Shutdown
When this feature is on, the system will immediately shutdown if no
upon gun trigger actuation. When this feature is off, the system (wire
arc
is initiated
feeder), when
actuated by the gun trigger, will feed wire for approximately three seconds at set
welding speed and then automatically switch to cold wire jog speed for approximately
one minute. The off feature is normally selected to allow threading wire with the gun
trigger.
Wire Feed Mode
Allows the selection of inches per minute or meters per minute for wire feed speed.
This mode is also used to select motor type; standard speed, low speed, or high
speed. High and low speed motors are available as factory options.
OM-1586 Page 13
OPERATION
SECTION 5
WARNING
a
ELECTRIC SHOCK
Always
Insulate
wear
kill.
can
Do not touch live electrical
p
parts.
~
dry insulating gloves.
yourself
from work and
Keep all panels and
covers
FUMES AND GASES
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
Wear
~
ground.
securely in place
be hazardous
Keep
or use
breathing
device.
can cause
fire
or
on
Allow work and
Injury.
over
drive rolls.
as
covers, and
guards closed
MAGNETIC FIELDS FROM HIGH CUR
RENTS can affect pacemaker operation.
Pacemaker
=9.
keep extinguisher nearby.
Do not locate unit
I
explosion.
Do not weld near flammable material.
Do not weld
can cause
Keep all doors, panels,
and securely in place.
Read Material Safety Data Sheets (MSDS5) and
manufacturers instructions for material used.
Watch for fire;
body protection.
Keep away from pinch points such
your head out of the fumes.
WELDING
helmet with correct shade of filter.
MOVING PARTS
can
to your health.
Ventilate area,
welding
Wear correct eye, ear, and
keep away.
wearers
Wearers should consult their doctor before
~.
near
any
going
welding operations.
combustible surfaces.
closed containers.
equipment
to cool before
1
See Safety Precautions at beginning of manual for ba
sic welding safety information.
~am3.l 10191
handling.
3
2
/
~~
1
Insulating
2
Safety Glasses With Side
Shields
3
Welding
Gloves
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
5 -1.
Safety Equipment
1
Work
Clamp
Use wire brush or
clean metal at weld
sandpaper
joint area.
Connect work clamp to
a
to
clean,
paint-free
Tools Needed:
as
location on workpiece,
close to weld area as possible.
2
Voltage Sensing Clamp
Connect to
workpiece,
(see Figure 3-10).
Use
slag
Fig ure
5-1.
5-2. Work And
if
chipping hammer
welding. R&.
after
applicable
to remove
ST-158 931-A
Voltage Sensing Clamps
Front Panel Controls
1
:J,I_
......_______
6
0
3
~:
Display
2
Parameter Select Button
3
Jog
4
Display Control
5
Trigger Hold
cator Light
6
Purge
Button
Knob
Button And Indi
Button
See Section 6 for information
using microprocessor controls.
on
Ref. ST-155 222
Figure 5-3. Front Panel Controls
OM-1586
Page
14
Parameter Select Button
1
Press button to
move
indicator>
on
display.
Ref. ST.153 976
Figure
5-4. Parameter Select Button
Display Control
1
Turning
knob
Knob
changes
value
se
lected.
Spin knob
to
quickly change pa
by clicks to
rameters or move knob
fine tune parameters.
Figure
5-5.
Display Control Knob
1
,~-
PURGE
Jog
Push Button
Push to
JOG
momentarily feed welding
energizing welding cir
shielding gas valve.
wire without
~
030
cuit
or
Jog speed
is varied using the DIS
PLAY CONTROL knob while JOG
button is pressed. Default setting is
200
7,__o
N
2
1pm.
When JOG button is released, unit
displays preset wire feed speed,
and previously selected parameter
is active.
1
~
JOG does not work when gun
ger is pulled.
Jog
2
15.
OV
Prg
-a
>200
I
PM
Jog
Purge
>1
5
.
260
OV
I
Prg
PM
MIG
justing
5-6.
shielding gas regulator
energizing the welding
Front panel controls, side panel
controls, and gun trigger do not
work when JOG or PURGE button
is
Figure
Push Button
Push to momentarily energize gas
valve. This allows purging of air
from gun shielding gas line, and ad
without
circuit.
Jog
trig
pressed.
Jog And Purge Buttons
OM-1 586
Page
15
I
Trigger
2
Indicator
Hold Button
Light
To weld without
throughout
holding gun trigger
cycle, press and
weld
release button to turn
2
on
indicator
light.
To start weld
cycle, and feed weld.
ing wire, press and release gun
trigger within the first three sec
onds after an arc has been struck.
If gun tri~9er 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.
cycle. To
end
press and release gun
Trigger
hold can not be started
while gun trigger is pressed.
Figure
5-2.
Trigger
5-7.
Hold Button
Side Panel Controls
o~
\
/
\
5
\
4
Figure
5-3.
Parameter Increase Button
Parameter Decrease Button
3
Parameter
4
Parameter Select Button
5
Mode Select Button
6
Mode
Display
Display
See Section 6 for information
using microprocessor controls.
/9 9\~
6
1
2
on
\
3
Ref. ST-I 55 223-A
2
5-8. Side Panel Controls
Rear Panel Controls
1
2
Power Switch
Use power switch to tum unit ON
and OFF.
2
CIrcuit Breaker (See Section
14-3)
Ref. ST-I56 931-A
Figure
OM.1586
Page
16
5-9. Power Switch
WARNING
a
BUILDUP OF SHIELDING GAS
harm health
can
Shut off shielding gas supply when not in
or
kill.
use.
w~m1I QIgl
1
Shielding Gas Cylinder
2
Valve
3
Gun
Trigger
Open valve
welding.
on
cylinder just before
Gun trigger turns weld Output and
gas flow on and off.
3
Close valve on cylinder when fin
ished welding.
sb5.1 0/82
Figure
H IGH FREQUENCY will
Turn off
high frequency
Completely
Install &
J
damage
when
using
)
Gas
this unit.
this unit.
disconnect this unit from power source when
Connect
Wire Feeder
Shielding
CAUTION
a
S
5-10.
5-0821.C
D)(See
System
Figure
3-1O)JJ
Do
~
Readjust
Install
Sample
Weld
FIgure
Welding
) )
J)
) 1
using high frequency.
Put On
Personal Safety
Equipment
Set All
4-12))
Turn On
) )
Controls
JJ ( Figure
Shieldi~\
Gas
(If Applicable)
)~Source
1
Turn On
Wire Feeder And
Control~\
And Prepare
For Production
J
5-11. Gas Metal Arc
(GMAW), Gas Metal Arc Pulse (GMAW-P),
Welding (FCAW)
-
And Flux Cored Arc
0
~jii
NC CC/~
Ret ST-150 Ill-B / Ref. SC-I45 332-0
Figure
5-12.
Setting Switches On Welding
Power Source
OM-1586 Page 17
SECTION 6 STEPPING THROUGH THE
MICROPROCESSOR CONTROLS
WARNING
4~
ELECTRIC SHOCK
can
WELDING WIRE can cause puncture
wounds.
kill.
Do not touch live electhcal parts.
Do not point gun towards any part of the body, other
people, or any metal when programming.
The welding wire is electrically live and moves out of
Control circuit and feeder operationai power are ON
when using or changing the microprocessor
settings.
the gun whenever the power switch is ON and the gun
thgger is pressed.
NOTE
6-1.
This unit is equipped with eight (8) pulse welding programs (see Section 7). When
the unit is turned ON for the first time program I comes up, therefore, program 1 is
illustrated throughout this manuaL Instructions are given later in this manual on
how to select or change a program.
Front Panel Micr oprocessor Controls
Turn ON welding power source and
wire feeder. Follow along with the
controls as shown.
1
Front Panel
2
Parameter Select Button
Display
Press parameter select button to
indicator>.
move
The indicator> points to parame
ters that are selected for change.
Parameter select button can move
indicator > between Trim (arc
length) and 1PM while welding.
Go to
150
120
Trim
0
>50
1PM
>200
Pulse
Tr
im
Prg
I
PM
Pulse
Tr
im
Prg
I
PM
Pulse
200
50
>Prg
Figure
6-2.
ii
1
1
ST-155 222
Figure
OM-1586
Page
18
6-1. Front Panel Parameter Select Button
1
Front Panel
Display
Select
parameter
(see Figure 6-1).
2
Display
to be
changed
Control Knob
one dick causes the
Turning
following changes to selected set
ting:
knob
Trim
2
(arc length) increases/de
creases
by
one.
The trim (arc
changed also
length) value being
changes on the side
panel parameter display (see
Figure 8-3).
Wire feed speed (1PM) increases/
decreases by one inch per minute.
>50
200
Trim
1PM
The wire feed speed value being
changed also changes on the side
panel parameter display (see
Figure 8-3).
Prg
Pulse
Program number (Prg #) increa
ses/decreases by one.
The
number
being
program
changed also changes on the side
panel parameter display (see
Section 11).
>55
200
Trim
1PM
The program number can not be
changed while welding, with ex
caption of Dual Schedule Mode
(see Section 11).
Prg
Pulse
DISPLAY CONTROL knob can be
used to set JOG speed when JOG
button is pressed (see Figure 5-6).
(C) Front Panel
Q
55
>200
Trim
1PM
Trim
k300
1PM
Parameter
Select
Go to
Figure
6-3.
Prg
Pulse
Prg
Pulse
Front Panel
Parameter
Select
I
55
300
50
200
Trim
1PM
Trim
1PM
>Prg
Pulse
>Prg
Put
2
se
ST-155 ~
FIgure
6-2. Front Panel
Display Control
Knob
OM-1586
Page
19
6-2.
Side Panel
Microprocessor Push Buttons
1
Mode
2
Mode Select Button
Display
Press Mode button to
tor> in left window
Go to
Figure
move
indica
display.
6-4.
Side Panel
Process
>S
e
q
u e n
c e
Dual Schd
Ca
r
d
Process
Sequence
>D
u a
Ca
r
I S c h d
d
Process
Sequence
L
Dual Schd
>C
a
r
d
Ref. ST-154 109
Figure
OM-1586
Page
20
6-3. SIde Panel Mode Select Button
I~
I
Parameter
2
Moving
Moving line is
be changed.
3
Display
Line
under value that
can
Side Panel Parameter Select
Button
Press side panel parameter select
button to move indicator> in right
window
Go to
display.
Figure 6-5.
Side Panel
1
2
Prg
~
1
035Steel
98Ar
2oxy
Pulse
035Steel
98Ar
2oxy
>Teach
OH
Ref. ST-154 109
Figure
6-4. Side Panel Parameter Select Button
OM-1586
Page
21
panel mode select button
mode to be changed
(see Figure 6-3).
Use side
to select>
Use side
panel parameter
button to select>
select
parameter
to be
changed (see Figure 6-4).
I
IIJ
1
Increase Button
Press button to increase value that
is underlined by the moving line.
c~c~9
2
Decrease Button
Press button to decrease value
that is underlined by the moving
line.
Side Panel
2
Re4. ST-154 109
FIgure 6-5. Side Panel
Parameter Increase And Decrease Buttons
SECTION 7- STANDARD PULSE WELDING PROGRAMS
following eight (8) pulse welding programs are in the memory of the wire feeder. Use these programs if it is neces
sary to customize a standard program, or as a basis to build yourown custom program. If at any time while customizing
a standard program, orwhile building your own custom program, you want to return to the standard program in the wire
feeder memory, see Section 13-9, Resetting Memory. NOTE: Resetting the memory erases all customized pro
grams and returns them to the appropriate standard factory-set pulse welding programs. Two model types of
factory programs exIst, see SectIon 13-15 for model type settIngs.
The
OM-1586
Page
22
Program
Wire
Program
#1
Program
Name: .035
Size/Type:
.035
1
Gas: 98 Ar 2
S-3
Card #_______________________
Steel, 98 Ar- 2 oxy
Flowrate:
Gun Model: MILLER GW
1PM
ApK
AbK
PPS
PWms
750
560
115
180
2.0
700
550
110
175
2.0
650
540
105
170
2.0
600
520
100
165
2.0
550
510
95
160
1.9
500
480
90
150
1.9
450
460
85
140
1.9
400
440
80
130
1.9
350
420
75
120
1.8
300
400
70
110
1.8
250
380
65
90
1.8
200
360
60
80
1.7
150
350
55
60
1.7
100
340
45
40
1.7
50
330
30
30
1.6
Preflow:
COMMENTS
Sec.
Run-in Thm:
1PM:
Crater Trim:
1PM:
Postfiow:
oxy
Sec.
