Miller Electric

Transcription

Miller Electric

OM-1 587
161 874R
November 1999
Miller
Processes
MIG
(GMAW) Welding
Pulsed MIG
The Power ofBlue.
(GMAW-P)
(FCAW) Welding
Self-Shielded)
Flux Cored
(Gas-
and
Description
Wire Feeder
(Use
CE
with CC/CV Power
D-64M
.~
0
Visit
our
website at
www.MillerWelds.com
OWNERS
MANUAL
Sources)
From Miller to You
Thank you and
you
get
can
the
congratulations on choosing Miller. Now
job done and get it done right. We know
have time to do it any other way.
you dont
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.
Thats
why
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.
Today,
the
~Jj~ftflfl~~
as hard as you do
every power source from
Miller is backed bythe most
hassle-free warranty in the
business.
Working
Miller
help
help you get the most out of your
designed
Please take time to read the Safety precautions. They will
Manual is
This Owners
products.
you protect
yourself against potential
hazards
~i iT~J~
~
on
the worksite. Weve
and easy.
With Miller you can count on years of reliable
service with proper maintenance. And if for
made installation and
1 1
.
-
to
operation quick
.
REGISTERED
the unit needs repair, theres a
Troubleshooting section that will help you
QUALITY SYSTEM
some reason
V
Miller is the first welding figure out what the problem is. The parts list
equipment manufacturer in will then help
you to decide which exact part
the U.S.A. to be
the ISO 9001
registered
to
you may need to fix the problem. Warranty and
service information for your particular model
Quality System
Standard.
are
also
provided.
Miller offers a ?ºchnical
Manual which provides
more detaIled service and
parts information for your.
unit. 7~ obtain a Technical
Manual, contact your local
distrIbutor, Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTA W,
GMAW and s3MAWP
,a~c
Miller Electnc manufactures
of welders and
welding
For information
products,
to
on
a
~I
:
full line
related
other
equipment.
quality Miller
contact your local Miller
receive the latest full line
distributor
catalog
or
A
individual
catalog
sheets. To locate your nearest
distributor call 1-800-4-A-Miller.
A
I.
TABLE OF CONTENTS
SECTION 1
WARNING
product, when used
for welding or cutting,
produces fumes or
-
SAFETY PRECAUTIONS
Symbol Usage
1-2.
Arc
1-3.
Additional
1-4.
Principal Safety
1-5.
EMF Information
Welding
READ BEFORE USING
1
1
1-1.
1
Hazards
Operation,
For Installation,
Symbols
And Maintenance
3
3
Standards
4
This
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et
SECTION 1
-
CONSIGNES DE SECURITE
1-1.
Signification
1-2.
Dangers relatifs
1-3.
-
LIRE AVANT UTILISATION
au
soudage a
Dangers supplØmentaires
en
5
larc
relation
avec
linstallation,
Principales
normes
1-5.
Information
sur
les
8
de sØcuritØ
champs ØlectromagnØtiques
8
seq.)
SECTION 2
-
Warning
Manufacturers
2-3.
Symbols
Label For CE Products
Rating
-
11
INTRODUCTION
11
11
INSTALLATION
11
Site Selection
Connection
Equipment
4-3.
Rear Panel Connections
4-4.
Rotating
The Drive
13
14
14-Pin
4-6.
Motor Start Control
4-7.
Gun Recommendation Table
4-9.
Wire
Information
Type, Size,
Installing
13
Assembly
4-5.
4-8.
12
Diagrant
4-2.
Plug
And
10
10
And Definitions
Specifications
SECTION 4
4-1.
-
9
Label Definitions
2-2.
3-1.
9
DEFINITIONS
2-1.
SECTION 3
14
And Feed
15
Speed Capability
Threading Welding
Table
Wire
15
16
SECTION 5- OPERATION
17
Terms
17
5-1.
Operational
5-2.
Pulse
Terms
17
5-3.
Front Panel Controls
18
5-4.
Side And Rear Panel Controls
19
SECTION 6
6-1.
-
Welding
SETTING SEQUENCE PARAMETERS
Sequence
SECTION 7
-
Parameters In A
Program
SETTING DUAL SCHEDULE PARAMETERS
Dual Schedule Pair
7-1.
Selecting
7-2.
Dual Schedule Switch
Diagrams
SECTION 8- USING THE OPTIONAL DATA CARD
8-1.
Installing
8-3.
Card
8-4.
Entering
8-5.
Security
-
20
20
21
21
22
23
23
Data Card Terms
8-2.
SECTION 9
OM-1 587
le fonctionnement
7
et Ia maintenance
1-4.
5
5
symboles
des
23
Data Card
24
Displays
25
Access Code
26
27
SYSTEM SETUP
The
Setup
9-1.
Accessing
9-2.
System Setup Display
Menu
Parameters
27
28
(Continued)
TABLE OF CONTENTS
STANDARD PULSE WELDING PROGRAMS
SECTION 10
FOR PHOENIXJINVISION 456 INVERTER WELDING POWER SOURCES
-
10-1.
Program
1
10-2.
Program
2
10-3.
Program
3
10-4.
Program
4
10-5.
Program
5
10-6.
Program
6
10-7.
Program
7
Program
8
10-8.
-
-
-
-
-
-
-
-
29
Steel
29
Steel
29
Steel
29
Steel
29
Stainless
30
Stainless
30
Metal Core
30
Metal Core
30
SECTION 11
FOR XMT 304 INVERTER WELDING POWER SOURCES
-
31
Steel
31
Steel
31
Steel
31
Program
4-Steel
31
11-5.
Program
5
11-6.
Program
6
Program
7
Program
8
11-1.
Program
1
11-2.
Program
2
11-3.
Program
3
11-4.
11-7.
11-8.
SECTION 12
12-1.
-
-
-
-
-
Stainless
32
Stainless
32
Nickel
Alloy
32
Metal Core
And
32
SharpArc CONTROL
Adjusting SharpArc
Control
-
33
33
34
15 Points
34
Teach Points
35
Using
Redefining
SECTION 14
-
TEACH POINTS
-
13-1. Teach
13-2.
-
SETTING
Selecting
SECTION 13
-
MAINTENANCE AND TROUBLESHOOTING
37
14-1. Routine Maintenance
37
14-2. Error
38
14-3.
Displays
Troubleshooting
SECTION 15
SECTION 16
-
-
39
ELECTRICAL DIAGRAM
40
PARTS LIST
42
Conformity for
European Community (CE) Products
Declaration of
Note ~
This in formation is
provided
for units with CE certification
Manufacturers
Name:
Miller Electric
Manufacturers
Address:
1635 W.
Declares that the
con forms
to the
on
unit).
Co.
Spencer Street
Appieton, Wi 54914 USA
D 64 IVI
product:
following
Mfg.
(see rating label
Directives and Standards:
Directives
Low
Voltage
Directive: 73/23/EEC
Electromagnetic Compatibility (EMC)
Machinery
Directive: 89/336/EEC
Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC
Standards
Arc
Welding Equipment Part
(September
I:
Welding
1998
Power Sources: IEC 60974-1
Second
-
Edition)
Welding Equipment: Wirefeed Systems: IEC
(September 1997 Draft Revision)
Arc
974-5
-
Degrees
of Protection Provided
(November
(IP Code): IEC
Edition)
Enclosures
By
1989
-
First
Equipment With Low-Voltage Systems:
Principles, Requirements and Tests: IEC 664-1
(October 1992 First Edition)
Insulation Coordination For
Part I:
-
Electromagnetic Compatibility, (EMC):
(August 1995)
European Contact:
Mr.
Luigi Vacchini, Managing
Europe S.P.A.
MILLER
Via Privata lseo
20098 San Giuliano
Milanese, Italy
Telephone:
Fax:
dec_con 11/96
529
39(02)98290-1
39(02)9828 1 -552
Director
EN 50199
.
SECTION 1
SAFETY PRECAUTIONS
-
READ BEFORE USING
-
_nd_4/98
som
SymbolUsage
1-1.
Means
a
A
Marks
1-2.
Arc
The
There
possible
are
possible
hazards
not
safety
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary
actions to avoid the hazards.
related.
Hazards
Welding
below are used
symbols shown
to call attention to and
throughout this manual
identify possible hazards. When you
symbol, watch out, and followthe related instructions
safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1 -4. Read and
follow all Safety Standards.
see
the
to avoid the hazard. The
A
Only qualified persons should install, operate, maintain,
A
and
this unit.
repair
~
are
special safety message.
a
~ Means Note;
A
Out!
Watch
Warning!
hazards with this procedure! The
shown in the adjoining symbols.
During operation, keep everybody, especially children, away.
If earth
with
grounding
or
another electrode from
kill
Wear
a
Keep
all
Clamp
safety
harness if
and
panels
work cable with
worktable
as near
Do not touch live electrical
Wear
hole-free
dry,
single
weld
use
a
Use AC
If AC
insulating gloves
and
AC output in damp areas, if movement is confined,
of falling.
or
if
is
required,
use
remote
output
control if
present
on
input power or stop engine before installing or
equipment. Lockout/tagout input power according
OSHA 29 CFR 191 0.147 (see Safety Standards).
this
install and
Manual and
ground
this
equipment according
to its
national, state, and local codes.
-
making input connections,
conductor first
-
attach
proper
grounding
double-check connections.
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
-
-
Turn off all
Do not
Do not
the weld
more
in
place.
as
practical.
not connected to
workpiece to prevent
object.
than
one
electrode
work cable to any
or
before
touching any parts.
FUMES AND GASES
can
be hazardous.
fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
Welding produces
=5~
use
equipment
worn,
drape
when not in
over
If ventilation is poor,
Read
the
Material
manufacturers
your
body.
exhaust at the arc to
use an
approved air-supplied respirator.
Safety
Data
Sheets
(MSDSs)
instructions for metals, consumables,
and
the
coatings,
cleaners, and degreasers.
a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the
breathing air is safe.
Do not weld in locations
operations.
form highly
poorly spliced cables.
near
degreasing, cleaning,
The heat and rays of the arc
toxic and irritating gases.
Do not weld
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
use
fumes and gases.
welding
cadmium
use.
damaged, undersized,
cables
head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or
Work in
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.
When
securely
metal-to-metal contact to workpiece
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
Keep your
output ONLY if required for the welding process.
Disconnect
Properly
good
above floor level.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
remove
Owners
ground,
body protection.
unit.
to
in contact with the work,
different machine.
danger
output
servicing
directly
parts.
yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the
work or ground.
Do not
it
output terminal,
Insulate
there is
are
working
clamp when
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.
a
covers
contact with any metal
live
Touching
required, ground
is
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Insulate work
can
workpiece
Do not touch electrode if you
or
ELECTRIC SHOCK
of the
separate cable.
a
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-1587
Page
1
ARC RAYS
bum eyes and skin
can
BUILDUP OF GAS
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.
Shutoff
shielding
Always
ventilate
can
gas
injure
kill
or
when not in
supply
confined
spaces
use.
use
or
approved air-supplied respirator.
awelding helmet fitted with a proper shade of filterto protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
Wear
HOT PARTS
helmet.
.
protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
protective clothing made from durable,
(leather and wool) and foot protection.
Do not touch hot
Allow
Use
Wear
can cause~severe
burns.
with side shields under your
approved safety glasses
Wear
parts bare handed.
cooling period
before
working
on
gun
or
torch.
flame-resistant
material
MAGNETIC FIELDS
WELDING
can cause
fire
or
explosion.
Pacemaker
can
wearers
affect
pacemakers.
keep away.
Wearers should consult their doctor before
closed
Welding
on
drums,
pipes,
containers, such
tanks,
as
going near arc welding, gouging,
welding operations.
them 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 metal objects can
cause sparks, explosion, overheating, orfire. Check and besurethe
area is safe before doing any welding.
Protect
yourself
or
can cause
and others from
Do not weld where
flying sparks
flying sparks
can
Remove all flammables within 35 ft
this is not
possible, tightly
Be alert that
small cracks and
Watch for
fire, and keep
Be
that
can cause
fire
Do not weld
on
welding
on
a
(10.7 m)
of the welding arc.
approved covers.
fire
openings
closed containers such
Do not
prevent welding
paths
as
and
as
causing
tip
when not in
Wear oil-free
Wear
approved
CYLINDERS
partition
or
tanks, drums,
or
ear
protection
or
Protect
can
explode
if
damaged.
cut off
welding
wire at
compressed gas cylinders from excessive heat,
slag, open flames, sparks, and arcs.
mechanical shocks,
Install
cylinders in an upright position by securing to a stationary
or cylinder rack to prevent falling or tipping.
support
Keep cylinders away from any welding
use.
protective garments
such
as
a
leather
gloves, heavy
cap.
lighter or matches,
Never
FLYING METAL an
injure eyes.
drape
Never allow
Never weld
a
a
welding
welding
on a
torch
over a
or
gas
approved safety glasses with side
shields even under your welding helmet.
Wear
cylinder.
electrode to touch any
pressurized cylinder
-
cylinder.
explosion
will result.
correct
Turn face away from valve outlet when
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
other electrical circuits.
shielding gas cylinders, regulators, hoses,
only
fittings designed for the specific application; maintain them
associated parts in good condition.
Use
2
if noise level is
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Since gas cylinders are normally part of the welding
process, be sure to treat them carefully.
pipes,
(see
to AWS F4.i
welding area as
traveling long, possibly
Remove any combustibles, such as a butane
from your person before doing any welding.
