Miller AUTOMATIC M Owner's manual

cover 5/94 − ST-801 440 PRINTED IN USA

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.

Give this manual to the operator.

For help, call your distributor

or: MILLER Electric Mfg. Co., P.O. Box 1079,

Appleton, WI 54912 414-734-9821

OWNER’S

MANUAL

March 1997 Form: OM-1595A

Effective With Serial No. KG091221

Microprocessor Weld Control For Automatic Wire Feed Welding

For GMAW, FCAW, And SAW Welding

Standard GMAW-P And Adaptive GMAW-P Welding

Can Be Used With Inverter Or Conventional Welding Power Source

Programmable Weld Parameters

Overload Protection

For Options And Accessories, See Rear Cover

Automatic M

Microprocessor Weld Control

OM-1595A 3/97

EMF INFORMATION

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 cellular

level and from studies with animals and people which clearly

establish that low frequency magnetic fields can interact with, and

produce changes in, biological systems. While most of this work is

of very high quality, the results are complex. Current scientific

understanding does not yet allow us to interpret the evidence in a

single coherent framework. Even more frustrating, it does not yet

allow us to draw definite conclusions about questions of possible risk

or to offer clear science-based advice on strategies to minimize or

avoid potential risks.”

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.

Considerations About Welding And The Effects Of Low Frequency Electric And

Magnetic Fields

NOTE

mod10.1 4/93

TABLE OF CONTENTS

SECTION 1 − SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − INSTALLATION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Typical Equipment Location 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Mounting Hole Layout 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Connection Diagram 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Welding Power Source Switch Settings 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Weld Cable Connections 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Bottom Panel Connections 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Installing Gas Supply 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Input/Output Connections 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Installing Hub 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10. Installing Welding Wire And Adjusting Hub Tension 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11. Connecting Optional Pendant To Microprocessor Weld Control 14. . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − OPERATIONAL TERMS 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − OPERATION 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Weld Enable Button Or User I/O Weld Enable 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Manual Weld Button Or User I/O Test Weld 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Setup Panel Microprocessor Push Buttons 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Shielding Gas 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Optional Pendant Controls 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − SETTING A MIG WELDING PROGRAM 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Changing To MIG Welding 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Setting Sequence MIG Welding Parameters On Setup Panel Display 26. . . . . . . . . . . . . . . . .

SECTION 7 − STANDARD PULSE WELDING PROGRAMS 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Pulse MIG Programs 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Standard Pulse Welding Programs 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − SETTING STANDARD PULSE WELDING PROGRAMS 39. . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − TEACHING A PULSE WELDING PROGRAM 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Pulse Waveform Explained 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. Teach Points Explained 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Teaching A Pulse Welding Program 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-4. Changing To Adaptive Pulse Welding 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − USING THE DATA CARD OPTION 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-1. Installing Data Card 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-2. Using The Data Card 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − SETUP 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-1. Setup Menu 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-2. Accessing The Setup Menu 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-3. Example Of Setting Output A In Setup 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-4. Selecting Wire Type 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-5. Resetting Memory 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-6. Starting Method For A Program 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-7. Remote Program Select 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12 − MAINTENANCE & TROUBLESHOOTING 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-1. Routine Maintenance 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-2. Overload Protection 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-3. Replacing The Hub Assembly 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-4. Error Messages 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-5. Interface Board PC5 Diagnostic LED’s 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-6. Customer Interface Board PC4 Diagnostic LED’s 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 13 − ELECTRICAL DIAGRAMS 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 14 − PARTS LIST 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 14-1. Case Section w/Components 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 14-2. Door w/Components 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

sr1.1.1 2/94

ARC WELDING SAFETY PRECAUTIONS

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN

AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.

In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The

safety information given below is only a summary of the more complete safety information that will be found in the

Safety Standards listed on the next page. Read and follow all Safety Standards.

HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY

QUALIFIED PEOPLE.

ARC WELDING can be hazardous.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks

or severe burns. The electrode and work circuit is

electrically live whenever the output is on. The input

power circuit and machine internal circuits are also

live when power is on. In semiautomatic or automatic

wire welding, the wire, wire reel, drive roll housing, and

all metal parts touching the welding wire are

electrically live. Incorrectly installed or improperly

grounded equipment is a hazard.

1. 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 power according

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 power cord for damage or bare wiring −

replace cord immediately if damaged − bare wiring can kill.