OM-1586 Page 23
Program
WIre
Program #2
Program
Name: .045
Size/Type:
.045
2
Gas: 95 Ar 5
S-3
Card #_______________________
Steel, 95 Ar -5 oxy
Fiowrate: 40 CFM
Gun Model: MILLER GW
1PM
ApK
AbK
PPS
PWms
750
560
140
230
3.0
700
560
130
230
2.9
650
560
120
220
2.8
600
550
115
210
2.7
550
550
105
200
2.6
500
540
100
190
2.5
450
530
90
180
2.4
400
520
90
170
2.4
350
510
80
160
2.4
300
490
80
150
2.3
250
470
70
130
2.3
200
440
70
110
2.2
150
410
60
90
2.2
100
380
40
70
2.1
50
330
30
50
1.9
Preflow:
Sec.
Run-in Trim:
1PM:
Crater Trim:
1PM:
Postf low:
OM-1586
Page
Sec.
24
oxy
COMMENTS
.
Program
WIre
Program
#3
Program
Name: .052
Size/Type:
.052
3
Gas: 95 Ar 5
S-3
Card #_______________________
Steel, 95 Ar -5 oxy
Flowrate:
Gun Model: MILLER GW
1PM
ApK
AbK
PPS
PWms
750
560
145
250
3.0
700
560
145
250
3.0
650
560
145
240
3.0
600
560
145
230
2.9
550
560
135
220
2.8
500
560
125
200
2.7
450
550
120
190
2.7
400
540
115
180
2.6
350
530
100
170
2.5
300
520
90
160
2.4
250
510
80
140
2.4
200
490
70
120
2.3
150
460
60
100
2.3
100
430
45
80
2.2
50
370
30
50
2.2
Prefiow:
COMMENTS
Sec.
Run-In Trim:
1PM:
Crater Trim:
1PM:
Postflow:
oxy
Sec.
OM-1586
Page
25
Program
WIre
Program #4
Program Name: .035
Size/Type:
309 L, 98 Ar 2
.035
4
Gas: 98 Ar 2
308 L
Card #_______________________
oxy
Gun Model: MILLER GW
Flowrate: 35 CFM
1PM
ApK
AbK
PPS
PWms
750
420
100
140
2.1
700
410
100
140
2.0
650
400
90
140
2.0
600
390
90
130
2.0
550
380
90
130
1.9
500
370
80
120
1.9
450
360
80
110
1.9
400
350
70
100
1.9
350
330
70
90
1.8
300
310
70
80
1.8
250
290
60
70
1.8
200
270
60
60
1.7
150
250
50
50
1.7
100
240
35
40
1.7
50
220
20
30
1.6
Preflow:
Sec.
Run-In Trim:
1PM:
Crater Trim:
1PM:
Postf low:
OM-1586
Page
Sec.
26
oxy
COMMENTS
Program
Wire
Program
#5
Program
Name: .045
Size/Type:
.045
5
Gas: 98 Ar 2
309 L
Card #_______________________
Steel, 309 L, 98 Ar -2 oxy
Flowrate: 35 CFM
Gun Model: MILLER GW
1PM
ApK
AbK
PPS
PWms
750
530
145
180
3.0
700
520
145
170
2.9
650
510
140
160
2.8
600
500
135
150
2.7
550
490
130
150
2.6
500
480
125
140
2.6
450
470
120
130
2.5
400
460
115
120
2.4
350
440
110
110
2.4
300
420
100
100
2.3
250
400
90
90
2.2
200
380
80
80
2.2
150
350
70
70
2.2
100
320
50
60
2.1
50
280
30
40
1.9
Preflow:
COMMENTS
Sec.
Run-In Trim:
1PM:
Crater Trim:
1PM:
Postflow:
oxy
Sec.
OM-1586
Page
27
Program
WIre
Program #6
Program Name: 3/64
Size/Type:
3/64
6
Gas:
4043
Card #_______________________
4043, Argon
Fiowrate: 40 CFM
Gun Model: MILLER GW
1PM
ApK
AbK
PPS
PWms
750
560
145
200
3.0
700
550
145
190
2.9
650
540
145
180
2.8
600
510
145
170
2.8
550
480
145
160
2.7
500
460
135
160
2.6
450
440
130
150
2.6
400
400
120
140
2.6
350
360
110
130
2.5
300
320
100
120
2.4
250
280
85
110
2.3
200
250
65
100
2.2
150
220
50
90
2.2
100
200
32
80
2.1
50
160
20
50
2.0
Pref low:
Sec.
Run-In Trim:
1PM:
Crater Trim:
1PM:
Postflow:
OM-1586
Page
Sec.
28
Argon
COMMENTS
Program
Wire
Program
#7
Program
Name: 3/64
Size/Type:
3/64
7
Gas: Argon
5356
Card #_______________________
5356
1PM
ApK
AbK
PPS
PWms
750
510
140
180
3.0
700
500
140
180
2.9
650
490
130
170
2.8
600
470
125
170
2.7
550
450
115
160
2.7
500
430
105
150
2.6
450
410
95
140
2.6
400
390
85
130
2.5
350
370
75
120
2.4
300
350
60
110
2.3
250
330
48
100
2.2
200
300
43
90
2.1
150
280
32
80
2.0
100
260
17
65
2.0
50
230
15
40
1.9
Pref low:
COMMENTS
Sec.
Run-In Trim:
1PM:
Crater Trim:
1PM:
Postf low:
CFM
Flowrate:
Gun Model: MILLER GW
Sec.
OM-1586 Page 29
Program
Wire
Program
# 8
Program
Name: .045
Size/Type:
.045
8
NI3Cr
Gas: Ar-25He Or Argon
NI3Cr
Card #________________________
Flowrate: 35 CFM
Gun Model: MILLER GW
1PM
ApK
AbK
PPS
PWms
750
470
120
150
4.1
700
460
115
140
4.0
650
450
110
135
4.0
600
440
110
130
3.9
550
430
100
125
3.9
500
420
90
120
3.9
450
410
80
115
3.8
400
400
70
110
3.7
350
390
65
105
3.6
300
380
60
100
3.5
250
360
55
90
3.4
200
340
45
80
3.3
150
320
35
70
3.2
100
300
30
60
3.1
50
260
20
40
2.9
Sec.
Preflow:
Run-In Trim:
1PM:
Crater Trim:
1PM:
Sec.
Postflow:
OM-1586
Page
30
COMMENTS
SECTION 8- GETTING STARTED
WARNING
a
ELECTRIC SHOCK
can
Do not touch live electrical
Always
wear
Insulate
kill.
p
parts.
~
dry insulating gloves.
yourself
from work and
and
all
panels
Keep
FUMES AND GASES
to your health.
covers
ground.
,.:.
or use
Read Material
Safety
WELDING
securely place
be hazardous
can
near
Watch for fire;
Do not weld
on
Allow work and
~
fire
body protection.
or
can cause
Keep away from pinch points
Keep all doors, panels,
and securely in place.
I
\
explosion.
flammable material.
over
helmet with correct shade of filter.
MOVING PARTS
0
device.
keep extinguisher nearby.
Do not locate unit
N OTE
breathing
can cause
Do not weld
welding
in
Data Sheets (MSDS5) and
instructions for material used.
manufacturers
Wear
Wear correct eye, ear, and
Keep your head out of the fumes.
Ventilate area,
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
i.
injury.
such
covers, and
as
drive rolls.
guards closed
MAGNETIC FIELDS FROM HIGH CUR
RENTS can affect pacemaker operation.
Pacemaker
wearers
keep away.
Wearers should consult their doctor before
near
any
going
welding operations.
combustible surfaces.
closed containers.
equipment to cool before handling.
See Safety Precautions at beginning of manual for ba
sic welding safety information.
wfwam3.l 10/91
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 type), and use these when setting up.
OM.1586
Page
31
8-1.
Welding
With
Only
Front Panel Controls
Turn ON
welding power source,
wire feeder, and gas.
I
Front Panel
Display
Program
5 0
Tr
im
I
PM
>Prg
1 is the default program
the first time the unit is turned on,
1
at other times the
200
last program
number selected is displayed. Use
the front panel parameter select
button to select> the Prg #.
Pulse
2
2
Prg3
Select the weld program from
Section 7 (1 through 8) which is
closest to your needs (by wire and
gas).
Tr
5 0
200
I
im
PM
>Prg
Strike
3
Pulsel
an arc
Trim
and
try a sample weld.
(Arc Length)
If necessary, select> Trim, and ad
to achieve the best arc.
just
U
4
Front Panel
Mode Select
1PM
If necessary, select> 1PM, and ad
just
to achieve the best arc.
Go to Section 8-2.
Trim
>50
200
1PM
Prg
3
Pulse
Display
Control
3
I>
Trim
55
200
1PM
U
55
Trim
>200
1PM
Trim
55
>2 5 0
1PM
Prg
3
Pulse
Front Panel
Mode Select
Prg
3
Pulse
Prg
3
Pulse
/
Figure
OM-1586
Page
32
8-1.
WeldIng
With
Only
Front Panel Controls
8-2.
Pulse
Setting Sequence
Welding
Parameters On Side Panel
Display
WARNING
a
ELECTRIC SHOCK
can
Do not touch live electrical
WELDING WIRE
kill.
can
cause
puncture
wounds.
parts.
Do not point gun towards any part of the body, other
people, or any metal when programming.
The welding wire is electrically live and moves out of
Control circuit and feeder operational power are ON
when using or changing the microprocessor
settings.
the gun whenever the power switch is ON and the gun
trigger is pressed.
NOTE ~
]
Figure 8-2 is a graphic layout of a weld cycle. Follow examples in Figure
through Figure 8-8 to adjust sequence welding parameters to fit your needs.
8-3
Weld Time 0.25 Sec.
Run-In Time
0-2.5 Sec.
a)
a)
a.
Run-In
Speed
~
I
I
I
Preflow Time
0-9.9 Sec.~
Trigger
Arc
Start
Crater Time
0-2.5 Sec.
/
Bumback Time
0-0.25 Sec.
/
a)
Posthow Time
0-9.9
/~
I
Li
Arc
Trigger
Sec.~
0~
Time
Out
Released
Pressed
Rłt. S-0271
FIgure
8-2. Weld
Cycle
OM-1 586
Page
33
I
Side Panel Mode Select Button
When unit is turned ON, Process is
the default mode, at other times,
use
side
panel mode select button
to select>
2
Sequence.
Side Panel Parameter Select
Button
Use side panel parameter select
button to select > parameters.
3
Process
>Sequence
Parameter ranges
>W~ld
50.
Weld Parameters
Trim
DualSchd
250
1PM
Card
0.0
Sec
Trim
follows:
(Arc Length), 0-99
Changes
are
Display
are as
also
to Weld
displayed
Sequence Trim
on front panel
display.
Wire Feed
Speed,
50-780 Inches
Per Minute, 1PM
Changes
are
Set Desired Weld
Go to Figure 8-4.
Weld
Trim
>50
Trim
be fine tuned
while welding,
see Figure 6-2.
can
200
1PM
0.0
Sec
~
Set Desired Weld Sequence
Wire Feed Speed
Side Panel
Parameter
Select
We I d
~orQ~j
Increase/
Decrease
60
Trim
>200
1PM
0.0
Sec
1PM can be fine
tuned while
see
welding,
Figure 6-2.
~J
Side Panel
Parameter
Select
Set Desired Weld Sequence
Weld Time, If Applicable
We I d
60
Trim
300
1PM
>0.0
Sec
Increase/
Decrease
Side Panel
Parameter
Select
Proceedtonextflgure.
We I d
~
60
Trim
300
1PM
>3.5
Sec
Increase
FIgure
OM-1586
Page
34
8-3.
SettIng
Sequence 1PM
on front panel
Seconds, 0-25.0 Sec.
I
lncrease/
to Weld
displayed
display.
Sequence Voltage
Decrease
also
Weld
Sequence Display
1
Crater Parameters
Parameter ranges
Trim
Display
are as
follows:
(Arc Length), 0-99
Wire Feed
Speed,
50-780 Inches
Per Minute, 1PM
Seconds, 0-2.5 Sec. If value
zero
Set Desired
Trim
Set Desired
Wire Feed
(O),no Crater sequence
formed.
Speed
Go to
Increase!
Trim
~
Sec
0.20
8-5.
Side Panel
Parameter
Select
Proceed to next
TrimLJ
60
1PM
150
Figure
Crater
£ a I ~
60
~
Increase!
Decrease
Decrease
set is
is per
Side Panel
Parameter
Select
figure.
150
1PM
>Q~QQ
Sec
Set Desired
Crater Time
Increase
Increase!
Decrease
Figure
8-4.
Setting
Crater
Sequence Display
I
1
>~utnba~K
Burnback
>a
u £ fl
D a C k
Burnback Parameters
Burnback can be
0-0.25 seconds.
Display
adjusted from
GotoFigure8-6.
000
Sec
Sec
Side Panel
Parameter
Select
Set Desired
Burnback Time
0.12
Side Panel
Parameter
Select
Sec
Proceed to next
figure.
