Miller D-64M WIRE FEEDER Owner's manual

Miller

March

1995

Form:

OM-1587B

Effective

With

Serial

No.

KF759252

OWNERS

MANUAL

T'

~

U



Read

and

follow

these

instructions

and

all

safety

blocks

carefully.

Have

only

trained

and

qualified

persons

install,

operate,

or

service

this

unit.

Call

your

distributor

if

you

do

not

understand

the

directions.

U

Give

this

manual

to

the

operator.



For

help,

call

your

distributor



or~

MILLER

Electric

Mfg.

Co.,

P0.

Box

1079,

Appleton,

WI

54912

414-734-9821

D-64M

Wire

Feeder



Microprocessor

Controlled

Constant

Speed

Dual

Wire

Feeder



Multi-Power

Source

Compatible



For

GMAW,

GMAW-P,

And

FCAW

Welding



For

.023

To

1/8

In

(0.6

To

3.2

mm)

Wires



Standard

Wire

Feed

Speed

Of

50

To

780

1PM

(1.3

To

19.8

MPM)



Programmable

Pulse

Weld

Parameters



See

Rear

Cover

For

Options

And

Accessories

cover

5/94



ST-800

179

'

1995

MILLER

BeCteC

Mfg.

Co.

PRINTED

IN

~SA

I

I

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

Effective

January

1,

1995

(Equipment

with

a

serial

number

preface

of

KD

or

newer)

This

limited

warranty

supersedes

all

wsrranties

snd

is

exclusive

with

no

other

guarantees

or

warranties

expressed

or

implied.

LIMITED

WARRANTY

Subject

to

the

tenns

end

conditions

below,

MILLER

Electric

Mfg.

Co.,

Appleton,

Wisconain,

warranta

to

its

original

retail

purchaser

that

new

MILLER

equipment

sold

afterthe

effective

date

of

this

limited

warranty

is

free

ot

de

fects

in

materiel

end

workmanship

et

the

time

it

is

shipped

by

MILLER.

THIS

WAR

RANTY

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTHER

WARRANT1ES,

EXPRESS

OR

IMPLIED,

INCLUDING

THE

WARRANTIES

OF

MERCHANTABILITY

AND

FIT

NESS.

Within

the

warranty

periods

listed

below,

MILLER

will

repair

or

replace

any

war-

rented

parts

or

components

that

fail

due

to

such

defects

in

materiel

orwortoiianahip.

MILLER

must

be

notified

in

writing

within

thirty

(30)

days

of

auch

defect

or

failure,

at

which

time

MILLER

will

provide

instructions

on

the

warranty

claim

procedures

to

be

followed.

MILLER

shall

honor

warranty

claims

on

warranted

equipment

listed

below

in

the

event

of

auch

a

failure

within

the

warranty

time

perioda.

All

warranty

time

perioda

start

on

the

date

that

the

equipment

was

delivered

to

the

original

retail

purchaser,

or

one

year

aher

the

equipment

ia

sent

to

a

North

American

distributor

or

eighteen

months

aher

the

equipment

ia

sent

to

an

Intemational

distributor.

1.

BYeamParta3YearaLabor

*

Original

main

power

rectifiers

2.

3

Years



Parta

and

Labor

Transformer/Rectifier

Power

Sources

Plasma

Arc

Cutting

Power

Sources



Semi-Automatic

and

Automatic

Wire

Feeders



Robota

3.

2

Yeara



Parts

and

Labor



Engine

Driven

Welding

Generators

(NOTE:

Engines

are

warranted

separately

by

the

engine

manufacturer.)



Air

Compreasora

4.

1

Year



Parts

and

Labor

Motor

Driven

Guns



Process

Controllera

*

Water

Coolant

Systems

*

HF

Unita

*

Grids

*

Spot

Weldera

*

Load

Banks



SDX

Tranaformera

*

Running

Gear/Trailers



Plasma

Cutting

Torchea

(except

APE

ZIPCUT

&

PLAZCUT

Modela)



Tecumseh

Enginea

*

Deutz

Engines

(outside

North

America)

*

ReId

Options

(NOTE:

Field

options

are

covered

under

True

BIueTM

for

the

remaining

warranty

period

of

the

product

they

are

installed

in,

or

for

a

minimum

of

one

year



whichever

ia

greater.)

6

Months



Batteries

go

Days



Parts

and

Labor

*

MIG

Guns/TIG

Torches



APE

ZIPCUT

&

PLAZCUT

Model

Plasma

Cutting

Torches

SI

*

Remote

Controla



Accessory

Kits

*

Replacement

Parts

MILLERS

True

BIueTM

Umited

Warranty

ahall

not

apply

to:

1.

Itema

fumiahed

by

MILLER,

but

manufactured

by

ethers,

such

as

engines

or

trade

accessories.

These

items

are

covered

by

the

manufacturera

warranty,

if

any.

2.

Consumable

componenta:

such

as

contact

ripe,

cutting

nozzlea,

contactors

and

relays

or

parts

that

fail

due

to

normal

wear.

3.

Equipment

that

has

been

modified

by

any

party

other

than

MILLER,

or

equip

ment

that

has

been

improperiy

inatalled,

improperiy

operated

or

misused

based

upon

industry

standards,

or

equipment

which

has

not

had

reaaonable

and

neceasary

maintenance,

or

equipment

which

has

been

used

for

operation

outside

of

the

apecificationa

for

the

equipment.

MILLER

PRODUCTS

ARE

INTENDED

FOR

PURCHASE

AND

USE

BYCOMMER

CIAL/INDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

IN

THE

USE

AND

MAINTENANCE

OF

WELDING

EOUIPMENT.

In

the

event

of

a

warranty

claim

covered

by

this

warranty,

the

excluaive

remedies

ahall

be,

at

MILLERS

option:

(1)

repair-;

or(2)

replacement;

or,

where

authorized

in

writing

by

MILLER

in

appropriate

caaea,

(3)

Ihe

reasonable

ccet

of

repairor

replace

ment

at

an

authorized

MILLER

service

station;

or

(4)

payment

of

orcredit

forthe

pur

chaae

price

(leas

reasonable

depreciation

based

upon

actual

use)

upon

retum

of

the

goods

at

customera

risk

and

expense.

MILLERS

option

of

repair

or

replacement

will

be

FOB.,

Factoryat

Appleton,

Wisconsin,

or

FOB.

at

a

MILLER

authorized

ser

vice

facility

as

determined

by

MILLER.

Therefore

no

compensation

or

reimburse

ment

for

transportation

coats

of

any

kind

will

be

allowed.

TO

THE

EXTENT

PERMITTED

BY

LAW,

THE

REMEDIES

PROVIDED

HEREIN

ARE

THE

SOLE

AND

EXCLUSIVE

REMEDIES.

