Miller SWINGARC DS-12 AND 16 User Owner’s Manual

UM-1584
139 168P
June 1998
Miller
The Power ~fB1ue.
Processes
~
MIG(GMAW)
Flux Cored
(Gas-
and
(FCAW)
Self-Shielded)
Submerged (SAW)
Description
Wire Feeder
(Use
with CV Power
Sources)
Swi ngarc
~:
DS-1 2 and DS-1 6
0
Visit
our
website at
www.MiltcrWelds.um
OWNERS
MANUAL
From Miller to You
congratulations on choosing Miller. Nov:~
get the job done and get it done right. We know
Thank you and
you
can
have time to do it any other way.
you dont
Thats
why
Today,
the
when Niels Miller first started
building arc
welders in 1929, he made sure his products offered
long-lasting value and superior quality. Like you, his
customers couldnt afford anything less. Miller products
had to be more than the best they could be. They had to
be the best you could buy.
people that build and sell Miller products continue the
tradition. Theyre just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
~flJ~flJTll~
WOrktngazhaFdazJondo~every
This Owners
Miller
help
Manual is
designed
help
you get the most out of your
Please take time to read the Safety precautions. They will
products.
to
yourself against potential
you protect
hazards
on
power source fvem Mflter is
backed by the must hassle-tree
warranty In the bus1niss~
the worksite. Weve
made installation and
operation quick and easy.
With Miller you can count on years of reliable
service with proper maintenance. And if for
~i 11111
jL~
1 1
1.
REGISTERED
1
the unit needs repair, theres a
Troubleshooting section that will help you
QUALITY SYSTEM
some reason
V
Miller is Ibe first welding equipmeNt
figure
manufacturer in the U.S.A. to be
registered to the ISO 9001 Quality
System Standard.
will then
out
what the
help
you
problem
is. The parts list
to decide
which exact part
you may need to fix the
service information for
are
also
problem. Warranty and
your particular model
provided.
em
Miller offers a Technical
Manual which provides
mote detailed service and
parts information for your
unit. To obialA a TechniCal
Manual, contact your local.
distributor, Your distributor
scan also supply you with
Welding Process Manuals
~
as
SM4W,GTAW
GMAW and GMAW-P
Miller Electric manufactures
of welders and
welding
For information
products,
on
a
full line
related
other
equipment.
quality Miller
contact your local Miller
to receive the latest full line
individual
distributor
catalog
or
catalog sheets. To locate your nearest
distributor call 1-800-4-A-Miller.
~:
:
TABLE OF CONTENTS
SECTION 1
-
SAFETY PRECAUTIONS
-
READ BEFORE USING
1-4.
Symbol Usage
Arc Welding Hazards
Additional Symbols for Installation, Operation,
Principal Safety Standards
1-5.
EMF Information
1-1.
1-2.
1-3.
SECTION 1
1-1.
1-2.
1-3.
-
1
1
1
and Maintenance
3
4
CONSIGNES DE SECURITE
-
Signification des symboles
Dangers relatifs au soudage a larc
Dangers supplØmentaires en relation
LIRE AVANT UTILISATION
5
avec
Iinstallation,
le fonctionnement
7
Principales
normes
1-5.
Information
sur
2-1.
-
les
de sØcuritØ
9
-
9
9
INSTALLATION
Swivel Into
3-4.
3-5.
Motor Start Control
3-6.
Equipment
3-7.
Control Box Connections
3-8.
14-Pin
3-2.
3-3.
3-9.
8
champs Ølectromagnetiques
INTRODUCTION
Installing
Installing
Installing
Installing
3-1.
8
Specifications
SECTION 3
Pipe
Control Box And
Boom And Reel
9
Post
Adjusting
Support
10
Tilt
10
11
Wire Guide Extension
Connection
11
12
Diagram
13
13
Information
Plug
Removing Safety
Collar And
Adjusting
14
Boom
14
3-10. Gun Recommendation Table
3-11. Wire
14
3-12.
15
3-13.
3-14.
Type, Size, And Feed Speed Capability Table
Installing And Threading Welding Wire
Optional Equipment DIP Switch Settings
Digital Voltage Control Option Changeover For Inverter-Type
SECTION 4
-
Front Panel Controls
4-2.
Volts Meter
4-3.
Overload Protection And
-
16
Power Source
17
18
OPERATION
4-1.
SECTION 5
18
18
Display
Optional Side
Panel Controls
MAINTENANCE & TROUBLESHOOTING
19
19
5-1.
Routine Maintenance
19
5-2.
Troubleshooting
20
SECTION 6
SECTION 7
-
-
WARRANTY
OM-1 584P
5
5
et Ia maintenance
1-4.
SECTION 2
3
ELECTRICAL DIAGRAM
22
PARTS LIST
24
SECTION 1
SAFETY PRECAUTIONS
-
READ BEFORE USING
-
nd5197
som
Symbol Usage
1-1
Means
4A
A
Marks
There
not
hazards
are
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary
Welding
symbols
actions to avoid the hazards.
related.
safety
Hazards
shown below
to call attention to and
the
possible
are
special safety message.
a
Arc
1-2
The
Out!
procedure! The possible
adjoining symbols.
shown in the
~ Means Note~
A
Watch
Warning!
hazards with this
are used throughout this manual
identify possible hazards. When you
watch out, and followthe related instructions
to avoid the hazard. The safety information given below is
see
symbol,
only
summary of the more complete safety information
found in the Safety Standards listed in Section 1 -4. Read and
If earth
with
a
grounding
of
theworkpieceis required, ground it directly
do not use work clamp or work cable.
cable
separate
-
Do not touch electrode if you
or
another electrode from
a
are
in contact with the
work, ground,
different machine.
a
follow all
A
A
Safety
Standards.
Use
only well-maintained equipment. Repair or replace damaged
at once. Maintain unit according to manual.
parts
Only qualified persons should install, operate, maintain,
repair this unit.
and
During operation, keep everybody, especially children, away.
Wear
a
Keep
all
safety
Clamp work
or
can
kill..
and
worktable
as near
clamp
good
Do not connect
electrical parts can cause fatal
shocks or severe burns. The electrode and work
circuit is electrically live whenever the output is on.
The input power circuit and machine internal
circuits are also live when power is on. In semiautomatic or
automatic wire welding, the wire, wire reel, drive roll housing, and all
metal parts touching the welding wire are electrically live. Incorrectly
installed or improperly grounded equipment is a hazard.
single
weld
securely
in
place.
metal-to-metal contact to workpiece
the weld
as
practical.
when not connected to
contact with any metal
live
Touching
above floor level.
working
covers
cable with
Insulate work
ELECTRIC SHOCK
harness if
panels
more
workpiece to prevent
object.
than
one
electrode
or
work cable to any
output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
Turn Off
inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
Do not touch live electrical parts.
Wear
hole-free
dry,
Insulate
big enough
or covers
work
body protection.
ground using dry insulating mats
prevent any physical contact with the
to
AC output in damp areas, if movement is confined,
danger of falling.
use
there is
a
Use AC
output ONLY
If AC
and
ground.
or
Do not
insulating gloves
yourself from work and
if
output is required,
required
use
for the
remote
welding
or
if
output control if present
on
Disconnect
to
input power or stop engine before installing or
equipment. LockoutJtagout input power according
OSHA 29 CFR 1910.147 (see Safety Standards).
Properly
Owners
this
install and
ground
this
equipment according
~
to
its
Manual and national, state, and local codes.
head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or
remove welding fumes and gases.
If ventilation is poor,
use an
Read
Safety
Material
the
manufacturers
Do not weld in locations
conductor first
-
double-check connections.
Frequently inspect input power cord for damage or bare wiring
cord immediately If damaged
bare wiring can kill.
replace
Turn off all
Do not
Do not
-
-
use
equipment
worn,
drape
when not in
damaged, undersized,
cables
over
your
body.
breathing
poorly spliced cables.
Data
Sheets
near
(MSDSs)
degreasing, cleaning,
The heat and rays of the arc
toxic and irritating gases.
Do not weld
and
the
coatings,
on
can
or
spraying
react with vapors to
coated metals, such as galvanized, lead, or
unless the coating is removed from the
plated steel,
weld area, the
or
approved air-supplied respirator.
alr is safe.
operations.
form highly
cadmium
use.
to
only if it is well ventilated, or while
air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the
When
grounding
arc
confined space
a
an
proper
exhaust at the
cleaners, and degreasers.
wearing
attach
use
instructions for metals, consumables,
Always verify the supply ground check and be sure that input
power cord ground wire is properly connected to ground terminal
in disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
making input connections,
be hazardous
fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
Work in
-
can
Welding produces
-
Keep your
process.
unit.
servicing
FUMES AND GASES
area
is well
ventilated, and if necessary,
while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
OM-1 584
Page
1
ARC RAYS
burn eyes and skin
can
BUILDUP OF GAS
Shut off
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
shielding
can
gas
injure
when not
supply
Always ventilate confined spaces
approved air-supplied respirator.
awelding helmetfitted with a proper shade of filterto protect
or watching (see ANSI Z49. 1
Z87.1 listed in Safety Standards).
kill
or
ri use.
or
use
Wear
your face and eyes when welding
and
approved safety glasses
Wear
HOT PARTS
cause
can
severe
burns;
with side shields under your
helmet.
Do not touch hot
protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
Allow
Use
parts bare handed.
cooling period
before
working
on
gun
or
torch.
protective clothing made from durable, flame-resistant
(leather and wool) and foot protection.
Wear
material
MAGNETIC FIELDS
WELDING
can cause fire or
Welding
on
drums,
pipes,
explosion.
Pacemaker
Protect
yourself
and others from
Do not weld where
flying sparks
flying sparks
can
Remove all flammables within 35 ft
this is not
possible, tightly
(10.7 m)
fire, and keep
Be
that
aware
can cause
fire
Do not weld
on
welding
on
a
of the welding arc.
approved covers.
NOISE
extinguisher nearby.
ceiling, floor, bulkhead,
closed containers such
Connect work cable to the work
Do not
Noise from
tip
some
processes
as
tanks, drums,
Wear
as
welder to thaw frozen
when not in
or
approved
CYLINDERS
close to the
welding
ear
protection
if noise level is
can
explode
if
damaged.
or
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.
area as
pipes.
cut off
welding
wire at
Protect
gas cylinders from excessive heat,
slag, open flames, sparks, and arcs.
compressed
mechanical shocks,
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding
use.
Remove any combustibles, such as a butane
from your person before doing any welding.
lighter or matches,
Never
FLYING METAL an
injure
drape
Never allow
Never weld
Use
only
a
a
welding
welding
on a
torch
over a
pressurized cylinder
-
shields
even
under your
welding
with
helmet.
side
cylinder.
explosion
will result.
shielding gas cylinders, regulators, hoses,
for the specific application; maintain them
parts in good condition.
and
fittings designed
and
eyes.
approved safety glasses
cylinder.
electrode to touch any
Turn face away from valve outlet when
Wear
other electrical circuits.
or
gas
correct
associated
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
2
can
Shielding
pipes,
(see
protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Page
equipment
high.
to AWS F4.1
Wear oil-free
OM-1584
or
damage hearing.
partition
or
prevent welding current from traveling long, possibly
paths and causing electric shock and fire hazards.
Remove stick electrode from holder
contact
damage hearing.
If
to
use
spot
the hidden side.
they are properly prepared according
Safety Standards).
unknown
can
or
fire
on a
unless
practical
keep away.
and hot metal.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Watch for
pacemakers~.
going near arc welding, gouging,
welding operations.
strike flammable material.
them with
cover
wearers
affect
Wearers should consult their doctor before
closed containers, such as tanks,
can causethem to blow up. Sparks
can fly off from the welding arc. The flying sparks,
hot workpiece, and hot equipment can cause fires
and burns. Accidental contact of electrode to metaJ objects can
cause sparks, explosion, overheating, or fire. Check and be sure the
area is safe before doing any welding.
or
can
opening cylinder
Keep protective cap in place overvalve except when
use or connected for use.
Read and follow instructions
associated
Standards.
equipment,
cylinder is in
compressed gas cylinders,
publication P-i listed in Safety
on
and CGA
valve.
Additional
1-3.
For
Symbols
Installation, Operation, And Maintenance
MOVING PARTS
FIRE OR EXPLOSION hazard.
Do not install
unit on, over,
place
or
Keep away
or near
combustible surfaces.
Do not install unit
is
near
be
building wiring
properly sized, rated, and protected
Do not overload
-
Keep
power
moving parts
from
doors, panels,
closed and
flammables.
sure
all
can cause
in
securely
injury.
such
as
covers, and
fans.
guards
place.
supply system
to handle this unit.
FALLING UNIT can cause
injury.
HF.. RADIATION can
lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
cause
interference.
Use
Use
equipment
of adequate
capacityto
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
lift and
support unit.
only qualified persons familiar with
equipment perform this installation.
Have
If
using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
electronic
unit.
The
responsible
is
user
having a qualified electrician
problem resulting from the
for
correct any interference
installation.
promptly
OVERUSE
Allow
can cause
cooling period;
Reduce current
starting
to weld
Do not block
STATIC
Put
or
(ESD)
on
handling
or
OVERHEATING
follow rated
reduce
duty cycle.
duty cycle
before
grounded
boards
or
wrist
strap
at once.
interference, stop using
regularly checked
the
and maintained.
Have the installation
S
Keep high-frequency source doors and panels tightly shut,
keep spark gaps at correct setting, and use grounding and
shielding to minimize the possibility of interference.
again.
damage PC
by
.
filter airflow to unit.
can
the FCC about
If notified
equipment
boards.
BEFORE
parts.
ARC WELDING
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
can cause
interference.
Electromagnetic energy can interfere
electronic equipment such
with
sensitive
as
computers and computer-driven equipment
MOVING PARTS
can cause
such
injury.
robots.
as
all equipment in the welding
electromagnetically compatible.
Be
Keep away from moving parts.
Keep away from pinch points such
as
To reduce
drive
possible,
rolls.
sure
WELDING WIRE
can cause
injury.
possible interference, keep weld cables as short as
together, and down low, such as on the floor.
welding operation
equipment.