Increase
Increase!
Decrease
Figure
8-5.
Setting
Burnback
Sequence Display
1
>EQaIf!Qw
1
Postflow
>EQa if I
Q~
Poetfiow Parameters
Postflow can be
0-9.9seconds.
Display
adjusted
from
GotoFigure8-7.
~_0.0
Sec
Sec
Side Panel
Parameter
Select
Set Desired
Postflow Time
1.2
Side Panel
Parameter
Select
Sec
Proceed to next
figure.
(~
Increase!
Decrease
Figure
8-6.
Setting
Increase
Postfiow
Sequence Display
OM-1586
Page
35
Preflow Parameters
1
Preflow
can
be
Display
adjusted from 0.9.9
seconds.
Go to
Figure
8-8.
__/
Pr e f
>~rQf!Q~
0.0
I
f I
__H!H__
ow
Sec
>Q~Q
Sec
Side Panel
a
1.2
Side Panel
Parameter
Select
Set Desired
Preflow Time
Parameter
Select
Q~
Sec
Proceed to next
figure.
Increase
lncrease/
Decrease
Figure
8-7.
Setting 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
(0), no Run-In sequence is
performed.
zero
>B
t~ 0
50.
0
Trim
200
1PM
0.0
Sec
~nin
>~Q
~
Side Panel
Parameter
Select
I
~
Trim1
200
1PM
0.0
Sec
~
Side Panel
Parameter
Select
Set Desired Trim
Runin
Trim1
55
>ZQQ
1PM
0.0
Sec
Set Desired
Wire Feed Speed
lncrease/
Decrease
lncrease/
Decrease
I
>Bunin
Runin
150
Triml
1PM ~
1
Sec
55
.1
~
~
Side Panel
Parameter
Select
Trim
150
1PM
I>~~
Sec
Set Desired
Run-In Time
lncrease/
Decrease
Figure
OM-1586
Page
36
8-8.
SettIng
Run-In
Sequence Display
?~
Side Panel
Parameter
Select
SECTION 9- TEACHING A PULSE WELDING PROGRAM
WARNING
A
ELECTRIC SHOCK
can
Do not touch live electrical
WELDING WIRE
wounds.
kill.
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
Control circuit and feeder operational power are ON
using or changing the microprocessor
when
settings.
the gun whenever the power switch is ON and the gun
trigger is pressed.
NOTE ~
See GMAW-P (Pulsed
MIG)
Process Guide supplied with unit for
more
information.
______________________
9-1.
Pulse Waveform
Explained
The wire feeder, not the
welding
power source, controls weld output
for pulsed welds.
Peak Current Of
ApK
1
150-565
ApK
Amperes
is the
high pulse of welding
Peak current melts the
welding wire and forms a droplet.
The droplet is forced into the weld
current.
puddle.
2
AbK
Background Current
Of 10-150 Amperes
AbK is the low weld current. Back
ground
current
preheats welding
wire and maintains the
background
When
low, the
Is unstable and hard to main
arc
C
arc.
current Is too
tain.
a)
PPS
Pulses Per Second Of
30-400
3
C)
U,
0.
E
1
2
e
*
PPS, pulse rate, and frequency
-~
(Hz)
are
PPS
or
60
Time
used
interchangeably.
A
pulse rate of 60 Hz means
pulses of current are produced
each second.
4
PWms
Pulse Width Of
1.0-5.0 Milliseconds
PWms is the time spent at peak
(1.2 ms is .0012 seconds).
This time must be long enough to
form a droplet of welding wire. The
stiffness or fluidity of the molten
weld puddle is controlled by
PWms.
current
R&. S-0259
Figure
9-1. Pulse Waveforms And
Explanation Of
Terms
OM-1 586
Page
37
Teach Points
9-2.
Explained
1PM
780
750
700
650
600
550
500
Example Of A
Synergic Setting
450
For 425 1PM
400
350
300
250
200
~
Apk
o
Abk
o
Pps
150
100
Pwms
50
150
180
210
240
270
300
330
360
370
420
450
480
510
540
565
Apk
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
Abk
30
55
80
105
130
160
185
210
235
260
290
315
340
365
400
Pps
1
2
The teach mode allows the
custom
user to
create
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 out
put. Each teach point corresponds to a wire
feed speed. The wire feed speeds (ipm)
teach
range between 50 and 750 inches per min
ute, are set at fifty inch increments, and
specific characteristics suitable for
certain joints and/or shielding gas mixtures.
create
Once the parameters have been setfor all 15
teach points, the unit will adjust the four pa
rameters for any wire feed speed beiween
the minimum and maximum teach points.
Pulse
MIG
programs made
Page
38
Figure
OM-1586
by
9-2.
MILLER
3
4
ELECTRIC have pulse waveform intormation entered for all 15 teach
points. The oper.
ator can modify the setting of one, or any
number of the 15 teach points if the factory
set information is not appropriate for a specific application,
5
Pwms
Trim, increases the actual arc length. Like
wise, decreasing the value of Trim will de
crease
actual
arc
length.
lnthePulsemode,theunitdoesnotmaintain
length with variations in elec
Adaptive Pulse mode,
the unit adjusts pulse frequency to maintain
a constant arc length regardless of vana
a
constant
arc
trical stick-out. In the
After the parameters at any teach point(s)
are established, the arc must be struck and
maintained for at least 5 seconds. This allows the wire feeder to learn the arc voltage
tions in electrical stick-out.
associated with the
When
ters. To ensure a proper arc
electrical stick-out must be
feed
taught pulse paramelength reading,
carefully maintamed, and the weld must be terminated by
releasing the gun trigger, not by pulling the
welding gun away from the work piece.
The
taught arc length represents a Trim (arc
length) setting of 50. Increasing the value of
Typical Teach
Point
Settings
And
using pulse MIG programs, any wire
speed from 50 to 750 inches per minute
at one ipm increments, can be selected. Be
yond 750 ipm, the unit limits wire feed speed
settings in pulse MIG to maintain all pulse
parameters within the capability of the unit.
Proceed to next
figure
to teach a
program.
Resulting Synergic Setting
pulse MIG
035Steel
Teaching
9-3.
A Pulse
Welding Program
READ SAFETY BLOCKS at start of
Section 9 before proceeding.
>P
r
Prg
0 C e S S
Pulse
1_
Pulse
Dual Schd
035Steel
Card
98Ar
98Ar
2oxy
>Teach
2oxy
Qff
Side Panel
Parameter
Select
Side Panel
Mode Select
450
>~4~
70
I
320
Apk
70
Abk
~J
lncrease/
Decrease
Decrease
I
I
1PM
?ncrease/
Decrease
I ncrease/
Teach
Q~
400
~>Teach
035Steel
Sequence
~
Apk1L_or_]>a4g
On
Teach
1PM
Abk
70
\Teach
I>4~Q
On
On
1PM
1PM
450
1
Apk
340
70
Abk
ApK
L_0r
Teach
AbK
On
>4QQ
1PM
340
Apk
70
Abk
Side Panel
Parameter
Select
I
I
__________
__________
__________
SidePanel
Parameter
Select
~~Side
U
Panel
Parameter
Select
i_~J
I ncrease/
Decrease
1PM
343
Apk
ZQ
Abk
~
160
PPS
1.9
PWms
343
Apk
92
Abk
280
PPS
343
Or
>
Pulse
]
El
035steel
98Ar2oxy~
>Teach
~
92
Abk/I
~
PWms
Parameter
7
6
Select
~~oxy
Pulse
Process
Display
on
When unit is first turned ON, Process is the
default screen, at other times use mode select button to select> Process.
Use parameter select button to select
Teach.
>
Use increase/decrease buttons to select
ON.
2
I
Qff
L
1
ApkA
450
1PM
lPMcanalsobechangedwiththefrontpanel
DISPLAY CONTROL knob if 1PM is selected
Figure
9-3.
Setting Side
the front
panel display.
When the Process Teach mode is ON, and
one of the following pulse parameters is Selected >: ApK, AbK, PPS, or PWms, the front
panelwitldisplaytheselectedpulseparame(arc length). When the
pulse parameter is selected > on the front
panel, the value can also be changed with
the front panel DISPLAY CONTROL knob.
ter instead of Trim
3
ApK
4
AbK
5
PPS
6
PWms
When values have been set at each teach
point, strike and maintain an arc for five see
onds. Repeat procedure at each teach point
until custom program is complete (see
Figure 9.2).
7
Custom Pulse Screen
The letter C will appear In the upper
ner of all customized programs.
To set
right cor
Sequence WeldIng Parameters,
see
Section 8.2.
Panel Teach Mode Parameters For A Pulse
Welding Program
OM-1586 Page 39
N OlE
~
Program #___________
Program
Make
Wire
copies
of this chart for future
use.
Size/Type_________________________ Gas__________________________
Name__________________________________________ Card #______________________
Gun Model_____________________________________________ Flowrate
1PM
ApK
AbK
PPS
PWms
CFM
COMMENTS
750
700
650
600
550
500
450
400
350
300
250
200
150
100
50
Preflow:___________________ Sec.
Run-In Trim:______________ 1PM:_________________________ Sec.:________________________
Crater Trim:________________ 1PM:____________________________ Sec.:__________________________
Postflow:________________ Sec.
OM-1586
Page
40
9-4.
Changing
To
Adaptive
Pulse
Welding
I
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
Adaptive
as
1
U
Side Panel
Mode Select
shown:
Side Panel
>Prg
>Process
Display
Default
first
turned
side
display when unit is
ON, at other times use
panel mode
>
/1
length. To change to
welding, proceed
Pulse
select button to select
Process.
1_
Sequence
Pulse
DualSchd
035Steel
Card
98Ar
2oxy
Side Panel
Parameter
Select
V
Prg
>Process
1
>EuI~~
Sequence
DualSchd
035Steel
Card
9BAr
U
2oxy
lncrease/
Decrease
>Process
Sequence
Prg 1
>AduptEuL~~
DualSchd
035Steel
Card
98Ar
Figure
9-4.
Changing
To
2oxy
Adaptive
Pulse
Welding
OM-1586 Page 41
SECTION 10-TEACHING A MIG WELDING PROGRAM
a
WARNING
ELECTRIC SHOCK
can
Do not touch live electrical
kill.
WELDING WIRE
wounds.
parts.
Controlcircuitandfeederoperationalpowerare ON
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
when
the gun whenever the power switch is ON and the gun
trigger is pressed.
A.
Changing
To MIG
Welding
1
U
Side Panel
Mode Select
panel
>
1
/
>Process~]
Sequence
>Prg
1
Pulse
DualSchd
035Steel
Card
98Ar
q
2oxy
Side Panel
Parameter
Select
+
>Process
Prg
Sequence
I
>EuI~e
DualSchd
035Steel
Card
98Ar
2oxy
lncrease/
Decrease
I
>Process
Prg
1
Sequence
DualSchd
Card
Figure
OM-1586
Page
42
Side Panel
Display
Default display when unit is first
turned ON, at other times use side
10-1.
ChangIng
To MIG In The Process Mode
mode select button to select
Process.
Go to
Figure
10-2.
B.
Setting Sequence
MIG
Welding
Parameters On Side Panel
Display
1
>Process
>W.sI
18. OVal
DualSchd
200
1PM
Card
0.0
Sec
2
t
Side Panel Parameter Select
Button
Use side panel parameter select
button to select > parameters.
3
~
Display
When unit is turned ON. Process is
the default mode, at other times,
use side panel mode select button
to select> Sequence.
Sequence
(~)
Side Panel
Weld Parameters
Parameter ranges
Side Panel
Mode
Select
Display
are as
follows:
Volts, 10.038.0 Volts
Wire Feed Speed, 50-780 Inches
Per Minute, 1PM
I
Seconds, 0-25.0 Sec. If value set is
(0), welding will continue until
zero
Process
>W~I
welding gun trigger
18. OVol
>Sequence
DualSchd
200
1PM
Card
0.0
Sec
t
Changes
to voltage and wire feed
speed (1PM) parameters in the
weld sequence are also displayed
on front panel display.
Go to
Set Desired
Figure
10-3.
Voltage
Side Panel
Parameter
Select
We I d
1>18.
Inc rease/ Weld Sequence Volts
Decrease
can be fine tuned
while
.
>We I d
QVo It
I PM
2 0 0
0
I
_________________
S
0
e C
welding
18.OVoI
~
200
1PM
0.0
Sec
Side Panel
Parameter
Select
Set Desired Wire Feed
Set Desired Weld Time,
If
is released.
Inductance, 0-99 %
Applicable
Weld
420
1PM
I>o..~
Sec
~Weld
20.OVoIt
30%lnduc
lncrease/
Decrease
>2QQ
1PM
0.0
Sec
I
lncrease/ Weld Sequence 1PM
Decrease
can be fine tuned
while welding
I
Side Panel
Parameter
Select
Side Panel
Parameter
Select
Speed
I
Set Desired Inductance,
If
Applicable
Proceed to next
Weld
I
I ncrease/
420
1PM
2.2
Sec
,
figure.