9. Turn 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.

15. Wear a safety harness if working above floor level.

16. Keep all panels and covers securely in place.

17. Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

ARC RAYS can burn eyes and skin;

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 burn 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.

ARC RAYS

2. Wear a welding helmet fitted with a proper shade of filter to

protect your face and eyes when welding or watching (see ANSI

Z49.1 and Z87.1 listed in Safety Standards).

3. Wear approved safety glasses with side shields.

4. Use protective screens or barriers to protect others from flash

and glare; warn others not to watch the arc.

5. Wear protective clothing made from durable, flame-resistant

material (wool and leather) and foot protection.

FUMES AND GASES can be hazardous

to your health.

Welding produces fumes and gases. Breathing these

fumes and gases can be hazardous to your health.

1. Keep your head out of the fumes. Do not breathe the fumes.

2. If inside, ventilate the area and/or use exhaust at the arc to

remove welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied respirator.

4. Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instruction for metals, consumables, coatings,

cleaners, and degreasers.

5. Work in 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.

6. Do not weld in locations near degreasing, cleaning, or spraying

operations. The heat and rays of the arc can react with vapors to

form highly toxic and irritating gases.

7. Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the

weld area, the 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.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high

pressure. If damaged, a cylinder can explode. Since

gas cylinders are normally part of the welding

process, be sure to treat them carefully.

1. Protect compressed gas cylinders from excessive heat,

mechanical shocks, slag, open flames, sparks, and arcs.

2. Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

3. Keep cylinders away from any welding or other electrical circuits.

4. Never drape a welding torch over a gas cylinder.

5. Never allow a welding electrode to touch any cylinder.

6. Never weld on a pressurized cylinder − explosion will result.

7. Use only correct shielding gas cylinders, regulators, hoses, and

fittings designed for the specific application; maintain them and

associated parts in good condition.

8. Turn face away from valve outlet when opening cylinder valve.

9. Keep protective cap in place over valve except when cylinder is

in use or connected for use.

10. Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in Safety

Standards.

sr1.1.1 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 garments 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.

WARNING

ENGINES can be hazardous.

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

1. Use equipment outside in open, well-ventilated areas.

2. If used in a closed area, vent engine exhaust outside and away

from any building air intakes.

ENGINE FUEL can cause fire or

explosion.

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 flames.

3. Do not overfill tank − allow room for fuel to expand.

4. Do not spill fuel. If fuel is spilled, clean up before starting

engine.

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.

2. Stop engine before installing or connecting unit.

3. Have only qualified people remove guards or covers for

maintenance and troubleshooting as necessary.

4. To prevent accidental starting during servicing, disconnect

negative (−) battery cable from battery.

5. Keep hands, hair, loose clothing, and tools away from moving

parts.

6. Reinstall panels or guards and close doors when servicing is

finished and before starting engine.

SPARKS can cause BATTERY

GASES TO EXPLODE; BATTERY

ACID can burn eyes and skin.

Batteries contain acid and generate explosive

gases.

1. Always wear a face shield when working on a battery.

2. Stop engine before disconnecting or connecting battery

cables.

3. Do not allow tools to cause sparks when working on a battery.

4. Do not use welder to charge batteries or jump start vehicles.

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. If the engine is warm and checking is needed, follow steps 2

and 3.

2. Wear safety glasses and gloves and put a rag over cap.

3. Turn cap slightly and let pressure escape slowly before

completely removing cap.

PRINCIPAL SAFETY STANDARDS

Safety in Welding and Cutting, ANSI Standard Z49.1, from American

Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-

dent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and Cut-

ting 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 Fire Protec-

tion Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 1235 Jefferson Davis Highway,

Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

Canadian Standards Association, Standards Sales, 178 Rexdale Bou-

levard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face Protec-

tion, ANSI Standard Z87.1, from American National Standards Institute,

1430 Broadway, New York, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from National

Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

OM-1595 Page 1

SECTION 1 − SAFETY INFORMATION

mod1.1 2/93

Read all safety messages throughout this manual.

Obey all safety messages to avoid injury.

Learn the meaning of WARNING and CAUTION.

1 Safety Alert Symbol

2 Signal Word

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

symbol shown.

7 NOTE

Special instructions for best

operation − not related to safety.

2

NOTE

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Disconnect input power before

installing or servicing.