Be
sure
according
Do not press gun
trigger
until instructed to do
is
close
Locate
tronic
area
this
welding
100 meters from any sensitive elec
machine
is installed
and
grounded
to this manual.
If interference still occurs, the user must take extra measures
as moving the welding machine, using shielded cables,
so.
such
point gun toward any part of the body,
people, or any metal when threading
welding wire.
using
Do not
line filters,
or
shielding
the work
area.
other
1-4.
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 Supennten
dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for
Cutting of Containers That Have Held Hazardous
Welding Society Standard AWS F4.i,
Welding Society, 550 N.W. LeJeune Rd, Miami, FL
American
Welding
and
Substances,
from American
33126
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe
Handling
of
Compressed Gases
in
Cylinders,
CGA
Pamphlet
P-i, from Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard Wi 17.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1 R3.
Safe Practices For
Occupation
And Educational
Eye
And Face
Protection, ANSI Standard Z87.i ,from American National Standards
Institute, 14.30 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51 B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-i584
Page
3
EMF Information
1-5
Considerations About Welding And The Effects Of Low
Electric And Magnetic Fields
Frequency
1.
Keep
Welding current, as it flows through welding cables, will cause electro
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: The body of evidence, in the
committees judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.
However, studies are still going forth and evidence continues to be
2.
Arrange
3.
Do not coil
examined. Until the final conclusions of the research
may wish to minimize your exposure to
welding
or
reached, you
electromagnetic
magnetic
procedures:
Page
or
one
drape
or
taping
side and away from the
cables around your
Keep welding power
practical.
source
Connect work
to
4.
and cables
them.
operator.
body.
as
far away from opera
tor as
5.
clamp
workpiece
as
close to the weld
as
possible.
About Pacemakers:
fields in the
workplace,
use
the
following
Pacemaker
then
4
cables to
together by twisting
fields when
cutting.
To reduce
OM-1584
are
cables close
wearers
following
consult your doctorfirst. If cleared by your
procedures is recommended.
the above
doctor,
SECTION 1
CONSIGNES DE SECURITE
UTI LISATION
-
LIRE AVANT
-
sam
Signification
1-1
symboles
Signifie Mise en garde! Soyez vigilant! Cette procedure
prØsente des risques de danger! Ceux-ci sont identifies
par des symboles adjacents aux directives.
a
A
des
ndtre 5/97
Identifie
message de sØcuritØ
un
Ce groupe de sym boles signifie Mise en garde! Soyez vigilant Ily a des
risques de danger relies aux CHOCS ELECTIRIQUES, aux PIECES EN
particulier.
MOUVEMENTetaux PIECES CHAUDES.
Reportez-vousauxsymboles
es mesures
prendre pour
etauxdirectivesci-dessous afin de connaItre
U7
Dangers relatifs
1-2
A
nest pas relatif
Signifie NOTA
Øviter tout
Ia sØcuritØ.
soudage
au
a
Iarc
Lea symboles prØsentØs ci-aprŁs sont utilisØs tout au long du
present manuel pour attirer votre attention et identifier les
risques de danger. Lorsque vous voyez un symbole, soyez
vigilant
danger.
et suivez les directives mentionnØes atm
consignes
Les
dØviter
prØsentØes ci-aprŁs
de sØcuritØ
ne
tout
font
que rØsumer Iinformation contenue dana les normes de sØcuritØ
ØnumØrØes a Ia section 1 -4. Veuillez lire et respecter toutes ces
normes de sØcuritØ.
A
vent Øtre conflØs
A
Au coursde
qu
des personnes
lutilisation,
reparations
qualifiØes.
et les
lutilisation, lentretien
Linstallation,
tenirtoute personne a lØcartet
danger.
ne
doi.
plus par
ticuliŁrement les entants.
Ne pas toucher lŁlectrode quand on est en contact avec Ia
une electrode provenant dune autre machine.
piŁce,
Ia
terre Cu
Nutiliser quun materiel en bon Łtat. RŁparer Cu remplacer sur-le
champ lea piŁces endommagØes. EntretenirlappareilconformŁment
a
ce
manuel.
Porter
un
harnais de aŁcuritŁ
Maintenir solidement
en
quand
place
on
travaille en hauteur.
tous les panneaux et
capots.
Fixer le cable de retour de facon a obtenir un bon contact mØtal-mŁtal
avec Ia piŁce a souderou Ia table detravail, le plus prŁs possible de Ia
soudure.
Isoler Ia
avec
pince de masse quand pas
objet mØtallique.
mis a Ia
piŁce
pour Øviter le contact
tout
UN CHOC ELECTRIQUE peut tuer
Un
simple
contact
avec
des
piŁces Ølectriques peut
provoquer une electrocution Cu des blessures graves.
LŁlectrode et le circuit de soudage sont sous tension
des que lappareil est sur ON. Le circuit dentrØe et es
circuits internes de lappareil sont Łgalement sous
tension ace moment-l. En soudage semi-automatique ou automatique,
le fil, le dØvidoir, le logement des galets dentraInement et les piŁces
mŁtalliques en contact avec le fil de soudage sont sous tension. Des
matŁriels mal installŁs Cu mal mis a Ia terre prŁsentent un danger.
Ne
jamais
toucher les
Ily a DU COURANT CONTINU IMPORTANT dans les
convertisseurs aprŁs Ia suppression de Ialimenta
tion Ølectrique.
charger lea condensateurs dalimentation
indiquŁes dana Ia partie entretien avant de
piŁces Łlectriques sous tension.
protection secs ne comportant
Porter des gants et des vŒtements de
pas de trous.
LES FUMEES ET
Œtredangereux.
de Ia piŁce et de Ia terre au moyen de tapis ou dautres
moyens isolants suffisammentgrands pourempŒcher le contact phy
sique Łventuel avec Ia piŁce ou a terre.
Sisoler
servir de source itlectrique courant electrique dans les
humides, dans les endroits confines ou l o on risque de tomber.
Ne pas
se
Se servir dune
procŁdŁ
de
source
soudage
Ølectrique
courant
electrique
se
Eloigner
UNIQUEMENT si le
dune source electrique courant electrique savŁre nØces
servir de Ia fonction de tØlØcommande Si lappareil en est equipe.
sŁcuritŁ).
Installeret mettre laterrecorrectementcetappareil conformŁment
et aux codes nationaux, provinciaux et
son manuel dutilisation
A
votre tŒte des fumŁes. Ne pas
respirer
Ia terre du cordon dalimentation
Verifier et sassu
que le flu de terre du cordon dalimentation est bien raccordØ ala
borne deterre du sectionneur Cu que Ia fiche du cordon est raccordØe
a une prise correctement mise a Ia terre.
-
rer
En effectuant lea raccordements dentrŁe fixer dabord le conducteur
approprie et contre-vŁrifier les connexions.
de mise a Ia terre
Verifier
frŁquemment le cordon dauimentation pour voir sil nest pas
endommagŁ ou dŁnudØ remplacer le cordon immŁdiatemenl sil eat
endommagØ un cable dŁnudŁ petit provoquer une electrocution.
ventiler Ia zone et/ou utiliser un echappement au ni
de larc pour evacuation des fumŁes et des gaz de soudage.
ventilation eat insuffisante, utiliser un respirateur a alimenta
lintŁrieur,
veau
Si
a
homologuŁ.
apŁciflcationsdesŁcuritŁ des matŁriaux (MSDSs) et lea ins
tion dair
Ure lea
tructions du fabricant concemant les mŁtaux, les consommables,
les revŒtements, lea nettoyants et lea dŁgraisseurs.
Travailler dans
en
municipaux.
Toujours verifier
pØuvent
les fumŁes.
le demande.
Couper lalimentationou arrŒter le moteuravant de procŁder linstal
lation, a Ia reparation ou a lentretien de lappareil. DŁverrouiller
lalimentation aelon Ia norme OSHA 29 CFR 1910.147 (voir normes
de
LESGAZ
Le soudage gŁnŁre des fumŁes et des gaz. Leur
inhalation peut Œtre dangereux pour votre sante.
zones
Si Iutilisation
saire,
Łlectrique, et dŁ
selon lea instructions
toucher lea piŁces.
ArrŒter lea convertisseurs, dŁbrancher le courant
un
espace fermŁ seulement sil est bien ventilŁ
Cu
portant un respirateur a alimentation dair. Demander toujoura a
se tenir a proximitØ. Des tumØes et
soudage peuvent dØplacer lair et abaisaer le niveau
doxygŁne provoquant des blessures Cu des accidents mortels.
Sassurer que lair de respiration ne prØsente aucun danger.
Ne pas souderdans des endroits situØs a proximitŁ dopØrations de
dŁgraissage, de nettoyage Cu de pulvŁrisation. La chaleur et les
rayons de larc peuvent rŁagir en presence de vapeurs et former
des gaz hautement toxiques et irritants.
un
surveillant dCiment formŁ de
des gaz de
-
-
hors tension
Mettre
lutilise pas.
lappareil
quand
Ne pas utiliser des cables uses, endommagŁs, de grosseur insuffi
sante ou mal ØpissØs.
on ne
Ne pas enrouler les cables autour du corps.
Si Ia
Ne pas souder des mØtaux munia dun revŒtement, tels que lacier
le revŒte
galvanisŁ, plaque en p10mb Cu au cadmium a moms que
soudure, que lendroit soit
portant un respirateur a afimenta
ment nait ØtŁ enlevŁ dans Ia zone de
bien
ventilŁ,
et 51 nŁcessaire
en
tion dair. Les revŒtements et tous lea mØtaux renfermant ces ØlŁ
ments peuvent degager des fumØea toxiques en cas de soudage.
piŁce soudŁe dolt Œtre mise laterre,
cable distinct
-
ne
le faire directementavec un
pas utiliser le connecteur de piŁce ou le cable de
retour.
OM-1 584
Page
5
LESRAVONS DE LARC peuventpro-~
les yCux et
voquer des brluresdns
sur Ia peau
LESACCUMULATIONSDE~GAZ ris
~queflt de provoquerdesbiessures
rnŒme Ia mort.
ou
:
,.
Le
du procØdØ de soudage
gØnAre des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer
des brOlures dans les yeux et sur Ia peau. Des Øtincelles sont projetees
Veiller
pendant le soudage.
rateur dadduction
Porter
un
rayonnement de larc
casque de
soudage
muni dun Øcran de filtre
Fermer lalimentation
du gaz
protecteur
en cas
de
utilisation.
non
toujours a bien aØrer
les espaces confines
Cu se
servir dun
respi
homologuØ.
dair
appropriØ pour
protØger votre visage et vos yeux pendant le soudage ou
der
pour regar
Z49. 1 et Z87. 1 ØnumØrØ dans les normes de sØcuritØ).
(voirANSI
Porter des
protections approuvØs pour les oreilles si
DES
le niveau sondre est
PIECES ICHAUDES peuvent
voquer des brlures
trop ØlevØ.
Utiliser des Øcrans
des barriŁres pour
ou
protØger des tiers de lØclair
lØblouissement; demander aux autres personnes de ne pas re
garder larc.
Porter des vŒtements de protection constituØ dans une matiŁre dura
ble, resistant au feu (cuir Cu lame) et une protection des pieds.
et de
LE SOUDAGE
incendie
Le
ou
peut provoquer
Ne pas toucher des
le
pØriode de
pistolet ou Ia
Porteurs de stimulateur
projection dØtincel
refroidissement avant
torche.
incendies et des brOlures. Le contact accidentel de electrode avec des
provoquer des Øtincelles, une explosion, un
surchauffement cu un incendie. Avant de commencer le soudage,
verifier et sassurer que lendroit ne prØsente pas de danger.
dabord
projection dØtincelles
cardiaque,
restez a distance.
consulter leur mØdecin avant de sapprocher
a arc, de gougeage ou
operations de soudage
soudage par points.
des
de
cardiaques.
porteurs dun stimulateur cardiaque doivent
Les
objets mŁtalliques peut
personnes de Ia
une
LES CHAMPS MAGN TIQUES peuvent
les, des piŁces chaudes et des Øquipements chauds peut provoquerdes
Se protØger et dautres
metal chaud.
PrŁvoir
dutiliser
affecter les stimulateurs
provo9uerleurØclatement. DesØtincellespeuventŒtre
de soudure. La
chaudes a mains
un
uneexplosion
effectuØ sur des conteneurs fermØs tels
que des reservoirs, tambours ou des conduites peut
de arc
parties
nues
souda9e
projetees
pro
graves..
et de
LE BRUIT
peut affecter IouIe.
Ne pas souder dans un endroit l oii des Øtincelles peuvent tomber
sur des substances inflammables.
Le bruit des processus et des
Iouie.
DØplacertoutes les substances inflammables a une distance del 0,7
mde arc desoudage. Encas dimpossibilitØ es recouvrirsoigneuse
ment avec des protections homologues.
Des Øtincelles et des matŁriaux chauds du soudage peuvent facile
ment passer dans dautres
des ouvertures.
zones en
traversant de
Porter des
Øquipements peut
protections approuvØs
affecter
pour les oreilles si
le niveau sondre est trop ØlevØ.
petites fissures et
SurveillertoutdØclenchementdincendieettenirunextincteuraproxi
mite.
Le
soudage effectuØ
peut dØclencher
un
Ne pas effectuer le
plafond, plancher, paroi
sur un
incendie de lautre
Si des BOUTEILLES sont endomma
gØes, elles pourrontexploser.
separation
ou
ctŁ.
Des bouteilles de gaz protecteur contiennent du gaz
haute pression. Si une bouteille est endomma
gee, elle peut exploser. Du faitque es bouteilles de gaz
font normalement partie du procØdŁ de soudage, les
des conteneurs fermØs tels que des
reservoirs, tambours, ou conduites, a moms quils naient ØtØ prØpa
rØs correctement conformØment a AWS F4.l (voir les normes de
soudage
sur
sous
sØcuritØ).
Brancher le cable sur Ia piŁce le plus prŁs possible de Ia zone de sou
pour Øviter le transport du courant sur une longue distance par
des chemins inconnus Øventuels en provoquant des risques dØlec
trocution et dincendie.
dage
Ne pas utiliser le poste de
lees.