20.OVoltsl
I
1PM
420
>
2.2
Sec
Increase
Decrease
Side Panel
Parameter
Select
Figure
10-2.
Setting
Weld
Sequence Display
OM.1586
Page
43
1
Crater Parameters
Parameter ranges
Display
are as
follows:
Volts, 10.0-38.0 Volts
Wire Feed
Per
Speed,
50-780 Inches
Minute, 1PM
Seconds, 0-2.5 Sec. If value
a
zero
18.OVol
200
1PM
0.0
Sec
(0),
set is
Crater sequence is per
formed.
Go to
~
no
Figure
10-4.
Side Panel
Parameter
Select
Crater
Crater
>1~QVol
t
Crater
24.OVoIt
24.OVott
~
250
1PM
0. OOSec
Set Desired
Voltage
1PM
>2~0
250
0. OOSec
Side Panel
Parameter
Select
Side Panel
Parameter
Select
Set Desired
Wire Feed Speed
Increase/
Decrease
1PM
>Q~QQSec
Set Desired
Crater Time
lncrease/
Decrease
Increase/
Decrease
28. OVo I
400
1
.
t
J
1PM
I 2Sec
Proceed to next
figure.
Side Panel
Parameter
Select
Increase
Figure
10-3.
Setting
Crater
Sequence Display
I
Bumback Parameters
Parameter ranges
are as
Display
follows:
Volts, 10.0-38.0 Volts
Seconds, 0-0.25 seconds. If value
set is zero
(0), no Burnback
quence is performed.
Go to
I>~uru~~ch
18.0
0.00
Volt
Sec
Burnback
~
J>16.Q
0.00
Side Panel
Parameter
Select
16.0
10-5.
>~urnbaQk
Volt
Sec
10-4.
Sec
Side Panel
Parameter
Select
Set Desired
Bumback Time
lncrease/
Decrease
SettIng Burnback Sequence Display
Side Panel
Parameter
Select
I
16.0
Volt~
0.12
Sec
-.~
lncrease/
Decrease
OM-1586 Page 44
Burnback
Volt
Set Desired
Burnback Volts
Figure
Figure
se
Proceed To
Next Figure
Increase
1
Postflow Parameters
Postfiow
______/
0-9.9 seconds.
______
I
f
>P~
______
Post f low
! ow
>E~ I f I
Side Panel
Side Panel
Set Desired
Postflow Time
Parameter
Select
Proceed to next
Parameter
Select
I ncrease/
Decrease
Figure
10-5.
Go to
2W
Increase
Setting Postflow Sequence Display
e
0.0
f
Prefiow Parameters
Prefiow can be
seconds.
/
r
10-6.
figure.
1
>P
Figure
Sec
1.2
Sec
Sec
0.0
Display
adjusted from
be
can
Pref low
I ow
Sec
>E
1.2
Sec
Side Panel
Parameter
Select
Side Panel
Parameter
Select
Set Desired
Prefiow Time
10-6.
I I
Q~tL
Go to
Figure
10-7.
Sec
Proceed to next
figure.
Increase
Increase/
Decrease
Figure
£ ~
Setting Preflow Sequence Display
1
Run-In Parameters
Parameter ranges
>Ru
n
I
Display
adjusted from 0-9.9
Display
are as
follows:
n
Volts, 10.0-38.0 Volts
18. OVo I
200
1PM
0.0
Sec
~
Wire Feed
Run in
Run in
J
>j8~QVoI
1PM
0.0
Sec
50-780 inches
Seconds, 0-2.5 Sec.
(0), no Run-In
performed.
zero
Side Panel
Parameter
Select
200
Speed,
per minute, 1PM
Run in
18.OVolt
1PM
0.0
For Conventional
MIG Welding
Set Desired Voltage
Side Panel
Parameter
Select
Sec
Set Desired
Wire Feed Speed
18.OVolt
--~-Side Panel
Parameter
Select
Increase!
Decrease
I ncrease/
Decrease
Figure
10-7.
SettIng
Run-In
If value set is
sequence is
~j
200
1PM
Sec
Set Desired
Run-In Time
Increase!
Decrease
Sequence Display
OM-1586 Page 45
SETTING DUAL SCHEDULE PARAMETERS
SECTION 11
WARNING
a
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
~
Control circuit and feeder operational power are ON
when using or changing the microprocessor
WELDING WIRE
wounds.
~
~/ I
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
settings.
can
the gun whenever the power switch is ON and the gun
trigger is pressed.
Dual Schedule can only be used
two consecutive weld pro
with
grams such as: I & 2, or 3 & 4, or
5 & 6, or 7 & 8. Any program type
MIG, Adaptive Pulse, or Pulse can
be combined in dual schedule. For
MIG, Prg 2 is
Adaptive Pulse,
and Prg 2 is Pulse, etc.
example, Prg
Pulse,
1
or
Prg
1
is
I is
Side Panel Mode Select But
ton
2
Mode
Display
Use mode select button to select>
Dual Schedule, then proceed
1
~nel
/3
Dual Schedule Parameters
Display
panel increase/decrease
buttons, or DISPLAY CONTROL
knob (see Figure 11-2) to select
dual schedule pairs.
>011
Sequence
-I
I>DualSchd
Mode
Select
r
d
Increase
lncrease/
Decrease
LPrg
On
~
3
Use side
Process
1& 2
0r
~
~f~r9
1&2~
Side Panel
Parameter
Select
Display
Control
If the two desired
welding programs
most common method to
are
not in the proper program order
(1 & 2,
or
3 & 4 etc..). the
in the proper order would be to write one program to a data card,
and then read the program from the card into the desired program number, see Section 12 for data
card information.
Figure
OM-1586
Page
46
get them
11-1.
Setting
as
shown:
Dual Schedule Pairs On Side Panel
Display
1
Front Panel Parameter Select
Button
2
Front Panel
Display
Press parameter select button to
select> program number on front
panel display.
Front Panel
3
24.
4
250
Display Control
Knob
OV
1PM
Welding Gun Trigger. Or
DSS-Type Switch
The dual schedule programs can
be alternately selected between
active programs A or B by turning
3
the DISPLAY CONTROL knob
Welding Gun
Welding Gun
OR
Trigger
click
clockwise
Display
wise,
or
Control
Knob
ing
DSS-lype
Switch
>Prg
Dual
2
Ar~~1ouai
B
one
counterclock
by squeezing and releas
welding gun trigger, or by an
external mounted OSS-type switch
mounted on the welding gun. See
Section 13-5 for specific switchinstructions.The
type
settings
shown on the front panel display
are
I>Pr~
~
or
the
for the active weld program.
When program B is active, turn dis
play control knob one click clock
wise to select another
schedule programs.
pair of
dual
Display
Control
Knob
ON, and PROCESS is selected on the
panel display, then the side panel increase/decrease
When dual schedule is
side
buttons
Figure
11-2.
can
be used to
Selecting
change program
numbers.
Between Active Dual Schedule
Programs
A And B On Front Panel
Display
OM-1 586
Page
47
SECTION 12- USING THE DATA CARD
12-1.
Installing Data Card
1
Data Card
The gold contacts need to be up
when card is inserted into slot.
2
Card Slot
3
Label
Use the label to record names of
programs stored on card.
3
ST-i 56 268-Al Ref. S-155 923
Figure
12-2.
Using
12-1.
Installing
Data Card
The Data Card
Use Mode Select button to select
Card.
I
Card Screen
2
Moving Line
Process
Sequence
DualSchd
Press
>Card
Moving line is under value
be changed.
Below
3
Card
that can
Program Number
____________________
The program card can holdup to 32
programs. When writing to the
0
~
>Write
Side Panel
Parameter
Select Once
card, the next available program
number is
,j/press iH___
MIG
~!ZEte
WriteDone
____
2
FIgure
OM-1586
Page
48
12-2.
Writing
Side Panel
Parameter
Select
To Card
/
3
automatically assigned.
2
MIG
Press
Side Panel
Parameter
Select
(Name Card Program Off)
Use Mode Select button to select
Card.
~~~~~~~1
Process
1
Card Screen
Sequence
2
Moving
DualSchd
Press
Below
>Card
Line
Moving line is
be changed.
can
Read Screen
3
Side Panel
Parameter And
Select Once
under value that
Select desired card program to
download. Select feeder program
Mode
Select
Once
number where the card program
goes.
Side Panel
Parameter
Select
J
WARN I NG:
Prgl
]
Be
Will
Prgl
Lost
Lose?
Be
Wi
Lose?
Yea
I
Lost
l~
#
1
NQ
Press
Press
Pulse
Press
Increase
Side Panel
Parameter
Select
Side Panel
Parameter
Select
Side Panel
________________
________________
I
I
I
I
Donel
Card
Prg1~~~
#
Select
Press
Figure
1
Pulsel
1
Prg
to
I
I
Parameter
Read
12-3.
Reading
Press
From Card
1
1
Write
WARNING
Warning
If there
Screen
no programs on the
card, this series of screens appear.
:
are
CardEmp ty
>Read
Delete
Press
Done
Below
Side Panel
Parameter
Select Once
Wr
i
t e
>Process
Read
De I
e
>Prg
Sequence
t e
2
Ml G
Dual Schd
>Done
Press
Card
Side Panel
Parameter
Select
Figure
12-4.
Reading (Or Deleting)
From An
Empty
Card
OM-1586 Page 49
_____________________
Use Mode Select button to select
Card.
_____________________
_________________
_________________
Process
1
Card Screen
Sequence
2
Moving Line
DualSchd
Press
Moving line is
be changed.
Below
>Card
_________________
under value that
can
_________________
3
Delete Screen
Select program number to be de
leted from card.
Side Panel
Parameter And
Select Once
~
L~!;te
Write
#
Mode
Select
Twice
WARN I NG:
MIG
~Press
____--1--H___
~
Side Panel
Parameter
Select
____
2
I
J
Delete
Delete
MIG
#2
rd~
Press
___
Increase
I
~
Card
Side Panel
Parameter
Select
Side Panel
Parameter
Select
#3
Prg2
MIG
J
Deleted
Press
Press
Side Panel
Parameter
Select
Figure
12-3.
12-5.
Deleting Programs
From Card
Naming Programs
1
1 ~
Se I fle St
Card
M em o
P
r
y
r o
g
Thedefaultsettingisoff.Toname
r am s
programs
r
f
e
written
e e
d
Press gun trigger
power off and back
the Process
Figure
OM-1586
Page
50
to
the
card,
changetoOn.
>Name
W i
Name Card Programs Screen
(See Section 13-10)
12-6. Default
System Setting
For Naming
Programs
briefly
screen.
on
or
turn
to return to
1
~-1
Section 13-2)
2
Selflest
Security/Setup Screen (See
Card Screen
Card
Use Mode Select button to select
Card.
Pr ograms
Memory
I>Name
>~n
3
ref eed
Moving
Line
Moving line is
changed.
under value that
can
be
2
__
4
Name Screen
If
no name is desired, writing a pro
gram to the card is the same as
Figure 12-2.
Process
Sequence
Pr
Dual Schd
>C
r
a
When
naming a program, the front
panel DISPLAY CONTROL knob
can be used to speed selection of
es S
Be low
d
-n
characters.
Side Panel
Parameter
Select
>Wr
I
t e
Read
De I
e
3
t e
Done
Allowable characters include: 0, 1, 2, 3, 4, 5,
Press
6,7,8,9,:,;, <,=,>,?, ~, A, B, C, D, E, F, G, HI,
J, K, L, M, N, 0, P, 0, R, S, T, U, V, W, X, Y, Z, (.
V,],~,_,,a,b,c,d,e,f,g,h,i,j,k,l,m,n,o,p,q,
r,s,t,u,v,w,x,y,z,!,,#,$,%,&,,(,),*,+,_,.,/,
lncrease/
Decrease
Side Panel
Parameter
Select
Name?
Name?
~
~es
Name?
Yes
5007992
-~
Frame
Press
Press
I
~P
Increase
I
~
Wr
i
teDone
~
Wr
i
teDone
Name?
Name?
ti~
F
2
#2
r
ame
Parameter
Select
Side Panel
Parameter
~
#
2
Increase
Side Panel
(~)
Side Panel
Parameter
Select
MIG
~ea
Press
I
I
~J
Side Panel
Parameter
Select
5007992
Press
'
e S s
0
Side Panel
Parameter
Select
to
Prg 2
CardPrg
r
Side Panel
Parameter
Select
Select
MIG
5007992
F
Press
r
ame
Press
Figure
12.7.
Naming Programs
And
Writing
To Card
OM-1586
Page
51
SECTION 13
Security/Setup
13-1.
