Miller DS-64M Swingarc Owner's manual

Miller
Brand
Miller
Model
DS-64M Swingarc
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Miller
July
1996
Form:
OM-1588C
Effe
ctive
With
Serial
No.
KG0471
32
t~llL~
~
~r'
~
OWNERS
MANUAL
DS-64M
SWINGARCTM
12
And
16
Foot
For
GMAW-P,
GMAW,
And
FCAW
Welding
Type
of
Input
Power
Welding
Power
Source
Type
Wire
Feed
Speed
Range
Wire
Diameter
Range
Welding
Circuit
Rating
Weight
24
Volts
AC
Single-Phase
10
Amperes
50/60
Hertz
Constant
Voltage
(CV)
DC
For
GMAW
Or
Constant
Voltage
(CV)
/
Constant
Current
(CC)
DC
For
GMAW-P
All
Need
14-Pin
And
Contactor
Control
Standard:
50
To
780
ipm
(1.3
To
19.8
mpm)
Optional
High
Speed:
92
To
1435
ipm
(2.3
To
36.5
mpm)
.023
To
1/8
in
(0.6
To
3.2
mm)
Max
Spool
Weight:
60
lb
(27
kg)
ioo
Volts,
750
Amperes,
100%
Duty
Cycle
12
ft
(3.7
m):
207
lb
(94
kg)
16
ft
(4.9
m):
280
lb
(127
kg)
I
cover_om
4/95
ST-BOO
172
'
1996
MILLER
Electnc
Mfg.
Co.
PRINTED
IN
USA
j-
I
MILLERS
TRUE
BLUEfi
LIMITED
WARRANTY
Effective
February
7,
1996
(Equipment
with
a
serial
number
preface
of
KD
or
newer)
This
limited
warranty
supersedes
sll
previous
MILLER
wsnanties
snd
is
exclusive
with
no
other
gusrsntees
or
wsrrsnties
expressed
or
implied.
LIMITED
WARRANTYSubject
tothe
terms
snd
conditions
below,
MILLER
Electric
Mfg.
Co.,
Appleton,
Wisconsin,
wsrrerrts
to
its
originsl
retsil
purchsser
thst
new
MILLER
equipment
sold
sfter
the
effective
dste
of
this
limited
wsrrsnty
is
free
of
de
fects
in
meterisl
snd
workmsnship
st
the
time
it
is
shipped
by
MILLER.
ThIS
WAR
RANTY
IS
EXPRESSLY
IN
UEU
OF
ALL
OTHER
WARRANTIES,
EXPRESS
OR
IMPUED,
INCLUDING
ThE
WARRAN11ES
OF
MERCHANTABIUTY
AND
FIT
NESS.
Within
the
wsrrenty
periods
listed
below,
MILLER
will
mpsir
or
replsce
eny
wsr
mnted
parts
or
components
thst
tsil
due
to
such
defects
in
msterisl
orworknrsnship.
MILLER
must
be
notified
in
writing
within
thirty
(30)
dsys
of
such
defect
orfsilure,
at
which
time
MILLER
will
provide
instructions
on
the
wsrranty
claim
procedures
to
be
followed.
MILLER
shsll
honor
warranty
clsims
on
wsrranted
equipmsint
listed
below
in
the
event
of
such
s
failure
within
the
warranty
time
periods.
All
wsrmnty
time
peflods
start
on
the
dste
that
the
equipment
wss
delivered
to
the
originsl
retail
purchaser,
or
one
year
sfter
the
equipment
is
sent
to
s
North
American
distributor
or
eighteen
months
after
the
equipment
is
sent
to
en
International
distributor.
1.
5YearaParta3YeamLsbor
*
Original
main
power
rectifiers
*
Invertem
(input
end
output
rectifiem
only)
2.
3YeamPartaandLabor
Tmnaformer/Rectifier
Power
Sources
*
Plasma
Arc
Cutting
Power
Sources
*
Semi-Automatic
end
Automatic
Wire
Feeders
Inverler
Power
Supplies
*
Intellitig
*
Robots
(1
year
labor)
3.
2YeamPartsandLabor
*
Engine
Driven
Welding
Generatom
(NOTE:
Engines
are
warranted
separately
by
the
engine
manufacturer.)
Air
Compressors
4.