En
de
soudage
pour
dŁgeler
des conduites ge
utilisation, enlever Ia baguette dŁlectrode du porte
couper le fil a Ia pointe de contact.
Porter des vŒtements de protection dØpourvus dhuile tels que des
gants en cuir, une chemise en matŁriau lourd, des pantalons sans re
vers, des chaussures hautes et un couvre chef.
cas
electrode
non
Cu
Avant de souder, retirer toute substance combustible de
telles quun allumeur au butane ou des allumettes.
vos
poches
DES PARTICULESVOLANTES
peuvent blesser
Le
es
yeux.
soudage, IØcaillement,
a Ia brosse
Porter des lunettes de sØcuntØ
en
fil de
avec
fer,
le passage de Ia
et le
Øcrans latØraux
ou un
avec
precaution.
Proteger
les bouteilles de gaz comprime dune chaleur excessive,
des chocs mØcaniques, du laitier, des flammes ouvertes, des Øtin
celles et des arcs.
Placer les bouteilles debout en es fixant dans un support station
naire ou dans un porte-bouteilles pour les empØcher de tomber ou
de
se renverser.
Tenir les bouteilles
cuits etectriques.
Ne
Jamais placer
eloignees des circuits de soudage ou autres cir
torche de
une
Une electrode de
une bouteille.
soudage
Ne
une
jamais
souder
ne
soudage sur une bouteille a gaz.
jamais entrer en contact avec
doit
bouteille
pressurisØe
-
risque dexplosion.
Utiliser seulement des bouteilles de gaz protecteur, regulateurs,
tuyaux et raccords convenables pour cette application specifique;
les maintenir ainsi que les ØlŁments associØs en ban Øtat.
Ne pas tenir Ia tŒte
bouteille.
piŁce
meulage gØnŁrent
desØtincellesetdesparticules mØtalliquesvolan
tes. Pendant Ia pŁriode de refroidissement des soudures, elles risquent
de projeter du laitier.
S
manipuler
en
face de Ia sortie
en ouvrant
Ia soupape de Ia
Maintenir le chapeau de protection sur Ia soupape, sauf
dutilisation ou de branchement de Ia bouteille.
en cas
Ure et suivre les instructions concernant les bouteilles de gaz corn
prime, les Øquipements associŁs et les publications P-i CGA Ønu
mØrØes dans les normes de sØcuritØ.
Øcran facial.
.
OM-1584 Page 6
1-3.
Dangers supplØmentaires
en
relation
avec
Iinstallation,
le fonctionnement
et Ia maintenance
Risque DINCENDJE
OU
DES
ORGANES MOBILES
provoquer des blessures.
DEXPLOSION~
Ne pas
placer lappareil
proximitØ
Ne pas installer
sur, au-dessus ou
a
Rester a lØcart
de surfaces infliammables.
Iappareil a proximitØ
de
peuvent
des organes mobiles
le
comme
ventilateur.
MaintenirfermØsetfixementen place es portes,
panneaux, recouvrements et dispositifs de
produits inflammables
Ne pas surcharger Iinstallation Ølectrique sassurer que lalimen
tation est correctement dimensionnØ et protØgØ avant de mettre
Iappareil en service.
-
LACHUTE DE
protection.
FRE
LE RAVONNEMENT HAUTE
QUENCE (H.F.) risque de provoquer
des interferences.
LAPPAREILpeut
bIesser~
Lerayonnementhautefrequence peutprovoquer
Utiliser lanneau de
des interferences
avec les Øquipements de ra
dio-navigationetdecommunication, lesservices
levage uniquement pour sou
lever lappareil, NON PAS les chariot, les bouteil
es de gaz ou tout autre accessoire.
engin dune capacitØ appropriee pour
lappareil.
En utilisant des fourches de levage pour dØplacer lunitØ, sassurer
que lesfourches sont suffisamment longues pourdØpasserdu ctØ
oppose de lappareil.
Utiliser
un
soulever
de sØcuritØ et les ordinateurs.
Demander seulement a des personnes qualifiees familiarisØes
avec des Øquipements Ølectroniques de faire fonctionner linstalla
tion.
Lutilisateur est tenu de faire
qualifiØ
corriger rapidement par
les interferences resultant de installation.
Si le FCC
un
Ølectricierr
signale des interferences, arrŒter immØdiatement lappa
reil.
Effectuer
LEMPLOI EXCESSIF peut
SURCHAUFFER LEOUIPEMENT.
PrØvoir
une pØriode de ref roidissement, respec
cycle opØratoire nominal.
RØduirelecourantou le cycle opØratoire avantde
recommancer le soudage.
regulierement
le contrle
ot lentretien
de installation.
Maintenir soigneusement fermØs les portes et les panneaux des
sources do haute frequence, maintenir les Øclateurs a une distance
correcte et utiliser une terre et et un blindage pour rØduire los inter
fØrences Øventuelles.
ter le
Ne pas obstruer les passages dair du
LES CHARGES
A LARC risque de
interferences.
des
provoquer
LE
poste.
ELECTROSTATIQUES
peuvent endommager
SOUDAGE
Lenergie
Ølectromagnetique
risque
de
provoquer des interferences pour lequipemont
Ølectronique sensible tel que les ordinateurs et
IØquipement commandØ par ordinateur tel quo
les circuits im
pnmØs.
los robots.
Etablir
Ia connexion avec Ia barrette de terre
avant de manipuler des caries ou des piŁces.
Utiliser des
pochettes
et des boltes
pour stocker, dØplacer
circuits imprimes.
ou
antistatiques
expØdier des caries de
Veiller ace que tout
lequipement de Ia zone de soudage soit com
patible ØlectromagnŁtiquement.
Pour rØduire Ia possibilitØ dinterfŁrence, maintenir es cables do
soudage aussi courts que possible, les grouper, ot los poser aussi
bas quo possible (ox. par terre).
Veiller a souder a une distance de 100 metres de tout Øquipement
electronique
DES
ORGANES MOBILES
provoquer des blessures.
Ne pas
sapprocher
peuvent
En cas dinterfØrences
incombe a lutilisateur
des organes mobiles.
Ne pas sapprocher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE
voquer des blessures.
sensible.
Veiller a ce que Co posto do soudago soit
conformØment a ce mode domploi.
peuvent pro
aprØs avoir pris
los
Ne pas
diriger
le
pistolet
avant den avoir
soi, dautres
en
per
engageant
mesures
prØcØdentes,
il
prendre des mesures supplØmentaires
telles quo le dØplacement du poste, lutilisation de cables blindØs,
lutilisation de filtres do tigne ou Ia pose de protecteurs dans Ia zone
de travail.
LES CHAMPS MAGNETIQUES peuvent
affecter les stimulateurs cardiaques.
cardiaque,
restez
a dis
tance.
Los
vers
piŁce mØcanique
soudage.
sonnes ou toute
le Ill de
gachette
et mis a Ia terre
de
Porteurs de stimulateur
Ne pas appuyer sur Ia
recu linstruction.
pose
porteurs dun stimulateur cardiaque doivent
dabord consutter leur mØdecin avant do sappro
cher des operations do soudage a arc, de gou
geage
ou
de
soudage
par
points.
OM-1584
Page
7
Principales
1-4
normes
de sØcurite
Safety in Welding and Cutting, norme ANSI Z49. 1, de lAmerican
ding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Wel
Safetyand Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
Safe
Handling
of
Compressed Gases
Cylinders, CGA Pamphlet
de sØcuritØ en soudage, coupage etprocØdØs connexes, norCSA Wi 17.2, de IAssociation canadienne de normalisation, vente
de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W
RŁgles
me
20402.
Recommended Safe Practice for the Preparation for Welding and Cut
of Containers Thai Have Held Hazardous Substances, norme
AWS F4.1 de American Welding Society, 550 N.W. Lejeune Rd, Mia
ting
,
mi FL 33126
1R3.
Safe Practices ForOccupationAndEducational EyeAnd Face Protec
tion, norme ANSI Z87.1, de IAmerican National Standards Institute,
1430
Code, NFPA Standard 70, de Ia National Fire Pro
Association, Batterymarch Park, Quincy, MA 02269.
Broadway,
New York, NY 10018.
Welding Processes, norme NFPA 51 B, de Ia National
Batterymarch Park, Quincy, MA 02269.
National Electrical
Cutting and
tection
Protection Association,
Information
1-5
sur
les
sur le soudage Ølectrique et sur les effets,
champs magnØtiques basse frequence
pour
Iorganisme,
Afin de rØduire les
de
soudage, pendant son passage dans les cables de sou
dage, causera des champs ØlectromagnØtiques. II y a eu et ii y a
encore un certain souci a propos de tels champs. Cependant, aprŁs
avoir examine plus de 500 etudes qui ont ØtØ faites pendant une pØ
National Research Council
a
un
comitØ
special
conclu: Laccumulation
ruban bleu du
Garder es cables ensembles en Ies torsadant
attachant avec du ruban adhØsif.
2
Mettre tous les cables du ctØ
3
Ne pas courber pas et
votre corps.
4
Garder le poste de
de vous.
de preuves, sui
jugement du comitØ, na pas dØmontrØ que Iexposition aux
champs magnØtiques et champs Ølectriques a haute frequence reprØ
champs ØlectromagnØtiques dans
lenvironnement
travail, respecter les consignes suivantes
1
Le courant de
node de recherche de 17 ans,
Fire
champs Ølectromagnetiques
DonnØes
des
in
P-i, de Ia Compressed Gas Association, 1235 Jefferson Davis High
way, Suite 501, Arlington, VA 22202.
ne
oppose
de
ou en
es
lopØrateur.
pas entourer pas les cables autour de
soudage
et les cables le
plus
loin
possible
vant le
risque a Ia sante humaine. Toutefois, des etudes sont
en cours et les preuves continuent a Œtre examinØes. En at
5
Relier Ia
pince
de
masse
le
plus prŁs possible
de Ia
zone
de
soudure.
sente un
toujours
tendant que les conclusions finales de Ia recherche soient Øtablies, 1
vous serait souhaitable de rØduire votre exposition aux champs Ølec
tromagnØtiques pendant
le
soudage
ou
le coupage.
Consignes relatives
aux
stimulateurs
cardiaques
Les personnes qui portent un stimulateur cardiaque doivent avanttout
consulter leur docteur. Si vous Œtes dØclarØ apte par votre docteur, il
est alors recommandØ de
respecter
es
consignes
ci-dessus.
.
.
OM-1584
Page
8
SECTION 2- INTRODUCTION
Specifications
2-1.
Type
of
Welding
Input
24 Volts AC
Constant
Single-Phase
10 Amperes
Speed
Range
Type
Range
Standard: 50 To 780
To 19.8 mpm)
ipm (1.3
Voltage (CV)
Optional High Speed:
1pm (2.3 To
36.5 mpm)
Contactor Control
100 Volts,
To 3.2
Amperes,
100% Duty Cycle
Max
92 To 1435
12 ft
Height With
4 ft
(1.2 m)
(3.7 m)
17 ft
Post
Vertical Lift Of Boom
Horizontal to 60
Welding Circuit
Rating
.023 To 1/8 in
(0.6
mm)
DC With 14-Pin And
50/60 Hertz
Maximum
Wire Diameter
Wire Feed
Power
Source
Power
Weight
l2ft(3.7m):
(94 kg)
207 lb
750
16ft(4.9m):
(127 kg)
Spool Weight:
(27 kg)
280 lb
60 lb
16 ft
Boom
(4.9 m)
21 ft
(5.2 m)
Above Horizontal
Boom
(6.4 m)
Above Horizontal
Horizontal to 60
SECTION 3- INSTALLATION
3-1.
Installing Swivel
Into
Pipe Post
1
Swingpak
2
Pipe
3
Steel Bolt
Secure
mum
Base
or
CBC Cart
Post With Base
shown
as
using
as a
mini
1/2 in diameter SAE grade 5
steel bolts.
4
Swivel
Insert
Assembly
pipe post. Lubricate
into
swivel.
2
5
Safety
A
Do
Collar
not
remove
until
instructed to.
1
3
Tools Needed:
~
3/4 in
ST-152 382
OM-1584
Page
9
Installing Control
3-2.
Box And
Adjusting
Tilt
1
Weld Control
2
Bracket
3
Screw
Bracket and
installed
screws are
onto bottom of control at
1
factory.
Swivel
4
Loosen
Place control
screws.
swivel and slide forward.
on
Tighten
screws.
Tilt Bracket
5
6
Rear Pivot Screw
7
Front Screw
6
Loosen
front
4
rear
pivot
Remove
screw.
Pivot control down
screw.
ward to desired
7
viewing angle. Re
place and tighten front screw.
Tighten pivot screw.
3
Tools Needed:
1T~ZTJnZZZ1J
3/8 in
ST-lbS 1741ST-801 280
3-3.
Installing
Boom And Reel
Support
1
Swivel Plates
2
Yoke
Remove
plates
3
hardware
and
as
shown.
Yoke Pin
4
Install
ter
swivel
Boom
Set boom into swivel
3
from
yoke.
pin
5
pin through yoke. Install
and spread ends.
cot
Bolt
7
Install
bolt,
washers,
Tighten hardware,
one
half turn.
6
Locking
and
nut.
and back bolt off
Knob
4
Install
locking
knob
but
do not
tighten.
6~
7
Reel
Support
Install reel
support.
2
a0
Tools Needed:
r
3/8, 3/4 in
ST-I 53 170
OM-1584
Page
10
S
3-4.
Installing
Wire Guide Extension
1
Wire Guide
2
Bolt
Fitting
3
Monocoil Liner
4
Wire Guide Extension
Tighten bolt to secure liner in wire
guide fitting. Do not overtighten
bolt and crush liner.
Repeat procedure
for
opposite
side.
Tools Needed:
cT~~TJ===in
3/8 in
ST-152 383
Motor Start Control
3-5.
To
change wire feed starting speed
proceed as follows:
Turn Off wire feeder and
power
welding
source.
Remove wrapper.
1
Front Panel
Front
panel
shown
open for il
lustration purposes.