SECURITY & SETUP
Flow Chart
,2
1
~Li >s
e c u
r
i
t y
g
Lock
Access
D
u a
T
r
I S
c
i g g e
Features
/
1
Screen Selections
Features
3
Settings
screens.
r
Settings
Screen
Section
Features
Program
Number
Lock
Off/On
>Wire Feed
13-3
Display
IPM/MPM
Motor
Standard
Type
Low
Section
13-11
Speed
High Speed
Off/On
Press
Mode
Select
13-4
~p~J
Press
Mode
Select
>Voltage
Switch
Type
Momentary 2-Pole
13.5
Maintained 2-Pole
,L~1
Maintained 1-Pole
YtJ
~J
Select
Off/On
17-Pin
Feedback
Volt Sense
No Volt Sense
Off/On
Run Hours
09999.99
Hours
0999,999
Cycles
13-12
Press
Mode
Select
~Shutdown
Press
Mode
Select
Program
Control
~
Trigger
>Trigger
Settings
Selection
Code
>Dual Schedule
be
Panel
Press
Mode
Select
>Access
Features that can
are as follows:
customized
Selection
>Security
1
2
Tosetupfeaturesthatcustomize
operation, use the Security/Setup
Of f
h d
Example Of Security Screen On Side
Screen
~3
/
r
Press
Mode
Select
>Arc Time
13-6
13-13
Press
Mode
Select
13-14
~
No Reset
Reset
>Remote
Parameter
lncrease/
Decrease
Off/On
13-7
I
I
Press
Mode
Select
~A~1
Press
~P~J
Select
Mode
>Model
Model
I
>Self Test
13-8
~J
Press
Mode
Select
No Reset
I
I
Arc Start
Type
13-9
Reset
~
Press
Mode
Select
I
Bench
Boom
13-15
Standard
Hot Start
13-16
DVC On/Off
13-17
Press
Mode
Select
>Arc Start
>Memory
Type
L
Press
Mode
Select
>Mig Type
Voltage
Correction
>Name
Card
Programs
Off/On
13-10
Press
Mode
Select
>Software
Figure
OM-1586
Page
52
13-1.
Security/Setup
Version
Flow Chart
Numberl
13-18
13-2.
Using Security/Setup Screens
1
Setup Screen
Front panel
2
display during setup.
Side Panel Mode And Para
meter Select Buttons
Press and hold down both buttons
turning ON unit.
while
3
Power Switch On Rear Panel
4
Security/Setup Screen
Follow this
procedure any time ac
required. Once in the secu
rity/setup screens, use the Mode
cess
is
Select button to select
a
particular
screen.
To
save any or all of the changes
made while in the security/setup
screens, turn power to the unit oft
and back
on or press the gun trig
ger to return to the Process screen.
2
3
/
/
/
/
4
/
>Secur
ity
Access
>Prog
Lock
ii
Of f
Dual Schd
Trigger
Side Panel
FIgure
13-2.
Display
Accessing Security/Setup Screens
OM-1586 Page 53
Selecting Security
13-3.
NOTE
~
Lock
Security
lock works
only
when
a
data card is inserted
(see Section 12-1).
Security Screen
I
Use this screen to lock a programs
weld parameters so that changes
can not be made using front panel
controls.
2
2
Program Number
Choose the program number (1
through 8) to be locked.
Program
3
Lock Screen
Security/Setup
Screen According
To Section 13-2
Increase
When lock is off, the operator can
change all weld parameters with
out restriction.
With
lock
on,
the operator can
but the range
change parameters
of
change
In the
is restricted.
example
ure, the
screens
in this
fig
operator could change the
value of trim –10 and wire feed
speed –100 ipm from programmed
settings are left at 0,
the operator cannot change values
from those programmed.
values. If the
Prog
I>Lock
Tr
rn
21
Q~J
0l
1PM
I
~~>Lock Qff~~~
Increase
~
21
l>Prog
Prog
Lock
Of
fi
/~i
Side Panel
Parameter
Select
3
Side Panel
Parameter
Select
Prog
2
Lock
On
>Trim
Q
1PM
0
~Prog 2~
Lock
On
>Trim
10
1PM
On
lo~
Trim
0
lncrease/
Decrease
21
Prog
Lock
>IPM
Side Panel
Parameter
Select
I
Increase/
Decrease
>Prog
al
Lock
>Prog
2~
Lock
Onj
Trim
ioj~~
1PM
1001
Increase
Page
54
Prog
2
Lock
On
Trim
>IPM
Side Panel
Parameter
Select
Figure
OM-1586
~
13-3.
SecurIty Screen
10
100
If dual schedule is on, the paired
are locked and unlocked
programs
together.
13-4.
Selecting Or Changing
N OTE
~
Access Code
Access code works
only when
a
data card is inserted
(see Section 12-1).
1
~ity/Setup~
Code Screen
With code
Access
ty/setup
off,
access
screens
to the securi
is not restricted.
With code on, the operator must
know and enter the access code to
access or change any of the securi
Press Mode
I
ty/setup
Select Once
2
screens.
Access Screen
With
a code set, this screen ap
pears when power is turned on
while holding the side panel Mode
and Parameter select buttons.
Code
I
I>Qn
AAA
~
Side Panel
Parameter
Select
I
Code
Ion
I
I
>AAA
~Press
~
Increase/Decrease
To Set Code
Parameter Select
To Move Cursor
Code
I
On
I
hzWx
I
~Press
Turn Power Off And Back On
And Access Security Screen
2
I
Ente
Ac
r
>Code
/
~AA
c e $ s
Code
~P_r_e_S_5
Figure
13-4. Access Code Screen
OM-1 586
Page
55
13-5.
Selecting Type Of
Dual Schedule Switch
1
Dual Schedule Screen
Choose type of external dual
schedule switch or use of the trig
ger as the dual schedule switch.
Increase
~ ~>Maint
Sw i
Increase
Increase
Increase
Figure
13-5. Dual Schedule Screens
1
Momen 2P (Momentary
Contact 2-Pole Switch Or
DSS-1 0)
>
2
Maint 2P (Maintained-Contact
2-Pole Switch Or DSS-9M)
2
3
Maint 1 P Or Trigger (Maintai
ned-Contact 1-Pole Switch Or
DSS-9 Or DSS-8)
(055-gM)
(DSS- 10)
1
1
~
2
>
2
1
A
B
2E~
I c h
3
4
p
3
1
(DSS-9)
1
Adapter
1
(DSS-8)
1
1
1
Adapter
1
>
2
2
3
2
2
3
TRI\____
3
3
>
A~>~$
4
>
Figure
OM-1586
Page
56
BO
A~>cQ~>
13-6. Dual Schedule Switch
Diagrams
2
2
>
3
>
4
>
3
13-6.
Selecting Trigger Program
Select
1
Trigger Screen
When
Program Select
trigger
can
is On, the
be used to switch be
tween programs that have at least
0.2 seconds of preflow time.
Briefly pressing and releasing the
trigger switches programs. For
gun
if programs 1, 2, and 6
example:
preflow time of at least 0.2 se
conds, pressing the trigger will
have
switch from program 1 to 2, 2 to 6,
and6to 1.
Access
Program
Security/Setup
Screen According
Se I
e c
~>Qn
To Section 13-2
Increase
Press
Mode Select
3 Times
Figure 13-7. Trigger Screen
13-7.
Selecting
Remote Increase/Decrease
Capability
1
Remote Screen
When Parameter Inc/Dec is On,
the
dual
momentary-contact
schedule switch can be used for
changing
weld
for
as
parameters
switching
as
well
between
programs.
For
example: when the front panel
parameter select is on Trim or
Volts, the dual schedule switch
can
be used to
remotely change the
value. When the front panel param
eter select is on Prg, the dual
schedule Switch
be used to
can
change the program
number. A
OSS-lO dual schedule switch is
recommended for this purpose.
Pa
I
r
n c
a m e
t e
r
/ Dec
>Q 0
Increase
FIgure
13-8. Remote Screen
OM-1586
Page
57
Using
13-8.
Self Test
I
Switch A
This checks the gun
crease
2
Access
Security/Setup
Screen According
1
Gun Increase
Switch
>
I>
~
6
Of f
flest
Gas
This checks the gas valve.
Remote
>Sel
trigger.
Wire feed
This checks the wire feed motor.
5
i gger
position.
Trigger
This checks the gun
4
Tr
Switch B
crease
3
Li
in
This checks the gun switch de
To Section 13.2
Press
Mode Select
5 Times
switch
position.
On
Contactor
This checks the
source
Memory
7
Increase
3
welding
power
contactor.
CV/CC
This tests the physical connection
to the pin at the 17-pin receptacle
that controls whether the unit is in
CC
(constant current)
voltage).
or
CV (con
stant
>1
Increase
I g g a
!
Of
ffr~
T~gug~r
4
5
I
Side Panel
Parameter
Select
_________________
>1
i g g
!
Increase
a
On
_____________
-~
>Wi
_________________
_________________
~
£ 0 f a 0
~
Press
Increase
Press
I>~5
~
Of
Pre
fi
ss
_____________
_____________
Side Panel
Parameter
Select
Increase
o t a Q t Q r
a
o f
p
r
e ~
The
welding wire and all metal parts in contact with
itcarryweid outputwhenthewelding power source
contactor is energized.
_____________
~
Side Panel
Parameter
Select
6
__On~
>GQcta~tQt
Side Panel
Parameter
Select
Increase
Press
Figure
OM-1586
Page
58
13-9. Self Test Procedure
0
r
e ss
13-9.
Resetting Memory
a
CAUTION
Resetting the memory erases all 8 programs and they revert back to original factory settings. If programs
need to be saved, record desired programs on data card first. All security/setup features also reset except
Model Type (see Section 13-15).
1
No Reset
Memory
2
cannot be reset.
Reset
Press Parameter Select button to
reset (clear) memory. Unit defaults
original factory settings. Model
Type setting is not affected by the
to
memory reset (see Section
13-15).
Access
Security/Setup
Screen According
3
Reset
1
Name Screen
(Default) Displays
To Section 13-2
2
Side Panel
Parameter
Select
Figure
13-10.
Selecting Program
13-10.
ResettIng Memory
Name Feature
When
a program card is used, the
programs written from the unit to
the card can be named.
~.~ro~rams
Ca
(s~r~~g)To Section 13-2
Press
Mode Select
7 Times
r
d
Increase
FIgure
13-11.
NamIng
Card
Programs
OM-1586 Page 59
Selecting
13-il.
Units For Wire Feed
Speed And
Motor
Type
Wirefeed Screen
1
The
can
displayed unit of wire speed
changed along with the wire
be
feed motor type.
Increase
Display
Display
I
1PM
Motor
Type~~
>
~
.
~Motor
>
I
Display
I
1PM
p~
Type~~
Motor
~
I
1PM
Display
,~
>MEM
~
Type~~
Motor
Parameter Decrease
Increase
Increase
Type
Standard
>
Select
Figure
13-12.
13-12. Wirefeed Screen
Selecting Voltage Sensing Method
Voltage Feedback Screen
1
When
using the 17 Pin setting, arc
voltage feedback is through the
welding power source and the
feedback signal is sent through the
17-pin cord to the feeder.
If the 17 Pin setting is used, it is rec
ommended that the voltage sens
ing terminals on the welding power
source be used to monitor arc volt
age at the workpiece.
When
using the V. Sense setting,
voltage feedback is through the
voltage sense leads connected to
the feeder. Use this setting when
there is more than 50 ft (15 m) of
arc
weld cable used.
1
Access
Increase
Security/Setup
Screen According
--(s
To Section 13-2
Figure
OM-1586
Page
60
13-13-
Voltage
Feedback Screen
Con t 01
-~ Feedback
r
L._~en~a
13-13.
Selecting Voltage
Error Shutdown
1
Voltage Shutdown Screen
With No Volt Sensed on, the unit
shuts down when no arc voltage is
sensed. An error message ap.
pears (see Section 14-4).
With No Volt Sensed off, the unit
continues to feed wire even when
there is no arc voltage sensed.
1
Access
Increase
Security/Setup
Screen According
--s
To Section 13-2
Figure
13-14.
Resetting
13-14.
Voltage
-~
No
Vol
Sen
s e
t
d
>0 f
Shutdown Screen
Arc Time
1
Arc Time Screen
The unit accumulates arc hours up
to 9999.99 hours or 999999 weld
cycles before rolling over to zero
(0). The arc timer
ing this screen.
l~ncrease~
Access
Security/Setup
Screen According
To Section 13-2
Figure
13-15.
Selecting
be reset
can
us~
SI
OCycli
0. OOH
>BQ~et
r
I
Press
13-15. Arc Time Screen
Bench Or Boom Model
Type
1
Model
Type Screen
The unit is
shipped from the factory
properly set. The setting loads the
parameters into
proper pulse
memory for the model used.