1
Year
ParIs
and
Labor
Motor
Driven
Guns
Process
Controllers
IHPS
Power
Sources
Water
Coolant
Systems
HF
Units
Grids
*
Spot
Welders
*
Load
Banks
*
SDX
Transformers
*
Miller
Cyclomatic
Equipment
Running
Gear/Trailers
Plasma
Cutting
Torches
(except
APT,
ZIPCUT
&
PLAZCUT
Models)
*
Tecumaeh
Engines
*
Deulz
Engines
(outside
North
America)
*
Field
Options
(NOTE:
Field
options
are
covered
under
True
Bluefi
tor
the
remaining
warranty
period
of
the
product
they
are
installed
in,
or
for
a
minimum
of
one
year
whichever
is
greater.)
5.
6
Months
Batteries
6.
90
Days
Parts
and
Labor
*
MIG
Guna/TIG
Torches
*
APT,
ZIPCUT
&
PLAZCUT
Model
Plasma
Cutting
Torches
Remote
Controls
Accessory
Kits
Replacement
Parts
MILLERS
True
Bluefi
Umited
Warranty
shall
not
apply
to:
1.
Items
furnished
by
MILLER,
but
manufactured
by
others,
such
as
engines
or
trade
accessories.
These
items
are
covered
by
the
manufacturers
warranty,
if
any.
2.
Consumable
components;
such
as
contact
tips,
cutting
nozzles,
conlactom
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
improperfy
installed,
improperly
operated
or
misused
based
upon
industry
standards,
or
equipment
which
has
not
had
reasonable
and
necessary
maintenance,
or
equipment
which
has
bean
used
for
operation
outside
of
the
specifications
for
the
equipment.
MILLER
PRODUCTSARE
INTENDED
FOR
PURCHASEAND
USE
BY
COMMER
CIAL11NDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
ThE USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
In
the
event
of
a
warranty
claim
covered
by
this
warranty,
the
exclusive
remedies
shall
be,
at
MILLERS
option:
(1)
repair;
or
(2)
replacement;
or,
where
authorized
in
writing
by
MILLER
in
appropriate
cases,
(3)
the
resaonable
coat
01
repairor
replace
ment
at
an
authorized
MILLER
service
station;
or
(4)
payment
of
orcredit
forthe
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
customers
risk
and
expense.
MILLERS
option
of
repair
or
replacement
will
be
P.0.5.,
Factory
at
Appleton,
Wisconsin,
or
FOB.
at
a
MILLER
authorized
ser
vice
facility
as
determined
by
MILLER.
Therefore
no
compensation
or
reimburse
ment
for
transportation
costs
of
any
kind
will
be
allowed.
TO
ThE
EXTENT
PERMITTED
BY
LAW,
THE
REMEDIES PROVIDED
HEREIN
ARE
ThE
SOLE
AND
EXCLUSIVE
REMEDIES.
IN
NO
EVENT
SHALL
MILLER
BE
UABLE
FOR
DIRECT,
INDIRECt
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL
DAMAGES
(INCLUDING
LOSS
OF
PROFIT),
WHETHER
BASED
ON
CON
TRACT,
TORT
OR
ANY
OTHER
LEGAL
ThEORY.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
ANDANY
IMPUED
WAR
RANTY,
GUARANTY
OR
REPRESENTA11ON
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OThER
LEGAL
ThEORY
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR
PURPOSE,
WITh
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
Some
states
in
the
U.S.A.
do
not
allow
limitations
of
how
long
an
implied
warranty
lasts,
or
the
exclusion
of
incidental,
indirect,
special
or
consequential
damages,
so
the
above
limitation
or
exclusion
may
not
apply
to
you.
This
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
provides
forcertain
additional
warranties
or
remedies
other
than
as
stated
herein,
and
to
the
estent
that
they
may
not
be
waived,
the
limitations
and
exclusions
set
out
above
may
not
apply.
This
Umited
Warranty
provides
specific
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
province
to
province.
WHO
DO
I
CONTACT?
For
help,
To
file
a
claim
for
loss
or
damage
during
Miller
Electric
Mfg.
Co.
contact
your
distributor
For
additional
information,
such
as
TeChnical
Manuals
(Service
And
Parts)
Engine
Manuals
Circuit
And
Wiring
Diagrams
shipment,
contact
tho
deliVering
Carrier
For
assistance
in
filing
or
settling
claims,
contact
your
distributor
and/or
equipment
manufaCturers
Transportation
Department
~j~jjj~j~
-
1T1
CALL:
414-735-4505
FAX:
800-637-2348
(in
USA),
or
414-735-4136
(outside
USA)
Process
Handbooks
.