2
3
Motor Board PCi
Motor Start Control Poten
tiometer R70
Turn
potentiometer clockwise to in
crease
time it takes the motor to
ramp up to speed. Remove protec
tive white rubber cap before mak
ing adjustment. Adjust potentiome
using a small nonconduc
ter R70
tive screwdriver.
Reinstall wrapper.
Tools Needed:
Non-Conductive
_
cTIJ==i1
114 in
Ref. ST-142 710-A / Ref. SB-146 882-D
OM-1584
Page
11
3-6.
Equipment Connection Diagram
Welding
Power Source
Remote 14 Connection
Negative (-)
Weld
Output
Cable
Positive
Cable
(+)
Weld
Output
Workpiece
Voltage Sensing
(Optional)
Weld Control
Boom
Gun
Swivel
Pipe
Post And Base
Gas Hose
Gas
Supply
.
OM-1584
Page
12
3-7.
3-8.
Control Box Connections
14-Pin
Plug Information
~j~*
REMOTE ~
jo
OA
H0
30 0M 0D
0
*The
remaining pins
are
Pin Information
A
24 volts
B
Contact closure to A
G
Circuit
C
+10 volts dc
D
Remote control circuit
common.
E
0 to +10 volts dc
command
H
Voltage feedback;
F
Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes.
ac
with
respect
common
to socket G.
completes
24 volts
ac
contactor control circuit.
for 24 volts AC circuit.
output
to remote control with
input
signal
respect
to socket D.
from remote control with
0 to +10 volts dc, 1 volt per 10
arc
respect
to socket D.
volts.
not used.
OM-1584
Page
13
Removing Safety
3-9.
Collar And
Adjusting
Boom
1
Locking
Tighten
Knob
knob
prevent boom
to
movement. Loosen knob to allow
movement. Change knob
position to limit upward movement.
boom
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
2
threads are through
vent boom falling.
4
E
yoke
to pre
Yoke
safety collar for use in
assembling or moving boom.
Retain
0
dis
1
Rod
Tools Needed:
~ 1-1/8
in
Increasing Spring
Decreasing Spring
Pressure For A
Pressure For A
Heavy
Gun
Lighter
Gun
ST-142 599-B
3-10. Gun Recommendation Table
Process
GMAW
FCAW
3-11. Wire
Motor
-
-
Hard
or
Gun
Cored Wires
Self-Shielding
Wire
GA-4OGL Or GA-5OGL
Wires
Type, Size,
Speed
M25, M40, GA-50C, GW-500, Or GW-600
Type
And Feed
Speed Capability
Table
Wire Size
Feed
Standard
All
Standard
All
3/32 To 7/64 in (2.4 To 2.8 mm)
Standard
All
1/8 in (3.2 mm)
Optional High
All
OM-1 584
Page
14
.023 To 5/64 in
.023 To 5/64 in
(0.6
(0.6
To
2mm)
To 2
Speed Capabiity
50 To 780
ipm (1.3
To 19.8
mpm)
50 To 700
ipm (1.3
To 17.8
mpm)
50 To 300 pm
mm)
92 To 1440
(1.3
ipm (2.3
To 7.6
mpm)
To 35.6
mpm)
.
3-12.
Installing
And
Wire
Threading Welding
Tools Needed:
3/8,15/l6in
3/16, 5/64 in
wire
Install
Adjust tension
wire
is
wire feed
taut
spool.
nut so
when
stops.
1~
Install wire
guide.
4-
-~
NONCONDUCTIVE
SURFACE
No Wire
Be
NONCONDUCTIVE
SURFACE
Wire
Slip
Slips
that outlet cable has proper
welding wire size.
ltT Forsoft wire orsmall diameter stainless
When installing gun, position liner
extending from outlet wire guide as
close as possible to drive rolls without
touching.
install gun. Lay gun cable out straight. Cut
offend of wire. Push wire through guides up
roll pressure from 0 to a maximum of 4
on the pressure indicator scale (so that
sure
size liner for the
to drive
Jog
rolls; continue
steel wire,
use
2 drive rolls and set drive
the inner
spring is compressed).
This setting will generally give the best
performance for these types of wires.
only
To
adjust
drive roll pressure, hold nozzle
about 2 in
(51 mm)
from nonconductive
surface and press gun trigger to feed wire
against surface. Tighten knob so wire does
not slip. Do not overtighten. If contact tip is
completely blocked, wire should slip at the
feeder (see pressure adjustment above).
Cut wire off. Close
Repeat
cover.
for other side.
to hold wire. Press
button to feed wire out gun.
ST-153 171 1 ST-153 073/ Ret ST-137 391-Al ST-142 597-A/ Ref. S-0627-A/ Ret ST-iSO 922
OM-1584
Page
15
3-13.
Optional Equipment
DIP Switch
Settings
I~T If wire feeder is equipped with
to the OFF position
sensing
X Means switch
I
can
be in either
Means switch must be in this
OM-1584 Page 16
position.
position.
a
voltage sensing lead,
set DIP switch S3
If wire feeder is NOT equipped with
lead, set DIP switch S3 to the ON position (down).
(up).
a
voltage
.
3-14.
Digital Voltage Control Option Changeover For Inverter-Type
.
Power Source
1
Digital Voltage Control Board
Connections For Standard
Use
2
Digital Voltage Control Board
Connections For Use With In
verter-Type Welding
Power
Source
Change
connections
plug
as
shown.
Calibration Potentiometer
R31
3
~ If wire feeder is being used
with
an
source
inverter-type power
has a voltage
that
range of 10 to 35 volts in the
CV mode, no calibration is re
quired.
Calibrate Volts meter
Rotate Schedule A
Voltage Control,
tive,
or
as
follows:
Schedule B
whichever is
to the maximum
ac
position.
Turn On wire feeder and
welding
source.
power
R31 until wire feeder Volts
Adjust
displays a voltage equal to
the maximum voltage listed on the
Voltage/Amperage control of the
welding power source nameplate.
meter
Make
a
sample
preset voltage)
weld
(at
desired
to see if actual arc
voltage displayed by the wire feed
er
Volts meter is different than pre
voltage due to cable resis
set arc
tance, poor connections,
there is
etc.
If
difference, R31 can be
adjusted until preset voltage is
a
closer to actual
Close and
arc
secure
voltage.
front
panel,
and
reinstall wrapper.
Tools Needed:
cI~1====4i
1/4 in
Ret ST.142710-A/S-0891
OM-1584
Page
17
SECTION 4- OPERATION
Front Panel Controls
4-1.
ST~152 647
Voltmeter
1
Wire
2
(Optional) (See
Speed
Meter
Section
4-2)
(Optional)
Factory set to display inches per minute. If
display of meters per minute is desired, see
control functions
as a
remote
control to
arc
voltage,
IJTT For dual schedule
schedule switch is
Section 3-13.
Schedule A
Speed Control
Voltage
5
Schedule B Indicator
6
Schedule B Wire
Control
a digital voltage control is used with
inverter-type welding power source, the
Volts Meter
~_Note_~J~
Ught (Optional)
9
10
Left And
Right
Jog/Purge
Indicator
B
.
Lights
Switch
momentarily feed welding wire at
Speed control without
energizing welding circuit or shielding gas
Push up to
7
Schedule B
8
Press To Set Button
Voltage
set on Wire
valve.
Speed Control
(Optional)
Push down to momentarily
valve to purge air from gun
Control
energize gas
adjust gas
or
regulator.
(Optional)
When
4-2.
applications, a dual
required for the gun.
speed
(Optional)
an
preset Schedule
speed and/or voltage.
Press and hold button to
wire feed
a proper dual schedule switch
and install according to its instructions.
The scale is calibrated in inches per minute
x 100 and meter per minute.
4
digital voltage
Obtain
Schedule A Wire
3
preset
Center
(Optional)
position
is off.
Display
Voltage displayed throughout
Voltage Control Type
Volts Meter
Display
the weld is the weld
Weld
voltage
at 5 seconds into the weld.
Not Weld
Hold
See Note
Weld value for 15 seconds, then 0
Monitor
Actual
0
Hold
See Note
Monitor
Actual
or
OCV
Standard 1-Turn Control
Digital
OM-1 584
or
OCV
Weld value for 15 seconds, then
10-Turn Control
Page
18
Preset
preset
.
4-3.
Overload Protection And
\
Optional
Side Panel Controls
\ HI
\~
00
\OOj
bbo
' ''
Ret. ST-143 258-B
1
If 0 to 2.5 seconds is desired,
Circuit Breaker CB1
CB1 protects wire feed motor from
load. Press to reset.
over-
4
Preflow Control
or a
Control sets time gas flows before
wire is
3
welding
Spot
Continuous Switch
Factory
Time Control
set for 0 to 5 seconds of
5
timed
an
spot
time.
struck. To end
6
untimed continuous weld
spot weld.
Trigger
Hold Switch
(Optional)
Push up to weld without holding gun
throughout the weld cycle.
energized.
Spot
Section
weld, press and release gun
trigger.
Switch selects
2
see
3-13.
Burnback Control
Control adjusts time welding wire is
gized after wire feed stops.
7
ener
Postflow Control
trigger
To start weld, press and release gun trigger
within three seconds after an arc has been
Control sets time gas flows after completion
of burnback.
Close side door.
SECTION 5- MAINTENANCE & TROUBLESHOOTING
5-1.
Routine Maintenance
A
Disconnect power before
maintaining.
OM-1584
Page
19
5-2.
Troubleshooting
Disconnect power before
A
Trouble
Remedy
Wire feeds, shielding gas flows, but
electrode wire is not energized.
Check
Wire feeder is on, meter(s) do not light
up, motor does not run, gas valve and
Check and reset CB1
welding
pull
power
source
troubleshooting
interconnecting cord
connections. If secure, check cord for
continuity and repair or replace (see
Sections 3-6 and 3-7).
(see
Section
4-3).
contactor do not
in.
Electrode wire feeding stops
erratically during welding.
or
feeds
Check gun
trigger connection.
Check gun
trigger.
Readjust
Change
Clean
or
Motor
runs
slowly.
to correct size drive roll
replace dirty
leased, and trigger
or worn
contact
tip
hold is not
Authorized Service
Factory
Check for
3-12).
7-1).
liner. See gun Owners
or
Section
guides.
Have
foreign
Manual.
matter from around nozzle
Agency
opening.
check drive motor
or
motor control board PCi.
input voltage.
a
short between
welding
trigger
leads and weld cable.
Repair
short
or
replace welding
a
short between
welding gun trigger
leads and weld cable.
Repair
short
or
replace welding
gun
gun.
on.
Check for
Unit does
Install, reconnect,
switch out of
wire
Table
(see
drive roll.
spatter
Gas valve in feeder is rattling loudly
along with possible erratic or slow wire
teed speed.
not
or
or worn
Manual.
Manual.
(see
Remove weld
Check for correct
Wire does notfeed until trigger is pulled,
but continues to feed after trigger is re-
See gun Owners
hub tension and drive roll pressure
Incorrect size
Replace
See gun Owners
Run-In
gun.
or
replace voltage sensing
lead.
Speed.
Wire feeder power is on, displays
up, but unit is inoperative.
Schedule A Wire Feed
light
Speed works,
Speed does
Check
welding gun trigger
DIP Switch Si
(i)
on
leads for
Option
continuity,
and
repair
leads
or
replace gun.
Interface Board PC7O must be in the On
position (see Section 3-13).
but Schedule B Wire Feed
not work or is erratic.
Wire Feed
display does
speed.
Set DIP Switch S2
on
Meter Board PC6O in Inches/Minute mode
arc voltage display on meter is
held after trigger is released, or arc volt
age does not change while welding.
Set DIP Switch S2
on
Meter Board PC6O in
Speed
Meter
(see
Section
3-13).
not match actual wire feed
Actual
OM-1584
Page
20
Voltage
Monitor mode
(see Section 3-13).
Notes
OM-1 584
Page
21
-~
SECTION 6- ELECTRICAL DIAGRAM
I_J 6
Pt.Ci06
3P
FlOW
I
r<
(~)
~
PLC8P
I I
-
~
-
-W;~-:,-
L~~J
I
~~I.Ei
I
~1T46E SEICE
_______
1~ ORIVE
H~
77
r~i
LEFT
12
7>
~1-5
>
) 5
>
)
2>1
72
2>
RCI-3>>----O---43
,<
RC1-.4>>~-
>4
4>
> 8
6
1_
/
7/
~
RC1-l>>~-
>i>-~
i>2~
RC1-6>>~-
>R>~
6>
P1.61
Pt.Gl
~
P-Oil
R02~4
P1017
Pd2
>>-~(<
RC2-2 >>-~4Z<
662-6 >>-~<<
RC2-1 >)-~<<
RC2-3 >,_L~.(<
662-5
P1627
P1.034
RC3O
5
3>
RdB
>
12
5>
845
645
.AJMPER B66~)
6623S
41
41
A
4~PLG33
IB
ARc37
41
41P1637
I
I~
A
6663-2
5
64
~
6663-4
1~
Rc53-l
j~
P1028
R~53-3
I?f<~
I~
St~ ~PL036
~
P1612
6646
Pcso
.(.L<114~E~11>__<
P1.628
6627
P1611
6664/P1054
I
(
I~H.1
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(OPIIOOIAL)
I
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41
~
6638M556
6654-I..