IN

NO

EVENTSHALL

MILLER

BE

UABLE

FOR

DIRECT,

INDIRECT,

SPECIAL

INCIDENTALOR

CONSEOUENTIAL

DAMAGES

(INCLUDING

LOSS

OF

PROFIT),

WHETHER

BASED

ON

CON

TRACT,

TORT

OR

ANY

OTHER

LEGAL

THEORY.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WAR

RANTY,

GUARANTY

OR

REPRESENTATION

AS

TO

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

OF

CONTRACT

TORT

OR

ANY

OTHER

LEGAL

THEORY

WHICH,

BUT

FOR

THIS

PROVISION,

MIGHT

ARISE

BY

IMPUCA11ON,

OPERA11ON

OF

LAW,

CUSTOM

OF

TRADE

OR

COURSE

OF

DEALING,

IN

CLUDING

ANY

IMPUED

WARRANTY

OF

MERCHANTABILITY

OR

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

TO

ANY

AND

ALL

EOUIPMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

AND

DISCLAIMED

BY

MILLER.

Some

atates

in

the

U.S.A.

do

nol

allow

limitationa of

how

long

an

implied

warranty

lasts,

or

Ihe exclusion

of

incidental,

indirect,

apecial

or

consequential

damages,

so

the

above

limitation

or

exclusion

may

not

apply

to

you.

Thia

warranty

provides

ape

cific

legal

rights,

and

other

rights

may

be

available,

but

may

vary

from

state

to

state.

In

Canada,

legislation

in

some

provinces

providea

for

certain

additional

warranties

or

remedies

other

than

as

stated

herein,

and

to

the

extent

that

they

may

not

be

waived,

the

limitationa

and

exclusions

aet

out

above

may

not

apply.

This

Umited

Warranty

provides

apecific

legal

righta,

and

other

rights

may

be

available,

but

may

vary

from

province

to

province.

J

.

5.

6.

1~.

S

RECEIVING-HANDLING

Before

Unpacking

equipment,

check

carton

for

any

damage

that

may

have

occurred

dUring

shipment.

File

any

claims

for

loss

or

damagB

with

the

delivering

carrier.

Assistance

for

filing

or

settling

claims

may

be

obtained

from

distributor

and/or

equipment

manufacturers

Transportation

Department.

When

requesting

information

about

this

equipment,

always

provide

Model

Designation

and

Serial

or

Style

Number.

Use

the

following

spaces

to

record

Model

Designation

and

Serial

or

Style

Numberof

your

unit.

The

information

is

located

on

the

rating

label

or

nameplate.

Model

_________

Serial

or

Style

No.

Date

of

Purchase

miller

1/95

ARC

WELDING

SAFETY

PRECAUTIONS

ELECTRIC

SHOCK

can

kill.

Touching

live

electrical

parts

can

cause

fatal

shocks

or

severe

bums.

The

electrode

and

work

circuit

is

electrically

live

whenever

the

output

is

on.

The

input

power

circuit

and

machine

internal

circuits

are

also

live

when

power

is

on.

In

semiautomatic

or

automatic

wire

welding,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live.

Incorrectly

installed

or

improperly

grounded

equipment

is

a

hazard.

1.

Do

not

touch

live

electrical

parts.

2.

Wear

dry,

hole-free

insulating

gloves

and

body

protection.

3.

Insulate

yourself

from

work

and

ground

using dry

insulating

mats

or

covers

big

enough

to

prevent

any

physical

contact

with

the

work

or

ground.

4.

Disconnect

input

power

or

stop

engine

before

installing

or

servicing

this

equipment.

Lockout/tagout

input

poweraccording

to

OSHA

29

CFR

1910.147

(see

Safety

Standards).

5.

Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual

and

national,

state,

and

local

codes.

6.

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.

7.

When

making

input

connections,

attach

proper

grounding

conductor

first



double-check

connections.

8.

Frequently

inspect

input

powercord

for

damage

or

bare

wiring



replace

cord

immediately

if

damaged



bare

wiring

can

kill.

9.

Tum

off

all

equipment

when

not

in

use.

10.

Do

not

use

worn,

damaged,

undersized,

or

poorly

spliced

cables.

11.

Do

not

drape

cables

over

your

body.

12.

If

earth

grounding

of

the

workpiece

is

required,

ground

it

directly

with

a

separate

cable



do

not

use

work

clamp

or

work

cable.

13.

Do

not

touch

electrode

if

you

are

in

contact

with

the

work,

ground,

or

another

electrode

from

a

different

machine.

14.

Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

Maintain

unit

according

to

manual.

Wear

a

safety

harness

if

working

above

floor

level.

Keep

all

panels

and

covers

securely

in

place.

Clamp

work

cable

with

good

metal-to-metal

contact

to

workpiece

or

worktable

as

near

the

weld

as

practical.

a

WARNING

ARC

WELDING

can

be

hazardous.

PROTECT

YOURSELF

AND

OTHERS

FROM

POSSIBLE

SERIOUS

INJURY

OR

DEATH.

KEEP

CHILDREN

AWAY.

PACEMAKER

WEARERS

KEEP

AWAY

UNTIL

CONSULTING

YOUR

DOCTOR.

In

welding,

as

in

most

jobs,

exposure

to

certain

hazards

occurs.

Welding

is

safe

when

precautions

are

taken.

The

safety

information

given

below

is

only

a

summary

of

the

more

complete

safety

information

that

will

be

found

in

the

Safety

Standards

listed

on

the

Read

and

follow

all

Safety

Standards.

HAVE

ALL

INSTALLATION,

OPERATION,

MAINTENANCE,

AND

REPAIR

WORK

PERFORMED

ONLY

BY

QUALIFIED

PEOPLE.

15.

16.

17.

ARC

RAYS

can

burn

eyes

and

skin;

ARC

RAYS

NOISE

can

damage

hearing;

FLYING

,_/~

SLAG

OR

SPARKS

can

injure

eyes.

Arc

rays

from

the

welding

process

produce

intense

visible

and

invisible

(ultraviolet

and

infrared)

rays

that

can

bum

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

Chipping,

grinding,

and

welds

cooling

throw

off

pieces

of

metal

or

slag.

NOISE

1.

Use

approved

ear

plugs

or

ear

muffs

if

noise

level

is

high.

2.

3.

4.

5.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

to

protectyourface

and

eyes

when

welding

orwatching

(see

ANSI

Z49.1

and

Z87.1

listed

in

Safety

Standards).

Wear

approved

safety

glasses

with

side

shields.

Use

protective

screens

or

barriers

to

protect

others

from

flash

and

glare;

warn

others

not

to

watch

the

arc.

Wear

protective

clothing

made

from

durable,

flame-resistant

material

(wool

and

leather)

and

foot

protection.

FUMES

AND GASES

can

be

hazardous

5.

Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

to

your

health.

Welding

produces

fumes

and

gases.

Breathing

=i~

b

these

fumes

and

gases

can

be

hazardous

to

your

health,

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.