WARNING

READ SAFETY BLOCKS at start of

Section 3-1 before proceeding.

WARNING

5

4

6

7

1 2

CAUTION

MOVING PARTS can injure.

• Keep away from moving parts.

• Keep all panels and covers closed

when operating.

3

Turn Off switch when using high frequency.

Figure 1-1. Safety Information

SECTION 2 − SPECIFICATIONS

Table 2-1. Weld Control

Specification Description

Type Of Input Power From Welding

Power Source

Single-Phase 115 Volts AC, 3.5 Amperes, 50/60 Hertz

Welding Power Source Type 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

Wire Feed Speed Range* Standard: 50 To 780 ipm (1.3 To 19.8 mpm)

Wire Diameter Range .030 To .062 in (0.8 To 1.6 mm)

Welding Processes Gas Metal Arc (GMAW), Gas Metal Arc - Pulse (GMAW-P), Flux Cored Arc (FCAW), And

Submerged Arc Welding (SAW)

Overall Dimensions Length: 15 in (381 mm); Width: 16 in (406 mm); Height: 8-1/2 in (216 mm)

Weight Net: 33 lb (15 kg); Ship 38 lb (17.2 kg)

*These are the wire feed speed ranges while GMAW welding. While Pulse welding, the wire feed speed ranges may be more limited (see

Section 9).

OM-1595 Page 2

Table 2-2. Operator Pendant

Specification Description

Interconnecting Cord With Plugs (Not

Supplied)

10 ft (3 m), 30 ft (9.1 m), Or 50 ft (15.2 m)

Program Selection Eight Programs

Control Capacity Single Microprocessor Weld Control

Overall Dimensions Height: 11-3/4 in (298 mm); Width: 7-1/4 in (184 mm); Depth: 4 in (102 mm)

Weight Net: 2-5/8 lb (1.2 kg)

SECTION 3 − INSTALLATION

3-1. Typical Equipment Location

ST-131 138-A

1 Welding Power Source

2 Gas Cylinder

3 Side Beam

4 Weld Control

5 Spool Support

6 Wire Drive Assembly

7 Automatic Welding Gun

1

2

3

4

5

6

7

Figure 3-1. Typical Equipment Location

OM-1595 Page 3

3-2. Mounting Hole Layout

Inches Millimeters

A 16-3/4 425

B 11 279

C 3/8 Dia 9.5 Dia

Ref. ST-801 440 / ST-080 486-C

A

B

C

E

D

F

Inches Millimeters

D 3-1/2 89

E 2-1/2 64

F 5/16 Dia 7.9 Dia

Spool Support Assembly

(Shown With Optional Wire Assembly

Figure 3-2. Mounting Hole Layout

3-3. Connection Diagram

Customer must supply wire drive assembly and drive rolls, gun, welding wire, weld

cables, control cables, and shielding gas or flux for desired application.

NOTE

1 Weld Control Bottom Panel

2 Voltage Sensing Cord

3 Accessory Equipment

Connection (Flux Valve,

Fixture, Remote Switch, Etc.)

4 Automatic Flux Valve

(Optional For SAW Welding)

5 Motor Control Cord

6 Wire Drive Assembly

7 Workpiece

8 Welding Power Source

9 Remote 14 Interconnecting

Cord

10 Remote 17 Interconnecting

Cord

11 Optional Pendant Control

12 Pendant Control

Interconnecting Cord

1

23

4

5

6

7

8

11

9

10

. For Options And Accessories, See Rear Cover

12

Figure 3-3. Typical Connections

OM-1595 Page 4

3-4. Welding Power Source Switch Settings

A. Setting Switches On Maxtron™ 450 Ampere Inverter Model Welding Power Source

Ref. ST-150 171-C / Ref. ST-165 852-B

Set switches as shown for all

welding processes when using

this interface unit.

Figure 3-4. Setting Switches On Maxtron™ 450 Ampere Inverter Model Welding Power Source

B. Setting Switches On Deltaweld® 452/652 Ampere Model Welding Power Source

ST-800 453 / Ref. ST-162 502-B

Set switches as shown for all

welding processes when using

this interface unit.

1

1 Voltage Adjustment Control

2 Voltage Control Switch

Position of Voltage Adjustment con-

trol does not matter when Voltage

Control switch is in REMOTE posi-

tion.