Page
can
high.
welding can
adjacent areas.
pipes.
shirt, cuffless trousers, high shoes, and
OM-1587
equipment
If
electric shock and fire hazards.
Remove stick electrode from holder
contact
or
close to the
current from
welder to thaw frozen
use
processes
the hidden side.
Connect work cable to the work
unknown
some
damage hearing.
extinguisher nearby.
they are properly prepared according
Safety Standards).
to
to
ceiling, floor, bulkhead,
on a
unless
practical
Noise from
strike flammable material.
them with
damage hearing.
can
and hot metal.
and hot materials from
welding sparks
easily go through
aware
cover
NOtSE
spot
or
Keep protective cap in place
use or connected for use.
over
Read and follow instructions
associated
Standards.
equipment,
valve
except when
and
valve.
cylinder is in
compressed gas cylinders,
publication P-i listed in Safety
on
and CGA
opening cylinder
and
1 3.
Additiohal
For Installation,
Symbols
And Maintenance
Operation,
MOVING PARTS can cause
FIRE OR EXPLOSION hazard.
Do not install
unit on, over,
place
or
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
or near
combustible surfaces.
Do not install unit
is
near
building wiring
properly sized, rated, and protected
Do not overload
-
FALLING UNIT
be
flammables.
sure
power
injury.
supply system
to handle this unit.
can cause
injury.
H.F. RADIATION
lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift and
can cause
interference.
Use
High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
Have only qualified persons familiar with
electronic equipment perform this installation.
support unit.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
The
unit.
responsible
is
user
promptly
having a qualified electrician
problem resulting from the
for
correct any interference
installation.
OVERUSE
Allow
can cause
cooling period;
Reduce current
starting
to weld
Do not block
STATIC
(ESD)
or
or
OVERHEATING
follow rated
reduce
duty cycle.
duty cycle
by
at
interference, stop using the
the FCC about
once.
Have the installation
before
regularly
checked and maintained.
Keep high-frequency source doors and panels tightly shut,
keep spark gaps at correct setting, and use grounding and
shielding to minimize the possibility of interference.
again.
filter airflow to unit.
can
If notified
equipment
damage PC boards.
Put
on
grounded wrist
handling boards or parts.
strap
BEFORE
ARC WELDING
static-proof bags and
store, move, or ship PC boards.
Use proper
can cause
interference.
boxes to
Electromagnetic energy can interfere with
electronic equipment such as
computers and computer-driven equipment
sensitive
MOVING PARTS
can cause
such
injury.
Keep
away from
Keep away
from
moving parts.
pinch points
as
robots.
all equipment in the welding
electromagnetically compatible.
Be
such
as
To reduce
drive
possible,
rolls.
sure
WELDING WIRE
can cause
injury.
Be
possible interference, keep weld cables as short as
together, and down low, such as on the floor.
welding operation
equipment.
sure
according
Do not press gun
trigger
until instructed to do
welding
machine
is
installed
and
grounded
to this manual.
such
point gun toward any part of the body,
people, or any metal when threading
Do not
welding
1 -4.
this
100 meters from any sensitive elec
If interference still occurs, the user must take extra measures
as moving the welding machine, using shielded cables,
so.
other
is
close
Locate
tronic
area
using
line
filters,
or
shielding
the work
area.
wire.
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 Superinten
dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances,
American Welding Society Standard AWS F4.1, from American
Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical
Code, NFPA Standard 70, from National
Batterymarch Park, Quincy, MA 02269.
Protection Association,
Fire
Safe
Handling
of
Compressed Gases
in
Cylinders, CGA Pamphlet
P-i, from Compressed Gas Association,
Highway, Suite 501, Arlington, VA 22202.
1235 Jefferson
Davis
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, 1430 Broadway, New York, NY 10018.
NFPA Standard 518, from National
Association, Batterymarch Park, Quincy, MA 02269.
Cutting And Welding Processes,
Fire Protection
OM-1 587
Page
3
EMF Information
1-5
And The Effects Of Low
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
Considerations About
Welding
Electric And
Fields
Magnetic
examined. Until the final conclusions of the research
may wish to minimize your exposure to
cutting.
To reduce magnetic
procedures:
welding
are
electromagnetic
Page
4
cables to
or
together by twisting
one
drape
or
taping them.
side and away from the operator.
cables around your
Keep welding power
practical.
source
Connect work
to
and cables
body.
as
far away from opera
tor as
5.
reached, you
clamp
workpiece
as
close to the weld
as
possible.
fields when
About Pacemakers:
or
OM-1587
4.
cables close
fields
in
the
workplace,
use
the
following
Pacemaker
then
wearers
following
consult your doctor first. If cleared by your
procedures is recommended.
the above
doctor,
SECTION 1
CONSIGNES DE SECURITE
UTI LISATION
-
LIRE AVANT
-
ndtre 4/98
som
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
Identifie
message de sØcuritØ
un
nt
Ce groupe de symbolea signifie Miae en garde! Soyez vigilant! II y a des
riaques de danger relies aux CHOCS ELECTRIQUES, aux PIECES EN
particulier.
MOUVEMENTetaux PIECES CHAUDES. Reportez-vouaauxaymbolea
etauxdirectiveaci-desaoua afin de connaltre lea meaures prendre pour
~
Signifie
n
Łviter tout
eat pas relatif A Ia sAcuritØ.
relatifs
Dangers
1-2.
A
NOTA
au
soudage a
Iarc
Nutiliaer quun materiel en bon Łtat. RŁparer ou remplacer aur-le
champ lea piŁceaendommagŁes. EntretenirlappareilconformŁment
symboles prØsentØs ci-aprØs sont utilisØs tout au long du
present manuel pour attirer votre attention et identifier les
risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnØes aim dØviter tout
danger. Lea consignes de sØcuritØ prØsentØes ci-aprØs ne font
Lea
a
lutilisation, lentretien
Linstallation,
vent Œtre confiØs
A
Au coursde
qu
reparations
qualifiØes.
et lea
des personnes
ne
avec
doi
jamais
toucher les
gants
contact
avec
piŁces Łlectriques
et des
sous
vŁtements de protection
piŁce a souder ou
secs ne
de
source
soudage
zones
Łlectrique courant Łlectrique UNIQUEMENT
si le
sŁcuritŁ).
lnatalleretmettrelaterre correctement cetappareil conformŁment
manuel dutilisation et aux codes nationaux, provinciaux et
son
municipaux.
Toujours verifier Ia terre
a
Verifier et aassu
du cordon dalimentation
rer que le fil de terre du cordon dalimentation eat bien raccordŁ a Ia
borne de terre du aectionneur ou que lafiche du cordon eat raccordŁe
a une priae correctement mise a Ia terre.
-
En effectuant lea raccordements dentrŁe fixer dabord le conducteur
de mise a Ia terre appropriŁ et contre-vŁrifier lea connexiona.
trŁquemment le cordon dalimentation pour voir sil neat pas
endommagŁ ou dŁnudŁ remplacer le cordon immŁdiatement ail eat
endommagŁ un cable dŁnudŁ peut provoquer une electrocution.
Mettre lappareil hors tension quand on ne lutiliae pas.
Ne paa utiliser des cables uaŁa, endommagŁa. de groaaeur inauffi
saute ou mat ŁpisaŁa.
Verifier
-
-
Ne pas enrouler lea cables autour du corps.
Si Ia piŁce aoudŁedoitŁtre mise laterre, lefairedirectementavec
cable distinct.
ou une
capots.
bon contact mŁtal-mŁtal
detravail, le plus prŁa possible de Ia
pea mis a Ia
pour eviter le contact
piŁce
DU COURANT CONTINU IMPORTANT dans les
convertisseurs
tion
quand
aprŁs
Ia
suppression
de Ialimenta
Ølectrique.
ArrŁter lea convertiaseura, dŁbrancher le courant Łlectrique, et dŁ
charger lea condensateura dalimentation aelon les instructions
indiquŁea
dana Ia
partie
LES
4s
entretien avant de toucher lea
piŁces.
FUMEES
ET LES GAZ
peuvent
Œtre dangereux.
~,V
Le aoudage gØnŁre des fumeea et des gaz. Leur
inhalation peut Œtre dangereux pour votre sante.
S__s
Eloigner
votre tŁte des fumŁea. Ne paa
reapirer
A IintŁrieur, ventiler Ia zone et/ou utiliaer un Łchappement au ni
veau de arc pour IŁvacuation des fumŁea et des gaz de aoudage.
Si Ia ventilation eat inauffiaante, utiliser un reapirateur a alimenta
tion dair homologuŁ.
Ure lea spŁcificationa de aŁcuritØ des matŁriaux (MSDSa) et lea na
tructiona du fabricant concernant lea mŁtaux, lea conaommables,
lea revŁtementa, lea nettoyants et lea dŁgraiaaeura.
Travailler dana
on
eat
en
contact avec Ia
piŁce,
un
eapace fermŁ aeulement au eat bien ventilŁ
ou
reapirateur a alimentation dair. Demander toujoura a
un aurveillant dment formŁ de ae tenir a proximitŁ. Dea fumŁea et
des gaz de aoudage peuvent dŁplacer lair et abaisser le niveau
doxygŁne provoquant dea blesaurea ou dea accidents mortela.
Saaaurer que lair de reapiration ne prŁsente aucun danger.
Ne paa aouderdana dea endroita aituŁa a proximitŁ dopŁrationa de
degraiaaage, de nettoyage ou de pulvŁriaation. La chaleur et lea
rayona de larc peuvent rŁagir en prØaence de vapeura et former
des gaz hautement toxiquea et irritants.
en
Ne paa toucher lŁlectrode
hauteur.
en
lea fumŁea.
Couper lalimentationou arrŁterle moteuravantde procŁderlinatal
lation, a Ia reparation ou a lentretien de Iappareil. DŁverrouiller
lalimentation aelon Ia norme OSHA 29 CFR 191 0.147 (voir normes
terre
Ia table
masse quand
objet mŁtallique.
le demande.
Si Iutilisation dune source Łlectrique courant Łlectrique savŁre nŁces
saire, se servir de Ia fonction de tŁlŁcommande si lappareil en est ŁquipŁ.
de
faon a obtenir un
Isoler Ia pince de
-
servir de source Łlectrique courant Łlectrique dans lea
humides, dana les endroits confines ou l o on risque de tomber.
procŁdŁ
travaille
comportant
se
Se servir dune
place
on
toua lea panneaux et
tension.
pas de trous.
Sisoler de Ia piŁce et de Ia terre au moyen de tapis ou dautres
moyens isolants suftisamment grands pour empŁcher le contact phy
sique Łventuel avec Ia piŁce ou Ia terre.
Ne pas
en
quand
ELECTRIQUE peut tuer.
circuits internes de lappareil sont Łgalement sous
tension ace moment-l. En soudage semi-automatique ou automatique,
le fil, le dŁvidoir, le logement des galets dentrainement et les piŁces
mŁtalliques en contact avec le fil de soudage sont sous tension. Des
matŁriels mal installŁs ou mal mis a Ia terre prØsentent un danger.
Porter des
Ia
avec tout
Ily
Ne
harnaia de aŁcuritŁ
soudure.
des piŁces Łlectriques peut
provoquer une electrocution ou des blesaures graves.
LŁlectrode et le circuit de soudage sont sous tension
des que lappareil est sur ON. Le circuit dentrŁe et es
simple
un
Fixer le cable de retour de
lutilisation, tenirtoute personne lØcartet plus par
Un
manuel.
Maintenir aolidement
ticuliŁrement lea enfants.
UN CHOC
ce
Porter
que rØaumer lintormation contenue dans lea normes de sØcuritØ
ØnumØrØes a Ia section 1-4. Veuillez lire et respecter toutes ces
normes de sØcuritØ.
A
danger.
portant
un
Ne paa aouder dea mŁtaux munia dun revØtement, tela que lacier
au cadmium a moms que le revŁte
ment nait ŁtŁ enlevŁ dana Ia zone de aoudure, que lendroit aoit
bien ventilŁ, et si nŁceaaaire, en portant un reapirateur a alimenta
tion dair. Lea revŒtementa et toua lea mŁtaux renfermant cea ele
galvaniaŁ, plaque en plomb ou
ments
peuvent dŁgager
des fumŁea
toxiques
en caa
de
aoudage.
un
Ia
electrode provenant dune autre machine.
OM-1587
PageS
LESRAVONS DEILARC peuvent.pr-,
:VOquer des.brlures danslŁs.yeLix et
surlapeau
de Iarc du procØdØ de soudage
gØnŁre des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer
des brOlures dans les yeux et sur Ia peau. Des Øtincelles sont projetØes
pendant le soudage.
Le
rayonnement
~
LESACCUMUATIONSDEGAZ.ris
f
quent;de provoquerdes:blØsures u
I
~
mØmela mort.
:.
.
Fermer Ialimentation
non
Veiller
toujours a bien aØrer
rateur dadduction
un casque de soudage muni dun Øcran de filtre appropriØ pour
protØger votre visage et vos yeux pendant le soudage ou pour regar
der (voir ANSI Z49. 1 et Z87. 1 ØnumØrØ dans les normes de sØcuritØ).
du gaz
protecteur
en cas
de
utilisation.
dair
les espaces confines
ou se
servir dun
respi
homologuØ.