1.

Keep

your

head

out

of

the

fumes.

Do

not

breathe

the

fumes.

6.

Do

not

weld

in

locations

near

degreasing,

cleaning,

or

spraying

operations.

The

heat

and

rays

of

the

arc

can

react

with

vapors

to

2.

If

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

form

highly

toxic

and

irritating

gases.

remove

welding

fumes

and

gases.

7.

Do

not

weld

on

coated

metals,

such

as

galvanized,

lead,

or

3.

If

ventilation

is

poor,

use

an

approved

air-supplied

respirator.

cadmium

plated

steel,

unless

the

coating

is

removed

from

the

4.

Read

the

Material

Safety

Data

Sheets

(MSDSs)

and

the

weld

area,

the

area

is

well

ventilated,

and

if

necessary,

while

manufacturers

instruction

for

metals,

consumables,

coatings,

wearing

an

air-supplied

respirator.

The

coatings

and

any

metals

cleaners,

and

degreasers.

containing

these

elements

can

give

off

toxic

fumes

if

welded.

CYLINDERS

can

explode

if

damaged.

4.

Never

drape

a

welding

torch

over

a

gas

cylinder.

Shielding

gas

cylinders

contain

gas

under

high

pressure.

If

damaged,

a

cylinder

can

explode.

Since

ec~in~J:~sur:r~

~

al~YmPc~e~iythe

welding

,

5.

6.

~,

Never

allow

a

welding

electrode

to

touch

any

cylinder.

Never

weld

on

a

pressurized

cylinder



explosion

will

result

Useontycorrectshieldinggascylinders,

regulators,

hoses,

and

flthngs

designed

for

the

specific

application;

maintain

them

and

associated

parts

in

good

condition.

1.

Protect

compressed

gas

cylinders

from

excessive

heat,

8.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

mechanical

shocks,

slag,

open

flames,

sparks,

and

arcs.

9.

Keepprotectivecapinplaceovervalveexceptwhencylinderis

2.

Install

cylinders

in

an

upright

position

by

securing

to

a

stationary

in

use

or

connected

for

use.

support

or

cylinder

rack

to

prevent

falling

or

tipping.

10.

Read

and

follow

instructions

on

compressed

gas

cylinders,

3.

Keep

cylinders

away

from

any

welding

or

other

electrical

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

circuits.

Standards.

srl.1.1

2/94

WELDING

can

cause

fire

or

explosion.

Welding

on

closed

containers,

such

as

tanks,

drums,

or

pipes,

can

cause

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,

or

fire.

Check

and

be

sure

the

area

is

safe

before

doing

any

welding.

1.

Protect

yourself

and

others

from

flying

sparks

and

hot

metal.

2.

Do

not

weld

where

flying

sparks

can

strike

flammable

material.

3.

Remove

all

flammables

within

35

ft

(10.7

m)

of

the

welding

arc.

If

this

is

not

possible,

tightly

cover

them

with

approved

covers.

4.

Be

alert

that

welding

sparks

and

hot

materials

from

welding

can

easily

go

through

small

cracks

and

openings

to

adjacent

areas.

5.

Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.

6.

Be

aware

that

welding

on a

ceiling,

floor,

bulkhead,

or

partition

can

cause

fire

on

the

hidden

side.

7.

Do

not

weld

on

closed

containers

such

as

tanks,

drums,

or

pipes,

unless

they

are

properly

prepared

according

to

AWS

F4.1

(see

Safety

Standards).

8.

Connect

work

cable

to

the

work

as

close

to

the

welding

area

as

practical

to

prevent

welding

current

from

traveling

long,

possibly

unknown

paths

and

causing

electric

shock

and

fire

hazards.

9.

Do

not

use

welder

to

thaw

frozen

pipes.

10.

Remove

stick

electrode

from

holder

or

cut

off

welding

wire

at

contact

tip

when

not

in

use.

11.

Wear

oil-free

protective

garrrrents

such

as

leather

gloves,

heavy

shirt,

cuffless

trousers,

high

shoes,

and

a

cap.

12.

Remove

any

combustibles,

such

as

a

butane

lighter

or

matches,

from

your

person

before

doing

any

welding.

a

WARNING

Engine

fuel

is

highly

flammable.

1.

Stop

engine

and

let

it

cool

off

before

checking

or

adding

fuel.

2.

Do

not

add

fuel

while

smoking

or

if

unit

is

near

any

sparks

or

open

flan

es:

ENGINES

can

be

hazardous.

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,

Ameri

can

Welding

Society

Standard

AWS

F4.

1,

from

American

Welding

So

ciety,

550

N.W.

LeJeune

Rd,

Miami,

FL

33126

National

Electncal

Code,

NFPA

Standard

70,

from

National

Fire

Pro

tection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

P-i,

from

Compressed

Gas

Association,

1235

Jefferson

Davis

High

way,

Suite

501,

Arlington,

VA

22202.

Code

for

Safety

in

Welding

and

Cutting,

CSA

Standard

Wi

17.2,

from

Canadian

Standards

Association,

Standards

Sales,

178

Rexdale

Bou

levard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

Safe

Practices

ForOccupationAndEducationalEyeAndFace

Protec

tion,

ANSI

Standard

Z87.1,

from

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

Cutting

And

Welding

Processes,

NFPA

Standard

51

B,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

~IJ~

P~~U

ENGINE

EXHAUST

GASES

can

kill.

Engines

produce

harmful

exhaust

gases.

1.

2.

Use

equipment

outside

in

open,

well-ventilated

areas.

If

used

in

a

closed

area,

vent

engine

exhaust

outside

and

away

from

any

building

air

intakes.

ENGINE

FUEL

can

cause

fire

or

3.

Do

not

overfill

tan

k



all

ow

room

fo

r

fuel

t

o

expand.

explosion.

4.

Do

not

spill

fuel.

engine.

If

fuel

is

spilled,

clean

up

before

starting



MOVING

PARTS

can

cause

injury.

~

Moving

parts,

such

as

fans,

rotors,

and

belts

can

cut

fingers

and

hands

and

catch

loose

clothing,

1.

Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

3.

4.

5.

6.

Have

only

qualified

people

remove

guards

or

covers

for

To

prevent

accidental

starting

during

servicing,

disconnect

maintenance

and

troubleshooting

as

necessary.

negative

()

battery

cable

from

battery.

Keep

hands,

hair,

loose

clothing,

and

tools

away

from

moving

parts.

Reinstall

panels

or

guards

and

close

doors

when

servicing

is

2.

Stop

eng

ne

before

installing

or

connecting

unit.

finished

and

before

starting

engine.

SPARKS

can

cause

BATTE

TO

EXPLODE;

BATTERY

RY

GASES

ACID

can

1.

2.