T~H0I4Et68 BOORS
71
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I
845
Rc53/11053
I
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cR101
u1~
66543
I~ I~ 111
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~
,~
,~
f~
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~n
P1033
p6~
~
6640
PCI
P1dB
8
~ 6>-~<
MOIOR
66101
i
~
P1617
6637
P1038
i
~
P1039
~RC54-5>)~-4~Rc68-3~
_____~U~-~<Rc68-6
~(RC98-I
8
(,0~
I ~t ~7-II ~P10l8
661mG,
RC3/PIG3
RcRlmogl
Rd62/DI.052
,
RcBo/11093
A
ARC3O
ARC4O
~
,~ ~P1028 ~ ,~ ,~P1038
A
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6663
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V
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VpL0IIV
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pcsi
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861
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~
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BC
<<6C94-7
V6637
V
7
2
P155
~
I,,
I
6652
I
II~
TAOI~dE1ER
I
6669/01668
((6664-6
~ ~-~
2
~-~-O2--~-~O-
~
I~ I~
IJ~J~7P-~~!~
~) ~PLG34~
P1610
R654/P1064
6c95/PL065
R696/P1096
R697/P1097
6686/P1058
I~IeI~
I~ t~ l~
A
i
L66I669
~~<U~
I I
60466
RcRo/P1090
V
V
RC6/P168
;v.-~Rc96_3
327
27
VPL62BV
V
VPI.039
6C4/P164
R65/P105
P63
RflM
L~668
21
4
/5
663-1 >
4321
P1O28~fl~
>>-~663-3 >>-~-~663-2
P1023
~6AAAA
P1024
4321
/9
4321
LEFT
BOlT
CC
r~r~:
~
I
I
,~
OIW
~8~5J~I IaI~J~I
RC47
EC
I
-
~18
8
~
~J ~
6660
6684I>
-~
6651>>
6652
:
<<6682-3
/0
I
--(<
6682-2
<<
RCR2-4
RC82/P1682
RC63/DEE F82TE
3
66842
551
I
<<
66168
>~( 6643-4
>>.
-J
6684-4>
9/
66645>
<<6682-5
3
3
I
I
____
Figure
OM-1 584
Page
22
>~~~L4~<
RC84_8>>~J
I
6-1. Circuit
Diagram
6C41 -2
BC/PLO
)<< RC433
66501
I
6657
FOR
I
((Ff04101.)
OWlillOl
(
I
RC64mG84
6821.11.
608~
60LTAOE
)<<R6435
6694-3>
665-3
7 ~ 7 7
T
~
6643B
I
>
I
66432
>>~~
6642-2
6642-3
7
~
~
>>~
5042-I >>
RC4I4)
V~V~V_________
RCR4-I
j
tj
AAAAThICAA
a
AAAAAAAA
9 9 9 9 9999
!~ f___S_C<RCJ5-T
r__!__tck
RCJG-I
RC354
AAAAAAA
Li
A
99999
~
RC353
1!
I
AAAAAAAA
ii~I
99999999
I
R0352
I
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AAAAAAAA
~
I
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I I I
(RIGHT)
a~a~ ~ ~a~a~a
a
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9000000000
a
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M
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1~
a
~
L_Mc~.~a,aaa ~
v-v----v-v-v-v-v-v
_____________________________
--
~1
ir
1
r
9.
L~i~iH~--
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Ill
p 0
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p
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9
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rL~ ~
L~!ALAJ
th
o
~
a
_Jj
SECTION 7- PARTS LIST
U~
Hardware is
common
and
not available unless listed.
I
~
i
p
.1
~_
C)
Ii-
cJ
F-.
cJ
c.1
CD
F-.
CD
r-.
C)
LI~
LL
ST-142 305-N
Figure
OM-1584
Page
24
7-1. Main
Assembly
Quantity
Dia.
Item
No.
Model
Part
No.
Mkgs.
Description
Figure
1
149 251
...
1
149 252
...
PLG23,25
PLG24,26
....
....
079 531
....
605 156
....
080 328
....
See Note
...
3
164 475
...
164 474
...
3
PLG27,28,37,38
.
....
079 739
....
....
4
159 297
...
5
139 600
...
l7ft
1
1
....
2
....
2lft
..
1
....
1
1
2
2
2
HOSE, gas
...
2
17ft
1
2
2
....
21ft
..
1
....
2
2
139599...HOSE,gas
.5
CABLE, weld cop strd No. 4/0 (order by ft)
602 243
WASHER, flat stl std .375
602 213
WASHER, lock stl split .375
601 872
NUT, sti hex full .375-16
080 947
BRACKET, spring retaining
151 626
BRACKET, spring retaining
132 053
SCREW, cap stl hexhd .375-16 x 1.500 Ig
hub & reel
7-2
SUPPORT,
Fig
149838...PIPEPOST,4ftw/baseor
PIPE POST, 6ft w/base
149 839
PIPE POST, 4ft w/base or
078 264
079216...PIPEPOST,6ftw/base
PIPE POST, 4f1 w/o base or
075078
PIPE POST, 6ftw/o base
079217
6
600 324
7
...
...
8
..
9
...
10
3oft
26ft
..
8
....
4
.
...
10
4
....
....
8
4
4
1
1
...
11
...
12
...
.13
13
...
13
4
4
1
1
1
1
1
...
.13
.14
.14
15
7-5
...
115 092
...
135 409
...
Fig
16
.
17
...
.
.
.
PLG11,17
PLG33,34
RC27,37
....
....
047 637
...
048 144
...
605 227
...
125 785
...
21
139 813
...
22
139 816
...
23
159 647
...
24
159 646
...
25
159 360
...
26
156 243
...
27
145 639
...
.28
134834
...
167 774
...
775
...
.30
157 295
...
31
604 612
...
32
082 050
...
33
167 780
...
....
19
20
2
CONNECTOR & PINS
CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2
CABLE, port No. 18/14 8/c (order byft)
HOSE ASSEMBLY, gas
163 519
18
2
1
CONNECTOR, circ clamp str rlf sz 11 Amp 206358-2
CABLE, port No. 184/c (order by ft)
CONNECTOR w/SOCKETS, free hanging
CONTROL BOX, (Fig 7-4)
CABLE, interconnecting (consisting of)
CABLE, interconnecting (consisting of)
047 636
16
2
CONNECTOR & PINS
....
I
Assembly
CABLE, trigger (consisting of)
CABLE, trigger (consisting of)
079 878
2
7-1. Main
12
GS1,2
29
29
167
33
167
781
...
33
167
782
...
1
1
1
BOOM ASSEMBLY
1
CONNECTOR & SOCKETS
CONNECTOR & PINS
CONNECTOR & SOCKETS
2
CONNECTOR, circ pin plug keying Amp 200821-1
NUT, nyl hex jam .75ONPST
VALVE, 24VAC 2 way custom port 1/8 orf
COVER, protector motor
PANEL, end cover
INSULATOR, motor clamp
CLAMP, motor base
INSULATOR, screw machine
CLAMP, motor top
STRIP, buna N compressed sheet .062 x 4.000sq
2
2
2
HOSE,SAE.187lDx.4100D(orderbyft)
DRIVE ASSEMBLY, wire RH
DRIVE ASSEMBLY, wire RH
(w/tach) (Fig 7-6)
(high speed) (Fig 7-6)
2
2
1
1
2
2
8
2
2
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
1
1
1
2
2
2
2
2
2
1
1
2
2
8
2
2
3ft.... 3ft
1
1
2
GUIDE, monocoil
4
SCREW, set stl sch 8-32 x .125 cup point
2
LINER, monocoil inlet wire
1
DRIVE ASSEMBLY, wire LH (w/tach) (Fig 7-6)
1
DRIVE ASSEMBLY, wire LH (high speed) (Fig 7-6)
DRIVE ASSEMBLY, wire LH (high speed w/tach) (Fig 7-6) 1
149322...CLAMP,hose.405-.485c1p
....
4
....
....
....
....
....
....
....
....
....
1
1
2
4
2
1
1
1
4
ordering Control Box contact factory service department for proper number.
factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Note: When
To maintain the
OM-1 584
Page
25
Item
No.
Part
No.
Description
Figure
1
2
3
....
058427
....
136684
....
605941
....
010233
....
057971
6....
010191
7
....
058628
....
058428
....
080393
4
5
8
9
124900
12... +168 104
166594
...13....
Support,
Hub & Reel
(Fig
7-1 Item
12)
RING, retaining spooi
NUT, stl slflkg hex reg .625-11 w/nyl insert
WASHER, flat stl .640 ID x 1.000 OD x l4ga thk
SPRING, cprsn .970 OD x .120 wire x 1.250
WASHER, flat stl keyed 1.SOOdia x .l2Sthk
WASHER, fbr .656 ID x 1.500 OD x .l2Sthk
WASHER, brakesti
HUB, spool
SUPPORT, reel
REEL, wire 60 lb (consisting of)
SUPPORT, reel spool
RETAINER, spool support (consisting of)
LABEL, caution falling wire reel can cause damage
NUT, spanner retaining
10... 108008
11....
7-2.
Quantity
168103
2
2
2
2
2
4
4
2
1
2
1
1
1
1
Hardware is
common
and
not available unless listed.
8
7
6
9
10
b
ST-081 760-C
Figure
7-2.
Support,
Hub & Reel
OPTIONAL
+When
ordering
component originally displaying
a precautionary label, the label should also be ordered.
factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
a
To maintain the
OM-1584
Page
26
Part
No.
Dia.
Item
No.
Mkgs.
Figure
R1,2
1
073562
149654..
2
3
4
136339
138548
5
134209
LED1,2
6
179203
....
172
173
134 209
179 203
5
6
7
825
748
LED71/81
S71/81
150 982
153 195
8
150 981
9
PLG43
PLG45
PLG47
PLG48
115 090
131 203
PLG68,74
131 204
115 094
131 204
Quantity
Description
7-3. Panel, Front
w/Components (Fig
7-4 Item
23)
POTENTIOMETER, C sltd sft iir 2W 10K ohm (Wire Feed Speed A)
PANEL, front
Part Of Option 181 948 Two Meter wflach
COVER, opening meter
DIGITAL VOLTAGE CONTROL, (see optional equipment)
NUT, speed push-on-type .250
LED, 5100 2.OV 2OmA green
DIGITAL DUAL SCHEDULE, RH (consisting of)
DIGITAL DUAL SCHEDULE, LH (consisting of)
NUT, speed push-on-type .250
LED, 5100 2.OV 2OmA green
SWITCH, PB MC SPDT 6A 125VAC (Press To Set)
NUT, faceal .250-40
BUTTON, switch black
CONNECTOR & SOCKETS, (RH only)
CONNECTOR & PINS, (RH only)
CONNECTOR & PINS, (RH only)
CONNECTOR & SOCKETS, (LH)
CONNECTOR & SOCKETS, (RH)
2
1
1
2
1
2
2
1
1
1
2
1
1
1
1
1
1
1
2
1
PLG72
131 054
R76,77/86,87
603 856
CONNECTOR & SOCKETS
POTENTIOMETER, WW sltd sft 1 0/T 2W 10K ohm
(Wire Feed Speed B/Voltage Control B)
2
097 922
KNOB, pointer
2
.11
RC8,9.... 048 282
134 846
S2,3
12
097 922
.10
13
Hardware is
common
See Figure 7-7 for additional parts
CONNECTOR w/SOCKETS
SWITCH, tgl SPIT 15A 125VAC (Jog/Purge)
KNOB, pointer
NAMEPLATE, (order by model and serial number)
2
2
2
1
and
not available unless listed.
*See
Option
that is
applicable
ST-143 227-C
Figure
7-3.
Panel, Front w/Components
OPTIONAL
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1 584 Page 27
Hardware is
common
and
not available unless listed.
1
7
3
4
25
Fig
15
7-7
14
~18
19
20
Fig
7-3
22
ST-142 307-C
Figure
7-4. Control Box
.
OM-1584
Page
28
Dia.
Item
No.
Part
No.
Mkgs.
Description
Figure
(Fig
7-1 Item
2)
140010
PANEL, side lower
1
PC2
134994
1
PLG53
115092
CIRCUIT CARD, tach jumper...
CONNECTOR & SOCKETS....
PLG54
115093
CONNECTOR & SOCKETS
1
PLG56
131 204
CONNECTOR & SOCKETS
1
CIRCUIT CARD, tach converter
CONNECTOR & SOCKETS
1
047637
CONNECTOR & SOCKETS
2
135409
CONNECTOR & SOCKETS
2
115092
CONNECTOR & SOCKETS
2
139231
1
1....
2....
7-4. Control Box
Quantity
2.... ..PC5O...
132
370
PLG51,57.
3.... RC3O,40
PLG12,18.
PLG29,39.
131
203
1
1
pci
183120
CASE SECTION, bottom/rear
CIRCUIT CARD, motor control
PLG1
115092
CONNECTOR & SOCKETS.
1
PLG2
115093
CONNECTOR & SOCKETS.
1
PLG3
115094
CONNECTOR & SOCKETS.
1
PLG4
115091
1
PLG5
130203
CONNECTOR & SOCKETS.
CONNECTOR & SOCKETS.
PLG6
136810
CONNECTOR & SOCKETS.
1
6
151 187
LATCH, slide flush
1
7
+140 008
WRAPPER
1
1
079739
LABEL, warning general precautionary
CIRCUIT BREAKER, man reset 1P 1OA 250V
SWITCH, rocker SPST 1 OA 25OVAC (Power Switch)
BUSHING, strain relief .840 ID x .875mtg hole
CABLE, port No. 18/14 8/c (order by ft)
CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2
141 162
CONNECTOR&PINS
1
158719
CONNECTOR & SOCKETS
1
131 204
CONNECTOR & SOCKETS
1
CLAMP, univ 50A
TUBING, plstc PVC .250 ID x .375 OD x 9.000
WIRE, lead mot l4ga (order by ft)
BUSHING, strain relief .120/.150 ID x .500mtg hole
1
4.
5.
134464
8.
CB1...
083 432
9.
Si....
111 997
10
010325
11
163519
12
13
....
PLG1O
....
PLG19
PLG75
14
601
222
15
176
089
16
600
399
138
044
17
18
Ci,2
147856
19
CR101
072817
20
SRi
035704
1
1
i7ft
1
1
35ft
1
CAPACITOR ASSEMBLY
RELAY, end 24VAC DPDT
1
1
131 052
CONNECTOR & SOCKETS
2
PLG93
115093
CONNECTOR & SOCKETS
1
PLG95
PLG96
PLG99
115092
CONNECTOR & SOCKETS
1
131 204
CONNECTOR & SOCKETS
1
115094
CONNECTOR & SOCKETS
1
CONTROL PANEL
2
22
++145 948
23
Fig
PC3
PLG92,94.