Porter
Porter des
protections approuves
DES PI¨CES CHAUDES peuvent pro
voquer des brlures graves.
pour les oreilles si le niveau sondre est
trop ØlevØ.
Utiliser des Øcrans
des barriŁres pour
ou
protØger des tiers
de IØclair
Ne pas toucher des
IØblouissement; demander aux autres personnes de ne pas re
garder Iarc.
Porter des vŒtements de protection constituØ dans une matiŁre dura
ble, resistant au feu (cuir ou lame) et une protection des pieds.
et de
m
~I
~.1
LE SOUDAGE peut provoquer
incendie
ou une
souda9e
etfectuØ
PrŁvoir
une
dutiliser
le
LES CHAMPS
provoquerleurØclatement.
projetØes de larc de soudure.
La
peuventØtre
projection dØtincel
incendies et des brCilures. Le contact accidentel de lØlectrode avec des
provoquer des Øtincelles, une explosion, un
surchauffement ou un incendie. Avant de commencer Ie soudage,
verifier et sassurer que Iendroit ne prØsente pas de danger.
dabord
Se protØger et dautres
metal chaud.
personnes de
projection dØtincelles
a
de
zones en
traversant de
petites fissures
peut dØclencher
un
plafond, plancher, paroi
sur un
incendie de lautre
ou
soudage
Ia
piŁce
poste
de
le
soudage
pour
degeler
des conduites ge
utilisation, enlever Ia baguette dŁlectrode du porte
couper le fil a Ia pointe de contact.
Porter des vŒtements de protection dŁpourvus dhuile tels que des
gants en cuir, une chemise en matØriau lourd, des pantalons sans re
vers, des chaussures hautes et un couvre chef.
non
ou
Avant de souder, retirer toute substance combustible de
telles quun allumeur au butane ou des allumettes.
vos
poches
DES PARTICULES VOLANTES
~
peuvent blesser les yeux.
soudage, lØcaillement, le passage de Ia piŁce
en fil de fer, et le meulage genŁrent
desØtincellesetdesparticules mŁtalliquesvolan
tes. Pendant Ia pØriode de refroidissement des soudures, elles risquent
de projeter du laitier.
Le
avec
Øcrans latØraux
ou un
es
oreilles Si
Des bouteilles de gal protecteur contiennent du gaz
haute pression. Si une bouteille est endomma
gee, elle peutexploser. Du faitque les bouteilles degaz
font normalement partie du procØdØ de soudage, les
sous
_____________
manipuler
avec
precaution.
ProtŁger les bouteilles de gaz comprimØ dune chaleur excessive,
des chocs mecaniques, du laitier, des flammes ouvertes, des Łtin
celles et des arcs.
Placer les bouteilles debout en les fixant dans un support station
naire ou dans un porte-bouteilles pour les empŒcher de tomber ou
de
Se renverser.
Tenir
es
bouteilles
electriques.
jamais placer
Øloignees des circuits de soudage ou autres cir
cuits
Ne
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
dolt
bouteille
pressurisØe
-
risque dexplosion.
Utiliser seulement des bouteilles de gaz protecteur, rØgulateurs,
tuyaux et raccords convenables pour cette application specifique;
les maintenir ainsi que les ŁlŁments associØs en bon Øtat.
Ne pas tenir Ia tŒte
bouteille.
a Ia brosse
Porter des lunettes de sØcuritØ
affecter
Si des BOUTEILLES sont endomma
gees, elles pourront exploser.
ctØ.
trocution et dincendie.
Ne pas utiliser le
lees.
Øquipements peut
Porter des protections approuvØs pour
le niveau sondre est trop ØlevØ.
sur
plus prŁs possible de Ia zone de sou
dage pour Øviter le transport du courant sur une longue distance par
des chemins inconnus Øventuels en provoquant des risques dØlec
sur
ou
louIe.
separation
sØcuritØ).
Brancher le cable
sapprocher
de gougeage
et
des conteneurs fermØs tels que des
reservoirs, tambours, ou conduites, a moms quils naient ØtØ prØpa
rØs correctement conformØment a AWS F4.1 (voir les normes de
Ne pas eftectuer le
a larc,
peut affecter louIe.
Le bruit des processus et des
SurveillertoutdØclenchementdincendie ettenir un extincteur proxi
mite.
soudage effectuØ
restez a distance.
consulter leur mØdecin avant de
operations de soudage
soudage par points.
LE BRUIT
ment passer dans dautres
des ouvertures.
cardiaque,
et de
DØplacer toutes es substances inflammables a une distance del 0,7
m de Iarcde soudage. En cas dimpossibilitØ les recouvrir soigneuse
ment avec des protections homologues.
Des Øtincelles et des matØriaux chauds du soudage peuvent facile
de
cardiaques.
porteurs dun stimulateur cardiaque doivent
des
Ne pas souder dans un endroit l ou des Øtincelles peuvent tomber
sur des substances inflammables.
cas
torche.
a
MAGNETIQUES peuvent
Porteurs de stimulateur
objets metalliques peut
En
ou
DesØtincelles
Les
electrode
de refroidissement avant
pØriode
pistolet
affecter les stimulateurs
sur
les, des piŁces chaudes et des Øquipements chauds peut provoquerdes
Le
chaudes a mains
un
explosion.
des conteneurs fermØs tels
que des reservoirs, tambours ou des conduites peut
Le
parties
nues
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
Lire et suivre les instructions concernant les bouteilles de gaz com
prime, les Łquipements associØs et les publications P-i CGA Ønu
mØrŁes dans les normes de sØcuritŁ.
Øcran facial.
.
OM-1587 Page 6
1-3.
Dangers supplØmentaires
en
relation
avec
linstallation, lefonctionnement
et Ia maintenance
Risque DINCENDIE
DES
OU
DEXPLOSION.
provoquerdes
placer lappareil
Ne pas
proximitØ
ORGANES
au-dessus
sur,
ou
Rester a lØcart
ventilateur.
a
de surfaces infliammables.
panneaux,
-
protØgØ
peuvent
des organes mobiles
MaintenirfermØs etfixement
lappareil a proximitØ de produits inflammables
Ne pas surcharger linstallation Ølectrique sassurer que lalimen
Ne pas installer
tation est correctement dimensionnØ et
lappareil en service.
MOBILES
blessures.
recouvrements
le
comme
place les portes,
dispositifs de
en
et
protection.
avant de mettre
RAVONNEMENT HAUTE FRE
QUENCE (H.F.) risque de provoquer
des interferenceS.
LE
LA CHUTE DE LAPPAREIL
peut
bIesser~
de
Utiliser lanneau
lever
PAS les chariot, les bouteil
lappareil, NON
les de gaz
ou
de sØcuritØ et les ordinateurs.
tout autre accessoire.
engin dune capacitØ appropriØe pour
soulever lappareil.
En utilisant des fourches de levage pour dØplacer lunitØ, sassurer
que les fourches sont suffisamment longues pourdØpasserdu ctØ
oppose de lappareil.
Utiliser
Le rayonnementhautefrequence peutprovoquer
des interferences avec les Øquipements de ra
dio-navigation etde communication, es services
levage uniquement pour sou
un
L~EMPLOI EXCESSIF peut
SURCHAUFFER LEQUIPEMENT.
Demander seulement a des personnes qualifiØes familiarisØes
avec des equipements Ølectroniques de faire fonctionner linstalla
tion.
Lutilisateur est tenu de faire corriger rapidement par
les interferences resultant de linstallation.
un
Ølectricien
qualifiØ
Si le FCC
reil.
signale des interferences, arrØter immØdiatement Iappa
Effectuer
rØguliŁrement
le contrle
et lentretien
de Iinstallation.
Maintenir soigneusement fermØs les portes et les panneaux des
sources de haute frequence, maintenir les Øclateurs a une distance
correcte et utiliser une terre et et un blindage pour rØduire les inter
une pØriode de refroidissement, respec
cycle opØratoire nominal.
RØduire le courant ou le cycle opØratoire avantde
recommancer le soudage.
PrØvoir
fØrences Øventuelles.
ter le
Ne pas obstruer les passages dair du poste.
LES CHARGES
ELECTROSTATIQUES
peuvent endommager les circuits im
pnmØs.
Etablir
Ia connexion
avant de
manipuler
Utiliser des
avec
Ia barrette de terre
ou des pieces.
des cartes
pochettes
et des boltes
pour stocker, dØplacer
circuits imprimes.
ou
antistatiques
expØdier des caries de
LE SOUDAGE A LARC
risque de
provoquer des interferences.
electromagnØtique
LØnergie
risque
lØquipement de Ia zone de soudage soit com
patible ØlectromagnØtiquement.
Pour rØduire Ia possibilitØ dinterfØrence, maintenir es cables de
soudage aussi courts que possible, es grouper, et les poser aussi
bas que possible (ex. par terre).
Veiller ace que tout
Veiller a souder a une distance de 100 metres de tout
electronique sensible.
ORGANES MOBILES
provoquer des blessures.
DES
Ne pas
sapprocher
peuvent
des organes mobiles.
Ne pas sapprocher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE
peuvent pro
voquer des blessures.
Veiller a ce que ce poste de soudage soit
conformØment a ce mode demploi.
Ne pas
diriger
le
pistolet
vers
avant den avoir
sol, dautres
piŁce mØcanique
soudage.
sonnes ou toute
le fil de
gachette
en
per
engageant
pose
equipement
et mis
a Ia terre
En cas dintertØrences apres avoir pris les mesures prØcØdentes, il
incombe a lutilisateur de prendre des mesures supplØmentaires
telles que le dØplacement du poste, lutilisation de cables blindØs,
lutilisation de filtres de ligne ou Ia pose de protecteurs dans Ia zone
de travail.
LES CHAMPS MAGNETIQUES peuvent
affecter les stimulateurs cardiaques.
Porteurs de stimulateur
Ne pas appuyer sur Ia
recu linstruction.
de
provoquer des interferences pour lØquipement
Ølectronique sensible tel que les ordinateurs et
lequipement commandØ par ordinateur tel que
es robots.
cardiaque,
restez a dis
tance.
Les porteurs dun stimulateur cardiaque doivent
dabord consulter leur mØdecin avant de sappro
cher des operations de soudage a larc, de gou
geage
ou
de
soudage
par
points.
OM-1587
Page
7
Principales
1-4
normes
de securitØ
Safetyin Welding and Cutting, norme ANSI Z49. 1, de American
ding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Wel
Safe
Handling
of
Compressed Gases
in
P-i, de Ia Compressed Gas Association,
Cylinders,
CGA
Pamphlet
High
1235 Jefferson Davis
way, Suite 501, Arlington, VA 22202.
OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Safety and Health Sandards,
Recommended Safe Practice for the Preparation for Welding and Cut
of Containers That Have Held Hazardous Substances, norme
AWS F4. 1, de lAmerican Welding Society, 550 N.W. Lejeune Rd, Mia
ting
mi FL 33126
National Electrical
Code, NFPA Standard 70, de Ia National Fire
Batterymarch Park, Quincy, MA 02269.
Pro
tection Association,
Information
1-5.
sur
les
RØgles de sØcuritØ en soudage,
coupage etprocØdØs connexes, norCSA Wi 17.2, de lAssociation canadienne de normalisation, vente
de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W
1R3.
me
Safe Practices ForOccupationAnd Educational EyeAnd Face Protec
tion, norme ANSI Z87.1, de lAmerican National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51 B, de Ia National
Protection Association, Batterymarch Park, Quincy, MA 02269.
champs ØlectromagnØtiques
DonnØes
Atm
des
de travail,
sur le soudage Ølectrique et sur les effets, pour lorganisme,
champs magnØtiques basse frequence
1
Le courant de
soudage, pendant son passage dans
les cables de
causera
encore un
node de recherche de 17 ans, un comitØ special ruban bleu du
National Research Council a conclu: Laccumulation
de preuves, sui
jugement du comitØ, na pas dØmontrØ que lexposition aux
champs magnØtiques et champs Ølectriques a haute frØquence reprØ
sente un risque a Ia sante humaine.
Toutefois, des etudes sont
toujours en cours et es preuves continuent a Œtre examinØes. En at
tendant que es conclusions finales de Ia recherche soient Øtablies, ii
vous serait souhaitable de rØduire votre exposition aux champs Ølec
tromagnØtiques pendant le soudage ou le coupage.
champs Ølectromagnetiques
respecter es consignes suivantes
de rØduire les
dans lenvironnement
Garder les cables ensembles en les torsadant
avec du ruban adhØsif.
les
ou en
attachant
sou
des champs ØlectromagnØtiques. II y a eu et il y a
certain souci a propos de tels champs. Cependant, aprŁs
avoir examine plus de 500 etudes qui ont ØtØ faites pendant une pØ
dage,
Fire
2
Mettre tous les cables du ctØ
3
Ne pas courber pas et
ne
oppose
de
lopØrateur.
pas entourer pas les cables autour de
votre corps.
4
Garder le poste de
de
soudage
et les cables le
plus
loin
possible
vous.
vant le
OM-1587
Page
8
5
Relier Ia
pince
de
masse
le
plus prŁs possible
de Ia
zone
de
soudure.
Consignes
relatives
Les personnes
aux
stimulateurs
cardiaques
stimulateur cardiaque doivent avant tout
consulter leur docteur. Si vous Øtes dØclarØ apte par votre docteur, il
est alors recommandØ de respecter les consignes ci-dessus.
qui portent
un
SECTION 2- DEFINITIONS
2-1.