Always

wear

Stop

engine

a

face

s

before

hield

when

working

on

a

battery.

disconnecting

or

connecting

battery

burn

eyes

and

skin,

cables.

3.

Batteries

contain

acid

and

generate

explosive

4.

Do

not

allow

tools

to

cause

sparks

when

working

on

a

battery.

Do

not

use

welder

to

charge

batteries

or

jump

start

vehicles.

gases.

5.

Observe

correct

polarity

(+

and

)

on

batteries.

.~

~

STEAM

AND

PRESSURIZED

HOT

COOLANT

can

burn

face,

eyes,

and

skin.

It

is

best

to

check

coolant

level

when

engine

is

cold

to

avoid

scalding.

1.

2.

3.

If

the

engine

is

warm

and

checking

is

needed,

follow

steps

2

and

3.

Wear

safety

glasses

and

gloves

and

put

a

rag

over

cap.

Tum

cap

slightly

and

let

pressure

escape

slowly

before

completely

removing

cap.

S

srl.1.1

2/94

EMF

INFORMATION

TABLE

OF

CONTENTS

SECTION

1



SAFETY

INFORMATION

1

SECTION

2

SPECIFICATIONS

1

SECTION

3

INSTALLATION

3-1.

Site

Selection

3-2.

Connection

Diagram

3-3.

Wire

Guide

And

Drive

Roll

Installation

3-4.

Welding

Gun

Connections

3-5.

Motor

Start

Control

3-6.

Control

Connections

3-7.

Shielding

Gas

And

Weld

Cable

Connections

3-8.

Welding

Wire

Installation

3-9.

Threading

Welding

Wire

With

Drive

Assembly

Horizontal

3-10.

Threading

Welding

Wire

And

Rotating

The

Drive

Assembly

SECTION

4-

GLOSSARY

SECTION

5-OPERATION

5-1.

Front

Panel

Controls

5-2.

Side

Panel

Controls

5-3.

Rear

Panel

Controls

5-4.

Setting

Switches

On

450

Ampere

Inverter

Model

Welding

Power

Source

SECTION

6-

STEPPING

THROUGH

THE

MICROPROCESSOR

CONTROLS

6-1.

Front

Panel

Microprocessor

Controls

6-2.

Side

Panel

Microprocessor

Push

Buttons

SECTION

7-

STANDARD

PULSE

WELDING

PROGRAMS

SECTION

8

GETTING

STARTED

36

8-1.

Welding

With

Only

Front

Panel

Controls

37

8-2.

Setting

Sequence

Pulse

Welding

Parameters

On

Side

Panel

Display

38

SECTION

9-

TEACHING

A

PULSE

WELDING

PROGRAM

42

9-1.

Pulse

Waveform

Explained

42

9-2.

Teach

Points

Explained

43

9-3.

Teaching

A

Pulse

Welding

Program

44

9-4.

Changing

To

Adaptive

Pulse

Welding

47

0M-15878

-

3)95

NOTE

~

Considerations

About

Welding

And

The

Effects

Of

Low

Frequency

Electric

And

Magnetic

Fields

The

following

is

a

quotation

from

the

General

Conclusions

Section

of

the U.S.

Congress,

Office

of

Technology

Assessment,

Biological

Effects

of

Power

Frequency

Electric

&

Magnetic

Fields



Background

Paper~

OTA-BP-E-53

(Washington,

DC:

U.S.

Government

Printing

Office,

May

1989):..

.

there

is

now

a

very

large

volume

of

scientific

findings

based

on

experiments

at

the

cellularlevel

and

from

studies

with

animals

and

people

which

clearly

establish

that

low

frequency

magnetic

fields

can

interact

with,

and

produce

changes

in,

biological

systems.

While

most

of

this

work

is

of

very

high

quality,

the

results

are

complex.

Current

scientific

understanding

does

not

yet

allow

us

to

interpret

the

evidence

in

a

single

coherent

framework.

Even

more

frustrating,

it

does

not

yet

allow

us

to

draw

definite

conclusions

about

questions

of

possible

risk

or

to

offer

clear

science-based

advice

on

strategies

to

minimize

or

avoid

potential

risks.

To

reduce

magnetic

fields

in

the

workplace,

use

the

following

procedures:

1.

Keep

cables

close

together

by

twisting

or

taping

them.

2.

Arrange

cables

to

one

side

and

away

from

the

operator.

3.

Do

not

coil

or

drape

cables

around

the

body.

4.

Keep

welding

power

source

and

cables

as

far

away

as

practical.

5.

Connect

work

clamp

to

workpiece

as

close

to

the

weld

as

possible.

About

Pacemakers:

The

above

procedures

are

among

those

also

normally

recommended

for

pacemaker

wearers.

Consult

your

doctor

for

complete

information.

modi

0.1

4/93

2

3

4

5

6

7

9

11

13

15

17

18

20

21

22

23

25

28

SECTION

10-

TEACHING

A

MIG

WELDING

PROGRAM

10-1.

Changing

to

MIG

Welding

10-2.

Setting

Sequence

MIG

Welding

Parameters

On

Side

Panel

Display

SECTION

11



SETTING

DUAL

SCHEDULE

PARAMETERS

52

SECTION

12-

USING

THE

OPTIONAL

DATA

CARD

12-1.

Installing

DataCard

12-2.

Using

The

Data

Card

SECTION

15-

ELECTRICAL

DIAGRAMS

76

48

49

SECTION

13SETUP

13-1.

13-2.

13-3.

13-4.

13-5.

13-6.

13-7.

13-8.

13-9.

13-10.

13-11.

13-12.

13-13.

13-14.

13-15.

13-16.

13-17.

13-18.

13-19.

13-20.

Setup

Flow

Chart

Using

Setup

Displays

Selecting

Process

Capability

Selecting

Welding

Power

Source

Range

Selecting

Security

Lock

Selecting

Or

Changing

Access

Code

Selecting

Voltage

Correction

Selecting

Voltage

Sensing

Method

Selecting

Regular

Or

Hot

Arc

Start

Selecting

Type

Of

Dual

Schedule

Switch

Selecting

Trigger

Program

Select

Selecting

Remote

Increase/Decrease

Capability

Resetting

Arc

Time

Using

Self

Test

Selecting

Units

For

Wire

Feed

Speed

And

Motor

Type..

Selecting

Bench

Or

Boom

Model

Type

Resetting

Memory

Selecting

Voltage

Error

Shutdown

Selecting

Program

Name

Feature

Software

Version

Number

SECTION

14

MAINTENANCE

&

TROUBLESHOOTING

14-1.

Routine

Maintenance

14-2.

Replacing

The

Hub

Assembly

14-3.

Overload

Protection

14-4.

Error

Screens

14-5.

Troubleshooting

54

58

59

60

61

62

63

64

65

66

67

68

69

70

71

72

73

74

SECTION

16

PARTS

LIST

Figure

16-1.

Main

Assembly

Figure

16-2.