Users
Guides
Distributor
Directories
r
i
WRITE:
Miller
Electric
Mfg.
Co.
contact
your
distributor
P0.
Box
1079
Appleton,
WI
54912
USA
Always
provide
Model
Name
and
Serial
or
Style
Number
L
.
.1
I
miIIeLwarl
3/96
SECTION
1
-
SAFETY
PRECAUTIONS
FOR
ARC
WELDING
ELECTRIC
SHOCK
can
kill.
Touching
!ive
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
nower
cord
around
wire
is
orooerlv
connected
to
around
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
workolece
or
worktable
as
near
the
weld
as
oractical.
OM-1
588C
7196
safety_somi
4/95
.
1-1.
Symbol
Usage
4A
Means
Warning!
Watch
Out!
There
are
possib!e
hazards
with
this
A
Marks
a
special
safety
message.
procedure!
The
possib!e
hazards
are
shown
in
the
adjoining
symbols.
~
Means
NOTE;
not
safety
related.
I
This
group
of
symbols
means
Warning!
Watch
Out!
possib!e
ELECTR!C
SHOCK,
MOVING
PARTS,
and
HOT
PARTS
hazards.
Consu!t
symbo!s
and
related
instructions
below
for
necessary
I
________________________________
actions
to
avoid
the
hazards.
1-2.
Arc
Welding
Hazards
A~
WARNING
The
symbols
shown
below
are
used
throughout
this
manual
to
call
attention
to
and
identify
possible
hazards.
When
you
see
the
symbol,
watch
out,
and
follow
the
related
instructions
to
avoid
the
hazard.
The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
found
in
the
Safety
Standards
listed
in
Section
1-4.
Read
and
follow
all
Safety
Standards.
Only
qualified
persons
should
install,
operate,
maintain,
and
repair
this
unit.
During
operation,
keep
everybody,
especially
children,
away.
ARC
RAYS
can
burn
eyes
and
skin;
ARC
RAYS
NOISE
can
damage
hearing;
FLYING
~
SLAG
OR
SPARKS
can
injure
eyes.
2.
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
to
protect
yourface
and
eyes
when
welding
or
watching
(see
ANSI
Arc
rays
from
the
welding
process
produce
intense
Z49.1
and
Z87.1
listed
in
Safety
Standards).
visible
and
invisible
(ultraviolet
and
infrared)
rays
3.
Wear
approved
safety
glasses
with
side
shields.
that
can
bum
eyes
and
skin.
Noise
from
some
processes
can
damage
hearing.
Chipping,
4.
Use
protective
screens
or
barriers
to
protect
others
from
flash
grinding,
and
welds
cooling
throw
off
pieces
of
metal
or
slag.
and
glare;
warn
others
not
to
watch
the
arc.
NOISE
5.
Wear
protective
clothing
made
from
durable,
flame-resistant
1.
Use
approved
ear
plugs
or
ear
muffs
if
noise
level
is
high.
material
(wool
and
leather)
and
foot
proteclion.
FUMES
AND
GASES
can
be
5.
Work
in
a
confined
space
only
if
it
is
well
ventilated,
or
while
~
hazardous
to
your
health.
wearing
an
air-supplied
respirator.
Always
have
a
trained
Welding
produces
fumes
and
gases.
Breathing
watchperson
nearby.
Welding
fumes
and
gases
can
displace
air
these
fumes
and
gases
can
be
hazardous
to
your
and
lower
the
oxygen
level
causing
injury
or
death.
Be
sure
the
health,
breathing
air
is
safe.
-.
6.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
1.
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
fumes.
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
form
highly
toxic
and
irritating
gases.
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
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
deaners,
and
degreasers.
containing
these
elements
can
give
off
toxic
fumes
if
welded.
OM-1588
Page
1
CYLINDERS
can
explode
if
damaged.
Shielding
gas
cylinders
contain
gas
under
high
pressure.
If
damaged,
a
cylinder
can
explode.
Since
gas
cylinders
are
normally
partof
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
fithngs
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-i
listed
in
Safety
Standards.