Warning
Label Definitions
1
Warning! Watch Out!
are possible hazards
shown
the
by
There
as
symbols.
2.
Drive rolls
3.
Welding wire and drive parts
are at welding voltage during
operation keep hands and
metal objects clear.
can
injure fingers
-
1
Electric shock
1.1 Wear
kill.
can
dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet
or
damaged gloves.
yourself from electric
by insulating yourself
from work and ground.
1.2 Protect
shock
1 .3 Disconnect
input plug
working
or
power before
machine.
2
on
fumes
Breathing welding
can
be hazardous to your health.
2.1
Keep your head out of the
fumes.
2.2 Use forced ventilation
exhaust to
2.3 Use
remove
ventilating fan
local
or
the fumes.
to
remove
fumes.
3
Welding sparks can
explosion or fire.
3.1
Keep flammables away from
welding. Dont weld near
cause
flammables.
3.2
Welding sparks
can cause
fires. Have a fire
nearby and have
person
ready
extinguisher
a
watch
to use it.
3.3 Do not weld on drums
closed containers.
or
any
4
Arc rays can burn eyes and
injure skin.
4.1
Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear
complete body
protection.
5
Become trained and read the
instructions before
on
6
the machine
or
Do not
remove or
(cover)
the label.
working
welding.
paint
over
OM-1 587
Page
9
Manufacturers
2-2.
Rating
Label For CE Products
For label location
S/N:
Section 4-3.
see
(E
U1=24 V4,
11= 10.OA
14,
50/60
Hz
1P23
&
U2100V
12=750A
X 100%
ST-178 794-A
2-3.
Symbols
Note 1EI~
And Definitions
Some symbols
are
fo und
only
on
CE
Output
h\_,
Alternating Current
Q
Off
)(
Duty Cycle
010
Jog
>
Parameter Select
Purge
products.
A
p
Amperes
Degree Of
Protection
Trigger
Read Instructions
Trigger
~/
Volts
Hz
Hertz
~J ~
Line Connection
Hold On
Trigger
Hold Off
L~
()
Hold On
Indicator
I
U2
1 ~
OM-1 587
Trigger
Increase
Page
Load
Voltage
Single Phase
10
Light
Primary Current
Trigger
Hold Off
0
Indicator
12
Rated Current
Light
~J1
Primary Voltage
O,/~
Percent
SECTION 3- INTRODUCTION
Specifications
Input
Welding
Source
Power
Type
Constant Voltage (CV)
DC For GMAW Or
AC
Amperes
Hertz
Constant
Voltage(CV) /
Constant Current (CC) DC
For GMAW-P
All Need 14-Pin And
Contactor Control
Wire Feed
Speed Range
Standard: 50 To
1pm (1.3 To
19.8 mpm)
780
Optional High
Speed: 92 To
1435 1pm (2.3 To
36.5 mpm)
Wire
Welding
Diameter
Circuit
Rating
Range
.023 To 1/8 in
(0.6 To 3.2
mm)
100
Amperes,
Duty
Cycle
Spool
Weight: 60
(27 kg)
lb
Overall
Dimensions
Weight
Length: 32 in
(812 mm)
Volts,
750
100%
Max
IP
Rating
IP 23
Width: 18 in
78 lb
(457 mm)
(35 kg)
Height: 14 in
(356 mm)
SECTION 4- INSTALLATION
4-1.
Site Selection
OM-1587
Page
11
Equipment Connection Diagram
4-2.
1
300/400 Ampere Model
CC/CV lnverter Welding
Power Source
settings shown for both
pulse MIG welding and MIG
welding.
lET Use
450
S
Ampere Model DC
Welding Power
Inverter
Source
3
14-Pin Cord
4
Positive
5
Negative (-)
Be
sure
Weld Cable
(+)
weld
Weld Cable
cables
are
sized
properly for peak amperage if
pulse welding (see welding power
source Owners
Manual).
PANEL
0
6
Workpiece
7
Voltage Sensing
(Optional Use)
Lead
Be sure gun is rated for peak
amperage if pulse welding. Install
according to its Owners Manual.
9
Wire Feeder
REMOTE
INDUCTANCE/DIG
V/A CONTROL
.
S
ST-162 129.A/ Ref. ST-154 197 / ST-146 127-C/ Ref ST-163 420-A
OM-1587
Page
12
4-3.
Rear Panel Connections
1
Customer
Supplied
Gas
Hose
2
Shielding
Gas Valve
Requires fitting
with
Fitting
5/8-18 right-
hand threads.
7
3
Weld Cable Terminal
4
Jumper
5
Weld Cable
6
14-Pin Cord
7
Rating
Weld Cable
Label Location
1
Tools Needed:
~r
9/16,5/8in
Ref. ST-i 52 567-C
4-4.
Rotating
The Drive
Assembly
OM-1587
Page
13
14-Pin
4-5.
Plug Information
*The
remaining pins
4-6.
Pin Information
~j~*
REMOTE 14
are
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
M
CC/CV Select (+24 V
N
Inductance
ac
with
to socket G.
A
common
respect
completes
24 volts ac contactor control circuit.
for 24 volts AC circuit.
output
to remote control with
input
0 to +10 volts
feedback; 0
to +10 volts
=
respect
signal from
to socket D.
remote control with
dc, 1 volt per 10
arc
respect
to socket D.
volts.
dc, 1 volt per 100 amperes.
CV)
(0-10V)
not used.
Motor Start Control
To
change wire feed starting speed
proceed as follows:
Turn Oft wire feeder and
power
welding
source.
Remove wrapper.
1
2
Motor Board PCi
Motor Start Control Poten
tiometer R70
Turn
potentiometer clockwiseto in
crease
Right
time it takes the motor to
ramp up to speed. Remove protec
tive white rubber cap before mak
Side
ing adjustment. Adjust potentiome
using a small nonconduc
ter R70
tive screwdriver.
Reinstall wrapper.
Tools Needed:
Non-Conductive
EII~IZjlJ
1/4 in
ST-162 132-Al Ref. SA-183 121-B
OM-1587
Page
14
.
4-7.
Gun Recommendation Table
Gun
Process
GMAW-P
GMAW
FCAW
4-8.
-
-
-
Hard
Hard
or
Speed
GW-500 Or GW-600
Cored Wires
M25, M40, Or GA-50C
Cored Wires
Self-Shielding
Wire
Motor
or
Wires
GA-4OGL Or GA-5OGL
Type, Size, And
Wire
Type
Feed
Speed Capability
Table
Feed
Wire Size
.023 To 5/64 in
To 2
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
Speed
All
.023 To 5/64 in
(0.6
(0.6
To 2
mm)
50 To 780
ipm (1.3
To 19.8
mpm)
50 To 700
ipm (1.3
To 17.8
mpm)
50 To 300
mm)
Speed Capability
92 To 1440
ipm (1.3
To 7.6
mpm)
ipm (2.31035.6 mpm)
OM-1587
Page
15
4-9.
Installing
And
Threading Welding
Wire
If necessary, move hub and spool sup
so wire runs straight from the
Install wire
port
anti-wear
guides
guide.
and
spool through the drive rolls. InstaJl
spool. Adjust tension nut so wire
wire
is taut when wire feed
stops.
-~
4,
Install drive rolls.
NONCONDUCTIVE
SURFACE
No Wire
Wire
Slips
that outlet cable has proper
welding wire size.
fl~ Forsoft wire or small diameter stainless
size liner for the
steel
When installing gun, position liner
extending from outlet wire guide as
roll pressure from 0 to a maximum of 4
on the pressure indicator scale (so that
close
only
Ur Be
sure
possible
as
to drive rolls without
to drive
rolls; continue
wire,
use
2 drive rolls and set drive
spring is compressed).
This setting will generally give the best
performance for these types of wires.
touching.
Install gun. Lay gun cable out straight. Cut
off end of wire. Push wire through guides up
Jog
Slip
NONCONDUCTIVE
SURFACE
To
the inner
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
cover.
to hold wire. Press
button to feed wire out gun.
Tools Needed:
3/16,5/64 in
15/16,3/8in
Ref. ST-156 929-A/ Ref. SC-150 922/Ref. ST-156 930 / S-0627-A
OM-1587
Page
16
SECTION 5- OPERATION
5-1.
Operational
Note ~
The
following
is
a
Terms
See Menu Guide for detailed
list of terms and their definitions
as
programming steps.
they apply
to this wire feeder:
General Terms:
Adaptive
Pulse
The wire feeder
Welding
less of
Cold Wire
change
automatically regulates pulse frequency
welding wire stickout.
to maintain a constant arc
length, regard
in
When weld amperage is not present, wire feeds for about three seconds at set wire feed speed.
Then the welding power source contactor deenergizes and wire continues to feed at the wire jog
Jog
speed.
Inductance
As inductance
Trim
Arc
Synergic
The
increases,
arc on
increases, and the weld puddle becomes
time
length adjustment in pulse welding. Increasing
placed by volts in MIG programs.
the
trim increases the actual
operator programs pulse parameters for a specific wire feed speed.
pulse parameters between these wire feed speed increments.
more
arc
fluid.
length.
Trim is
re
The wire feeder determines
Side Panel Terms:
Is used to select the
Process Mode
Sequence
type of process
to be
used, including Pulse, Adaptive Pulse,
Is used to select and program the weld sequences which include weld, crater,
and run-in.
Mode
or
Mig.
burnback, postflow,
preflow,
Dual Schedule Mode
Is used to select
a
Card Mode
Is used to select
use
Security
Mode
Only
functions with
rameter
5-2.
Pulse
Welding
pair
a
of programs that
of the
optional
can
be used
data card
data card. Allows
using
together.
storage
and retrieval
the lock feature for
capabilities.
restricting range
of program pa
changing.
Terms
1
Apk
Peak
=
Amperage
Increasing Apk increases penetra
tion.
Vpk
Peak
=
Voltage
voltage during peal current
phase of the pulse waveform. This
determines
arc
length during
adaptive pulse welding.
Arc
3
/
2
\
I
Amps
\
I
\
l~
\
3
/
/
/
/
/
2
arc
=
increasing
\.
4
4
1
PPS
Background Amperage
=
/
/
J
Abk
Maintains
pulses.
PPS increases travel
Pulse Width In
Milliseconds
PWms
Increasing
4
between
Pulses Per Second
=
PWms increases bead
width.
Time
/
OM-1587
Page
17
Front Panel Controls
5-3.
1~1
iIDr
I
2
3
8
7~
4
5
1
Display
2
Parameter Select Button
click
Press button to
move > on
causes
program number
crease/decrease by
Display
Control
Pulse is
Turn control to
change
value
pointed
to
by
>.
Turning control one click causes Trim (arc
length) to increase/decrease by one or Volt
to increase/decrease by 0.1.
When 1PM is selected,
click causes wire feed
crease/decrease by
When
MPM
three clicks
to increase
When
Prg
is
by
turning control one
speed (1PM) to in
(see Section 7).
default setting. To change type of
(Pulse, Adaptive Pulse, or MIG)
panel controls.
Active Side Indicator Light
Trigger Hold Button And Indicator
Light
a
process
use side
4
5
Trigger
Hold
can
basis. Indicator
be set
wire feed
speed (MPM)
0.1.
# is selected,
turning
control
one
been struck. To end weld
release gun
on a
per program
light comes on for programs
cycle, press
and
trigger.
6
Side Select Button
7
Jog
Button
Push to momentarilyfeed welding wire with
energizing welding circuit or shielding
out
gas valve.
Jog speed is varied using the Display Con
Jog button is pressed. Default set
ting is 200 1PM.
trol while
8
Purge
Button
momentarily energize gas valve
energizing the welding circuit.
where this feature is active.
Push to
To weld without
holding gun trigger through
without
out weld
press and release button to
Holding the Jog and Purge buttons atthe
time displays pulse parameters on
the side panel display and voltage on
front panel display.
one.
selected, turning control
causes
to in
The program number cannot be changed
while welding, with exception of Dual
display.
Schedule Mode
3
(Prg #)
one.
cycle,
turn feature on
(indicator light
turns
on).
To start weld cycle, press and release gun
trigger within three seconds after an arc has
same
ST-162 127
OM-1 587
Page
18
.
5-4.
Side And Rear Panel Controls
1
Mode
2
Mode Select Button
Display
Press button to
move >
in
display.
3
Parameter
4
Parameter Select Button
Display
Press button to move> in
display.
5
Parameter Increase Button
6
Parameter Decrease Button
7
Power Switch
8
Circuit Breaker CB1
CB1 protects the wire feeder from
overload.
Ref. ST-i 62 128/ Ref. ST-I 62 1 33-A
OM-1587
Page
19
SECTION 6- SETTING SEQUENCE PARAMETERS
U~
programming steps.
length.
If set to zero,
Trim is
arc
length
length
is short. If set to
If
is
time
99,
arc
arc
long.
is
set
to
zero
in
Weld
sequence, welding continues until
gun trigger is released.
If time is set to zero in any timed
the
except Weld,
sequence
sequence is skipped.
.
X
=
Setting
available.
Weld Time
0
Preflow
Time
-
25
sec.
Crater
r
Time
Burnback
Time
/
/
Start
Time
/
Time
Burnback
Run-In
Arc
Postflow
Trigger
Released
OM-1 587
Page
20
Sequence
End
Strike
SECTION 7- SETTING DUAL SCHEDULE PARAMETERS
7-1.