2

Figure 3-5. Setting Switches On Deltaweld® 452/652 Ampere Model Welding Power Source

OM-1595 Page 5

C. Setting Switches On Dimension™ 452 Or 652 Ampere Model Welding Power Source

ST-800 166-B / Ref. ST-161 964-A

Set switches as shown for all

welding processes when using

this interface unit.

1 Arc Force (Dig) Control

2 Hot Start Switch

3 Amperage/Voltage Adjustment

Control

Setting at controls and switch posi-

tion does not matter when Process

Selector switch is in GMAW posi-

tion and remote Amperage/Voltage

Control switch is in REMOTE posi-

tion.

ST-800 091 / ST-162 500-A

132

12

14

16

18

20

22

24

26

28

30

32

34

36

1

Set switches as shown for all

welding processes when using

this interface unit.

1 Arc Force (Dig) Control

2 Amperage/Voltage Adjustment

Control

Setting at controls does not matter

when Process Selector switch is in

GMAW position and remote Am-

perage/Voltage Control switch is in

REMOTE position.

2

Dimension 452 Model

Dimension 652 Model

Figure 3-6. Setting Switches On Dimension™ 452 Or 652 Ampere Model Welding Power Source

OM-1595 Page 6

D. Setting Switches On XMT® 304 Inverter Model Welding Power Source

ST-801 192 / Ref. ST-175 086

Set switches as shown for all

welding processes when using

this interface unit.

1

234

1 Voltage/Amperage Adjustment Control

2 Mode Switch

The Mode switch setting determines both the

process and output On/Off control. Source of

control (panel or remote) for the amount of

output is selected on the V/A Control switch.

. Unit does not support remote MIG to

PULSED MIG selection.

3 Voltage/Amperage Control Switch

For front panel control, place switch in Panel

position and use the V/A Adjust control.

For remote control, make connections to Re-

mote 14 receptacle, and place switch in Re-

mote position. Remote control is a percent of

V/A Adjust control setting. Value selected on

V/A Adjust is maximum available on remote.

4 Inductance/Dig Control

When set towards minimum, short-circuit

amperage at low arc voltage is the same as

normal welding amperage.

When set towards maximum, short-circuit

amperage is increased at low arc voltage to

assist with arc starts as well as reduce stick-

ing while welding.

Select setting best suited for application.

Control adjusts inductance when a MIG

(GMAW) position is selected on the mode

switch. Inductance determines the “wetness”

of the weld puddle. When set higher, “wet-

ness” (puddle fluidity) increases.

. Inductance is only used in MIG (non-

pulsed) welding applications.

Figure 3-7. Setting Switches On XMT® 304 Inverter Model Welding Power Source

OM-1595 Page 7

E. Setting Switches On Invision 456P Inverter Model Welding Power Source

Set switches as shown for all

welding processes when using

this interface unit.

1 Voltage Adjustment Control

2 Inductance Control

Inductance determines the “wetness” of the

weld puddle. When set higher, “wetness”

(puddle fluidity) increases.

3 Remote On/Off Receptacle (Optional)

Sockets 1 and 2 are connected in parallel with

the Power On/Off switch. For remote On/Off

control, connect a suitable plug from a remote

switch to the receptacle and place front panel

Power On/Off switch in Off position. Unit can

then be turned On and Off through the use of

the remote switch.

1

2

ST-180 311-B

3

Figure 3-8. Setting Switches On Invision 456P Inverter Model Welding Power Source

3-5. Weld Cable Connections

sb6.1* 8/92 − Ref. S-0653

1 Weld Output Cables

Determine total cable length in weld

circuit and maximum welding am-

peres according to welding power

source Owner’s Manual.

Do not use damaged cables.

2 Terminal Lug

Use lugs of proper amperage

capacity and hole size for connect-

ing to wire drive assembly and work

connection.

If weld cable connections are for

pulse welding, be sure to use 4/0

cables regardless of welding

speed.

12

2

Tools Needed:

Figure 3-9. Weld Cable Connections

OM-1595 Page 8

3-6. Bottom Panel Connections

1 Receptacle

2 Keyway

3 14-Pin Receptacle (Connection To

Welding Power Source)

4 17-Pin Receptacle (Connection To

Welding Power Source With 17-Pin

Receptacle)

5 19-Socket Receptacle (Motor/Shield-

ing Gas Control Connection To Motor

Drive Assembly)

6 37-Socket Receptacle (Optional Pen-

dant Control Connection Or User

Interface Connection)

A customer supplied matching amphenol

plug (Part No. MS3106A28-21P) is required

for user interface connection.