Fig
7-3
7-7
120 304
119 951
107983
024103
000527
Part
1
151 147
134201
25
1
RECTIFIER, integ 40A 800V
STAND-OFF SUPPORT, PC card .312
BRACKET, mtg control box
PANEL, front w/components
CIRCUIT CARD, relay
21
24
1
BLANK,
BLANK,
BLANK,
BLANK,
BLANK,
snap-in
snap-in
snap-in
snap-in
snap-in
nyl
nyl
nyl
nyl
nyl
.25Omtg
.437mtg
.500mtg
.75Omtg
.875mtg
1
12
1
1
1
hole
hole
11
6
.
hole
2
hole
1
hole
4
of
Option 138 544 One Meter w/Tach & 181 948 Two Meter w/Tach.
ordering a component originally displaying a precautionary label, the label should also be ordered.
++Not part of Control Box Assembly
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
i-When
OM-1 584
Page
29
Hardware is
common
and
not available unless listed.
0
111111fl71
V
\
C~J
0)
~
\
L()
\
\
\
\
\
\
CD
\
14)
a)
c..J
/
/
/
/
0).
04
a)
cJ
ST-142 306-G
Figure
OM-1584
Page
30
7-5. Boom
Assembly
134327
Quantity
Model
Part
No
Item
No.
____________
Description
L16
12
-
____
Figure
1
010313
2
010910
3
079622
4
079621
5
079667
5
080812
6
079632
7
079665
7
080811
8
9
079664
139633
10
159999
10
160513
11
073742
12
13
073741
079029
14
075462
15
602250
16
079020
17
155335
18
149858
18
151625
19
150258
20
024605
21
075101
22
079030
23
+174 754
080157
24
174688
142804
25..
073666
26..
047224
27..
602246
28..
010493
29..
139818
+When
ordering
a
7-5. Boom
Assembly (Fig
7-1 Item
15)
PIN, cotterhair.072x1.437
WASHER,flatstlSAE.375
WASHER, shld .381 ID x .750 OD
PULLEY, V sgl grv 7.75Odia x 8.000P x .625 bore
PIPE, plstc .500 x 133.750
PIPE, plstc .500 x 181.750
BOLT, U stl .250-20 x .875 wide x 1.375 deep
GUIDE, wire
GUIDE, wire
GUIDE, wire inlet
LINER, monocoil 3/32-1/8 wire x 15.687
BOOM, dual
BOOM, dual
PIN, clevis .750 OD x 2.156 Ig
CLEVIS, .812 yoke 6.062 Ig .750-l6thd
NUT, sti hexfullfnsh .750-16
SHAFT, boom counterbalance
WASHER, flatstlSAE .750
NUT, stl hex elastic stop .750-16
PIPE, blk 3.000 x .875
SPRING, cprsn 3.750 OD x .625 wire x 36.000
SPRING, cprsn 3.750 OD x .640 wire x 36.000
RETAINER, spring
BEARING, ball thr sgl row .750 x 1.625 x .625
NUT, stl hex special .750-16x 1.250
WASHER, lock stl ext tooth .750
BASE, swivel boom (consisting of)
FITTING, grease 1/8NPT
BRACKET, mtg control tilt
LABEL, Swingarc caution heavy spring
LABEL, warning general precautionary
BOLT, mach stl hexhd .750-16 x 2.750
KNOB, T-bar .500-l3thd
WASHER, flat stl std .500
BUSHING, snap-in nyl .625 ID x .875mtg hole
GUARD, motor protector
component originally displaying
a
precautionary label, the
4
6
2
2
4
....
6
....
2
....
2
....
2
2
8
10
....
2
2
2
2
2
....
2
....
1
1
1
1
2
1
2
1
1
....
1
....
2
....
1
....
2
....
1
....
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
....
1
....
1
....
1
....
1
....
1
....
1
....
1
....
1
....
1
....
1
....
1
....
1
....
1
....
label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1 584
Page
31
El~ Hardware is
common
and
not available unless listed.
See Table 7-1 For
Drive Roll & Wire Guide Kits
18
19
20
22
23
16
7
10
12
26
27
28
38
36~~
32
31
ST-801 456-A
Figure
OM-1 584
Page
32
7-6. Drive
Assembly,
Wire
Item
No.
Dia.
Part
No.
Mkgs.
Description
Figure
010 668
..
172 075
..
149 962
149 486
4
5
..
..
7
163282
165 798
165799
8
132750
..
9
150 520
..
10
133 493
..
11
133350
..
6
12
12
M1,2
M1,2.
...
156354
156 353
153 491
..
..
..
..
..
.
.
.
153 492
*153 493
155 098
153 550
155 099
155 100
133493
184 136
13
14
182 414
15
182415
137 248
16
.
.
...
.
.
..
..
129 351
..
18
602 200
..
19
22
604 772
182 156
182 155
132 746
23
181 522
..
24
132 747
..
...25
....
133739
183 330
153 631
131 204
....
604 311
131 203
21
26
27
PC51
PLG57
PLG58
....
..
..
..
..
..
..
.
..
.
..
..
132 611
29
149 959
..
30
179 265
..
31
108 940
604 538
151 437
128 237
+179 263
32
.33
34
35
178 937
..
..
..
..
..
..
.
.
..36
601 872
37
40
602 213
602 243
601 966
167 387
41
168 825
..
42
133 308
..
38
39
Part
..
..
..
..
..
Wire
(Fig
7-1 Items 29 &
33)
SCREW, cap sti sch .250-20 x 1.500
CARRIER, drive roll w/components 24 pitch
SPACER, carrier drive roll
PIN, rotation arm rocker
NUT, .250-28st1
SPRING, pressure arm retaining
WASHER, fIat .257 ID stl
ARM, pressure
SPACER, rotation pin
RING, retaining ext .250 shaft x .O25thk
PIN, hinge
MOTOR, gear 1/8hp24VDC272RPM (consisting of)
MOTOR, gear 1/8hp 24VDC 500RPM (consisting of)
KIT, brush replacement (consisting of)
CAP, brush
BRUSH, carbon
KIT, cover motor gearbox (consisting of)
COVER, motor gearbox (consisting of)
GASKET, cover
SCREW, cover
RING, rtngext.25oshaftgrvx.O2Sthk
KIT, brush holder
WASHER, flat
4
4
4
2
2
2
2
2
2
2
1
1
1
1
.
2
2
1
.
1
1
5
1
.
1
1
1
1
x
.500
1
WASHER, lock sti split No. 8
WASHER, flat sti SAE No. 8
SPRING, cprsn
SPRING, cprsn
BUSHING, spring
SHAFT, spring
CARRIER, shaft
WASHER,flat.375IDx.625ODx.062
KNOB, extension
CIRCUIT CARD, digital tach (consisting of)
..
28
Assembly,
PIN, cotterhair
SPRING, indicator
SCREW, hexwhd-slt stl slffmg 8-32
..
17
20
.
7-6. Drive
Quantity
.
1
1
2
1
2
1
1
1
1
1
CONNECTOR & SOCKETS
GROMMET, rbr .250 ID x .375mtg hole
CONNECTOR & PINS
OPTICAL ENCODER DISC
FITTING, brs barbed M 3/l6tbg x .312-24
ADAPTER, gun/feeder LH
SCREW, cap stl hexwhd .250-20 x .750
WASHER, flat stl SAE .312
1
.
1
.
1
1
1
1
4
1
KNOB, plstcT 1.125 Ig x .312-18 x 1.500 bar
SCREW, hexwhd-slt stl slffmg 10-32 x .500
COVER, drive roll (consisting of)
LABEL, warning electric shock and pinch
NUT, stl hex full .375-16
WASHER, lock stl split .375
WASHER, flat stl .375
SCREW, cap stl hexhd .375-16 x 1.250
SPACER, locating
DRIVE, pinion 40T 24P .376 bore
RING, retaining ext .375 shaft x .O25thk
1
2
1
1
.
1
1
1
1
2
1
1
of 132 129
Optional High Speed Motor
Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
*Recommended
OM-1584
Page
33
Item
No.
Dia.
Part
No.
Mkgs.
Description
Figure
1
S31,32...
+011 770
2
PC7O....
+150 591
3
+
PLG16,54,76
PLG78,88..
PLG79,89
PLG8O,90..
PLG84,86,97
..
PLG85
PLG98
115 443
+115 093
+115094
+115 091
+135531
+131 204
...
+131 203
...
+131 056
+138
542
+138
547
4
126689
PC3O
5
188834
7-7. Control Panel
7-4 Item
25)
SWITCH, tgl SPDT 6A 125VAC (Trigger Hold/Spot)
CIRCUIT CARD, option interlace
STAND-OFF, No. 6-32 x .750 Ig
2
4
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
3
CONNECTOR&SOCKETS
CONNECTOR&PINS
1
2
1
CONNECTOR & SOCKETS, (LH
CONNECTOR & PINS, (LH only)
CONNECTOR & SOCKETS
only)
SPOT/BURNBACK PREFLOW/POSTFLOW, RH (consisting of).
SPOT/BURNBACK PREFLOW/POSTFLOW, LH (consisting of)
STAND-OFF, No. 6-32 x 1.500 Ig
CIRCUIT CARD, timer 4-in-i
KNOB, .i2Sdia shaft w/.125 setscrews
6
093551
7
180636
8
133 344
PLATE, control
PANEL, option
3
1
2
1
4
PLG1,21,31
PLG22,32
115 092
CONNECTOR & SOCKETS
3
135 409
2
PLG35
115 094
PLG9O
PLG91
131 204
CONNECTOR&SOCKETS
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
115 093
120 304
7
180635
8
133344
+Part of
172 825
Part
138 542
Part
(Fig
Quantity
Option
Option
of Option
of
138
1
1
1
BLANK, snap-in nyl .2SOmtg hole
PLATE, control
PANEL, option
Dual Schedule RH/i 73 748
Digital
Digital
Spot/Burnback, Preflow/Posttlow RH.
547 Spot/Burnback, Preflow/Posthow LH.
1
2
2
Dual Schedule LH.
OPTIONAL
To maintain the
factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
4
ST-146 340-B
Figure
OM-1584
Page
34
7-7. Control Panel
Dia.
Description
Part No.
Mkgs.
Quantity
Optional Equipment
...181948..
C61....
147853..
....PLG5...
130203..
....PC5O...
132370..
....PC6O...
157719..
PLG62
131055..
PLG63
138045..
PLG64
.084198..
.081378..
PLG95
115092..
R3,4.... .603856..
115443..
097132..
138548..
PC4O
PLG41,61
171 608..
....
PLG42,84,86,97..
PLG43,44
....
PLG47,49,85
R75,85
...
115094..
131 204..
084 198..
081378..
131 203..
603 856..
097922..
108008..
172825..
173748..
138542..
138547..
132129..
132130..
159288..
000571
159772..
159769..
057020..
159289..
000571
159770..
159771
057020..
180 314
157 719
603 856
R3,4
PLG5
PLG62
PLG63
PLG64
....PLG95
130 203
131 055
138 045
167361
115092
151490
131203
138045
115090
603 856
R75,85
PLG42,84,86,97.. 131 204
131 203
PLG47,49,85
...
....PLG41
115094
115091
167361
132611
PC51
153631
603115
TWO METER, w/tach (consisting of)
CAPACITOR
CONNECTOR&SOCKETS
CIRCUIT CARD, tach converter
CIRCUIT CARD, meter kit (two meter)
CONNECTOR&SOCKETS
CONNECTOR&SOCKETS
CONNECTOR, rect 6skt plug Amp 87159-6
CONNECTOR, rect skt 22-l8ga Amp 102100-2
CONNECTOR & SOCKETS
POTENTIOMETER, WW sltd sft 10/12W 10K ohm (Wire Feed Speed A)
STAND-OFF, No. 6-32 x .750 Ig
STAND-OFF, No. 6-32 x .375 Ig
See Fig 7-3 & 6 for additional parts
DIGITAL VOLTAGE CONTROL, (consisting of) (see Fig 7-3 Item 4)
CIRCUIT CARD, control voltage digital
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
CONNECTOR, rect 6skt plug Amp 87159-6
CONNECTOR, rect skt 22-l8ga Amp 102100-2
CONNECTOR&PINS
POTENTIOMETER, WW sltd sft 10/12W 10K ohm (Voltage Control A)
1
1
1
1
1
1
1
1
6
1
2
2
4
1
1
1
2
1
2
6
1
..
2
KNOB, pointer
REEL, wire 60 lb (see Fig 7-2)
DIGITAL DUAL SCHEDULE, RH (see Fig 7-3)
2
DIGITAL DUAL SCHEDULE, LH
1
1
1
(see Fig 7-3)
1
SPOT/BURNBACK PREFLOW/POSTFLOW, RH (see Fig 7-7)
1
SPOT/BURNBACK PREFLOW/POSTFLOW, LH (see Fig 7-7)
HIGH SPEED MOTOR, right side dual (see Fig 7-6)
1
HIGH SPEED MOTOR, left side dual (see Fig 7-6)
1
1
KIT, water hose 12SS (consisting of)
1
HOSE, water lOft
1
HOSE, water 14ft
1
HOSE, water 23ft
3
FITTING, hose brs coupler .625-18 LH
1
KIT, water hose 16SS (consisting of)
1
HOSE, water lOft
1
HOSE, water 18ft
1
HOSE, water27ft
3
FITTING, hose brs coupler .625-18 LH
1
KIT, meter D-60 Digital Display (consisting of)
1
METER, voltage WFS dual
POTENTIOMETER, WW sltd sft 10/1 2W 10K ohm (Wire Feed Speed A) 2
....
CONNECTOR
CONNECTOR
CONNECTOR
CONNECTOR
CONNECTOR
& SOCKETS
& SOCKETS
& SOCKETS
& SOCKETS
& SOCKETS
CONNECTOR, rect univ 039
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
POTENTIOMETER, WW sltd sft 10/1 2W 10K ohm
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
CONNECTOR & SOCKETS
OPTICAL ENCODER
CIRCUIT CARD, assembly
WEATHERSTRIPPING, adh (order by ft)
1
1
1
1
1
1
1
1
1
(Voltage Control A).
2
4
3
1
2
1
1
1
ift
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
aM-i 584
Page
35
Table 7-1. Drive Roll and Wire Guide Kits
C)
.~
Wire Size
~
E5
E~
(~
~(~
V-GROOVE
U-GROOVE
VK-GROOVE
UC-GROOVE
.