Selecting
Dual Schedule Pair
Dual Schedule is used with two
consecutive weld programs 1 & 2,
3 & 4, 5 & 6, or 7 & 8. Any program
type (MIG,
Pulse)
Adaptive Pulse,
or
be combined in dual
can
schedule.
1
Side Panel
Use side
1
See
Display
panel
Menu
to turn feature on.
Guide
detailed
for
programming steps.
2
Front Panel
Press front
Display
panel parameter
select
button to select program number.
Display
Control
3
Front Panel
4
Section
U~ Switch
(See
7-2)
type
is set in
System
Setup.
5
Welding Gun Trigger
Selecting dual schedule program A
B is done by using Display Con
or
trol, dual schedule switch,
trigger
setup).
(depending
on
or
gun
system
When program B is active, turn
Display Control one click clock
wise to select another
pair
of dual
schedule programs.
ff7 Programs
can
be
in desired order
rearranged
using the data
card. See Section 8.
18.
200
OV
>Prg
1PM
Dual
~j
I
4~I
Or
5
U~
Display
Control
I
I>Prg
21
IDual BI
Display
Control
I>Prg
Dual
31
Al
OM-1587
Page
21
7-2.
Diagrams
1
Momen2P
(Momentary-Contact
Switch)
2
:
>
2
>
>
>
4
lishing
3
a
scheduling after estab
welding
arc.
2
1
>
0
(Maintained-Contact
Switch)
Trigger
Allows dual
A
(Maintained-Contact
Switch)
Maint 1 P
1-Pole
2
>
Maint 2P
2-Pole
3
2
2
A
3
If
trigger
is
used
schedule switch,
is disabled.
B
4
p
4
p
3
4
1
>
2
TR
1
>
2
>>
I
3
I
BO
>
4
>
OM-1 587
Page
22
2-Pole
Adapter
1
I
I
>
2
>
3
TR\___
for
Trigger
dual
Hold
SECTION 8- USING THE OPTIONAL DATA CARD
8-1.
Data Card Terms
CARD SCREEN TERMS
WRITE
Programs
To Card
~
>Wr
R
I
i
e a
t e
I
d
I
Delete
Done
READ
Programs
From Card
PULSE MIG TERMS
PpS
Amperage
(Pulses Per
Second)
I
r
SA-158 435
8-2.
Installing
Data Card
1
Label
label to data card. Write pro
gram information on label.
Apply
2
Data Card
3
Card Slot
For Blank Data Card:
Insert card into slot. To format card,
3
turn On power. Select Card from
menu. Data card formats when unit
enters Card mode.
2
For Power Source Data Card:
Insert card into slot. Turn On pow
Push Parameter Select button
er.
within 3 seconds and the 8 pro
grams and setup information are
read into the wire feeder memory.
Unit is
Wait
front
ready
to
use
when Please
disappears
panel display.
message
from
ST.156 266-B
OM-1587
Page
23
8-3.
Card
Displays
ll~ See Menu Guide for detailed
programming steps. Security
mode only functions with a
data card.
1
Card
2
Moving
Display
Line
Moving line is
be changed.
Sequence
3
.
under value that
can
Write
Dua I Schd
>Card
Pr
Security
ess
Below
Transfers program data from unit
to card. The program card can hold
up to 32 programs. When writing to
the card, the next available pro
gram number is automatically
as
signed.
4
Read
Transfers program data from card
to unit.
5
3
Delete
Deletes program data from card.
6
4
Done
Exits card
display.
5
2
.
OM-1587
Page
24
8-4.
Entering
Access Code
Security Display
1
only when a data card is inserted and
Setup screen is turned On.
Access code works
access
mode in
Lock
2
Program
3
Access Code
With
code
a
set,
Pressing
this
display
to turn off a
trying
appears when
program lock.
exit the
Display
Display
Mode Select button will
access
code
display.
If any character is incorrect
during code entry, pressing
side panel Parameter Select
button will
Side Panel
Parameter
Select
Press side
>Code
Enter
Acc
AAA
e S S
Code
~~J
NextChar
Press
~Press
~
Prog
>Lock
QflI
Trim
551
Range
10~
i
I
Select
Parameter Select
access
the correct letter is
ing
side
button
code. When
entered, press
Parameter Select
indicator to the next
panel
moves
character. When the final
code character is
access
entered, press
panel Parameter Select
to automatically change
display to the program lock display.
button
Side Panel
_________________
Parameter
Select
panel
button to enter
side
Increase!
Decrease
Mode
the indicator
beginning of
character set to allow entering
access code again.
2
ii
cause
to move back to
p
I
~
1
I
o
g
o c
k
QflI
Trim
551
Range
10~
>L
r
Increase!
Sequence
>Prog
1
DualSchd
Lock
On
Card
Trim
55
Range
10
Decrease
V
>Secur
i
ty
I Prog
ii
>
QU~
OM-1587
Page
25
8-5.
Security
security feature
The
allows
a
mini
and maximum range limit to
be defined for trim, inches per min
mum
g~
The
security feature
works
only when a
data card is inserted.
(1PM),
12).
ute
tion
2
Press
Mode
Select
5 Times
>Prog
1
DualSchd
Lock
Off
When the
security lock is On, the
range of values available for each
parameter is the defined value plus
ity
or
minus the defined range.
For
example,
fined
Side Panel
Parameter
Select
2
ii
onL
Lock
I>Tr
im
50
Range
~
Prog
>Lock
Trim
Range
ii
Prog
/
_ Q1L~
Qn~
50
Increase!
Decrease
Q
Increase!
Decrease
if the 1PM value is de
125, and the range is de
fined as 50, the actual range of
as
available 1PM is 75to 175 1PM
minus 50, and 125
1
Card
2
Moving Line
(125
plus 50).
Display
Moving line is under value that can
be changed. Change program
number to
access
desired
pro
gram.
Lock On!Off
3
Side Panel
Parameter
Select
Sec
security lock is Off, the
full range of values is available for
each parameter.
Car d
I Prog
ShpArc (see
When the
Sequence
>Secur
and
Off.
Toggles security feature
On
Definable
displayed
values
are
or
when Lock On is selected.
Use
side
val
panel
controls to
change
ues.
4
Trim And
Range Display
5
1PM And
Range Display
6
ShpArc
And
Range Display
Definable Values:
Trim: 0-99
Range:
1PM: 70-875
ShpArc
In
:
0-20
0-99
Range:
0-875
Range:
0-20
the
example displays, the
operator could change the value of
Trim to 55 and its Range to –10%.
Also, the operator could change
the value of 1PM to 225 and its
from
–100
Range to
ipm
programmed values. If the range
settings are left at 0, the operator
cannot change values from those
programmed.
Trim
55
Range
~
1PM
>Range
>Prog
1
Lock
On
225
Trim
55
~
Range
10
Side Panel
Parameter
Select
OM-1587
Page
26
.
SECTION 9- SYSTEM SETUP
9-1.
Accessing
The
Setup Menu
1
Setup
2
Power Switch
Panel
Press and hold down both buttons
while
3
Main
4
turning On
Main
unit.
Display
display during setup.
Setup Display
procedure any time
required. Once in the
setup displays, use the Mode
Follow this
access
is
Select button to select
a
particular
display.
2
4
Setup Display
System
>
>
Invisn 456
>
Model
/
System
Process
Model
Capability
Pulse/Mig
Access
System
Access
Mig Type
Reset Now
Mig Type
>
Press
Mode Select
To Change Menu Item
OM-1587
Page
27
9-2.
System Setup Display
Note ~
DISPLAY SETTING
>System
*
Parameters
programming steps.
NOTES
Select the process the
welding power
source
is able to do.
For the Invision 456 and XMl 304 selections, pulse data and
are automatically loaded in. For the Other
selection,
>Model*
values
welding power
welding power
source
source
minimum and maximum
minimum and maximum
voltage
voltage
and amperage values must be entered. Pulse data defaults to XMT 304 values.
>Access
When on, restricts
>Mig Type
Default is Off. Set to On
use
of
setup
only
screens.
for older CV
welding
Default is 14-pin receptacle. Use V. Sense when
>Voltage
power
source
without
than 50 ft
more
(1 5m)
voltage
feedback at 14-socket
of weld cable is used
receptacle.
(including gun
cable
length).
>Arc Start*~
Use Hot Start only with Inverter Model
switches to CC.
>Dual Schedule
See Section 7-2.
>Trigger
When on,
trigger
welding
power
source
and
large
diameter wires. The
be used to switch between programs that have at least 0.2 seconds of
can
arc
starts in CV and
preflow
time pro
grammed.
>Remote
When on,
a
dual schedule switch
panel display
>
can
be used to
change
Volts
or
Trim, 1PM,
>Arc Time
Displays
>Wire Feed
Choose to
>Memory
No Reset: allows
accumulated
display
arc
time and
System
inches per minute
operator
or
meters per minute and motor
to exit memory reset
Reset: unit defaults to
in card
on
where the front
parameter
without
type, but installed
resetting any
original factory settings
data.
program.
for all programs and
motor must match selection.
Setup
information does not
setup excluding System
and Arc Time. If
slot, program will be loaded from card.
Total Reset: unit defaults to
setup
Prg depending
cycles.
Program Reset: unit defaults to original factory setting for the last active
change. If setup card is in card slot, program will be loaded from card.
setup card is
or
is.
original factory settings
for all programs and
setup including System
and Arc Time. If
card is in card slot, program will be loaded from card.
>Shutdown
When on, the system
age is sensed.
>Gas Flow
Setting
>Ramps
Turns start and crater
immediately
must be Meter Off if
option
ramping On
shuts down if
no arc
voltage
is sensed. When
off, wire feeds
even
if
no arc
volt
is not installed.
or
Off. When On,
output power is tapered from
start to weld and from weld to
crater.
>Software
*
Automatically
Can be used
-~
Know this when
talking
with service
personnel.
set if power source data card is used.
only when optional data card is inserted.
Selection does not appear on display when MIG Only is System choice.
Must remain set to Meter Off if option is not installed to prevent system
error.
S
OM-1587
Page
28
SECTION 10- STANDARD PULSE WELDING PROGRAMS
FOR PHOENIX/INVISION 456 INVERTER
WELDING POWER SOURCES
Note ~
Apk
=
PPS
=
Peak
Amperage, Vpk
factory set programs.
interpolations from the
10-1.
Wire
Program
1
-
=
Peak
Pulses Per Second, PWms
=
Voltage,
If selection is set
4
Abk
Background Amperage,
(milliseconds). Four teach points were use d for
for fifteen teach points, the remaining points are
=
Pulse Width
taught points.
Steel
Size/Type: .035
Gas: Ar
-
CO2
or
Ar
OxyI
-
40 CFH
(19 Urn)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
700/17.8
440
36.7
160
180
2.9
400/10.2
385
32.4
108
126
2.3
200/5.1
335
28.7
61
81
2.0
100/2.5
328
27.4
37
47
1.7
10-2.
Wire
Program
Size/Type:
2
-
Steel
Gas: Ar
.045
-
CO2
or
Ar
-
Oxy /40
CFH
(19 1/rn)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
700 / 17.8
518
35.0
195
205
3.6
400/10.2
466
31.3
147
158
2.9
200/5.1
412
28.5
93
106
2.4
100/2.5
375
26.5
50
66
2.2
10-3.
Wire
Program
Size/Type:
3
-
Gas: Ar
.052
-
CO2
or
Ar
-
Oxy /
40 CFH
(19 1/rn)
Apk
Vpk
Abk
PPS
PWms
625/15.9
560
39.3
200
229
3.6
400/10.2
525
36.2
148
189
3.5
200/5.1
475
31.7
102
131
2.7
100/2.5
445
29.6
50
80
2.4
Wire
Program
Size/Type:
4
-
Gas: Ar
Apk
400/10.2
COMMENTS
Steel
.062
1PM / MPM
COMMENTS
Steel
1PM / MPM
10-4.
COMMENTS
-
CO2
or
Ar
-
Oxy /
40 CFH
(19 1/rn)
Vpk
Abk
PPS
PWrns
550
36.8
200
195
4.1
300/7.6
510
36.3
145
175
3.8
200/5.1
480
31.6
110
155
3.2
100/2.5
460
28.7
69
94
2.6
COMMENTS
.
OM-1587
Page
29
10-5.
Wire
Program
Size/Type:
5
-
Stainless
.035
Gas: Ar
-
He
-
CO2 /
40 CFH
(19 1dm)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
700/ 17.8
403
33.9
132
191
2.8
400/10.2
318
31.6
87
146
2.4
200/5.1
295
28.5
53
94
1.9
100/2.5
280
26.0
32
45
1.8
10-6.
Wire
Program
Size/Type:
6
-
Stainless
.045
Gas: Ar- He
-
CO2 /40
CFH
(19 L/m)
Vpk
Abk
PPS
PWms
480
39.0
200
227
3.2
400/10.2
425
32.4
155
185
2.5
200/5.1
360
28.0
100
115
2.0
100/2.5
350
26.2
40
70
2.0
IPM/MPM
Apk
700/17,8
10-7.
Wire
Program
Size/Type:
7
-
Gas: Ar
-
CO2 /
40 CFH
(19 1dm)
IPM/MPM
Apk
Vpk
Abk
PPS
PWms
700/17.8
490
37.4
165
210
3.1
400 / 10.2
440
33.8
115
155
2.5
200/5.1
400
29.2
70
120
1.9
115/2.9
395
26.3
41
96
1.4
10-B.