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
oft
from
the
welding
arc.
The
flying
sparks,
hot
workpiece,
and
hot
equipment
can
cause
fires
and
bums.
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
theyare
property
prepared
according
t0AWS
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.
Wearoil-free
protective
garments
such
as
leathergloves,
heavy
shirt,
cuftless
trousers,
high
shoes,
and
a
cap.
12.
Remove
any
combustibles,
such
as
a
butane
lighter
or
matches,
from
your
person
before
doing
any
welding.
FIRE
OR
EXPLOSION
can
result
from
placing
unit
on,
over,
or
near
combustible
surfaces.
1.
Do
not
locate
unit
on,
over,
or
near
combustible
surfaces.
2.
Do
not
install
unit
near
flammables.
FALLING
EQUIPMENT
can
cause
serious
personal
injury
and
equipment
damage.
1.
Use
lifting
eye
to
lift
unit
only,
NOT
running
gear,
gas
cylinders,
or
any
other
accessories.
Use
equipment
of
adequate
capacity
to
lift
unit.
~f
using
lift
forks
to
move
unit,
be
sure
forks
are
long
enough
to
extend
beyond
opposite
side
of
unit.
HOT
PARTS
can
cause
severe
burns.
1.
Do
not
touch
hot
parts
bare
handed.
2.
Allow
cooling
period
before
working
on
gun
or
torch.
MOVING
PARTS
can
cause
injury.
1.
Keep
away
from
moving
parts
such
as
fans.
2.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
can
affect
pacemaker
operation.
1.
Pacemaker
wearers
keep
away.
2.
Wearers
should
consult
their
doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
operations.
MOVING
PARTS
can
cause
injury.
1.
Keep
away
from
moving
parts.
2.
Keep
away
from
pinch
points
such
as
drive
rolls.
FLYING
PIECES
OF
METAL
or
DIRT
can
injure
eyes.
1.
Wear
safety
glasses
with
side
shields
or
face
shield.
1.
Do
not
press
gun
trigger
until
instructed
to
do
so.
2.
Do
not
point
gun
toward
any
part
of
the
body,
other
people,
or
any
metal
when
threading
welding
wire.
HIGH-FREQUENCY
RADIATION
can
interfere
with
radio
navigation,
safety
services,
computers,
and
communications
equipment.
Have
only
qualified
persons
familiar
with
electronic
equipment
perform
this
installation.
The
user
is
responsible
for
having
a
qualified
electrician
promptly
correct
any
interference
problem
resulting
from
the
installation.
If
notified
by
the
FCC
about
interference,
stop
using
the
equipment
at
once.
Have
the
installation
regularly
checked
and
maintained.
Keep
high-frequency
source
doors
and
panels
tightly
shut,
keep
spark
gaps
at
correct
setting,
and
use
grounding
and
shielding
to
minimize
the
possibility
of
interference.
.
1-3.
Additional
Installation,
Operation,
And
Maintenance
Hazards
~i1~
2.
3.
,4~
WELDING
WIRE
can
cause
puncture
~
wounds.
.
OM-i588
Page
2
<~
~
~y
I
I
OVERUSE
can
cause
OVERHEATED
1.
Allow
cooling
penod.
EQUiPMENT.
2.
Reduce
current
or
reduce
duty
cycle
before
starting
to
weld
again,
3.
Follow
rated
duty
cycle,
SIGNIFICANT
DC
VOLTAGE
exists
after
1.
Turn
Off
inverter,
disconnect
input
power~
and
removal
of
input
power
on
inverters.
discharge
input
capacitors
according
to
instructions
in
Maintenance
Section
before
touching
any
parts.
on
circuit
boards.
1.
Put
on
grounded
wrist
strap
BEFORE
handling
STATIC
ELECTRICITY
can
damage
parts
boards
or
parts.
2.
Use
proper
static-proof
bags
and
boxes
to
store,
move,
or
ship
PC
boards.
I
BUILDUP
OF
SHIELDING
GAS
can
harm
health
or
kill.
1.
Shutoff
shielding
gas
supply
when
not
in
use.
1-4.