4 RoIl
Drive
4 RoIl
Drive
4 Roll
Drive
4 RoIl
Drive
Kit
Roll
Kit
Roll
Kit
Roll
Kit
Roll
149518
151024
087130
150 993
149 518
151 025
053 695
mm
150993
149518
151 026
053700
151 036
072000
151 052
132958
mm
150993
149518
161 189
053696
~
Fraction
Metric
.023-.025in
0.6mm
150993
.030 in.
0.8
mm
.035 in.
0.9
.040 in.
1.0
~
.045 in.
1.1/1.2mr
150994
149519
151 027
053697
151 037
053701
151 053
132957
151 070
083489
.052 in.
1.3/1.4mr
150994
149519
151 028
053698
151 038
053702
151 054
132956
151 071
083490
151 029
053699
151 039
053706
151 055
132955
151 072
053708
151 056
132959
1.6
mm
150995
149520
1.8
mm
150995
149520
(.079 in.)
2.0
mm
150995
149520
151 040
053704
151 057
132960
151 073
053710
(.094 in)
2.4
mm
150 996
149 521
151 041
053 703
151 058
132 961
151 074
053 709
(110 in)
2.8
mm
150 996
149 521
151 042
053 705
151 059
132 962
151 075
053 711
(15)
3.2
mm
150997
149522
151 043
053707
151 060
132963
151 076
053712
.068-072 in
5/64 in.
Each Kit Contains An Inlet Guide Intermediate
Guide,
And 045 233 Antiwear Guide With 604 612 Setscrew 8-32
x
.125, Along
With 4 Drive Rolls.
2 Kits
Required
For Dual Models.
S-O~I9-D
.
OM-1584
Page
36
Notes
Notes
Index No. M/13.0
Issued April1997
~flftL~1Wfl~
Swi nga rcM
Boom-Mounted
Processes
Swingarc
Single
and Dual Wire Feeders
boom-mounted semiautomatic wire
feeders
bring an extra dimension of flexibility and
efficiency to high-production wire welding stations.
MIG(GMAW)
Welding
You
Flux Cored
(FCAW) Welding
(Gas- and Self-shielded)
get an effective solution that maximizes output,
especially when dealing with large weidments and
hard-to-reach areas.
Swingarc wire feeders accommodate various wire
types and sizes ranging from .023-1/8 in (0.632mm). Both single-wire and dual-wire versions
are
be
Submerged (SAW)
Welding
Power Sources
ideal when
a
operated at a lime).
convenient to
The feeders connect to all Mifier constant voltage
needed. And once in place, the
position the boom exactly where its
Swingarc stays where
you want it. With a 360~ turning radius, 60~ lift angle,
power sources having a 14-pin receptade and 24 volt
AC supply. All Swingarc models are equipped with
(4.9 m) lengths, the Swingarc system
Use with CV
are
The unique counterbalanced design makes it easy and
and models available in both 12 ft (3.7 m) and 16 ft
Description
available. Dual-wire models
standby gun is needed or when two different wire
sizes and/or types are required (only one gun can
creates a
free
Mifiers popular four roll Posifeed Wire Drive
Assembly.
working access range of up to 2800 square ft (260 m2).
Ordering Information
SS-12, SS-16 Single-Wire Swingare
DS-12, DS-16 Dual-Wire Swingarc
Standard
Standard
Digital
SS-12
#131789
SS-16
#131790
SS-12D
#131 789-01-23
SS-16D
#131 790.01.24
Note: D models
Certified
(Digital)
include
Digital
DS-12
#131791
DS-16
#131792
DS-12D #131 791-01-21
DS-16D #131 792-01.22
digital meters/tachometer feedback and presettable WFS and voltage control.
by Canadian Standards Association to both the Canadian and U.S. Standards.
(Use with
CVPower
Specifications
Miller Electric
eavy
n
us na
5o~s)
(Subject to change wftho~noll~.)
Input Power
Electrode Wire Diameter
24 VAC,
50/60 Hz
.0231/8
in
Capacity
(0.63.2 mm)
Wire
Speed
50780
1PM
(1.319.8 rn/mm)
Boom
Length
Net Boom
Weight
12 ft
(3.7 m)
160 lb
(72.6 kg)
16 ft
(4.9 m)
210 lb
(95.3 kg)
12 ft
(3.7 m)
207 lb
(93.9 kg)
16 ft
(4.9 m)
280 lb
(127 kg)
Mfg. Co.
An Illinois Tool Works
Company
1635 West Spencer Street
Appleton, WI 54914 USA
International
HeadquartersUSA
Phone: 920-735-4505
USA and Canada FAX: 920-735-4134
International FAX: 920-735-4125
European HeadquartersUnited Kingdom
Phone:
FAX: 4.4
44(0)1625-525556
(0)1625-537553
Web Site www.millerwelds.com
The Power ofB&
Gun not included.
Features
Benefits
Available in
and 16ft
single and dual
(4.9 m) lengths
models in 12 ft
(3.7 m)
Accommodates a wide variety of applications to fill
large weldments and hard to reach welding areas.
virtually any semiautomatic wire feed requirement. Ideal
Unique counterbalanced boom
Easy to raise and lower boom and automatically holds its position.
3601 turning radius and 601 lift angle
Can extend the working range of the welder
In boom cable
Low
routing
Organizes
voltage control
The maximum
Totally solid-state speed
Wide range of wire feed
1.319.8 rn/mm)
Accommodates
a
hose and cables,
control and brake circuit
speed (50780 1PM!
wide variety of
voltage present
Excellent speed control and
service life.
Accommodates
internally installed,
helps
a
over a
to eliminate
floor space of up to 2800 sq ft
damage,
at the feeder is 24 VAC
and offers
or
a
clean and
the DC open circuit
(260 m2).
orderly
work station.
voltage of the
power source.
regulation; eliminates the need for electrical/mechanical relays and
wide range of wire sizes, .023 1/8
Easy to upgrade feeder as the
customers needs and
in
for
means
increased
(0.63.2 mm).
requirements change.
plug-in options
Ouick-change drive
4 sealed ball
rolls
bearing
all
No tools required.
gear-driven
drive
Smooth, positive and
accurate wire feed with
long and uninterrupted service life.
roll carriers
Quick-release, calibrated drive roll pressure
adjustment arm
Allows drive roll
Covered drive roll
Protects drive rolls and gears from dust, dirt, and other atmospheric contaminents.
assembly
Easy loading and threading of welding wire
Wire threads
change without losing spring preload setting.
easily through drive system without having
Gas purge control
Purges gas line without feeding welding wire.
Wire
Feeds
jog
control
Polarity insensitive
welding
Can be used
wire without
on
straight
energizing
or reverse
to release the drive roll pressure
arm
contactor.
polarity.
Control Panels
~MiIer~
I]
60 Series
60 Series
2flW~Fd
010
240 PD,, Feeder
Vv~1
010
4
woe SPEED
~
~e:~
,~
A
6
B
2
Qj~Q-1~
3
~Q ~ł
Q~O QjO
i joc
SS Swhigait
1.
2.
3.
4.
Trigger Hold Control*
Jog/Gas Purge Switch
Trigger Receptacle
Voltage and Wire Speed
DS
8.
identified
Speed
Voltage Controls for Dual
Schedule
9. Press to Set Schedule B
Meters
Speed Control
Voltage Contml
5. Wire
6.
(dual)
7. Wire Feed
Note: Power on/off switch is
back pane!
0ptional
on
models have two sets of the controls
on
the SS
(left).
Typical
Installations
lOft
Miller CV power
Hose
(supplied
with
feeder
source
equipped with a 14-pin
receptacle and 24 VAC
supply
Standard or
D* Model
lOft
(3m) 24 VAC, Contactor, and
Voltage Control Cord ( with feeder
(3m) Weld Power Cable (supplied
lOft
lOft
Miller
(3 m) Gas
(3m) Gas
Hose
with
(supplied
feeder)
with
feeder
electrically
controlled CV and
CC/CV power
with
a
Standard
source
(3m) 24 VAC, Contactor, and
Voltage Control Cord (supplied with feeder)
14-pin receptacle
supply
and 24 VAC
10 ft
lOft
(3m) interconnecting
connecting
connectors
on
a
4-pin
10 ft
connector
to PSA-2 control and Hubbell
older-style
Weld Power Cable
(supplied
Miller CV power
(3 m)
with
feeder)
Optional PSA-2 Control**
(supplied with feeder
cord included
with PSA-2 control. Includes
for
(3 m)
or
D* Model
lOft
Gas Hose
~
p
sources.
! lft(305mm)
Miller CV or competitive
CV power source wiTh
Standard
4-pin Connector
D
or
Model
only 115 VAC power or
competitive power source
requiring contact closure
for contactor control
10 ft
When
(3 m)
Weld Power Cable
(supplied
using the 0 model with Miller power sources that 00 NOT have remote voltage
capabilities, i.e., CP type, the voltage control in the feeder IS NOT functionaL
with
feeder)
~lf using the SS
control
(#141 604,
or
Power
OS feeders with
power source
is required.
a
Supply Adapter)
having only 115 VAC supply, the PSA-2
Drive Roll Kits
Select drive roll kits from chart below according to type and wire size
necessaiy guides and feature an anti-wear sleeve for inlet guide.
being
used and the type of wire drive
assembly (two-drive-roll
or
four-drive-roll
U
~.
V
groove
for hard wire
Wire size
.023/.025 in
(0.6 mm)
(0.8 mm)
#151 025
.035 in
(0.9 mm)
#151 026
.040 in
(1.0 mm)
#161 190
.045 in
(1.1/1.2 mm)
.052 in
(1.3/1.4 mm)
1/l6in(1.6mm)
.068/.072 in
.
J
V
knurled
for hard-shelled
cored wires
cogged
for
wire or soft
shelled cored
wires (i.e., hard
facing types)
#151 036
#151 052
#151 027
#151 037
#151 053
#151 070
#151 028
#151 038
#151 054
#151 071
#151 029
#151 039
#151 055
#151 072
(1.8 mm)
#151 056
(2.0 mm)
#151 040
#151 057
#151 073
3/32 in
(2.4 mm)
#151 041
#151 058
#151 074
7/64 in
(2.8 mm)
#151 042
#151 059
#151 075
#151 043
#151 060
#151 076
1/8 in
the
#151 024
.030 in
5/64 in
U
groove for
soft wire or
soft-shelled
cored wires
system). Drive roll kits include
(3.2 mm)
Nylon Wire Guides for Feeding Aluminum Wire
Wire Size
Inlet Guide
Intermediate Guide
.047 in
#151 203
#151 204
#151 206
(1.2 mm)
1/l6in (1.6 mm)
3/32 in (2.4 mm)
#151 205
#151 207
#151 208
Note: U~ groove drive rolls
are recommended when
feeding aluminum wire.
3
Mounting Equipment for SwingarcM Booms
One of the following is
the SS and DS
~
required for mounting
Swingarc booms:
Swingpak Base pipe post with base plate
CBC Cart (for use with 12 ft 3.7 ml model
only) the 6 ft (1.8 m) pipe post without base
plate (ordered separately)
Pipe Post
The
Swingpak~ Bases
Order a Swingpak-12 base to
mount a 12
ft
(3.7 m) boom. The Swingpak-16 base is for use
with a 16 ft (4.9 m) boom.
Each base accommodates
a
power source,
Swingarc feeder system, water coolant system,
and gas cylinder. The base plate is solid to
help better organize components and cables.
Base includes a three-compartment storage
locker. The entire unit can be moved with
a
forklift truck
Order pipe post with base separately.
Specifications and Ordering Information
CBC Cart
For use with
12ft (3. 7m) boom only. The CBC
Cart accommodates a power source, 12 ft (3.7 m)
Swingarc feeder, and two gas cylinders. Designed
to provide mobility and a neat, orderly
arrangement of welding equipment. The CBC
heavy-duty cart is designed for use on rough or
Model
Stock No.
Length
Width
Swingpak-12
#950 567
65 in
(1.7 m)
50-7/8 in
Swingpak-16
#950 568
79 in
(2.0 m)
6-7/8 in
CBC Cart
#152 637
70 in
(1.8 m)
34 in
Net
(1.3 m)
Weight
Ship Weight
412 lb
(187 kg)
418 lb
(1.7 m)
504 lb
(229 kg)
510 lb (231
(190 kg)
(864 mm)
328 lb
(149 kg)
510 lb
kg)
(231 kg)
_______________
Pipe Post Model
For 12 ft Boom (3.7 m)
(18 in 1457 mml Base Plate)
For 16 ft (4.9 m) Boom
(24 in 1610 mm] Base Plate)
____________
surfaces and features 12 in (305 mm)
diameter by3 in (76 mm) wide wheels.
uneven
base
#075 078
#015 018
#149 838
#078 264
6tt(1.8m)nobase
#079217
#019217
6ft(1.8m)withbase
#149839
#079216
4 ft
(1.2 m)
no
_____________
4 ft
(1.2 m)
with base
_______________
Note: The 6 ft
(1.8 m) pipe post #079219 is required. The
4 ft (1.2 m) pipe post is not recommended for use with the
CRC Cart. The 16 ft (4.9 m) Swingarc feeder cannot be used.
__________________
CBC Cart Features
2000 lb (907
kgj load capacity
Multi-position boom
Swing-out outriggers
Wide front-wheel stance and automotive-
type steering
Mounting facilities for most Miller CV
power sources
Compartment in base of cart to add ballast
weight when using lightweight power sources.
Minimum ballast weight of 300 lb (136 kgj
required
Fold-up gas bottle loading ramp
.
Options and Accessories
Skill Level Index
The box
A
following the stock
options contains
number of field-installed
letter and number. The letter indicates
a
the skill level required to install the option. The number
indicates the approximate time required for installation (see
legend).
S-model
trigger
hold control on
front
B
May require the use of an ohmmeter and the
ability to read a circuit diagram. Repair or replacement
of component parts is complex.
DTechnical.
Easy. No previous experience needed.
Average. Requires removal of service panels.
Mechanical ability is helpful.
CDifficult.