To connect matching interconnecting cord to

one of the above receptacles, align keyway,

insert plug, and tighten threaded collar. Con-

nect remaining end of cord to matching re-

ceptacle on applicable equipment (see

Figure 3-3).

7 4-Pin Receptacle (Optional External

Voltage Sensing Connection)

To connect interconnecting cord to recep-

tacle, align keyway, insert plug, and tighten

threaded collar.

Secure ring terminal on end of cord to work-

piece.

8 Interface Panel (User Connections)

Optional strain relief (Part No. 044 426)

allows routing user cord inside unit to make

connections at terminal strips for I/O signals.

8

3

4

5

6

7

1

B

M

C

N

L

D

RS

K

E

G

J

F

H

P

T

A

2

Ref. ST-801 440

Example Receptacle

Figure 3-10. Bottom Panel Connections

OM-1595 Page 9

3-7. Installing Gas Supply

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.

BUILDUP OF SHIELDING GAS can harm

health or kill.

• Shut off shielding gas supply when not in use.

warn4.1 9/91

Obtain gas cylinder and chain to

running gear, wall, or other station-

ary support so cylinder cannot fall

and break off valve.

1 Cap

2 Cylinder Valve

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

Fitting has 5/8-18 right-hand

threads. Obtain and install gas

hose.

6 Flow Adjust

Typical flow rate is 20 cfh (cubic feet

per hour). Check wire manufactur-

er’s recommended flow rate.

Make sure flow adjust is closed

when opening cylinder to avoid

damage to the flowmeter.

7CO

2

Adapter

8 O-Ring

Install adapter with O-ring between

regulator/flowmeter and CO

2

cylinder.

ssb3.1 5/94 − ST-158 697-A

7 8

3

1

2

4

5

6

1

2

3

OR

Argon Gas

CO

2

Gas

Tools Needed:

1-1/8, 5/8 in

Figure 3-11. Typical Regulator/Flowmeter Installation

OM-1595 Page 10

3-8. Input/Output Connections

1 Terminal Strip 4T

2 Terminal Strip 5T

3 Optional Strain Relief (Part

No. 044 426)

Route customer-supplied cord from

external connections thru strain

relief for lead connections to termi-

nal strips 4T and 5T.

4 Receptacle RC10

A customer supplied matching

amphenol plug (Part No.

MS3106A28-21P) is required for

connecting to receptacle RC10.

5 Plug

6 Keyway

3

4

1

2

Ref. ST-801 440

5

B

M

C

NL

D

R

S

K

EGJFH

P

T

A

6

U V W X Z

cdbfae

gj mhk

pr sn

Example Plug

Figure 3-12. Receptacle RC10 And Terminal Strips 4T And 5T

User I/O connections are provided at two locations on the unit, 37 socket receptacle RC10 on the outside of the bottom

panel and the terminal strip pair 4T and 5T on the inside of the bottom panel.

Wiring for the terminal strip pair 4T − 5T and receptacle RC10 are parallel electrical

connections. The letter designations for receptacle sockets and terminal strip

poles do not match. To determine desired connections, use Table 3-1, Table 3-2,

Table 3-3, and Table 3-4 for lead identification and matching terminal strip pole or

receptacle socket.

NOTE

OM-1595 Page 11

Table 3-1. Analog Designators*

Function Lead No. Socket No. Terminal Strip Pole Description

Analog Common 115 f 4T−G Common to any analog output signal from

the unit.

Volts Feedback + 116 Z 4T−H 0 - 10 volt output signal (shows 0 - 100

volts).

Current Feedback + 103 d 4T−E 0 - 10 volt output signal (shows 0 - 1000

arc amps).

*These outputs are analog signals from the unit and can source up to 100 mA per channel.

Table 3-2. Input Designators*

Function Lead No. Socket No. Terminal Strip Pole Description

Flow Switch 117 R 5T−T When setup menu is enabled and a closure

is made, flow is detected for water or gas

monitoring (see Section 11-1).

Start Input 113 P 5T−S When a closure is made, start signal is re-

ceived (see Section 11-6).

Remote Program Select A 111 D 5T−R When a closure is made, bit is active or on

(see Section 11-7).