Principal
Safety
Standards
Safety
in
Welding
and
Cutting,
ANSI
Standard
Z49.1,
from
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami
FL 33126
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
Safety
and
Health
Standards,
OSHA
29
CFR
1910,
from
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
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
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
Recommended
Safe
Practices
for
the
Preparation
for
Welding
and
Cutting
of
Containers
That
Have
Held
Hazardous
Substances,
American
Welding
Society
Standard
AWS
F4.i,
from
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126
Safe
Practices
For
Occupation
And
Educational
Eye
And
Face
Protection,
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
Electrical
Code,
NFPA
Standard
70,
from
National
Fire
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
MA
02269.
1-5.
EMF
Information
Considerations
About
Welding
And
The
Effects
Of
Low
Frequency
To
reduce
magnetic
fields
in
the
workplace,
use
the
following
Electric
And
Magnetic
Fields
procedures:
The
following
is
a
quotation
from
the
General
Conclusions
Section
of
the
U.S.
Congress,
Office
of
Technology
Assessment,
Biological
1.
Keep
cables
close
together
by
twisting
or
taping
them.
Effects
of
Power
Frequency
Electric
&
Magnetic
Fields
Background
Papei
OTA-BP-E-53
(Washington,
DC:
U.S.
2.-
Arrange
cables
to
one
side
and
away
from
the
operator.
Government
Printing
Office,
May
1989):.
. .
there
is
now
a
very
large
volume
of
scientific
findings
based
on
experiments
at
the
3.
Do
not
coil
or
drape
cables
around
the
body.
cellular
level
and
from
studies
with
animals
and
people
which
clearly
4.
Keep
welding
power
source
and
cables
as
far
away
as
establish
that
low
frequency
magnetic
fields
can
interact
with,
and
practical.
produce
changes
in,
biological
systems.
While
most
of
this
work
is
of
very
high
quality,
the
results
are
complex.
Current
scientific
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
understanding
does
not
yet
allow
us
to
interpret
the
evidence
in
a
possible.
single
coherent
framework.
Even
more
frustrating,
it
does
not
yet
allow
us
to
draw
definite
conclusions
about
questions
of
possible
About
Pacemakers:
risk
or
to
offer
clear
science-based
advice
on
strategies
to
minimize
The
above
procedures
are
also
recommended
for
pacemaker
or
avoid
potential
risks.
wearers.
Consult
your
doctor
for
complete
information.
OM-1588
Page
3
SECTION
1
-
CONSIGNES
DE
SECURITE
POUR
LE
SOUDAGE
A
LARC
safetysoml_fr
4/95
1-1.
Signification
des
symboles
I
I
I
I
I
~
I
a
Signifie
Mise
en
garde!
Soyez
vigilant!
Cette
procedure
prØsente
A
Identifie
un
message
de
sØcuritØ
particulier.
des
nsques
de
danger!
Ceux-ci
sont
identifies
par
des
symboles
07
Sign/tie
NOTA;
nestpas
relatif
Ia
sØcuntØ.
adjacents
aux
directives.
I
Ce
groupe
de
symboles
signifie
Mise
en
garde!
Soyez
vigilant!
II
y
a
des
risques
de
danger
relies
~
aux
CHOCS
ELECTF1IQUES,
aux
PI¨CES
EN
MOUVEMENT
et
aux
PI¨CES
CHAUDES.
Reportez-vous
aux
symboles
et
aux
directives
ci-dessous
atm
de
connaitre
les
mesures
a
prendre
I
pour
Øviter
tout
danger.
1-2.
Dangers
relatifs
au
soudage
a
Iarc
4A
MISE
EN
GARDE
Les
symboles
prØsentØs
ci-aprŁs
sont
utilisØs
tout
au
long
du
present
manuel
pour
attirer
votre
attention
et
identifier
les
risques
de
danger.
Lorsque
vous
voyez
un
symbole,
soyez
vigilant
et
suivez
les
directives
mentionnØes
afin
dØviter
tout
danger.
Les
consignes
de
securitepresentees
ci-aprŁs
ne
font
que
rØsumer
linformation
contenue
dans
les
normes
de
sØcuritØ
ØnumØrØes
a a
section
1-4.
Veuillez
lire
et
respecter
toutes
ces
normes
de
sØcuritØ.
Linstallation,
lutilisation,
Ientretien
et
les
reparations
ne
doivent
Øtre
confiØs
qua
des
personnes
qualifiØes.
Au
cours
de
Iutilisation,
tenir
toute
personne
a
lØcart
et
plus
particuliŁrement
les
enfants.
.
.