This selection does not change
when a memory reset is done.
Figure
13-16. Model
Type
Screen
OM-1586
Page
61
13-16.
Selecting Regular Or
Hot Arc Start
1
Arc Start Screen
Use the Hot Start mode when high
initial weld current is necessary to
start
large
Do not
diameter
welding wires.
setting for
(9 mm) welding wire. The
use
.035 in
the Hot Start
welding
arc
power source starts the
in the CV mode and switches to
CC
once
Increase
the
arc
is started.
ArcStart
Type
>1121
Figure
13-17.
~ta!t
13-17. Arc Start Screen
Selecting Voltage Correction
1
Mig Type Screen
With DVC
the unit
from the
sensing
Voltage Correction On,
closed-loop feedback
17-pin cord or voltage
uses
leads to maintain set pa
If on, be sure voltage
rameters.
sensing leads are connected or
voltage feedback is available
through the 17-pin receptacle via
the welding power source.
With DVC Voltage Correction Off,
feedback from the arc is not used.
Figure
13-18.
13-18.
MIg Type Screen
Software Version Number
1
Version Number Screen
When talking with service person
nel, this number may be required.
The factory keeps this number on
file with the serial number of the
unit to provide the customer with
updated software as necessary.
FIgure
OM-1586
Page
62
13-19. VersIon Number Screen
SECTION 14
MAINTENANCE & TROUBLESHOOTING
WARNING
a
ELECTRIC SHOCK
can
HOT PARTS
kill.
Do not touch live electrical parts.
S
Turn OFF wire feeder and welding power source,
and disconnect input power before inspecting,
maintaining,
or
servicing.
MOVING PARTS
I~
can cause
away from
pinch points
burns.
can cause severe
cooling period
before
servicing gun
or
unit.
47~j~~
injury.
Keep away from moving parts.
Keep
Allow
Maintenance
such
as
drive rolls,
to
be
performed
only by qualified
persons.
wtwarn4 1 9/92
14-1. Routine Maintenance
OFF all
a Turn
maintaining.
-~
before
power
6 Months
Blow Out
Or
Vacuum
Inside
Clean
Drive
Rolls
Figure
14-2.
Replacing
The Hub
I
14-1. MaIntenance
Assembly
~
~
READ SAFETY BLOCKS at start of
Section 14 before proceedIng.
VI
Turn OFF wire feeder and welding
power source. Retract wire onto
spool and remove. Take hub apart
as shown.
7
1
Retaining Ring
2
Nut
3
Flat Washer
4
Spring
5
Keyed
6
Fiber Washer
7
Brake Washer
8
Rub
9
HubSupportShaft
6
1
Replace
slide
Tools Needed:
Washer
worn or
parts
broken parts, and
shaft in order
onto
shown.
~:
~
15/16 in.
Tighten
hex nut until a slight force
is needed to turn hub. Install wetd
ing
wire
(see Section 3.10).
ST.142 709
Figure
14-2. Hub
Assembly
OM-1 586 Page 63
14-3. Overload Protection
&~
1~
READ SAFETY BLOCKS at start of
Section 14 before proceeding.
Turn OFF wire feeder and
power
welding
source.
Circuit Breaker CB1
1
CB I protects the wire feeder motor
from overload, If 081 trips, the wire
feeder shuts down. Check for
jammed wire, binding drive gear, or
misaligned drive rolls. Correct
problem.
Allow
cooling period
and
manually
reset breaker.
134 905/Ret. ST-156 931.A
Figure
14-3. Circuit Breaker CB1
14-4. Error Screens
I
Error Screen
Trigger
This appears if the trigger is closed
when the Unit power is turned on, or
if the trigger is stuck or defective.
1
2
R e
I
e
a
s
e
T
i
g g
e
r
r
No Volt Sensed Error Screen
The
I
arc voltage sense circuit is not
receiving feedback. Check voltage
sensing connections. Check connections at 17-position plugs/recep
2
3
Release
tacles at the unit and
~
~
~
welding power
source.
Tum unit off and back
N
on
after
cor
recting problem.
Sensed
M
e m o
r
y
C R C
E
P
E
r
r
o
r
3
Memory CRC Error
Screen
The data in the program indicated is
not the same data that was saved.
Press the front panel parameter Se
r
g
Q
r
r
0
Q
IectbuuontocIear(E~orremainson
display).
r
Theprogramcanberunbuttheweld
settings may vary from those last
saved.
M em
R
a
n
o
g
r
e
y
j 1P
E
r
r
1
g
r
0
4
Memory Range
Error Screen
Thedata in theprogram indicated is
out of usable range. Press the front
r
panel parameter select button
(Error remains on display).
to
clear
The program
can
be
run
but the pro
gram may stop when it tries to weld
with
out-of-range settings.
Ref. ST-155 222
Figure
OM-1586
Page
64
14-4. Error Screens
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
97
input
power before
inspecting
or
maintaining.
81064532
I
Tools Needed:
CIIIII~J1J
1/4 in.
ST.156 927 / ST-157 363
Turn OFF wire feeder and
source.
welding power
Remove wrapper.
There
are nine LEDs on Interface Board
PC5O. These LEDs can be used to check
certain functions during troubleshooting.
LED2
Indicates +5 VDC with
board common.
Indicates 15 VDC with respect to PS
mon on the board.
4
7
to circuit
LED6
On when the contactor is not
LED3
board
respect
com
Indicates +15 VDC with respect to circuit
Circuit Board PC5O
1
3
common.
8
energized.
LED7
On when the CV mode is used.
LEDs 1
er
2
is
through 5 should all be on when pow
applied to the wire feeder.
5
Indicates 15
LED1
board
Indicates
mon on
+
15 VDC with
the board.
respect
9
LED4
VDC with respect to circuit
common.
to PS com
6
LED5
Figure
LED8
On when the gas valve is not energized.
10
LED9
On when the wire feed motor is not
running.
14-5. IndIcator LEDs
OM-1586 Page 65
14~6.
Troubleshooting
WARNING
a
ELECTRIC SHOCK
kill.
can
Do not touch live electrical
HOT PARTS
IA?
parts.
Turn OFF wire feeder and welding power source,
and disconnect input power before inspecting,
maintaining,
or
servicing.
MOVING PARTS
'
Keep away from
can cause
Troubleshooting
such
drive rolls.
as
Table 14-1.
shielding gas flows,
energized.
do not
light
-~
to be
burns.
gun
or
unit.
performed only by qualified
wfwam4.l 8/92
Troubleshooting
Check
Section
cord connections. If secure, check cord for
interconnecting
and repair or replace.
continuity
electrode wire is not
meter(s)
servicing
Remedy
but
Wire feeder is on,
before
persons.
Trouble
Wire feeds,
can cause severe
cooling period
injury.
moving parts.
Keep away from pinch points
Allow
1-Ii
3.7
Check and reset CBI.
14-3
up, motor does not run, gas valve and
welding power contactor do not pull in.
Electrode wire
feeding stops
or
feeds
-~
Check gun
trigger
Check gun
trigger.
connection.
3-5
-~
erratically during welding.
*
--
Readjust
drive roll pressure.
~
3-12
Readjust
hub tension.
--~
3-10
-~
3-4B
-~
14-1
-~
3-4A
Change
Clean
to correct size drive roll.
or
replace dirty
Incorrect size
Replace
with
Have
wire
or worn
contact tube
Remove weld
ing
or worn
a
spatter
or
or
drive roll.
guides.
liner.
*
-~
foreign
matter from around nozzle open
*
-~
wood stick.
Factory Authorized Service Station check drive motor or mo
-~
tor control board PCi.
Motor
runs
Check for correct input
slowly.
Wire does not feed until
trigger is pulled,
trigger is re
j
-ł
but continues to feed after
leased, and trigger hold is not
cable.
a
short between
Repair
short
or
welding gun trigger leads
replace welding gun.
--~~i
and weld
on.
Gas valve in feeder is rattling loudly
along with possible erratic or slow wire
feed speed.
~i~t
Check for
-
voltage.
does not switch out of RUN-IN
-0
Check for
cable.
i
-~
a
short between
Repair short
Install, reconnect,
or
or
welding gun trigger
replace welding gun.
replace
reed
relay
or
leads and weld
voltage sensing lead.
-~
3-6, 3-7, 3-8
I
I
SPEED.
_________________________________________________
___________
Wire feeder power is on, displays
up, but unit is inoperative,
*See gun Owners
OM-1586
Page
66
Manual.
light
~
-~
Check welding gun trigger leads for continuity, and repair leads
replace gun.
or
-~
NOTES
OM-1586 Page 67
SECTION 15- ELECTRICAL DIAGRAMS
DSPL2
DISPLAY
SIDE
~
~
,v!vii~ivvvvvvv~
DATA
I
IHOREMENT
DECREMENT
-a-
S
o
P841
0
0
P842
o
I
I
P843
P844
I
-a-
-a
I
0
0
0
~ I
I
00000000~0000
RC6I
PC6O
I
RC6GIPLG6G
RC6I/DATACARD
I
I
lIZ
PC4O
666
ii~~~~&I
/PLG4I
0
LvvvvvJ
~4I,
PARHiETER
SELECT
CE
SELECT
~
CARD
~
_____________
111111111
QIQ
lillillil
I
I
I
I
I
I
I
I
I
I
I
I
I
ifi
~i~I~I
1J
~
~
PARAMETER
~
)~)RC36~
-i____________
1RC29
0RC331
s_
________
)>RC36
)> RC36
RB
TRIGGER
HOLD
PIPGE
-a-
-a-
~
I
0
I
E
7
080
_J
B
0.~
08
qj
&i:~
U)
DIz
))RC36
RC3III
)> RC36
I
I
o6on6
&&&&~
34
MICROPROCESSGE BO4PO
______________
REQ
BC 10/PLO ID
__________
1RC22
RC321
)>RC36
______________
_____________
RC24
I
I
)>RC36
COI~OJCTDE
CABLE
PCIO
LEO
I
~
CABLE
tC/CAAA
I
?
I
CaOXTDE
16
t*?~0)
0
P822
IRC2G
II
) RC36
_____________
BC Il/PLO II
I
i
__________
_R
10
II
)>RC36
I
)> RC36
DR
I
2 CGD.CTDE
CABLE
00
0
0
P823
P821
I
R/W
>-
I
P831
RC
JOG
SELECT
)> RC3A
-
12
)>RC36
13
)>RC36
__________
~-
)>RC3A
I
IS
___
16
4.IV
)>RC37
)>RC37
I
I
PC
30
I
I
I
I
I
C~TDE
CABLE
L
PC20
I
I
dSWIPG*RC~
<IIETAQIENT YT. I I
RC2D/PLG25
4
3>~~3>3
~
2),)J2!
>~J1S~
PLG2B
PLG231
RCI6/PLGI6
RC27>
RC23
~i
~
RC26 >>-~-
BC 17/PLO 17
4>)14>
______
BC I 5/PLO 15
I
RC24/PLG24
wr~ ~im
BC I 2/PLO I 2
I
tIJ_1701I
2
?t?T~7
I
I
______________
I
0 00 0 0 0
~
Mvvvi
I I
vv~vv
I
~
TRIGGER
____
DECREMENT
________________
TRIGGER
o
51
I I>i I~
r
O.E.I
I
DCREANT
08TICAL
I
SWIMEARC 08
DETAO+NT
I
I
081108
I
~
I
CQ4OI
PLGB7/PL058
~0
<2<
BLU/
BOY
____
17e>7>174-~
REO/
I
11<
I
BOY
I
I
I
I
DEN
114>
I
>C~
I
<
/
BOY
oq6IE).6>.q6<
.
I
RED
6S14
2~ 44~-)~4>~~:j4<
I
5cjs4>s>-4sC
L
Figure
OM-1586
Page
68
15-1. Circuit
Diagram
I
BOY
For Wire Feeder
J
2
.
SCSI-F>
7
SCSI-C>
1
PIN
CC/CA
COI44IY4
(+154-CY)
PC8I-E>CUPPENT
4
PIN
PCI 2
I
IQ4cN
CCPCB2-2
> I+IDVCVI << PCP2-4
; FSZIBAO( I 14/184
PC54-IO>)~ IPe1~TA4tE (0-104
PC549>>~-~48 F~AO.1 (14/ISV kc PCB2-5
CURRENT ~
PC82-3
~ ~
PCSO
PC5O
INTERFACE BOARD
PCBI-G>
PCS4-I
PCBI-M>voL.TAGE
PC54-7
I
FEEDBACK
I
>>-~--<
_________________<C
(14/104)
PEED
~
H1
4<
r)JSEOwrm SWZ1CAPC
~ DETACI4NT ~1IDN
C< RCS2- 10
PCS I/PLOD I
(14/1006)
(0-by)
PC7O/Pt.070
PCP7
PCBB
FEEDBACK
IICIUCTAVCE
NI~
~
RC02/PLGD2
PCS3/PLG7D
PCII-4>)
PCII-8>>-
~
PCII-6>)
PCI1-3)>
PCII-7>)
I
58.1St
PCS2-2):
PC55~055
-
-
-
PC84>>P<B(~)8~~7~
-
cc ~cas-i
__________________________
cc::::
SEIcE CLAPc
PC89-I
<<REDS-I
PCII-5>>~-8.