Remote Program Select B 110 C 5T−P When a closure is made, bit is active or on

(see Section 11-7).

Remote Program Select C 109 J 5T−N When a closure is made, bit is active or on

(see Section 11-7).

Jog + 97 G 5T−E When a closure is made, wire advances at

set jog speed (see Section 11-1).

Jog − 96 F 5T−D When a closure is made, wire retracts at

set jog speed (see Section 11-1).

Gas 98 E 5T−F When a closure is made, gas solenoid will

open.

Common 99 N 5T−H All closure are in respect to this point.

Stop Input 102 X 5T−L When a closure is made, program will go to

a stop condition.

Remote Dec. Input 101 W 5T−K When a closure is made, selected weld pa-

rameter will decrease.

Remote Inc. Input 100 V 5T−J When a closure is made, selected weld pa-

rameter will increase.

Error Reset 94 U 5T−B When a closure is made, most errors will

clear. Stop − Error Detected and Ground

Current Detect will need program stopped

or cycle power to clear respective error.

Test Weld 95 T 5T−C When a closure is made, unit will begin

welding without setting any outputs.

Arc Enable 93 S 5T−A When a closure is made, status of arc

enable will change. A disabled arc unit will

only sequence through a weld program

only activating output devices.

Inc/Dec Selector 131 L 5T−U Works with remote inc/dec. A closure se-

lects volts/trim parameter and an open

selects wire feed speed.

Common 99 M 5T−H All closure are in respect to this point.

*These inputs are best described as pull to common type inputs. They typically are used with Common (common for discrete inputs) and either a set of

normally open relay contacts or a transistor. Electrically, whichever device is used to pull these inputs to Common must have a minimum rating of 24 V

DC and 15 mA. A closure should be maintained for a minimum of 50 milliseconds for the unit to detect the signal and any closure must be maintained for

the full time that the signal is required for the operation.

OM-1595 Page 12

Table 3-3. Output Designators*

Function Lead No. Socket No. Terminal Strip Pole Description

Output A (N.O.) 120 c 4T−J Two lines for isolated, programmable dry

contact output closure (see Sections 11-1

Output A (N.O.) 121 b 4T−K

contact output closure

(

see

S

ections 11-1

and 11-3).

Output B (N.O.) 122 a 4T−L Two lines for isolated, programmable dry

contact output closure (see Sections 11-1

Output B (N.O.) 123 g 4T−M

contact output closure

(

see

S

ections 11-1

and 11-3).

Error (N.O.) 124 m 4T−N Two lines for isolated, dry contact output

l h it i i a diti

Error (N.O.) 125 k 4T−P

yp

closure when unit is in an error condition.

Arc Estab. (N.O.) 126 j 4T−R Two lines for isolated, dry contact closure

to indicate state of welding arc Closed

Arc Estab. (N.O.) 127 h 4T−S

to indicate state o

f

welding arc.

C

losed

when arc is lit.

Arc Enable (N.O.) 104 e 4T−F Two lines for isolated, dry contact closure

to indicate state of arc enable Closed

Arc Enable (N.O.) 135 B 5T−X

to indicate state o

f

arc enable.

C

losed

when arc is enabled.

*These outputs are isolated relays with ratings of 0.6 A at 110 V DC or 2.0 A at 30 V DC. The output signal will settle within 30 milliseconds of the function

it is dedicated to starting. The two sides of the relay are indicated by the two listings in Table 3-3.

Table 3-4. Special Input Designators*

Function Lead No. Socket No. Terminal Strip Pole Description

Current Sense 12 n 4T−A Provides a pair of leads to take the place of

current feedback signals. Leads should be

shorted together when welding current is

present (closure from magnetic reed

Current Sense 13 p 4T−B

presen

t (

c

l

osure

f

rom

magne

ti

c

ree

d

switch). Typically used when welding pow-

er source does not provide analog current

feedback.

E-Stop 14 r 4T−C Provides for a remote Emergency Stop sig-

nal. When jumper is removed from termi-

E-Stop 15 s 4T−D

nal

.

When jumper is removed from termi

nals 3T−A and 3T−B, these lines are open

causing unit go into an E-Stop condition.