Control

Box

Figure

16-3.

Panel,

Front

w/Components

Figure

16-4.

Drive

Assembly,

Wire

Figure

16-5.

Panel,

Side

w/Components

Table

16-1.

Drive

Roll

And

Wire

Guide

Kits

80

82

85

86

88

89

.

SECTION

1

-

SAFETY

INFORMATION



Read

all

safety

messages

throughout

this

manual.

Obey

all

safety

messages

to

avoid

injury.



Learn

the

meaning

of

WARNING

and

CAUTION.

Figure

1-1.

Safety

Information

SECTION

2-

SPECIFICATIONS

Table

2-1.

Wire

Feeder

modl.1

2/93

*These

are

the

wire

feed

speed

ranges

white

GMAW

welding.

While

Pulse

welding,

the

wire

feed

speed

ranges

may

be

more

limited

(see

Section

9).

OM-1587

Page

1

2

a

WARNING

2

\

/

a

CAUTION

______________

3

______________

~

ELECTRIC

SHOCK

can

kiII~~



Keep

away

from

moving

parts.

I



Do

not

touch

live

electncal

parts.

Ii

~

MOVING

PARTS

can

injure.



Keep

all

panels

and

covers

closed



Disconnect

input

power

before

installing

or

servicing.

when

operating.

I

5

6

a

WARNING

1

Safety

Alert

Symbol

2

SignaiWord

WARNING

means

possible

death

or

serious

injury

can

happen.

CAUTION

means

possible

minor

injury

or

equipment

damage

can

happen.

3

Statement

Of

Hazard

And

Result

4

Safety

Instructions

To

Avoid

Hazard

5

Hazard

Symbol

(If

Available)

6

Safety

Banner

Read

safety

blocks

for

each

sym

bol

shown.

7

NOTE

Special

instructions

for

best

oper

ation



not

safety.

READ

SAFETY

BLOCKS

at

start

of

Section

3-1

before

proceeding.

H

NOTE

~

Turn

Off

switch

when

using

high

frequency.

Specification

Type

Of

Input

Power

Maximum

Weld

Circuit

Rating

Welding

Power

Source

Type

Description

Wire

Feed

Speed

Range

From

Welding

Power

Source:

Single-Phase

24

Volts

AC,

10

Amperes,

50/60

Hertz

100

Volts,

750

Amperes,

100%

Duty

Cycle

Constant

Voltage

(CV)

DC,

With Contactor

And

14-Pin

Remote

Control

For

GMAW

Welding

Constant

Voltage

(CV/Constant

Current

(CC)

DC

Inverter,

With

Contactor

And

14-Pin

Remote

Control

For

GMAW-P

Welding

Standard:

50

To

780

iprn

(1.3

To

19.8

mpm)

High

Speed:

92

To

1435

ipm

(2.3

To

36.5

mpm)

Wire

Diameter

Range

Welding

Processes

Input

Power

Cord

Overall

Dimensions

Weight

loft(3.1

m)

.023

To

1/8

in

(0.6

To

3.2

mm)

Gas

Metal

Arc

(GMAW),

Gas

Metal

Arc

-

Pulse

(GMAW-P)

And

Flux

Cored

Arc

Welding

(FCAW)

Length:

32

in

(812

mm);

Width:

18

in

(457

mm);

Height:

14

in

(356

mm)

Net:

74

lb

(33.6

kg);

Ship:

82

lb

(37.2

kg)

3-1.

Site

Selection

SECTION

3-

INSTALLATION

WARNING:

FALLING

WIRE

FEEDER

can

cause

serious

personal

injury

and

equipment

damage.



Do

not

put

wire

feeder

where

it

will

tip

or

fall.



Put

all

four

rubber

feet

solidly

on

a

flat

surface.

CYLINDERS

can

explode

if

damaged.



Keep

cylinders

away

from

welding

and

other

electrical

circuits.



Never

touch

cylinder

with

welding

electrode.



Always

secure

cylinder

to

running

gear,

wall,

or

other

stationary

support.

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.

The

welding

wire,

drive

rolls,

drive

assembly,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live

when

welding

or

feeding

wire

using

gun

trigger.

wfwam7.1

9/91

WARNING

I.

--o-,c~-J

.

Do

not

put

feeder

where

welding

wire

hits

cylinder.

1

Wire

Feeder

2

Rubber

Feet

3

Base

Slot

If

installing

wire

feeder

over

a

lifting

eye

on

a

welding

power

source,

se

lect

the

slot

that

allows

all

four

rub

ber

feet

on

base

of

feeder

to

sit

se

curely

on

top

of

welding

power

source.

4

Wire

Spool/Reel

5

Gas

Cylinder

(Customer

Supplied)

6

Welding

Power

Source

Position

wire

feeder

on

welding

power

source

or

cart

so

that

weld

ing

wire,

or

wire

spool/reel,

does

not

touch

gas

cylinder.

5

4

2

6

Figure

3-1.

Installing

Wire

Feeder

5T-156925-A/ST-162

131

/ST-162

130

OM-1

587

Page

2

3-2.

Connection

Diagram

1

Welding

Power

Source

2

17-Pin

Plug

And

Intercon

necting

Cord

3

14-Pin

Plug

And

Intercon

necting

Cord

4

Positive

(+)

Weld

Cable

5

Negative

()

Weld

Cable

6

Workpiece

7

Voltage

Sensing

Lead

8

Gun

ST-162

1~

N

OTE

~

If

using

wire

feeder

with

an

engine-driven

power

source,

place

engine

control

____________________

switch

in

Run

(high

speed)

position.

Some

wire

feeders

may

work

with

switch

in

Run/Idle

position.

9

Wire

Feeder

10

Gas

Hose

With

Y

Adapter

11

Gas

Cylinder

2.

11.

3-

4

5-

10

8

Figure

3-2.

Connection

Diagram

OM-1

587

Page

3

3-3.

Wire

Guide

And

Drive

Roll

Installation

a

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

wire

feeder

and

welding

power

source,

and

disconnect

input

power

before

inspecting

or

installing.

A.

Wire

Guide

Installation

B.

Drive

Roll

Installation

.

wfwaml.1

2/93

When

changing

wire

size

or

type,

check

guide

size

(see

Table

16-1).

1

Drive

Rolls

Remove

drive

rolls

before

install

ing

wire

guides

(see

Figure

3-4).

2

Wire

Guide

Securing

Screws

Loosen

wire

guide

screws.

3

Antiwear

Guide

Install

antiwear

guide

onto

inlet

wire

guide,

and

secure

with

set

screw.

Use

existing

antiwear

guide

when

changing

inlet

wire

guide

size.

4

InletWire

Guide

Install

inlet

guide

so

wire

guide

screw

is

centered

in

groove

in

guide.

5

Intermediate

Wire

Guide

Insert

intermediate

guide

until

flange

on

guide

rests

against

cast

ing,

and

secure

with

guide

screw.