I-2)~~
42
POD4~G04
CCPCD84
~
PCII-I>>PCI
>
PCS2- I
SENSE
~
t~-c
+154
15<cp~-o
ciPcsS-s
~
~I5V
503
RESS-2
<<P(~55-7
I
~
SCS3-2>>48
<CRESS-S
I5V
2
.,
2.
2.
2.
2.
2
2.
2.
2.
-
N
1.
2.
2.
3~~%~4P
14
<<502-6
PIN
PC89-3)
2.
PC8O
~ § § § § § § §
~
PCBS-2)
FILTER BOARD
PC8O>HF
~
STUD
/0
P109
+104
C,
C
~
IOD4(APC
~
>E
P.S.
~tO.1
~
>
D
)
H
>
B
>
A
>
~
T0T~5
4
A
CCPC4-I
4
-~
.+APCA
/CAA
C
I
~
~
C
PC49)>~
P.S.
?
~
PC6-I>>
PC6-2 >
24VAC
PC I
MOTOR BOARD
~
2
~fl1T6CTDB
CT
,~p
~
TAC
AC1
24VAC
~ao
N/~
PC I /PLG I
Pc2/PLG2
C<PC4-6
P0/PIES
RCA/PICA
50/PIGS
PC6/PIG6
2
PC4-4
<<50-4
CC
50-158 848
OM-1586
Page
69
I
PC2O
FRONT DISPLAY
PCI
MOTOR BOARD
YEl_(PI_G387~
BLU(P1G38-8)
RED(Pt638-4)
RW/EU( (Pt_G38-3]
~
~N(PLG3B-I I)
-
(PLG38-~)
Affi~l(PLG38-6)
PLG37
PLG2B
Figure
OM-1586
Page
70
15-2.
Wiring Diagram
For Wire Feeder
I
I
I
I
I
I
I
I
I
DATA
CARD
I
28(PLG6-4)
I
28(PC80-RC86
I0O)PC8O-RC85)~
RC6O/
PLG6O
St~~ AC~I{j/J
-
CBI
IOC(PI 2
63A)PLG)5-3)
-
~Al~~I~-2l
0~*AIP~ IIIR-Rl
648 (PIG 15-4
1
~4IrE)PLG9-Gfl I
~6IAIPIGI5~
________
I8(PLG6-30A(PLGA-3)T
I)~ ~~~L ~~I H
_________
__________
:
AC
cICS
POWER
SIDE
RC42
RC7O
PC4O
DISPLAY
-
-
o
45A(PC
PC8O
6O-RC87
~flwL~I
~,
C
~8O-~88~
46A(PC
0
I
/
1~
~4fC
~
RIB8~~
72A(PLGI -2)
70A)RC7-7)
RCI6/PLGI6
0
RC) 5/
PLGI5
RI ~82/
O_~z,~OI
G82
~
H
~
--~~/IJ
~
0.
0
8C80
,~
L
1
*
Lii
0
U
C
a
0
PC 0
MICROPROCESSOR
~09(~1-2)
4~1i1A(Pt.G25-4) I
*
RC Ill
PLOII
~
Rd
7/
0
W~4XTE)SR I-AC)
,,-,--,-,
Rc53/~l
PLc153~j~J
A(PLGI-4)
RA 10C7-R I
48A(P1G82-6)
BL).RI(Pt.075-2)
49A(P1j382- II
~A1RIE(PLG75-3)
68A IPC7-R1
32A(PLGI-3)
IOA)PLGI-8)
36A(PLG2-6)
1.L,4~4
LL8L~
~
~
RC5/
PIGS)
05EEN(Pt.G75-I)
RC54/
PLG~4
~)A
(
558 I P1082-3
_______
)50A
I~7i~71.
52A(PLG82-9)
RD(PLG4-9
~
I~6A
1~G82
PC5O
INTERFACE
1Z?~1~7L
I 0
'
PLG9
BLAO((SI-~C
54A(Pt.G82-5
83A)PLGAS-I I
I,
PLG~5
~(~I.082~)
~
42A(PL082-8)
C
r
o
C
RC 40
/G~
(QjX~fifi
5A(RC4O-S)
PLG38
7B(RC4O-6)
Id
0
70A(RC4O-7)
a
65A(8C40-8)
m~
wrj~
PLG39
: ~
RC7
SD~158 846
OM-1586
Page
71
SECTION 16- PARTS LIST
0
N
In
(I,
In
C,)
In
(0
(0
.~
C)
E
LI~
U)
U)
4
U)
U)
C,)
U.
0)
(0
C)
U-
C)
C)
C,)
C)
C)
In
C)
(0
nJ
(~nj-
(0
C)
U-
C,)
OM-1586
Page
72
079216
145639
Quantity
Mode
Part
No.
Dia.
Item
No.
Mkgs.
Description
Figure
1.
149251
1.
149252
079 878
PLG23
.
079 535
079531
605156
PLG28
..2.
..3.
..3.
PLG38
080 328
079 534
See Note
139597
139598
047 636
079 535
079 739
135 304
PLG37
135409
114 656
139 600
139 599
010 603
010 606
603106
056112
600 324
REED.
.8
PLG7O
10
.
140
789
079531
079 878
079 535
149884
080 947
602 243
12
602213
601 872
13
132 053
14
Fig
15
149 838
15
.149 839
15
.078 264
11
16-2
15
16
075
16
079
217
17
Fig
16-5
18
19
.
.
GS1
20
21
22
.
078
605227
125785
139265
156243
020 279
23
24..
153631
25..
132611
26.. .M1....
156354
26..
Ml....
153491
27..
153492
Fig 16-4
28..
150998
29
604 612
.
16-1. Main
116
12
Assembly
CABLE, trigger (consisting of)
CABLE, trigger (consisting of)
HOUSING PLUG & PINS, (consisting of)
CONNECTOR, circ pin push-in 18-l4ga
CONNECTOR, circ clamp str rif
CABLE, port No. 18 4/c (order by ft)
RECEPTACLE w/SOCKETS, free hanging (consisting of)
CONNECTOR, circ skt push-in 24-l8ga
CONTROL BOX, (Fig 16-3)
CABLE, interconnecting (consisting of)
CABLE, interconnecting (consisting of)
HOUSING PLUG & PINS, (consisting of)
CONNECTOR, circ pin push-in 18-l4ga
CONNECTOR, circ clamp str rlf
CABLE, port No. 18 8/c (order by ft)
HOUSING PLUG & SOCKETS, (consisting of)
CONNECTOR, rect pin 24-l8ga
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 if)
FITTING, hose brs ferrule .475 ID x .718 Ig
CABLE, weld cop strd No. 4/0 (order by if)
SWITCH, reed (consisting of)
CONNECTOR, circ clamp str rlf
HOUSING PLUG & PINS, (consisting of)
CONNECTOR, circ pin push-in 18-l4ga
BRACKET, spring retaining
BRACKET, spring retaining
WASHER, flatstl std .375
WASHER, lock stl split .375
NUT, stl hex full .375-16
SCREW, cap stl hexhd .375-16
SUPPORT, hub & reel
PIPE POST, 4ff w/base or
PIPE POST, 6ff w/base
PIPE POST, 4ff w/base or
PIPE POST, 6ff w/base
.4.4
.2.2
.l7ft.. 2lft
1
14.
1
1
14
.
....
1 6ff
8
.1
.
1
...
.
.
.
1
2Oft
..
.
8
1
2
.2
.2.2
26tt
30ft
..
.2....2
26ft
.1
.1
.1
30ff
..
....
....
1
1
....
1
....
8
....
4
1
1
8
4
4
x
1 .500
Ig
PIPE POST, 4ff w/o base or
PIPE POST, 6ff w/o base
BOOM ASSEMBLY
NUT, nyl hex jam .75ONPST
VALVE, 24VAC 2 way custom port 1/8 oil
COVER, motor & components
CLAMP, motor top
CLAMP, stl cush .7SOdia x .281 mtg hole
STRIP, buna N compressed sheet .062 x 4.000sq
CIRCUIT CARD, digital tach
OPTICAL ENCODER DISC
MOTOR, gear 1/8hp 24VDC 272RPM
(consisting of)
MOTOR, gear 1/8hp 24VDC 75RPM (consisting of)
KIT, brush replacement (consisting of)
CAP, brush
WIRE DRIVE ASSEMBLY
GUIDE, wire inlet
SCREW, set stl sch 8-32 x .125 cup point
4
1
4
...
4
..
....
1
1
1
1
1
.1
.1
.1
.1
.1
1
....
....
....
....
....
1
1
1
1
1
....1
1
....1
1
....1
1
1
2
....2
1
1
1
OM-1586
Page
73
Quantity
Item
No.
Model
Part
No.
Dia.
Mkgs.
Description
Figure
082 050
30
.31..
PLG7....
115092
113746
32..PLG57
131 204
.
113746
131 203
33..PLG58
114656
146544
34
Note: When
ordering
.
16-1. Main
Assembly (Continued)
LINER, monocoil inlet wire
HOUSING PLUG & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-1 8ga
HOUSING PLUG & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga
HOUSING PLUG & PINS, (consisting of)
CONNECTOR, rect pin 24-l8ga
CLAMP, motor base
Control Box contact
factory service department
1
1
8
1
3
1
3
1
for proper number.
OPTIONAL
.
Part of
Option
156 725 Low
Speed
Motor.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1586 Page 74
16
12
.
.
.
....
....
....
....
.
.
.
.
....
1
1
8
1
3
1
3
1
..
..
Item
No.
Part
No.
Description
Figure
1
142399
2
010 191
3
058 628
058 428
4
5
6
7
8
008
900
905
904
9
057 971
10
010233
605 941
136684
058 427
..
11
12
..
..
.108
124
124
124
13
.
.
.
.
.
.
..
.
.
.
.
.
.
.
.
.
.
.
.
..
.
.
..
..
.
16-2.
Support,
Hub & Reel
SUPPORT, reel
WASHER, fbr .656 ID x 1.500 OD
WASHER, brake sti
HUB, spool
REEL, wire 60 lb (consisting of)
SUPPORT, reel spool
RETAINER, spool support
NUT, spanner spool support
(Fig
Quantity
16.1 Item
14)
1
x
.l25thk
2
2
1
1
1
.
1
.
1
.
WASHER, flat stl keyed 1.500dia
SPRING,cprsn .9700Dx
x
.l25thk
1
.l20wirex 1.250
1 .000 OD x 1 4ga thk
1
WASHER, flat stl .640 ID x
NUT, stl slf 1kg hex reg .625-11 w/nylon insert
RING, retaining spoo1
1
1
1
3
5
3
9
10
11
12
13
SC-146 339
Figure
16-2.
Support,
Hub & Reel
OPTIONAL
BE SURE TO PROVIDE MODEL AND SER1AL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1 586
Page
75
508-A
ST-157
21
22
19
~
28
27
18
26
Box
13
36
Control
37
16-3.
38
39
Figure
10
9
8
40
7
5
10
2
34
41
42
43
46
0
Ui 0) -o CD Ca CD
a)
45-
44
PLG54
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure
.2
.3....
4
...
PC4O....
PLG16,41
.5....
PC6O....
PLG6O
.6....RC7O....
.7
.8....
PC5O...
PLG51
PLG52
155024.
144844.
158160.
155023.
156623.
153501
147995.
048 282.
079 534.
079 532.
079 535
079531
154938.
158817.
158720.
147995.
158719.
147995.
PLG53
PLG55
PC1O...
PLG11
131204.
113746.
148439.
147995.
115092.
113746.
158921
115092.
113746.
PLG15
153501.
147995.
PLG17
115093.
113746.
155022.
10
PLG1O,24
11
159371
12
155629.
PLG12,50
126689.
13
14
097132.
15
138044.
16
600399.
17
603106.
601222.
18
151187.
19
.20
134464.
21
+154927.
22
155261
SRi
035704.
.23
CB1
.24
083432.
Si....
111997.
.25
000527.
26
27
073756.
158578.
28
PC8O, RC8O
PLG75
131204.
113746.
PLG82
158720.
147995.
29
010325.
30
.110015.
PLG9.... 141 162.
.31
134731
32
079 739.
.33.... RC4O.... 047637.
079 534.
048144.
.9....
...
...
..
...