Wire
Program
Size/Type:
.052
8
-
Metal Core
Gas: Ar
-
CO2 /
40 CFH
(19 1dm)
Apk
Vpk
Abk
PPS
PWms
700/ 17.8
510
38.0
240
250
3.3
400 / 10.2
460
33.3
135
200
2.5
250/6.4
425
31.0
100
170
2.2
175/4.4
410
28.6
75
Page
30
COMMENTS
Metal Core
1PM / MPM
OM-1 587
COMMENTS
Metal Core
Metal Core
.045
COMMENTS
COMMENTS
SECTION 11
FOR XMT 304 INVERTER WELDING POWER SOURCES
-
Note ~
Apk
Peak
=
PPS
=
factory
Amperage, Vpk
=
Peak
Pulses Per Second, PWms
=
Voltage,
Abk
Background Amperage,
(milliseconds). Four teach points were use d for
fifteen teach points, the remaining points are
=
Pulse Width
set programs. If selection is set for
the 4 taught points.
interpolations from
11-1.
Wire
Program
Size/Type:
1
-
Steel
.035
Gas: Ar
-
CO2
or
Ar
-
Oxy /40
CFH
(19 Urn)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
700/17.8
400
36.7
127
137
1.8
400/10.2
340
32.4
84
98
1.6
200/5.1
305
28.7
52
60
1.4
100 /2.5
285
27.4
30
30
1.4
11-2.
Wire
Program
Size/Type:
2
-
Steel
.045
Gas: Ar
-
CO2
or
Ar
-
Oxy /40
CFH
(19 U/rn)
PPS
PWms
IPM/MPM
Apk
Vpk
Abk
700/17.8
400
37.6
170
188
2.3
400/10.2
400
36.1
95
113
2.0
200/5.1
370
30.3
53
70
1.8
100/2.5
350
27.7
32
36
1.7
11-3.
Wire
Program
Size/Type:
3
-
.052
Gas: Ar
-
CO2
or
Ar
-
Oxy /
40 CFH
(19 Urn)
Apk
Vpk
Abk
PPS
PWms
625 / 15.9
400
39.3
200
200
3.7
400/10.2
395
36.2
165
165
3.4
200/5.1
375
31.7
97
97
2.7
100/2.5
366
29.6
54
54
2.4
Wire
Program
Size/Type:
4
-
COMMENTS
Steel
1PM / MPM
11-4.
COMMENTS
COMMENTS
Steel
.062
Gas: Ar
-
CO2
or
Ar
-
Oxy /
40 CFH
(19 U/rn)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
400/10.2
315
36.6
70
94
1.7
300/7.6
290
34.8
60
72
1.6
200/5.1
280
31.5
45
46
1.5
100/2.5
265
28.3
26
25
1.4
COMMENTS
OM-1 587
Page
31
11-5.
Wire
5
Program
Size/Type:
-
Stainless
Gas: Ar-He
.035
-
C02/40 CFH (19 L/m)
1PM! MPM
Apk
Vpk
Abk
PPS
PWms
700 / 17.8
400
33.9
95
200
2.0
400/10.2
370
31.6
50
145
1.8
200/5.1
315
28.5
38
80
1.6
100/2.5
300
26.0
30
36
1.4
11-6.
Wire
6
Program
Size/Type:
-
Gas: Ar
.045
-
He
-
CO2 /
40 CFH
(19 Urn)
Apk
Vpk
Abk
PPS
PWms
700/ 17.8
400
39.0
180
312
2.5
400/10.2
395
32.4
112
185
2.1
200/5.1
370
28.0
72
100
2.0
100/2.5
337
26.2
40
60
1.9
Wire
Program
Size/Type:
.035
7
-
Nickel
Nickel
Gas: Ar
Alloy
He /40 CFH
-
(19 U/rn)
Apk
Vpk
Abk
PPS
PWrns
700/17.8
400
34.5
150
167
1.8
400/10.2
380
30.0
95
105
1.5
200/5.1
330
27.5
47
60
1.3
100/2.5
315
25.1
21
30
1.2
Wire
Program
Size/Type: .045
8
-
COMMENTS
Alloy
IPM/MPM
11-8.
.
Stainless
1PM / MPM
11-7.
COMMENTS
COMMENTS
Metal Core
Metal Core
Gas: Ar
-
CO2 /40 CFH (19 L/m)
1PM / MPM
Apk
Vpk
Abk
PPS
PWms
625 / 15.9
400
34.0
200
220
2.8
500/12.7
400
34.0
155
190
2.6
300/7.6
370
31.3
105
140
2.4
150/3.8
352
27.7
60
108
1.7
COMMENTS
.
OM-1 587
Page
32
SECTION 12
12-1.
Selecting
And
-
SharpArcTM CONTROL
SETTING
Adjusting SharpArc~ Control
*4
1
Arc
is Arc
SharpArc~
It is used to
and
arc
on
adjust
the
display.
width
arc cone
characteristics.
Use front
panel parameter
button to
move>
Display
setting.
Control
select
to select Arc. Use
to
adjust
Arc
1
SharpArc~ setting range is from 0
factory default is set at
zero (0). When Arc value is in
S t
creased toward 20, the arc cone
narrows and the weld puddle be
to 20. The
50
Tr
im
I
PM
200
>Prg
0 3 5
comes
/
Parameter
Select
50
200
I
50
2 00
V
Tr
im
Prg
1
I
PM
>Arc
0
Tr
im
I
PM
II
less fluid.
>
A
r
c
0F
1
Prg
2
Ref. S-0259
OM-1587
Page
33
SECTION 13- TEACH POINTS
13-1. Teach
Using
15 Points
r!1i~pH *4
L~
Apk
=
Peak
Amperage
A
Vpk
=
Peak
Voltage
U
Abk
=
Background Amperage
0
PPS
1PM / MPM
Pulses Per Second
=
PWms
Pulse Width
=
(Milliseconds)
780 / 19.8
750/19.1
700/17.8
650/16.5
600 / 15.2
550/14.0
500 / 12.7
450/11.4
Example Of A Synergic
Setting For 425 1PM With
400/10.2
All Teach Points Set At 50
1PM
(1.3 MPM)
350 /8.9
Increments
300/7.6
250/6.4
200/5.1
150/3.8
100/2.5
50/1.3
450
480
510
540
45
48
51
54
100
180
210
240
270
300
330
360
370
420
10
18
21
24
27
30
33
36
37
42
Abk
10
20
30
40
50
60
70
80
90
100
110
120
130
PPs
20
55
80
105
130
160
185
210
235
260
290
315
340
Apk
Vpk
2
PWms
The teach mode allows the
user
to create
pulse programs. The teach mode
selection for 15 teach points gives a more
defined curve for a specific range. At each
teach point, the user can adjust five param
eters to shape the pulse waveform of the
weld output. The six parameters are: 1PM
(MPM), Apk, Vpk, Abk, PPS, and PWms.
custom
OM-1587
Page
34
3
Apk, Vpk, Abk, PPS, and PWms acting
together provide the energy necessary to
burn off welding wire at a set wire feed
speed. The graph below shows that as wire
feed speed increases, energy increases
(Apk, Vpk, Abk, PPS, and PWms acting
synergically).
Apk
Vpk
140
200
Abk
365
400
PPS
5
4
Under
56
565
some
PWms
conditions, the wire feeder lim
its wire feed speed to maintain all pulse pa
rameters within the capability of the system.
.
13-2.
Redefining
Teach Points
*4
1
position
~
Redefining
1PM
1PM determines the weld metalde
1PM Teach Point
rate.
Redefining 1PM is not normally
required unless special wire or
unusual
is
joint
design
needed.
Trim
50
1PM
>450
,,,/
Purge
~
Trim
50
Use front panel parameter select
buttontomove>toselectlPM. Use
Display Control to select teach
1
Prg
Pulse
point
Press and hold Purge button while
turning Display Control to redefine
the ipm teach point. For example:
there are teach points at 150, 200,
and 250 ipm; the teach point at 200
can be adjusted to a wire feed
speed of 151 to 249 pm.
Ar~d
1
Prg
2
>460
I
PM
Pul
value.
se
Vpk
Peak
-
voltage during peak current
phase of the pulse waveform. This
determines
arc
length during
adaptive pulse welding.
3
Apk
4
Abk
Peak
-
depend
Pulse Parameters
power
5
Amperage
Background Amperage
-
Peak and
Redefining
Voltage
Arc
on
background amperage
welding
the range of the
source.
PPS
-
Pulses Per Second Of
20-400
6
PWms
Pulse Width Of
-
1.0-5.0 Milliseconds
panel controls to change
parameters. See Menu
Use side
pulse
Guide for detailed
programming
steps.
2
After values
maintain
are
an arc
set, strike and
for five seconds.
Do this for each teach
point.
by releasing gun trigger,
not by pulling gun out of weld. Re
peat for each custom teach point.
End weld
The
Trim
taught arc length represents
(arc length) setting of 50.
a
Once the teach
points are set, the
parameters be
points synergically.
wire feeder adjusts
tween teach
3
I
I
385
Apk
108
Abk
32.4
Vpk
Vpk
385
Apk
Apk
>108
Abk
1>126
PPS
108
Abk
126
PPS
2.3
PWms
385
Apk
108
Abk
400
I
32.4
1>385
1PM
126
PPS
>
PWms
Ref.
S-0259/ Ref. 5T-154 109
OM-1 587
Page
35
Date___________________ Program Number
Wire Size/Type_
Gas
Flowrate_
Equipment
Used
-
Power Source
Serial Number
Serial Number
Wire Feeder
Gun Model
Wed
Wire Manufacturer________________
Mfg.
1PM / MPM
..CFH(L/min)
Vpk
Apk
Cable
-
Positive
Negative
Date
Abk
PPS
PWms
COMMENTS
.
Preflow Seconds:_________
Run-In Trim/Volts:_________ 1PM /
MPM:_____________________________________ Seconds:_____________________________
Crater Volts:_____________________ 1PM / MPM:_____________________________ Seconds:_____________________________
Posttlow Seconds:________
OM-1567 Page 36
SECTION 14- MAINTENANCE AND TROUBLESHOOTING
14-1. Routine Maintenance
A
Disconnect power before
maintaining.
OM-1587
Page
37
14-2. Error
Displays
Release
Trigger
I
0~~
2
No
Vol
t
Sensed
1Error
1
3
Prg
Memory
Er
CRC
ror
4
Release
I
emo
r
R ang
e
y
2
No Volt Sensed Error
The
arc
voltage
sense
Display
circuit is not
voltage
connections.
Check
14-position plugs!
receptacles at the unit and welding
connections at
Er
power
Turn
5
Display
feedback. Check
Prg
ror
Error
Trigger
This appears if the trigger is closed
when the unit power is turned on, or
if the trigger is stuck or defective.
receiving
sensing
M
00
source.
back
unit off and
after
on
correcting problem.
N
N
S
Tach
o
ens
e
d
6
Arc
Start
1Er
1Er
If this
when
continues
to
it may
occur
help
to
select Hot Start.
ror
Memory
CRC Error
Display
a
system
reset.
Memory Range
Error
Mi
n
C F H
x
x
GasFlow
9
Ma
x
C F H
GasF
x
x
low
10
Gas
of
11
Range
Coo
12
Out
I
1Er
1Er
1Er
end of the weld. If there is high
used in the area,
frequency being
turn it off. A motor brake circuit
problem
Press
through pulse parameters to
make sure they do not exceed
settings of the Range display or
perform a system reset.
5
No Tach Sensed Error
Display
The motor tach feedback is not
reaching the control. Check
connections.
panel
this
error.
Parameter
error.
This appears when gas flow falls
below the minimum CFH set (xx in
example). Adjust gas
flow to
bring
it above set value.
front
panel
Select to clear
Parameter
error.
Maximum Gas Flow Error
panel
Parameter
6
Display
front
Select to clear
Press
10
Parameter
panel
error.
Gas Out Of
Range
Error
appears when gas flow is
greater than 100 CFH. To protect
the internal sensor, the unit shuts
down until the gas flow can be
adjusted below 100 CFH.
This
Coolant Flow Error
This appears only when coolant
flow switch option is installed.
coolant
recirculating
system.
started.
correct program
and
voltage
voltage sensing
Check
and
pulse parameters
settings. Check
connections.
Unlocked
Program
Error
Display
This appears when pulse welding
and current is detected but the arc
be
bring
error.
Arc Start Error
cannot
flow to
it below set value.
12
ror
cause
Minimum Gas Flow Error
8
Check
Press
front
Select to clear
ror
also
Select to clear
11
ror
can
front
example). Adjust gas
Display
Go
8
Display
saved.
Perform
ror
Error
Stop
9
The data in the program indicated
is out of usable range.
Er
Arc
This appears when gas flow is
above the maximum CFH set (xx in
4
Stop
7
Parameter
The data in the program indicated
is not the same data that was
ror
Arc
panel
error.
This appears when pulse welding
and the motor does not stop at the
Press
3
7
I
error
pulse welding,
front
Press
Select to clear
This appears when attempting to
run an unlocked program while
other programs are locked. Either
lock the unlocked program or
select
a
different program that is
locked.
ant
Flow
Unlocked
Program
Er
ror
1Error
Ref. ST- 155 222
OM-1 587
Page
38
S
14-3.