Install

drive

rolls

(see

Figure

3-4).

Repeat

procedure

for

opposite

side

of

wire

feeder.

ST-153

125-B

/

ST-137

377-0

Tools

Needed:

5/64

in

Figure

3-3.

Wire

Guide

Installation

When

changing

wire

size

or

type,

check

drive

roll

size

(see

Table

16-1).

1

Spring

Shaft

Carrier

2

Drive

Roll

Nut

3

Drive

Roll

Carrier

Turn

nut

one

click

until

lobes

of

nut

line

up

with

lobes

of

drive

roll

carrier.

4

Drive

Roll

Slide

drive

roll

onto

drive

roll

carrier.

Turn

nut

one

click.

Repeat

procedure

for

all

drive

rolls.

5

Drive

Assembly

Cover

Close

cover.

Repeat

procedure

for

opposite

side

of

wire

feeder.

ST-137

377-D

4

Figure

3-4.

Drive

Roll

Installation

OM-1

587

Page

4

3-4.

Welding

Gun

Connections

4A

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Oft

wire

feeder

and

welding

power

source,

and

disconnect

input

power

before

inspecting

or

installing.

wfwaml.1

2/93

3-5.

Motor

Start

Control

a

WARNING

Ci~1===zn

1/4

in

~:~==~

Non-conductive

1

Gun

Securing

Knob

2

Gun

Block

3

Gun

End

Loosen

gun

securing

knob.

Insert

end

into

block.

Position

as

close

as

possible

to

drive

rolls

without

touching.

Tighten

knob.

4

Gun

Trigger

Plug

5

Gun

Trigger

Receptacle

Insert

plug

into

receptacle,

and

tighten

threaded

collar.

6

Drive

Assembly

Cover

Close

cover.

Repeat

procedure

on

opposite

side

of

wire

feeder.

ST-162

1.83/

Ref.

ST-167

703

Figure

3-5.

Gun

And

Trigger

Lead

Connections



Do

not

touch

live

electrical

parts.

ELECTRIC

SHOCK

can

kill.



TumOftwirefeederandweldingpowersource,and

disconnect

input

power

before

inspecting

or

installing.

on

circuit

boards.

STATIC

ELECTRICITY

can

damage

parts



Put

on

grounded

wrist

strap

BEFORE

handling

boards

or

parts.

wfwaml

.1



2/93

To

change

wire

feed

starting

speed

proceed

as

follows:

Turn

Oft

wire

feeder

and

welding

power

source.

Remove

wrapper.

1

Motor

Board

PCi

2

Motor

Start

Control

Poten

tiometer

R70

Turn

potentiorneterclockwiseto

in

crease

time

it

takes

the

motor

to

ramp

up

to

speed.

Remove

protec

tive

white

rubber

cap

before

mak

ing

adjustment.

Adjust

potentiome

ter

R70

using

a

small

nonconduc

tive

screwdriver.

Figure

3-6.

Motor

Start

Control

On

Motor

Control

Board

PCi

Reinstall

wrapper.

ST-162

132/Ref.

SB-14$8~-D

OM-i

587

Page

5

3-6.

Control

Connections

*The

remaining

pins

are

not

used.

OM-1

587

Page

6

17-Socket

Receptacle

(See

Table

3-1)

2

Keyway

To

connect

interconnecting

cord

to

receptacle,

align

keyway,

insert

plug,

and

tighten

threaded

collar.

3

Weld

Current

Sensor

Recep

tacle

(For

Use

With

Field

Op

tion

Only)

4

35

ft

(10.6

m)

Voltage

Sens

ing

Lead

Connect

to

woiipiece

to

read

arc

voltage

at

the

arc

when

welding

power

source

has

a

17-pin

connec

tion

(see

Figure

3-2).

5

Threaded

Collar

6

14-Pin

Plug

(See

Table

3-2)

To

connect

plug

to

matching

recep

tacle

on

welding

power

source,

align

keyway,

insert

plug,

and

tight

en

threaded

collar.

6

Figure

3-7.

Control

Connections

With

Information

S-162

132/Ref.

S-0512

I

S-0003-A

/

S-0628

Table

3-1.

Remote

17

Socket

Information

.

REMOTE

17

Socket*

Socket

Information

B

,

~

C

G

CC/CV

select;

+13

to

+24

volts

dc

is

CV,

0

volts

dc

is

CC.

Arc

controllinductance

control;

0

to

+10

volts

dc.

E

Actual

weld

current

output

signal;

+1

voltdc

is

100

amps.

M

Actual

weld

voltage

output

signal;

+1

voltdc

is

10

volts

dc.

F

H

Current

feedback

from

welding

power

source;

0

to

+10

volts

dc,

1

volt

per

100

amperes.

Voltage

feedback

from

welding

power

source;

0

to

+10

volts

dc,

1

volt

per

10

arc

volts.

*The

remaining

sockets

are

not

used.

Table

3-2.

Remote

14

Information

REMOTE

14

Pin*

Information

A

24

volts

ac.

(CONTACTOR)

B

G

Contact

closure

to

A

completes

24

volts

ac

contactor

control

circuit.

Circuit

common

for

24

volts

ac

circuits.

C

+10

volts

dc

input

to

remote

control.

Ai~I

AMPERAGE

MIV

VOLTAGE

D

E

Remote

control

circuit

common.

0

to

+10

volts

dc

output

command

signal

from

feeder

voltage

control.

3-7.

Shielding

Gas

And

Weld

Cable

Connections

a

WARNING

CYLINDERS

can

explode

if

damaged.



Keep

cylinders

away

from

welding

and

other

electrical

circuits.



Never

touch

cylinder

with

welding

electrode.



Always

secure

cylinder

to

running

gear,

wall,

or

other

stationary

support.

A.

Shielding

Gas

Connections

To

Regulator/Flowmeter

E



LECTRIC

SHOCK

can

kill.

Do

not

touch

live

electrical

parts.



Turn

Oft

wire

feederand

welding

powersource,

and

disconnect

input

power

before

inspecting

or

installing.

BUILDUP

OF

SHIELDING

GAS

can

harm

health

or

kill.



Shut

oft

shielding

gas

supply

when

not

in

use.

warn4.19/91

/wfwaml.1

2/93

Obtain

gas

cylinder

and

chain

to

running

gear,

wall,

or

other

station

ary

support

so

cylinder

cannot

fall

and

break

off

valve.

1

Cap

1-1/8,5/8

in

2

Cylinder

Valve

Remove

cap,

stand

to

side

of

valve,

and

open

valve

slightly.

Gas

flow

blows

dust

and

dirt

from

valve.

Close

valve.

3

Cylinder

4

Regulator/Flowmeter

Install

so

face

is

vertical.

5

Gas

Hose

Connection

Fifting

has

5/8-18

right-hand

threads.