16-3. Control Box
Quantity
(Fig
16-1 Item 2)
LENS, clear anti glare .030 x 2.000
STAND-OFF, No. 6-32 x .875 Ig
CIRCUIT CARD, schd side
x
4.250
2
14
1
CABLE, ribbon 24posn 6.000 in
CIRCUIT CARD, cyber card
1
HOUSING PLUG & SOCKETS,
(consisting of)
CONNECTOR, rect skt 22-lBga
RECEPTACLE w/SOCKETS, (consisting of)
i
CONNECTOR, circ skt push-in 24-l8ga
CONNECTOR, circ 4 pin Amp 211882-1
CONNECTOR, circ pin push-in 18-l4ga Amp 66359-6
CONNECTOR, circ clamp str rlf Amp 206358-2
STRIP, mtg PC card
CIRCUIT CARD, interface
HOUSING PLUG & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-lBga
HOUSING PLUG & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-1 8ga
HOUSING PLUG & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga
HOUS1NG PLUG & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-1 8ga
HOUSING PLUG & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga
CIRCUIT CARD, processor w/proms
HOUSING PLUG & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga
HOUSING PLUG & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-1 8ga
HOUSING PLUG & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga
CABLE, ribbon 34posn 12.000 in
KIT, EPROM service (part of PC1O Processor Circuit Card)
CABLE, ribbon l4posn 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 1 4ga blk 600V 1 05C (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 1g..
LABEL, warning general precautionary
4
1
1
1
1
12
1
2
1
3
1
10
1
8
.8
1
6
1
6
1
1
.
1
4
4
1
.
35ft
ift
1
1
1
WRAPPER
PANEL, side lower
1
RECTIFIER, integ 40A 800V
CIRCUIT BREAKER, man reset 1 P 1 OA 250V
SWITCH, rocker SPST 1OA 250 VAC
BLANK, snap-in nyl .875mtg hole
STAND-OFF, No. 6-32 x .625 Ig
CIRCUIT CARD, HF filter
HOUSING PLUG & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga
HOUSING PLUG & SOCKETS, (consisting of)
CONNECTOR, rect skt 22-l8ga
BUSHING, strain relief .840 ID x .875mtg hole
CABLE, port No. 18 7/c (order by ft)
HOUSING PLUG & PINS, (consisting of)
CONNECTOR, circ pin push-in 18-l4ga
CONNECTOR, circ clamp str rlf
HOUSING RECEPTACLE & SOCKETS, (consisting of)
CONNECTOR, circ skt push-in 24-l8ga
CONNECTOR, circ pin plug keying in sockets
1
1
1
1
1
4
1
1
3
1
12
1
l2ft
1
14
1
1
14
2
OM-1586 Page 77
Item
No.
Part
No.
Dia.
Mkgs
Description
Figure
134 201
34
PCi
PLG1
.35
..
155114..
PLG2
PLG3
115 092
.
.
113 746
.
.
115 093
.
.
113 746
.
.
.
.
115 094
.
PLG6
.
.
.
115 091
113 746
.
.
.
.
136 810
.
.
.
1
.
.
....
PLG39
....
RC7
37
....
.
38
40
...
PC2O,30
PLG25
.41
.42
.43
.44
.45
.46
.47
.48
.49
When
ordering
a
..
...
CONNECTOR,
.
CONNECTOR,
CONNECTOR,
HOUSING PLUG
.
.
135409..
114 656
.
.
CONNECTOR,
HOUSING PLUG
(consisting of)
1
24-l8ga
& SOCKETS, (consisting of)
rect skt 24-l8ga
& SOCKETS, (consisting of)
rectskt24-l8ga
& SOCKETS, (consisting of)
8
rect skt
rect skt
24-l8ga
& SOCKETS, (consisting of)
rectskt20-l4ga
& SOCKETS, (consisting of)
rect skt 24-1 8ga
& SOCKETS, (consisting of)
rect pin 24-l8ga
CONNECTOR,
158702.. CASE SECTION, bottom/rear
145948.. BRACKET, mtg control box
158 104.. CIRCUIT CARD, schd front
150317.. HOUSING, term plug nyl 4cont
147995.~ CONNECTOR, rect skt 22-l8ga
154932.. PANEL, front
157113.. WASHER, shldr delrin .257 ID x .500 OD x .343 x .187 shldr
097924.. KNOB, pointer
144842.. ACTUATOR, switch
089032.. LENS, LED 4341 red
NAMEPLATE, (order by model and serial number)
030170.. BUSHING, snap-in nyl .750 ID x 1 .000mtg hole
154933.. PANEL, inner control
154109.. PLATE, ident inner control
059712.. CLIP, component .437dia mtg adh back
158373.. CABLE, interconnecting (consisting of)
097868..
CONNECTOR, circ 1 7skt MS-31 06A-20-29S
039734..
CONNECTOR, circ clamp str rlf AN-3057-1 2
600343..
CABLE, port No. 16 5/c (order by ft)
097866..
CONNECTOR, circ 17 pin MS-3106A-20-29P
.
.39
CONNECTOR,
HOUSING PLUG
115092..
113 746
CONNECTOR,
HOUSING PLUG
114066....
36
2) (Continued)
8
HOUSING PLUG
.
16-1 Item
CIRCUIT CARD, motor control
HOUSING PLUG & SOCKETS,
HOUSING PLUG
.
(Fig
STAND-OFF SUPPORT, PC card .312/.375
113746....
PLG4
16-3. Control Box
Quantity
.
.
component originally displaying
a
precautionary label,
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1586
Page
78
1
6
1
4
1
10
1
4
1
8
1
8
1
1
1
1
4
1
1
1
8
1
1
1
1
1
2
1
1
2
1 Oft
1
Item
No.
Part
No.
Description
Figure
1
....
2....
3....
4....
5....
6
7
8
9....
10....
11....
12....
13....
....
....
....
14....
.15....
16....
17....
18....
19....
20....
21....
22....
23....
24....
25....
26....
27....
28....
29....
30....
.31....
32....
33....
34....
35....
010668..
150147..
149962..
149486..
132750..
150520..
133493..
133350..
152241..
133739..
132824..
010837..
132747..
132746..
133603..
137248..
604772..
602200..
602082..
154031..
133530..
133308..
134834..
149959..
149746..
108940..
604538..
151437..
151290..
149527..
601872..
602213..
602243..
149964..
601966..
16-4. Wire Drive
Quantity
Assembly (Fig
16-1 Item
27)
SCREW, cap sti sch .250-20 x 1 .500
CARRIER, drive roll w/components
SPACER, carrier drive roll
PIN, rotation arm rocker
ARM, pressure
SPACER, rotation pin
RING, retaining ext .250 shaft
x
4
4
4
2
2
2
2
.O25thk
PIN, hinge
KNOB, w/extension
WASHER, flat buna .375 ID x .625 OD x .O62thk
SHAFT, spring
PIN, spring cs .093 x .625
CARRIER, shaft
BUSHING, spring
SPRING, cpsrn .724 OD x .082 wire x 1.000
SPRING, indicator
WASHER, flat stl 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
ADAPTER, gun/feeder LH
SCREW, cap stl hexhd .250-20 x .750
WASHER, flat stl SAE .312
KNOB, plstcT 1.125 Ig x .312-18 x 1.500
SCREW, mach stl hexwhd 10-32 x .500
COVER, drive roll
NUT, sti 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
See Table 16-1, Page 82
For Drive Roll &
Wire Drive Kits
1
1
1
1
1
1
2
2
1
1
1
1
2
1
1
2ft
1
1
4
1
1
2
1
1
1
1
2
1
9
15
16
18
19
6
5
2
SC-137 222-D
Figure
16-4. Wire Drive
Assembly
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1586
Page
79
0
cJ
Lt)
(0
N-
~
>.
C)
E
C)
C,,
C,,
4
0
E
U,
0
0
((5
C)
I
C)
(0
c,J
cJ
CU
OM-1586
Page
80
LI~
Quantity
Model
Part
No.
Item
No.
Description
Figure
..
..
..
..
..
..
..
..
1
.
.
.
.
.
.
.
.
.
.
.
.
2
2
3
3
4
5
..
.
..
.
6
.
..
..
..
8
9
10
11
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
..
..
..
..
..
..
..
.
.
.
.
.
.
.
.
.
079 030
..
..
..
..
..
..
..
..
..
..
..
.
16.
.
17..
18
+139 831
080 157
.
.
.
.
.
.
.
19
.
20
.
21
..
.
.
.
.
.
.
.
.
.
.
.
.
.
22
23
23
24
25
..
.
.
.
.
27..
.
28
.
26
+When
079 029
075 462
.
14.
15
073 742
073 741
.
12
13
.
080811
079 664
139 633
602 250
079 020
149 858
080 723
150 258
024 605
075 101
12
..
.
.
7
..
.
057 357
139 338
139 643
079 665
.
.
142 804
134 327
602 246
047 224
073 666
079
080
079
602
139
667
812
632
243
590
010313
139 336
ordering
a
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
.
1.l25mtg hole
.
.
.
..
.
1
.
.
.
1
1
1
x
15.687
.
a
.
1
1
1
PIN, clevis .750 OD x 2.156 Ig
CLEVIS, .812 yoke 6.062 Ig .750-l6thd
NUT, stl hex full fnsh .750-16
SHAFT, boom counterbalance
WASHER, flat stl SAE .750
NUT, stl hex elastic stop .750-16
SPRING, cprsn 3.750 OD x .625 wire x 36.000
SPRING, cprsn 3.750 OD x .687 wire x 33.750
RETAINER, spring
BEARING, ball thr sgl row .750 x 1 .625 x .625
NUT, stl hex special .750-16 x 1.250
WASHER, lock stl ext tooth .750
BASE, swivel boom (consisting of)
FITTING, grease 1/SNPT
LABEL, Swingarc caution heavy spring
LABEL, warning general precautionary
WASHER, flat stl std .500
KNOB, T-bar .500-13 thd
SCREW, mach sti 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,cotterhair.072x1.437
GUARD, motor protector
component originally displaying
16
17)
1
LINER, monocoil 3/32-1/8 wire
..
.
x
16-1 Item
GUIDE, wire inlet
..
..
Assembly (Fig
BUSHING, snap-in nyl .937 ID
BOOM, single
BOOM, single
GUIDE, wire
GUIDE, wire
..
..
.
16-5. Boom
I
12
precautionary label,
.
..
1
1
2
1
2
1
1
...
.
..
.
1
.
1
.
..
.
.
.
.
1
.
2
..
.
.
..
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
.
.
.
..
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
1
..
.
1
1
1
1
1
1
.
.
.
.
1
1
1
4
4
1
.
.
5
4
...
.
.
.
.
1
.
2
....
1
..
2
1
.
.
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1586 Page 81
Drive Roll
083489 083490 053708
Roll Kit
070
.
UC-GROVE
151
4
077
Roll Kit
151
2
.
Roll Kit
4
Kits
2
Drive
.
U-GROVE
Roll
Roll Kit
151
151
061
151
062
151
4
Roll Kit
Drive
151
2
16-1.
151
Table
151
15 063
064
151
132960 132961 132962
15 057 15 058 15 059
132963
15 06
151
Roll Kit
15 024 15 025
15 03 15 031
026
027
151
151
032
033
151
151
2
.~E~-o .~ .E
E~c~
149518 149518
1509 3 1509 3
053704 053703 053705
15 04 15 041 15 042
15 048 15 049 15 05
.
151
05370 053697 053698 05369
Roll Kit
15 06 15 067 15 068
151
087130 053695
4
15 065
151
Drive Roll
.
a)
079
0720 053701 053702 053706
037
036
15 038 039
045
044
15 046 047
Drive Roll
And
15 078
151
053712
15 076
-0527-B
S
15 083
Rol s
Drive
4
Or
2
Roll Kit
Wire
072
132958 132957 132956 13295 13295
053
052
15 054 055151 15 056
Drive Roll
VK-GROE
15 071
053710 053709 05371
15 073 15 074 15 075
15 08 15 081 15 082
15 028
15 034
15 069
with
along
.125,
05370 8-32
15 043 Setscrew
x
15 051
612
w/604
Guide
Aritwear
029
233
045
151
And
035
Guide,
151
149518 149519 149519 149520 149520
1509 3 1509 4 1509 4 1509 5 1509 5
149520 149521 149521
1509 5 1509 6 1509 6
14952 Intermdia
1509 7 Guide, D-64
Inlet
Metric
.
Size
Wire
0.6m 0.8m
Fraction .023- 5in
.03 in.
0.9m
.035in.
1. m
.045in.
1.3m
1.6m
.052in.
~
2.0m
1.8m
.068-72in
in.
5/64
2.4m 2.8m
(.079in.) (.0941n.)
3.2m
(15)
An
&
D-62
for
Contains Required
Kit
Each Kits
2
0
(n 0) -D 0) (0 CD 0) I)