UN
CHOC
ELECTRIQuE
peut
tuer.
Un
simple
contact
avec
des
piŁces
electnques
peut
provoquer
une
electrocution
ou
des
blessures
graves.
LØlectrode
et
Ic
circuit
de
soudage
sont
sous
tension
des
que
lappareil
est
sur
ON.
Le
circuit
dentrØe
et
les
circuits
intemes
de
lappareil
sont
Øgatement
sous
tension
a
ce
moment-l.
En
souda9e
semi-automati
que
ou
automatique,
le
fit,
le
dØvidoir,
le
logement
des
galets
dentrainement
et
tes
piŁces
mØtal!iques
en
contact
avec
le
fit
de
soudage
sont
sous
tension.
Des
matØriels
mat
installØs
ou
mal
mis
ala
terre
prØsentent
___________
un
danger.
1.
Ne
jamais
toucher
les
piŁces
electriques
sous
tension.
2.
Porter
des
gants
et
des
vŒtements
do
protection
secs
ne
com
portant
pas
de
trous.
3.
Sisoler
de
Ia
piŁce
et
de
Ia
terre
au
moyen
de
tapisou
dautres
moyens
isolants
suffisamment
grands
pour
empŒcher
le
contact
physique
Øventuel
avec
a
piŁce
ou
Ia
terre.
4.
Couper
latimentation
ou
arrŒter
Ic
moteur
avant
de
procØder
a
linstallation,
ala
reparation
ou
a
lentretien
de
lappareil.
DØver
rouiller
lalimentation
seton
Ia
norrrie
OSHA
29
CFR
1910.147
(voir
normes
de
sØcuntØ).
5.
Installer
et
mettre
a
Ia
terre
correctement
cot
appareil
contormØ
ment
a
son
manuel
dutilisation
et
au
codes
nationaux,
provin
ciaux
et
municipaux.
6.
Toujours
verifier
Ia
terre
du
cordon
dalimentation
Verifier
et
sassurer
quo
le
fil
do
terre
du
cordon
dalimentation
est
bien
rac
cordØ
ala
bome
de
terre
du
sectionneur
ou
quo
Ia
fiche
du
cor
don
est
raccordØe
a
une
prise
correctement
mise
a
Ia
terre.
7.
En
effectuant
les
raccordements
dentrØe
fixer
dabord
le
con
ducteurde
misc a
laterre
appropiie
et
contre-vØrifier
los
connex
ions.
8.
VØnfierfrequemment
Ic
cordon
dalimentation
pour
voir
sil
nest
pas
endommage
ou
dØnudØ
remplacer
Ic
cordon
immediate
ment
sil
est
endommage
un
cable
dØnudØ
pout
provoquer
une
electrocution.
9.
Mettre
tappareil
hors
tension
quand
on
ne
Iutilise
pas.
10.
Ne
pas
utiliser
des
cables
uses,
endommagØs,
de
grosseur
insuffisante
ou
mat
episses.
11.
Ne
pas
enrouler
los
cables
autour
du
corps.
12.
Si
Ia
piŁce
soudØe
dolt
Œtre
misc
a
Ia
terre,
Ic
faire
directement
avec un
cable
distinct
ne
pas
utiliser
Ic
connecteur
de
piŁce
ou
Ic
cable
de
retour.
13.
Ne
pas
toucher
electrode
quand
on
est
en
contact
avec
Ia
piŁce,
Ia
terre
ou
une
electrode
provenant
dune
autre
machine.
14.
Nutiliserquun
materiel
en
bon
Øtat.
Reparerou
remplacersur
Ic-champ
les
piŁces
endommagees.
Entretenir
lappareil
confor
mØment
a
cc
manuel.
15.
Porter
un
hamais
de
sØcuntŁ
quand
on
travaille
en
hauteur.
16.
Mamntenir
solidement
en
place
tous
les
panneaux
et
capots.
17.
Fixer
Ic
cable
de
retour
de
faon
a
obtenir
un
bon
contact
metal
metal
avec
Ia
piŁce
a
souder
ou
Ia
table
de
travail,
Ic
plus
pres
possible
de
Ia
soudure.
LE
RAYONNEMENT
DE
LARC
peut
RAVONNEMENT
DE
LARC
brGler
les
yeux
et
Ia
peau.