Obtain

gas

hose

and

in

stall

between

cylinder

and

Y

adapter

(see

Figure

3-9).

6

Flow

Adjust

Check

wire

manufacturers

recom

mended

flow

rate.

Make

sure

flow

adjust

is

closed

when

opening

cylinder

to

avoid

damage

to

the

flowmeter.

7

CO2

Adapter

8

0-Ring

2

Install

adapterwith

0-ring

between

regulator/flowrneter

and

CO2

cylinder.

ssbar

5/94

-

ST-158

697-A

Figure

3-8.

Typical

RegulatorlFlowmeter

Installation

2

r

3

OR

Argon

Gas

4

3

CO2

Gas

Tools

Needed:

OM-1

587

Page

7

B.

Shielding

Gas

And

Weld

Cable

Connections

At

Feeder

1

Y

Adapter

Hose

(Supplied)

2

Shielding

Gas

Fitting

When

using

one

source

of

shield

ing

gas,

route

and

connect

Y

adapter

and

gas

hose

as

shown.

If

two

sources

of

shielding

gas

are

being

used,

obtain

two

gas

hoses

with

5/8-18

right-hand

threaded

fit

tings.

Route

a

hose

from

each

shielding

gas

source

under

spool

support

arm,

and

connect

to

appro

pnate

shielding

gas

fitting.

3

Weld

Cable

Terminal

4

Jumper

Weld

Cable

Install

one

end

of

jumper

weld

cable

to

each

weld

cable

terminal.

5

Weld

Cable

(Customer

Supplied)

Select

and

prepare

weld

cables

ac

cording

to

welding

power

source

Owners

Manual.

When

possible,

route

weld

cable

under

spool

support

arm,

and

con

nect

to

either

weld

cable

terminal.

If

there

is

not

enough

room

under

spool

support

arm,

route

cables

and/or

hoses

along

side

of

spool

support

arm.

9/16,5/8in

Figure

3-9.

Shielding

Gas

And

Weld

Cable

Connections

Ref.

ST-152

567-A

.

I

4

5

Connect

To

Regulator/

Flowmeter

Connect

To

Positive

(+)

Weld

Output

Terminal

On

Welding

Power

Source

For

Direct

Current

Electrode

Positive

(DCEP),

Or

Con

nect

To

Negative

()

Weld

Output

Terminal

On

Weld

ing

Power

Source

For

Di

rect

Current

Electrode

Neg

ative

(DCEN)

Tools

Needed:

OM-1

587

Page

8

3-8.

Welding

Wire

Installation

A.

Positioning

Spool

Support

Arm

Figure

3-10.

Positioning

The

Spool

Support

Arm

Wire

feeder

is

shipped

from

factory

with

spool

support

arm

installed

to

handle

a

wire

spool/reel

up

to

12

inches

in

diameter.

If

a

larger

spool/reel

is

to

be

used,

reposition

spool

support

arm

as

instructed.

1

Base

2

SpoolSupportArm

3

Self-Tapping

Securing

Screws

Install

spool

support

arm

in

the

po

sition

that

allows

the

spool/reel

to

turn

without

touching

the

wire

feed

er

or

gas

cylinder,

while

allowing

the

welding

wire

to

run

the

straight

est

line

from

the

wire

spooVreel,

through

the

drive

rolls.

Tools

Needed:

~

3/8

in

ST-152

565

B.

Installation

Of

Spool-Type

Wire

8

3

2

1

Hex

Nut

Remove

hex

nut.

2

Hub

Support

Shaft

3

Holes

For

Positioning

Hub

Support

Shaft

Install

shaft

into

hole

that

allows

welding

wire

to

run

the

straightest

line

from

wire

spool,

through

the

drive

rolls.

Reinstall

hex

nut.

4

Spacer

5

Hub

6

Hub

7

Spool

8

Retaining

Ring

Remove

retaining

ring,

and

slide

wire

spool

onto

hub

(wire

may

feed

from

top

or

bottom

of

spool,

see

Figure

3-14

and

Figure

3-1

6).Tum

spool

until

hub

fits

hole

in

spool.

Reinstall

retaining

ring.

9

Hub

Bracket

Repeat

procedure

using

hub

bracket

to

install

spool-type

wire

Tools

Needed:

onto

right

side

of

wire

feeder.

r

15/l6in

ST-152

564-A

1

Figure

3-11.

Installation

Of

Spool-Type

Wire

OM-1

587

Page

9

C.

Installation

Of

Optional

Wire

Reel

And

Reel

Type

Wire

D.

Adjusting

Hub

Tension

Figure

3-13.

Adjusting

Hub

Tension

.

11

12

9

1

Hub

Support

Shaft

2

Hex

Nut

7

Remove

hex

nut.

3

Holes

For

Positioning

Hub

Support

Shaft

6

Install

shaft

into

hole

that

allows

welding

wire

to

run

the

straightest

line

from

wire

spool,

through

the

drive

rolls

withouttouching

the

wire

feeder

or

gas

cylinder.

Reinstall

hex

nut.

5

43

4

Spacer

5

Hub

6

Hub

7

Wire

Reel

8

Wire

13

9

Wire

Retainer

10

Spanner

Nut

11

Lock

12

Retaining

Ring

Remove

retaining

ring.

Pull

lock

and

turn.

Remove

spanner

nut,

wire

retainer,

and

wire

reel

from

hub.

~i~I

Lay

wire

reel

assembly

on

flat

sur

face,

and

install

wire

as

shown

(wire

may

be

installed

to

feed

from

top

or

bottom

of

reel).

Tools

Needed:

Tighten

spanner

nut

until

lock

is

in

position

over

hole

in

wire

retainer.

Pull

lock

and

turn

to

insert

locking

into

wire

retainer.

15/16

in

Wire

Installation

Slide

wire

reel

assembly

onto

hub,

and

turn

assembly

until

hub

is

seated

in

hole

in

reel.

Reinstall

re

taining

ring.

13

Hub

Bracket

Figure

3-12.

Installation

Of

Optional

Wire

Reel

And

Reel

Type

Wire

Repeat

procedure

using

hub

bracket

to

install

reel-type

wire

onto

right

side

of

wire

feeder.

ST-i

52

563-B

/

ST-i

52

463/

Ref.

ST-157

999-A

Toots

Needed:

~iiiiii~i~ir

15/16

in

Turn

Off

wire

feeder

and

welding

power

source.

1

Hex

Nut

2

Spool

Grasp

spool

in

one

hand

and

turn

while

using

a

wrench

to

adjust

hex

nut.

When

a

slight

force

is

needed

to

turn

spool,

tension

is

set.

Repeat

procedure

to

adjust

hub

tension

on

right

side

of

wire

feeder.

ST-i

52

562-A

OM-1587

Page

10

3-9.