Troubleshooting
r!1
~
A
Remedy
Trouble
Wire
feeds, shielding gas flows,
electrode wire is not
but
power
source
Check
interconnecting
Sections 4-2 and
energized.
Wire feeder is on, meter(s) do not light
up, motor does not run, gas valve and
welding
pull in.
Check and reset CB1
or
feeds
Check gun
trigger
Check gun
trigger.
Change
Clean
or
Replace
Have
or worn
contact
tip
or
Wiredoesnotfeed until trigger is pulled,
but continues to feed after trigger is re-
leased, and trigger hold is
Gas valve in feeder is
feed
wire
(see
Table
4-9).
16-1).
guides.
liner. See gun Owners
or
Section
drive roll.
foreign
Manual.
matter from around nozzle
Factory Authorized Service Agency
Check for
(see
opening.
check drive motor
or
motor control board PCi.
input voltage.
a
short between
welding gun 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.
not on.
rattling loudly
erratic
or worn
Manual.
Manual.
See gun Owners
replace dirty
Check for correct
slowly.
possible
speed.
continuity and repair or replace (see
5-4).
connection. See gun Owners
Remove weld spatter
with
Section
to correct size drive roll
Incorrect size
along
(see
hub tension and drive roll pressure
Readjust
runs
cord connections. If secure, check cord for
4-3).
contactor do not
Electrode wire feeding stops
erratically during welding.
Motor
troubleshooting
Disconnect power before
or
slow wire
Unit does not switch out of Run-In
Check for
gun.
Install, reconnect,
or
replace voltage sensing
lead.
Speed.
Wire feeder power is on, displays
up, but unit is inoperative.
light
Check
welding gun trigger
leads for
continuity,
and
repair
leads
or
replace gun.
OM-1587
Page
39
SECTION 15- ELECTRICAL DIAGRAM
.
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Figure
OM-1587
Page
40
15-1. Circuit
Diagram
~
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pPEl42Nc__~!!!<<
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7115 ruits TO RE
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0.~2lI F~
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ST
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(o1OQ)
u_lIRE P158151
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SD-184 796-B
OM-1 587
Page
41
SECTION 16- PARTS LIST
flT Hardware is
common
and
not available unless listed.
Co
cJ
.
c~J
cj
C.)
CD
U-
(0
E
a)
(0
C~)
~
a)
UC.)
C
c~J
CD
C)
U-
Figure
OM-1 587
Page
42
16-1. Main
ST-BOO 084-E
Assembly
Item
No.
Part
No.
Figure
..
..
..
.
.
168 103
.
...
3
+168 104
.
...
124 900
.
...
5
143 160
.
.
6
058 427
7
180 573
108
166 594
..
..
..
...
..
..
...
..
...
..
..
4
.
...
.
...
1
.
...
2
10
010191
.
...
2
11
058 628
.
...
2
058428
.
WASHER, flat .632 ID x 1.500 OD x .l25thk stl
WASHER,flat.656IDx1.5000Dx.l25thkfbr
WASHER, brake stl
HUG, spool
TUBING, stl .875 OD x l2ga wall x 2.375
NUT, .625-11 .94hex .77 high stl elastic stop
SCREW, .375-16 x .750hexhd
SUPPORT, spool
...
FOOT, rubber 1 .2SOdia x 1 .375high
BRACKET, mtg spool RH
WASHER, lock .380 ID x .683 OD x .ll5thk stl split
NUT, .375-16 .56hex .34 high stl
4
12
13
071 730
.
...
14
135 205
.
...
601 964
.
.
141 411
.
.
.
.
..
18
142 838
.
.
..
19
602 213
.
.
..
20
601 872
.
.
21
139226
.
.
22
083639
.
.
23
159 360
.
.
24
159 646
.
.
..
25
159 647
.
.
..
26
139 752
.
.
167 768
.
.
.
.
..
1
1
057 971
134 306
..
1
1
9
17
..
1
...
16
..
1
.
..
...
1
010 233
15
..
Assembly
8
..
..
16-1. Main
REEL, wire 60 lb (consisting of)
NUT, spanner retaining
RETAINER, spool support (consisting of)
LABEL, caution falling wire reel can cause damage
SUPPORT, reel spool
HUB & SPINDLE ASSEMBLY, (consisting of)
RING, retaining spool
SHAFT, support spool
SPRING, cprsn .970 OD x .120 wire x 1.250
008
2
1
Quantity
Description
27
27
.
167
.
770
..
28
.
156 243
.
.
..
29
.
145 639
.
.
..
30
.
125 473
.
.
..
31
.
167 762
..
31
..
32
.
.
764
.
.
16-2
.
.
600 324
.
.
167
.
Fig
.
1
1
1
1
2
1
1
2
2
BASE
1
ift
WEATHERSTRIPPING,adh .125x1.500(orderbyft)
INSULATOR, screw machine
CLAMP, motor base
INSULATOR, motor clamp
SPACER, stl .500 OD x l2ga wall x 3.750
DRIVE ASSEMBLY, wire RH (Fig 16-3)
DRIVE ASSEMBLY, wire RH (high speed) (Fig 16-3)
CLAMP, motor top
STRIP, buna N compressed sheet .062 x 4.000 x 4.000
HOSE, SAE .187 ID x .410 OD
DRIVE ASSEMBLY, wire LH (Fig 16-3)
DRIVE ASSEMBLY, wire LH (high speed) (Fig 16-3)
8
2
2
1
1
1
2
2
2
1
1
CONTROL BOX
1
3ft
CABLE, weld cop strd No. 4/0 (order by ft)
OPTIONAL
+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.
OM-1587
Page
43
Hardware is
common
and
cJ
Lfl
c,J
.
N
cJ
\
\
(0
-
cJ
)
U
N
C.)
0
C.)
LI)
(0
tn~
C.)
0)
UC)
Figure
OM-1 587
Page
44
C)
C~J
C)
C)
16-2. Control Box
ST-800 111.C
C)
Item
No.
Dia.
Part
No.
Mkgs.
Figure
161707
1
GS1,2
2
125785
134201
3
PCi
PLG1
4
PLG2
PLG3
PLG4
PLG6
198037
....
115092
....
115093
....
....
....
5
CB1
Si
PC8O
PLG81
PLG82
PLG89
PLG9O
6
7
8
9
115094
115091
136810
184824
083432
111 997
182403
115093
158720
131 054
153 501
073756
.10
151187
11
+161 710
12
010290
13
134464
13
178936
163520
141 162
079739
601222
603106
600399
138044
107983
048 282
000527
605227
14
PLG9
15
16
.17
19
20
21
RC7O
22
...23
...24
CR101
SRi
....
072817
035704
030170
...27
Fig
28
...29...
PLG12,50
..
16-4
155629
154938
097132
PC5O
PLG51
PLG52....
PLG53....
PLG54....
PLG55....
...32
....
....
189124
158720
158719
131 204
148439
115092
126689
PC1O
PLG11
PLG15....
PLG17....
PLG18....
.35...
...36...
....
191996
....
115092
PLG1O,24
PLG16,41
153501
115093
162382
..
170980
..
155023
Figl6-5
010146
164059
+When
ordering
a
Quantity
Description
16-2. Control Box
(Figure
16-1 Item
32)
PANEL, side lower
VALVE, 24VAC 2 way custom port 1/8 orf
STAND-OFF SUPPORT, PC card .312/.375
CIRCUIT CARD, motor control
1
2
10
1
CONNECTOR & SOCKETS (RC1)
CASE SECTION, bottom/rear
CIRCUIT BREAKER, man reset 1P 1OA 250V
SWITCH, rocker SPST 1OA 25OVAC
CIRCUIT CARD, HF filter dual
CONNECTOR & SOCKETS (RC9O)
STAND-OFF, 6-32 x .625 Ig
LATCH, slide flush mtg hole 1.000 wide
1
1
1
1
1
1
1
1
1
1
1
1
1
4
x
1.500
1
Ig
WRAPPER
1
BUSHING, strain relief 1.030 ID
LABEL, warning general precautionary
LABEL, warning general precautionary CE
CABLE, port No. 18/14 11/c (order by ft)
CONNECTOR & PINS, (consisting of)
CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2
CLAMP, univ 50A
HOSE, nprn brd No. 1 x .250 ID (order by ft)
WIRE, strd l4ga blk 600V 105c (order byft)
BUSHING, strain relief .120/.150 ID x .SOOmtg hole
BLANK, snap-in nyl .500mtg hole
1
1
1
12ft
1
1
1
ift
35ft
1
1
CONNECTOR w/SOCKETS
1
BLANK, snap-in nyl .875mtg hole
NUT, .750-14 knurled 1.68dia .41 high nyl
RELAY, end 24VAC DPDT
RECTIFIER, integ 40A 800V
BUSHING, snap-in nyl .750 ID x 1 .000mtg hole
PANEL, front w/components
CABLE, ribbon l4posn (RC12) (RC5O)
STRIP, mtg PC card
CIRCUIT CARD, interface
CONNECTOR
CONNECTOR
CONNECTOR
CONNECTOR
CONNECTOR
& SOCKETS
& SOCKETS
& SOCKETS
& SOCKETS
& SOCKETS
1
2
1
1
3
1
1
1
4
1
1
(RC51)
(RC52)
(RC53)
(RC54)
(RC55)
1
1
1
1
STAND-OFF, 6-32 x 1.500 Ig
CIRCUIT CARD, processor w/proms (16 M)
4
CONNECTOR &SOCKETS(RC11)
CABLE, ribbon 34posn (RC1O) (RC24)
CABLE, ribbon 24posn (RC16) (RC41)
PANEL, side w/components
1
CLAMP, nyl .625 clamp dia
HOSE ASSEMBLY, gas
1
component originally displaying
a
precautionary label,
1
1
1
1
1
1
1
1
the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturers Suggested
OM-1587
Page
45
fET Hardware is common and
See Table 16-1 For
Drive Roll & Wire Guide Kits
15
17
19
14
13
23
2
24
.
25
27
30
29
6
28
5
4
2
ST-152 711-0
Figure
OM-1587
Page
46
16-3. Drive
Assembly,
Wire
Item
No.
Dia.
Mkgs.
Part
No.
Figure
16-1 Items 27 &
31)
133 493
115 092
CONNECTOR &SOCKETS
131 203
CONNECTOR&PINS
1
135 409
CONNECTOR&PINS
WASHER, flat
PIN, cotter hair
1
1
182 156
SPRING, indicator
SCREW, hexwhd-slt stl slffmg 8-32 x .500
WASHER, lock stl split No. 8
WASHER,flatstlSAENo.8
SPRING, cprsn .573 OD x .088 wire x 1.062 Ig
182 155
SPRING
1
132 746
BUSHING, spring
SHAFT, spring
CARRIER, shaft
WASHER, flat .375 ID x .625 OD x .062
KNOB, extension
CIRCUIT CARD, digital tach (consisting of)
2
149962
4
149486
5
132750
6
150520
7
133493
8
133350
9
156354
M1,2
M1,2.... 156353
153491
153492
153493
184136
155098
153550
155 099
155 100
154 031
11
182 414
.12
182 415
137 248
129 351
602 200
604 772
182 522
132 747
...22
133 739
...23
183 330
24..
(Figure
1
3
17
Wire
MOTOR, gear 1/8hp 24VDC 272RPM (consisting of)
MOTOR, gear 1/8hp 24VDC 500RPM (consisting of)
KIT, brush replacement (consisting of)
CAP, brush
BRUSH, carbon
KIT, brush holder repair
KIT, cover motor gearbox (consisting of)
COVER, motor gearbox (consisting of)
GASKET, cover
SCREW, cover
SPACER, locating
RING, rtng ext .250 shaftgrvx.O2Sthk
172075
PLG11,17
PLG51,57
RC7,8
Assembly,
4
010668
10
16-3. Drive
SCREW, cap sti sch .250-20 x 1.500
CARRIER, drive roll w/components 24 pitch
SPACER, carrier drive roll
PIN, rotation arm rocker
ARM, pressure
SPACER, rotation pin
RING, retaining ext .250 shaft x .O25thk
PIN, hinge
1
2
9
Quantity
Description
4
4
2
2
2
2
1
1
1
2
2
1
1
1
1
5
2
1
1
1
1
1
1
1
2
1
1
1
1
TK1,2/PC51
198 004
PLG57
131 204
CONNECTOR & SOCKETS
1
604311
GROMMET, rbr .250 ID
1
132 611
OPTICAL ENCODER DISC
1
149 959
FITTING, brs barbed M 3/l6tbg x .312-24
ADAPTER, gun/feeder LH
ADAPTER, gun/feeder RH
SCREW, cap stl hexwhd .250-20 x .750
WASHER, flat stl SAE .312
KNOB, plstcT 1.125 lgx .312-18x 1.500 bar
SCREW, hexwhd-slt stl slffmg 10-32 x .500
COVER, drive roll
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 .O2Sthk
LABEL, warning electric shock
1
179 625
179 624
108 940
604 538
.30
151 437
.31
128 237
.32
179 263
.33
601 872
.34
602 213
.35
602 243
.36
601 966
167387
168825
133308
178937
x
1
.375mtg hole
1
1
4
1
1
2
2
1
1
1
1
2
1
1
1
Optional High Speed Motor
To maintain the factory original performance of your equipment, use only Manufacturers
Suggested
OM-1587
Page
47
Item
No.