Le
BRUIT
peut
endommager
louIe;
les
~
ECTIONS
~
DE
LAITIER
OU
LES
ETINCELLES
peuvent
blesser
les
yeux.
Larc
de
soudage
produit
des
rayons
visibles
et
invi-
sibles
intenses
(ultravio!ets
et
infrarouges)
qui
peuv-
ent
brUler
les
yeux
et
Ia
peau.
Le
bruit
produit
par
cer
tains
procedØs
peut
endommager
louie.
Des
projec-
tions
de
metal
ou
de
laitier
sont
produites
par
le
piquage,
Ie
meulage
ou
le
refroidissement
des
sou-
dures.
BRUIT
1.
Utiliser
des
bouche-oreilles
ou
des
serre-tŒte
antibruit
approu-
yes
si
le
niveau
de
bruit
est
Øleve.
2.
3.
4.
5.
Porter
un
masque
a
serre-tŒte
muni
dun
verre
filtrant
de
nuance
appropnee
pour
proteger
le
visage
et
les
yeux
quand
on
soude
ou
observe
Ia
travail
de
soudage
(voir
les
nomies
ANSI
Z49.1
et
Z87.1
donnØes
sous
Ia
rubrique
Principales
nomies
de
sØcu
rite).
Porter
des
Iunettes
de
sØcuntØ
approuvØes
avec
Øcrans
late
raux.
Utiliser
des
paravents
ou
des
bamŁres
de
protection
pour
pro
tØger
les
personnes
a
proximitO
contre
les
coups
darc
et
lØ
btouissement;
avertir
les
autres
personnes
de
ne
pas
regarder
larc.
Porter
des
vŁtements
de
protection
en
tissu
ignifuge
durable
(lame
et
cuir)
et
des
chaussures
de
sØcuritØ.
OM-1
588
Page
4
LES
CHAMPS
MAGNETIQUES
PRO
DUITS
PAR
LES
COURANTS
MAGNETI
QUES
ELEVES
peuvent
nuire
au
fonc
tionnement
dun
stimulateur
cardiaque.
1.
Les
personnes
qui
portent
un
stimulateur
cardia
que
doivent
se
tenir
Øloignees
des
postes
de
sou
dage.
Elles
devraient
consulter
leur
mØdecin
avant
de
sapprocherdun
poste
de
soudage
a
Iarc,
de
gou
geage
ou
de
soudage
par
points.
LES
PI¨CES
EN
MOUVEMENT
peuvent
causer
des
blessures.
1.
Rester
a
lØcart
des
piŁces
en
mouvement.
2.
Eviter
les
risques
de
pincement
relies
parexemple
aux
galets
dentrainement.
LE
FIL
DE
SOUDAGE
peut
percer
Ia
peau.
Attendre
les
instructions
avant
dappuyer
sur
Ia
gchette.
Ne
pas
pointer
le
pistolet
vers
vous,
ou
vers
toute
autre
personne
ou
piŁce
metallique
au
moment
denfiler
le
fil
de
soudage.
UNE
SURUTILISATION
peut
SUR
CHAUFFER
LAPPAREIL.
Laisser
lappareil
refroidir.
RØduire
le
courant
ou
le
facteur
de
marche
avant
de
poursuivre
le
soudage.
Respecter
le
facteur
de
marche
nominal.
LACCUMULATION
DE
GAZ
DE
PROTECTION
peut
Œtre
nocif
a
Ia
sante
ou
mortelle.
1.
Fermer
lalimentation
du
gaz
de
protection
lors
quon
ne
lutilise
pas.
LELECTRICITE
STATIQUE
peut
endom
mager
les
piŁces
des
cartes
PC.
1.
Porter
un
bracelet
antistatique
AVANT
de
manipuler
une
carte
ou
une
piŁce.
2.
Utiliserdes
sacs
et
des
boites
antistatiques
appro
priØs
pour
ranger,
dØplacerou
expedierdes
caries
PC.
LE
RAVONNEMENT
A
HAUTE
FRE
QUENCE
peut
perturber
le
fonctionne
ment
de
Ia
radionavigation,
de
services
de
securitØ,
dordinateurs
et
dappareils
de
communications.
1.
Linstallation
de
materiel
Ølectronique
doit
Œtre
ef
fectuØe
par
des
personnes
qualitiees.
2.