May require the use of an ohmmeter and/or
splicing of electrical wires. Repair or replacement of
Example:
component parts is
I
more
difficult.
Digital Meters with Presettable WFS and
Voltage Control
~
panel
#180312
~
Factory_____
#180 313 Field
4-in-i Control
Includes:
For DS Model
and
#180 314
spot/burnback, preflow/posifiow,
trigger hold.
#132 137
Meters
Factory_____
#132138 Field
#138 542
IA 1:15
Factory left side only
Factory right side only
Fieldleftorrightside I
______
#138543
This control is mounted on
includes 0 (zero)
to 5
an
1:15 I
A
inside panel and
second gas
to 0.25
range of 90 to 1400 1PM (2.3 to 35.6 mlmin).
Note: The high-speed motor is not recommended for wire
sizes larger than 5/64 in (2.0 mm) diameter.
11:201
back-lit liquid crystal
trigger hold control allows the
operator to make long extended welds without
having to hold the gun trigger.
Voltage Control (Non-Digital)
For SS Model
display
If a
are
standard-speed motor and high-speed motor are used
on the DS Model, the optional Digital Meters
in combination
cannot be used.
potentiometers allow the power source voltage
and wire feed speed to be accurately preset on
the digital meters. Once the arc is established,
actual arc voltage and wire feed speed is
displayed.
option is compatible with the following Miller
electronically controlled CVor CCJCV power sources:
Note: This
Power
Effective with seflal
source
XMT 304, Invision, Phoenix
All
Deltaweld
KG 141349
Maxtron 450
KG 111783
Dimension
KG253517
no.
PSA-2 Control
#141604
For power sources manufactured prior to these serial numbers,
please consult the factoiy. For mechanically controlled power
sources, such as the CPs, the voltage control is not functionaL
______
#133425 Field
only IA 1:10 I
For DS Model
#138 527 Field
only IA 1:10 I
Installs in front
panel of feeder to allow remote
voltage control of Mifier electrically controlled
CV or CC/CVpower sources having a 14-pin
receptacle.
Dual Schedule Switches
For
use
with
DSS-8
0
#079693
Al :051
A two-position
which attaches to
#173 750
the
gunhandle
trigger for
Factory_____
I
B
a
4-pin receptacle is hard wired
the control. A 10 ft (3m) interconnecting
cord with a 4-pin plug for connection to the
PSA-2 and Hubbell connectors for older-style
Mifier CV power sources is included. The
PSA-2 control
can
also be used with
competitive power sources requiring a contact
closure for contactor control.
Extension Cord #047 813 25 ft (7.6 m)
Can be used to extend the loft cord
DSS-9
Factory
#172826 Field
I
B
1:40 I
1
I
with the PSA-2 control
supplied
(4-pin to 4-pin
connection).
two-position
slide switch which
Factory
#173749 Field
#071 833
Al :051
A
For left side of DS Model
B
attaches to the
1:20 I
gun handle and is
used to select the
Allows two separate welding conditions
(voltage and wire feed speed) to be used with
wire. The parameters can be
short cord with
dual scheduling.
1:40 I
For right side of DS Model
#173748
con
veniently mounted on the wire feeder or
positioned at the power source. The control is
equipped with a 14-pin receptacle for direct
and is used in place of the standard
#173751 Field
#172825
VAC available. The PSA-2 control can be
to
Digital Dual Schedule Control
For SS Model
IAI:101
Required when using the SS and DS wire
feeders with power sources having only 115
connection of the wire feeder control cord. A
digital dual schedule control
trigger switch
accurately
preset on the digital meters.
Note: The
Factoryonly
high-speed motor has a wire feed speed
seconds of bumback
control. The
one
Skill Level: B, Time: 30 minutes
preflow and
postflow control, up to 5 seconds of spot weld
time, and up
use a
B
I
#132 130
The
I
:30
For left side of DS Model
1:45 I
easy to read in virtually any lighting
condition. The display and the ten-turn
which
ForDS Model
#138 547
B
Factory_____
#180 315 Field
For SS Model
I
I
High-Speed Motor
For SS and right side of DS Model
#132 129 Factoryonly
For SS Model
~s o~,;~
B
Digital Meters option is required to install the
Digital Dual Schedule Control. Select an appropriate Dual
desired welding
condition for dual schedule purposes. The gun
trigger operates as a standard gun trigger.
Schedule Switch.
OMifier.
5
Options and Accessories
(Confinued)
Water Coolant
Systems
-~
Watermate 1A
Coolmate 4
1
Polarity Reversing Isolation Conirol
For DS Model only
#042871
Adjustable spool carrier
#096075 Field only IA 1:20 I
Designed for use with 6 ft (1.8 m) pipe post
only. Replaces the standard spool assembly,
allowing the spools or coils of wire to be
positioned lower for easier loading and
unloading. Not recommended for use with
Swingarc feeder system mounted on CBC
cart
IAI:151
A dual-function control
designed for use with
#108008
For6Olb
of wire.
reversing capabilities are required. For example,
one wire of the DS feeder can be electrically cold
while welding with the other wire. The wires
can also be run on opposite or the same
polarity (straight or reverse). Both fimctions
can be performed at the same time.
coil
on
top of the
Extension Cords
#122 973 25 ft
(27kg)
~1
-
where electrical isolation and/or poiarity
Note: Includes bracket to mount control
dual feeder.
Wire Reel Assembly
~
the DS dual-wire feeder or any application
Coolmate~3
#043007
115VAC
Coolmatem 3
#043 008
230 VAC
#042495
115 VAC
#042288
115 VAC
Watermate~
Coolmate
1A
4
For use with water-cooled guns. Refer to
Literature Index No. AY/7.2 for additional
coolant system infonnation.
Guns
(7.6 m)
50ft(15m)
75ft(23m)
Provides 14-pin, 24VAC,
#122974
#122975
contactor and
voltage
control Can be added to the standard lOft (3m)
feeder cord to extend feeder farther from
power
source.
MifierM Series MIG Guns
The M series includes 150,250 and 400 amp
MIG guns. They are fully compatible with all
current Miller wire feeders. Select 10, 12 or 15 ft
cable length. Adapter kits also available to easily
make the guns usable with feeders from other
manufacturers, including European designs.
Refer to Literature Index No. M/10.O
Notes
@Mffler.
System Checklist
Options
Equipment
and
SS
Models
OS
(Single)
(Dual)
Models
and Quotation Sheet
Stock No.
Description
#131 789
12 ft boom
Wy.
#131 790
l6ftboom
#131 789-01-23
#131 790-01-24
l2ftboorn, digital
16ft boom, digital
#131 791
12ft boom
#131 792
l6ftboom
#131 197-01-21
12 ft boom,
#131 792-01-22
16ft boom, digital
Price
digital
Power Source
CP Series
See Lit Index No. DCI13.0
Deltaweld Series
See Lit Index No. DC/16.2
Dimension Series
See Lit Index No. DC/19.2
Invision 456
See Lit Index No. DC/20.O
Phoenix 456
See Lit Index No. DC/21.O
Feeder
0
Options
4-in-i Control
See page 5 for details
on
this
option
Voltage Control
See page 5 for details
on
this
option
Digital Meters
See page 5 for details
on
this
option
See page 5 for details
on
this option
See pages for details
on
this
Digital
Dual Schedule
Hig h-Speed Motor
Digital Dual Schedule Switch
DS
#079 693
DSS-8
#071 833
DSS-9
option
Only Options
Polarity Reversing
Iso.
#042 871
Miscellaneous
Drive Roll Kit
See drive roll kit table
PSA-2 Control
#141604
Required for power
PSA Extension Cord
#047 813
25ft
Spool Carrier, Adjustable
#096 075
Wire Reel
#108 008
Assembly
Extension Cords
Water Coolant
Systems
Welding Gun
Primary
#122 973
25 ft
#122 974
5Oft
#122975
75ft
source
w/o 24 VAC
See Lit Index No. AY/7.2
See Lit Index No. M/1O.O
Power Cable
Secondary Power Cable
Ground Cable with
Gas
Clamp
Cylinder
Gas Hose with Fittings
Regulator/Flownieter
Welding Wire
Spare Consumables
Helmet
Welding Gloves
Date:
Distributed
Miller
The Power ~fB1ue.
Litho in USA
Total Quoted Price:
by
F
Effective January 1, 1008
with
a serial number preface of UfiJif or newer)
(Equipment
Warranty Questions?
Call
1 .80044M1LLEN::
fur your local
.1MiIlv distributor.;
This limited
LIMITED WARRANTY
below,
to
its
after the effective date of this limited
equipment sold
workmanship at the time it is
shipped by Miller. THIS WARRANTY IS EXPRESSLY IN
OF
LIEU
ALL OTHER WARRANTIES, EXPRESS OR
INCLUDING
THE
WARRANTIES
OF
IMPLIED,
Service
notified in
of such defect
provide
instructions
Replacement Parts (No labor)
*
Spoolmate
Kits
185
True Bluefi Limited
Items furnished
such
as
covered
2.
to be followed.
3.
periods. All warranty time periods start on the date that
equipment was delivered to the original retail purchaser,
or one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to
an
1.
help
you, every
of the way.
-
shall not
apply
to:
Miller, but manufactured by others,
trade accessories. These items are
by
engines or
manufacturers
the
by
warranty,
if any.
Consumable components; such as contact tips, cutting
nozzles, contactors, brushes, slip rings, relays or parts
Equipment
3 Years Labor
wear.
that has bean modified
by any party other
equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has nol had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
than Miller,
International distributor.
5 Years Parts
Warranty
or
the
on
Miller shall honor warranty ctaims on warranted equipment
listed below in the event of such a failure within the warranty
the
step
Accessory
*
that fail due to normal
time
there to
Remote Controls
*
Millers
thirty (30) days
failure,
warranty claim procedures
Need fast answers to the
Contact your distributor.
The.expertise of the
distributor and MUler is
within
writing
at which time Miller will
Support
tough welding questions?
Torches
*
is free of defects in material and
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
reliable response you
~edM0st repicenient
parts can be in your
hands in 24 hours.
other
warranty
MERCHANTABILITY AND FITNESS.
Sways get the fast,
no
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
-
Electric
Yourdistr(butor also gives
You
*
Subject to the terms end conditions
Mfg. Co., Appleton, Wisconsin,
original retail purchaser that new Miller
Miller
warrants
warranty supersedes all previous Miller warranties and is exclusive with
guarantees or warranties expressed or implied.
or
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
*
Original
*
Inverters
main power rectifiers
(input
and
output rectifiers
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
only)
AND MAINTENANCE OF WELDING EQUIPMENT.
2.
3 Years
Parts and Labor
In the event of
*
3.
Transformer/Rectifier Power Sources
*
Plasma Arc
*
Semi-Automatic and Automatic Wire Feeders
*
Inverter Power
*
Intellitig
*
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
engine manufacturer.)
1 Year
Power Sources
Cutting
Supplies
the
Parts and Labor
*
Motor Driven Guns
*
Process Controllers
*
Positioners and Controllers
*
Automatic Motion Devices
*
Robots
IHPS Power Sources
*
Water Coolant
*
HF Units
*
Grids
*
Spot
*
Load Banks
*
SDX Transformers
*
Miller
*
Running Gear/Trailers
*
Plasma
warranty
claim covered
by this warranty, the
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the
goods at customers risk and expanse. Millers option of
repair or replacement will be FOB., Factory at Appleton,
Wisconsin, or FOB. at a Miller authorized service facility as
determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be
allowed.
(w/exception
*
a
exclusive remedies shall be, at Millers option: (1) repair; or
(2) replacement; or, where authorized in writing by Miller in
of
Spoolmate 185)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE
FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEOUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
Systems
AND ANY
IMPLIED
WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
MIGHT
ARISE
BY
PROVISION,
IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
Welders
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
WITH
TO
ANY
AND
ALL
RESPECT
PURPOSE,
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED
AND DISCLAIMED BY MILLER.
Cyclomatic Equipment
Cutting Torches (except APT,
Models)
ZIPCUT &
PLAZCUT
*
Deutz
*
Field
Engines (outside
North
America)
indirect, special
Options
(NOTE: Field options are covered under True Bluefi
for the remaining warranty period of the product they
installed in, or for
whichever is greater.)
are
a
minimum of
one
Some states in the U.S.A. do not allow limitations of how long
implied warranty lasts, or the exclusion of incidental,
an
year
consequential damages, so the above
apply to you. This warranty
provides specific legal rights, and other rights may be
limitation
6 Months
5.
90
*
Days
Batteries
Parts and Labor
MIG Guns/TIG Torches
or
exclusion may not
available, but may vary from
In Canada,
legislation
additional
warranties
herein,
4.
or
in
state to state.
some
or
provinces provides
remedies
and to the extent that
other than
they may
not be
for certain
as
stated
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 vary from
province
to
province.
miller
wsrr
119e
Owners Record
0
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purcbase Date
(Date which equipment
was
delivered to
original customer.)
Distributor
:.
..
.
Address
City
State
lip
.
Resources Available
Always provide Model Name and Serial/Style Number.
Contact your Distributor top:
To locate distributor nearest you call
1-800-4-A-Miller.
Welding Supplies
Options
and Consumables
and Accessories
Personal
Safety Equipment
Service and
Repair
Replacement
MiMer Etectnc Mtg Co
:MIllsToolW~rksCompafl
1635;westspencer.Street
~Appteton, Wl54914 USA. :1.
Parts
E.
~
.
Training (Schools, Videos, Books)
International
Technical Manuals
and Parts)
(Servicing
Information
Headquarters-USA
Phone: 920-735-4505
USA & Canada FAX 920-735-4134
International FAX 920-735-4125
Circuit
Diagrams
European Headquarters
Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
-
Welding
United
Process Handbooks
e~ww.MiHetWelds.corn
Contact the Ieliveriui Carrier fur:
File
a
claim for loss
or
damage during
shipment.
For assistance in
filing
contact your distributor
manufacturers
settling claims,
and/or equipment
or
Transportation Department.
I
PRINTED IN uSA
'
The Thwer~pfB&
1998 Miller Eledric
Mfg. Co. 5198
:~