Part
No.
Dia.
Mkgs.
Figure
165 484
CONNECTOR & SOCKETS
164 842
144 844
PC2O,30
PLG25
See
PLG24
.7....
159 264
.8....
167 633
..10.
179 201
11
Panel, Front w/Components (Figure 16-2 Item 28)
171 814
147 139
.6....
16-4.
NAMEPLATE, (order by model and serial number)
PANEL, front
TAPE, adh acrylic double sided .010 x .500 x 3.000
METER LENS, w/gasket
CIRCUIT CARD, schd front
167 697
.3
Quantity
Description
153 169
.12.
010 291
.13.
167 700
Figure
15-2 Item 35
(RC25)
(RC24)
RING, ext .625 shaft grv x .O45thk E style
WASHER, shldr .612 ID
LENS, LED 4345 green panel mtg
ACTUATOR, switch
WASHER, flat .625 ID nylafil
KNOB, pointer
1
1
2
1
9
1
1
1
1
4
6
1
1
3
~ET Hardware is
common
and
.
9
13
12
11
ST-800 111-C
10
Figure
To maintain the
Replacement
16-4.
Panel, Front w/Components
factory original performance of your equipment, use only Manufacturers Suggested
required when ordering parts from your local distributor.
Parts. Model and serial number
.
OM-1 587
Page
48
Item
No.
Dia.
Part
No.
Mkgs.
Figure
16-5.
Panel, Side w/Components (Figure
.3
154 933
TAPE, adh acrylic double sided .010
LENS, clear anti-glare
PANEL, inner control
.4
PC6O.... 156 623
PLG6O.
153 501
PLG41
CIRCUIT CARD, data card
CONNECTOR & SOCKETS (RC6O)
See Figure 15-2, Item 36 (RC41)
147 139
155 024
.5
.6
PC4O....
CIRCUIT CARD, side
STAND-OFF,
.8
154 109
.9
153 169
PLATE, ident inner control
ACTUATOR, switch
common
6-32
x
x
.500
x
16-2 Item
37)
2
3.000
1
1
1
1
1
display
Ig
144 844
Hardware is
Quantity
Description
4
.875
1
4
and
7
8
ST-Boo 113-B
Figure
To maintain the
Replacement
16-5.
Panel, Side w/Components
factory original performance of your equipment, use only Manufacturers Suggested
required when ordering parts from your local distributor.
Parts. Model and serial number
OM-1587
Page
49
Table 16-1. Drive Roll and Wire Guide Kits
C,
~
Wire Size
E~
C,
V-GROOVE
U-GROOVE
UC-GROOVE
VK-GROOVE
E~
~C~
.
.
4 Roll
Drive
4 Roll
Drive
4 Roll
Drive
4 Roll
Drive
Kit
Roll
Kit
Roll
Kit
Roll
Kit
Roll
149518
151 024
087130
150993
149518
151 025
053695
0.9mm
150993
149518
151 026
053700
151 036
072000
151 052
132958
1.0
150993
149518
161 189
053696
~
Fraction
Metric
.023-.025in
0.6mm
150993
.030 in.
0.8
mm
.035in.
.040 in.
mm
.045in.
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
068-072 in
1.6
mm
150995
149520
1.8
mm
150995
149520
2.0mm
150 995
149 520
151 040
053 704
151 057
132 960
151 073
053 710
2.4
mm
150 996
149 521
151 041
053 703
151 058
132 961
151 074
053 709
2.8
mm
150996
149521
151 042
053705
151 059
132962
151 075
053711
3.2
mm
150997
149522
151 043
053707
151 060
132963
151 076
053712
5/64 in.
(.079 in.)
S
3/32 in.
(.094 in.)
(15)
Each Kit Contains An Inlet
Guide, Intermediate Guide, And 045 233 Antiwear Guide With 604612 Setscrew 8-32
x
.125, Along
With 4 Drive Rolls.
2 Kits
Required
For Dual Models.
s-o5~-o
S
OM-1 587
Page
50
Notes
OM-1 587
Page
51
Notes
.
OM-1587
Page
52
Miller
SERWCE WDEOS
SERVICE TRAINING
FROM MILLER ELECTRIC
These Service Videos will
help
-
you learn about main
tenance, troubleshooting, and servicing specific Miller
equipment.
Also, if you
Miller Certified Service Technician,
are a
these videos
can
included test will
help you recertify. Passing the
five points towards the forty
earn
points needed.
You will find each of these
professionally produced
videos to be very informative and
your Service Video Library.
11
a
valuable
part of
1i
XMT 304 Video Kit
(#197 018)
Feeder Series
Package
(#197 006)
$86.00
324-1035
(2
videos
-
S-62& S-54 &
60M)
324-1009
$126.00
324-1014
$86.00
p
l~
(#197 019)
I~
1i
Additional Bobcat 225 NT Test Sheet
$86.00
324-1030
(#197 009)
LI
Additional S-62 & S-64 Test Sheet
324-1016
$3.00
324-1031
$86.00
324-1018
$3.00
324-1032
$86.00
Deltaweld 452 Video Kit
(#197 010)
LI
S-MM Video Kit
(#197 015)
11
(#197 007)
LI
S-62 & S-64 Series Video Kit
(#197 014)
Bobcat 225 NT Video Kit
$3.00
324-1008
(#197 012)
Li
1J
Additional XMT 304 Test Sheet
Additional Deltaweld Test Sheet
(#197 011)
324-1019
Additional S-MM Test Sheet
(#197 017)
Payment
Check
$3.00
324-1017
Information
or
Send check
Money Order
or
money order
payable
to:
Neenah
Attn:
Printing
Literature Distribution Center
P.O. Box 506
Neenah, WI 54957-0506
Mastercard
Purchase Order
Visa
__________________
Name of Card holder
Account #
__________________________________
Cardholders
Exp. Date
signature
To Order call 920-751-2120
Distributor
or
Fax 920-751-2121
Name_______________________________
Customer #
$3.00
Miller
WELDING EQUIPMENT
SERWCE ENGINEERING
SELF-PACED
TRAINING COURSE
FROM MILLER ELECTRIC
Learn the basics of
welding equipment troubleshooting
servicing with this three module course designed
for home study, industrial and educational use. This
course will provide the basic knowledge to begin a
act as a
career in servicing welding equipment,
refresher, or provide a welding salesman or technician
service and troubleshooting techniques.
and
A certificate of completion is awarded by the
Training Department upon successful completion
Miller
of the
course.
MODULE 1
Inspection
High Frequency
Safety
Load Bank
.~
;1
MODULE 3
MODULE 2
Electronic
Symbols
Component Identification
Troubleshooting
Volt-ohm Meter
Visual
Operation
Operation
.~
1~1O] ;~~
I
~ c] ~ ~
1J
(#145 870)
Welding Equipment
Engineering Training
Course
Service
$60.00
~
4~k~L
~ir~Z ~1r~L~
(#145 871)
Additional Text
(Includes
text and
registered
answer
card.)
(Includes text, videotape, exams, and
registered
answer
card.)
Payment Information
Check
or
Money
Send check
Order
or
money order
payable
to:
Neenah
Attn:
Printing
Literature Distribution Center
P0. Box 506
Neenah, WI 54957-0506
ii]
Purchase Order
LI
Mastercard
Visa
________________
Name of Card holder
Account #
Exp.
__________
Cardholders
Date
signature
To Order call 920-751-2120
or
Fax 920-751-2121
Distributor Name
Customer
#________________
$35.00
.
0
F
Effective January 1, 1999
with a serial number preface of KK
(Equipment
Warranty Questions?
This limited
LIMITED WARRANTY
i-8OO-4~A-MlLLE9:
-
warranty supersedes
guarantees
Subject
all
or
to its
retail
original
purchaser
Miller warranties and is exclusive with
warranties expressed or implied.
*
to the terms snd conditions
that
new
after Ihe effective date ot this limited
in material and
workmanship
Miller
equipment
warranty is free of defects
shipped by Miller.
at the time it is
warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such detects in material or workmanship. Miller must be
notitiad in writing within thirty (30) days of such detect or
tailure, at which time Miller will provide instructions on the
warranty claim procedures to be totlowed.
Service
always get the fast,
reliable response you
need. Most replacement
parts can be in your
bands in 24 hours.
*
Remote Controls
*
Accessory
Kits
*
Replacement
*
Spoolmate
Miller shall honor
wsrranty
claims
on
warranted
equipment
Millers
Parts
(No labor)
185
such
equipment was delivered to the original retait purchaser, or
year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to en
as
covered
Warranty
shalt not
apply
to:
by Miller, but manufactured by others,
engines or trade sccessories. These items are
by the manutacturers warranty, it any.
Consumable components; such as contact tips, cutting
nozzles, contactors, brushes, slip rings, relays or parts
that tail due to normal wear.
2.
listed below in the event of such a failure within the warranty
periods. All warranty time periods start on the date that
Support
True Bluefi Umited
Items furnished
1.
time
Need fast
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Within the
you...
You
other
Torches
WARRANTIES OF MERCHANTABILITY AND FITNESS.
gives
no
sold
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
Your distributoratso
newer)
previous
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
for your local
Miller distributor
or
the
answers
to the
one
tough welding questions?
contact yourdistributor.
The expertise of the
that has been modified by any party other
Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable end necessary maintenance, or equipment
which has been used for operation outside of the
Equipment
3.
than
International distributor.
1.
distributor and MilIer:is
there to help you, every
step of the way.
2.
3.
5 Years Parts
*
Original
*
Inverters
3 Years Lsbor
-
main power rectifiers
(input
and
Transformer/Rectifier Power Sources
*
Plasma Arc
*
Semi-Automatic and Automatic Wire Feeders
*
Inverter Power
Supplies
*
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 YearParts
and Labor
Motor Driven Guns
(w/exception
of
Spoolmate
185)
r
*
Process Controllers
*
Positioners and Controllers
*
Automatic Motion Devices
*
Robots
*
RFCS Foot Controls
In the event ot a warranty claim covered by this warranty, the
exclusive remedies shell be, at Millers option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
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
risk and expense. Millers option of repair or
at customers
replacement wilt be FOB., Factory at Appleton, Wisconsin, or
FOB. at a Muter authorized service tacility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs ot any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
*
IHPS Power Sources
OR
INCIDENTAL
INDIRECT,
SPECIAL,
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
*
Water Coolant
ANY
*
HF Units
*
Grids
DIRECT,
Systems
Maxstar 140
*
Spot
MIGHT
ARISE
BY
IMPLICATION,
PROVISION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
ALL
RESPECT
AND
WITH
ANY
TO
PURPOSE,
Welders
*
Load Banks
*
SDX Transformers
*
Miller
*
Running Gear/Trailers
*
Plasma Cutting Torches
PLAZCUT Models)
*
EXPRESS WARRANTY NOT PROVIDED HEREIN
IMPLIED
ANY
WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
LEGAL THEORY WHICH, BUT FOR THIS
OTHER
AND
*
N
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
Cyclomatic Equipment
DISCLAIMED BY MILLER.
(except APT,
ZIPCUT &
Options
(NOTE: Field options are covered under True
Bluefi for the remaining warranty period of the
product they
year
are
installed in,
whichever is
Some states in the U.S.A. do not allow limitations ot how long
implied warranty lasts, or the exclusion ot incidental,
an
Field
one
or
for
greater.)
a
minimum of
consequential damages, so the above
apply to you. This warranty
provides specitic legal rights, and other rights may be
indirect, special
limitation
or
or
exclusion may not
available, but may vary from
In
Canada, legislation in
additional warranties
I
equipment.
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
Power Sources
*
*
tor the
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
*
Cutting
specitications
output rectifiers only)
Parts and Labor
3 Years
4.
6 Months
5.
90
*
Days
Batteries
Parts
MIG Guns/TIG Torches
state to state.
some
provinces provides
Warranty provides specitic legal rights, and other rights may
be available, but may vary from province to province.
miller
i
for certain
remedies other thsn as stated herein,
end to the extent that they may not be waived, the limitations
end exclusions set out above may not apply. This Limited
or
warr
919a
Owners
Please
complete
Record
and retain with your
Number
Serial/Style
Model Name
Purchase Date
(Date
which
equipment
was
.
records.
personal
delivered to
original customer.)
Distributor
Address
City
Zip
State
Resources Available
Always provide
Model Name and
Contact your Distributor for:
To locate
near
a
distributor
or
service agency
or visit our
you, call 1-800-4-A-Miller
website at www.MillerWelds.com
Serial/Style
Number.
Welding Supplies and Consumables
Options
and Accessories
Personal
Safety Equipment
Service and
Repair
Miller Electiic
Replacement Parts
1635 West Spencer
Appleton, WI 54914
Training (Schools, Videos, Books)
International
Technical Manuals
and Parts)
Mfg.
An Illinois Tool Woils
(Servicing Information
Co.
company
Street
uSA
Headquarters--USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX:920-735-4134
International F~A)(: 920-735-4125
Circuit
Diagrams
Welding
European Headquarters
United Kingdom
Process Handbooks
Phone: 44
FAX~ 44
(0)
(0)
-
1204-593493
1204-598066
www.MiilerWelds.com
Contact the
Delivering
Carrier for:
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.
~//A Millet
The Thwer~fB&
PRINTED IN USA
'
1999 Miller Electric
Mfg. Co. 9/99

Miller Electric

Transcription

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