*These inputs are isolated signals to the unit and not common to anything else. The input signal for the E-Stop function requires a set of normally closed

contacts so that when the contacts open, the unit goes into the Emergency Stop condition (jumper between terminals 3T−A and 3T−B must be removed

for external E-Stop to function [see circuit diagram]). The input signal rating is 35 V at 50 mA. Current Sense is only used with earlier model Deltaweld

welding power sources prior to the Deltaweld 452 and 652 models. Current Sense takes the place of Current Feedback from the weld as an input to the

weld control.

3-9. Installing Hub

ST-126 870-A

Spool support is typically installed

on top of side beam (see

Figure 3-1).

1 Spool Support

Choose hole in support that allows

wire to enter drive assembly in the

straightest line.

2 Tension Adjustment Nut

3 Fiber Washer

4 Brake Washer

5 Hub Assembly

6 Hub Support Shaft

Remove nut from shaft. Install hub

assembly as shown.

1

2

3

4

5

6

Figure 3-13. Installing Hub

OM-1595 Page 13

3-10. Installing Welding Wire And Adjusting Hub Tension

A. Installing Spool-Type Wire And Adjusting Hub Tension

ST-161 001

1 Retaining Ring

2 Wire Spool

3 Hole In Spool

4 Hub

Remove retaining ring and slide

spool onto hub. Turn spool until hub

pin fits hole in spool. Reinstall re-

taining ring.

5 Tension Adjustment Nut

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.

1

2

3

4

5

Tools Needed:

9/16 in

Figure 3-14. Installing Welding Wire And Adjusting Hub Tension

B. Installing Optional Reel-Type Wire

ST-161 000-A / ST-152 463 / Ref. ST-157 999-A

1 Retaining Ring

2 Lock

3 Spanner Nut

4 Wire Retainer

5 Welding Wire

6 Wire Reel

7 Hub

Remove retaining ring. Pull lock

and turn. Remove spanner nut, wire

retainer, and wire reel from hub.

To install wire lay wire reel on flat

surface and install wire as shown.

Tighten spanner nut until lock is in

position over hole in wire retainer.

Pull lock and turn to insert locking

pin into wire retainer.

Slide wire reel assembly onto hub.

Turn assembly until hub pin is

seated in hole in reel. Reinstall re-

taining ring.

3

4

5

6

134

5

6

7

2

Wire Installation

Unlocked

Figure 3-15. Installing Optional Reel-Type Wire

OM-1595 Page 14

3-11. Connecting Optional Pendant To Microprocessor Weld Control

Ref. ST-801 440 / ST-801 475

Y Turn Off welding power

source and weld control.

1 Microprocessor Weld Control

2 Interconnecting Cord

3 Pendant

To make connections, align key-

way, insert plug, and tighten

threaded collar.

4 Terminal Strip 3T Location

Remove emergency stop jumper

between 3TA and 3TB.

1

2

3

4

Figure 3-16. Connecting Optional Pendant To Microprocessor Weld Control

SECTION 4 − OPERATIONAL TERMS

The following is a list of terms and their definitions as they apply to this weld control:

General Terms:

Adaptive Pulse Welding When the “adaptive pulse” welding process is selected, the unit will automati-

cally regulate pulse frequency in order to maintain a constant arc length, re-

gardless of change in welding wire stickout.

Abk (Background

Amperage)

Abk is the low weld current. Background current preheats welding wire and

maintains the arc. When background current is too low, the arc is unstable and

hard to maintain.

Apk (Peak Amperage) Apk is the high pulse of welding current. Peak current melts the welding wire

and forms a droplet. The droplet is forced into the weld puddle.

Inductance In short circuit GMAW welding, an increase in inductance will decrease the

number of short circuit metal transfers per second (provided no other changes

are made) and increase the arc-on time. The increased arc-on time makes the

pool more fluid.

Mig Welding This is standard Gas Metal Arc Welding (GMAW) where the weld control deter-

mines wire feed speed and the welding power source controls arc voltage and

inductance.

PPS (Pulses Per Second) PPS, pulse rate, and frequency (Hz) are used interchangeably. A PPS or pulse

rate of 60 Hz means 60 pulses of current are produced each second.

Pulse Welding The weld control controls the wire feed speed and pulse parameters (Peak Am-

perage, Background Amperage, Pulse Frequency and Pulse Width).

PWms (Pulse Width in Milli-

seconds)

PWms is the time spent at peak current (1.2 ms is .0012 seconds). This time

must be long enough to form a droplet of welding wire. The stiffness or fluidity

of the molten weld puddle is controlled by PWms.

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