Threading

Welding

Wire

With

Drive

Assembly

Horizontal

a

WARNING

CYLINDERS

can

explode

if

damaged.



Keep

cylinders

away

from

welding

and

other

electrical

circuits.



Never

touch

cylinder

with

welding

electrode.



Always

secure

cylinder

to

running

gear,

wall,

or

other

stationary

support.

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.

The

welding

wire,

drive

rolls,

drive

assembly,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live

when

welding

or

feeding

wire

using

gun

trigger.

WELDING

WIRE

can

cause

puncture

wounds.



Do

not

press

gun

trigger

until

instructed

to

do

so.



Do

not

point

gun

toward

any

part

of

the

body,

other

people,

or

any

metal

when

threading

welding

wire.

HOT

SURFACES

can

burn

skin.



Allow

gun

to

cool

before

touching.

if

wfwam2.1

/wfwam7.1

9/91

OM-1

587

Page

11

1

Wire

SpooVReel

2

Wire

Guide

3

Pressure

Adjustment

Knob

4

Drive

Rolls

5

Spring

Shaft

Carrier

Close

spnng

shaft

carrier.

6

Drive

Roll

Pressure

Indicator

Scale

7

JO9

Button

8

Gun

Conduit

Cable

Lay

gun

conduit

cable

out

straight.

9

Drive

Assembly

Cover

Repeat

procedure

for

opposite

side

of

wire

feeder.

If

desired,

either

side

drive

assembly

may

be

rotated

(see

Figure

3-15).

OFF

Wire

Feeder

(see

Figure

5-10)

I~1

See

Figure

5-13

for

switch

positions

of

450

ampere

inverter

model

welding

power

source

or

see

welding

power

source

Owners

Manual

for

other

models.

Welding

Power

Source

Push

wire

thru

guides

up

to

drive

rolls;

continue

to

hold

welding

wire.

Press

Select

button

(see

Figure

5-6)

to

choose

active

side

of

wire

feeder.

Press

Jog

button

(see

Figure

5-8)

until

drive

rolls

grab

wire.

Adjust

tension

until

wire

does

not

slip.

Indicator

is

for

reference

only.

Press

Jog

button

until

wire

comes

out

gun.

-*

Feed

wire

to

check

drive

roll

pressure.

Adjust

knob

enough

to

prevent

slipping.

Pat.

ST-i

53

091

/

Ref.

ST-i

50

922

/

Ref.

ST-i

61

713

/

S-0627-A

Figure

3-14.

Threading

Welding

Wire With

Drive

Assembly

Horizontal

Tools

Needed:

Set

switches.

Hold

wire

tightly

to

keep

it

from

unraveling.

~6in~

(150

mm)

Pull

and

hold

wire;

cut

off

end.

-~

JOG

o~o

0

-,o

Cutoff

wire.

Close

cover.

OM-1

587

Page

12

3-10.

Threading

Welding

Wire

And

Rotating

The

Drive

Assembly

a

WARNING

CYLINDERS

can

explode

if

damaged.



Keep

cylinders

away

from

welding

and

other

electrical

circuits.



Never

touch

cylinder

with

welding

electrode.



Always

secure

cylinder

to

running

gear,

wall,

other

stationary

support.

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.

The

welding

wire,

drive

rolls,

drive

assembly,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live

when

welding

or

feeding

wire

using

gun

trigger.

WELDING

WIRE

can

cause

puncture

wounds.



Do

not

press

gun

trigger

until

instructed

to

do

so.



Do

not

point

gun

toward

any

part

of

the

body,

other

people,

or

any

metal

when

threading

welding

wire.

HOT

SURFACES

can

burn

skin.



Allow

gun

to

cool

before

touching.

wfwam2.1

Iwfwam7.1*

9191

A.

Rotating

Drive

Assembly

Figure

3-15.

Rotating

The

Drive

Assembly

4

Feeder

is

shipped

with

drive

as

sembly

in

a

horizontal

position.

To

rotate

drive

assembly,

proceed

as

follows:

Remove

screws

(6)

from

front

edge

of

wrapper,

and

loosen

screws

on

back

edge

of

wrapper.

1

Front

Panel

Remove

screw

from

upper

left

car

nerof

nameplate,

and

open

hinged

front

panel.

2

Drive

Assembly

Rotation

Ad

justment

Openings

3

Drive

Assembly

4

Wire

SpoollReel

Insert

3/16

in

allen

wrench

into

opening,

and

loosen

socket

head

cap

screw.

Turn

drive

assembly

to

a

position

that

allows

welding

wire

to

run

the

straightest

line

from

spooVreel,

through

the

drive

rolls

(wire

may

feed

from

top

or

bottom

of

spool/reel,

see

Section

3-8.).

Tighten

bolt.

Close

and

secure

front

panel,

and

go

to

Figure

3-16.

Tools

Needed:

Ref.

ST-i

53

093/

STBOO

289

3

3/16

in

OM-1

587

Page

13

B.

Threading

Welding

Wire

With

Drive

Assembly

Rotated

1

Wire

Spool/Reel

2

Wire

Guide

3

Pressure

Adjustment

Knob

4

Spring

Shaft

Carrier

Close

spring

shaft

carrier.

5

Drive

Roll

Pressure

Indicator

Scale

6

Jog

Button

7

Gun

Conduit

Cable

8

Drive

Rolls

9

Drive

Assembly

10

Drive

Assembly

Cover

If

position

of

drive

assembly

needs

further

adjusting,

go

back

to

Figure

3-15.

Press

Jog

button

until

wire

comes

out

gun.

-*

Feed

wire

to

check

drive

roll

pressure.

Adjust

knob

enough

to

prevent

slipping.

Ref.

ST-153

093/

Ref.

ST-i

50

9~

I

Ref.

ST-iOi

713

/

S-0627-A

Figure

3-16.

Threading

Welding

Wire

With

Drive

Assembly

Rotated

.

Hold

wire

tightly

to

keep

it

from

unravel

ing.

Tools

Needed:

ci

6

in

(150

mm)

See

Figure

5-13

for

ON

switch

positions

of

450

ampere

inverter

model

~

welding

power

source

or

....+

see

welding

power

source

Owners

Manual

OFF

for

other

models.

Wire

Feeder

(see

Figure

5-10)

Welding

Power

Source

Set

switches.

Pull

and

hold

wire;

cut

off

end.

JOG

SELECT

O~,O

~oo~

Press

Select

button

(see

Figure

5-6)

to

choose

active

side

of

wire

feeder.

Press

Jog

button

(see

Figure

5-8)

until

drive

rolls

grab

wire.

Push

wire

thru

guides

up

to

dnve

rolls;

continue

to

hold

welding

wire.

Adjust

tension

until

wire

does

not

slip.

Indicator

is

for

reference

only.

Cut

off

wire.

Close

cover.

OM-1

587

Page

14

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Miller D-64M WIRE FEEDER Owner's manual

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