Si
des
problŁmes
dinterfØrence
surviennent
aprŁs
linstallation,
lutilisateur
de
lappareil
doit
avoir
recours
immØdiatement
au
service
dun
Ølectncien
afin
de
les
cornger.
3.
Si
un
avis
de
Ia
Commission
fØdØrale
des
commu
nications
vous
est
transmis
concemant
votre
ap
pareil,
arrØtez
de
lutiliser
sur-le-champ.
4.
Faire
verifier
et
entretenir
lappareil
penodique
ment.
5.
Tenir
les
portes
et
les
panneaux
de
Ia
source
de
haute
frequence
bien
fermØs,
maintenir
lØcarte
ment
des
electrodes
a
une
position
appropiiee,
et
utiliser
une
mise
a
Ia
terre
et
un
Øcran
de
protec
tion
pour
reduire
les
interferences.
UNE
TENSION
CC
IMPORTANTE
est
toujours
prØsente
mØme
aprŁs
que
Ionduleur
alt
ØtØ
dØbranchØ.
1.
Avant
de
toucher
a
une
piŁce,
mettre
hors
tension
londuleur,
dØbrancher
lappareil
et
decharger
les
condensateurs
selon
les
directives
de
(a
section
Entretien.
1-4.
Principales
normes
de
sØcuritØ
.
.
.
a
Safety
in
Welding
and
Cutting,
norrne
ANSI
Z49.1,
de
American
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
Welding
Society,
550
N.W.
Lejeune
Rd,
Miami
FL 33126
P-i,
de
Ia
Compressed
Gas
Association,
1235
Jefferson
Davis
Safety
and
Health
Sandards,
OSHA
29
CFR
1910,
du
Highway,
Suite
501,
Arlington,
VA
22202.
Superintendent
of
Documents,
U.S.
Govemment
Printing
Office,
Regles
de
sØcuritØ
en
soudage,
coupage
et
procØdØs
connexes,
Washington,
D.C.
20402.
norme
CSA
Wi
17.2,
de
lAssociation
canadienne
de
normalisation,
vente
de
normes,
178
Rexdale
Boulevard,
Rexdale
(Ontario)
Recommended
Safe
Practice
for
the
Preparation
for
Welding
and
Canada
M9W
1
R3.
Cutting
of
Containers
That
Have
Held
Hazardous
Substances,
Safe
Practices
For
Occupation
And
Educational
Eye
And
Face
norme
AWS
F4.i
,
de
lAmerican
Welding
Society,
550
N.W.
Lejeune
Protection,
nomie
ANSI
Z87.1,
de
lAmencan
National
Standards
Rd,
Miami
FL
33126
Institute,
1430
Broadway,
New
York,
NY
10018.
National
Electrical
Code,
NFPA
Standard
70,
de
a
National
Fire
Cutting
and
Welding
Processes,
norme
NFPA
51
B,
de
a
National
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
1-5.
Information
sur
les
champs
ØlectromagnØtiques
DonnØes
sur
le
soudage
electrique
et
sur
es
effets,
pour
Atm
de
rØduire
les
champs
electromagnØtiques
dans
Iorganisme,
des
champs
magnetiques
basse
frequence
lenvironnement
de
travail,
respectez
les
consignes
suivantes
Lextrait
suivant
est
tire
des
conclusions
generales
du
document
1.
Gardez
es
cables
ensembles
en
les
torsadant
ou en
les
intitulØ
Biological
Effects
of
Power
Frequency
Electric
&
Magnetic
attachant
avec
du
ruban
adhØsit.
Fields
Background
Paper,
OTABPE53
(Washington
DC:
U.S.
Government
Printing
Office,
mai
1989),
publiØ
par
le
Office
of
2.
Mettre
tous
les
cables
du
cotØ
oppose
de
IopØrateur.
Technology
Assessment
du
CongrŁs
amØricain
:
...
1
existe
maintenant
dabondantes
donnØes
scientifiques
compilees
a
Ia
3.
Ne
courbez
pas
et
nentourez
pas
les
cables
autour
de
vous.
suite
dexperiences
sur
Ia
cellule
ou
dØtudes
sur
des
animaux
et
~
Gardez
le
poste
de
soudage
et
les
cables
le
plus
loin
des
humains,
qui
montrent
clairement
que
les
champs
possible
de
vous.
Ølectromagnetiques
basse
frequence
peuvent
avoir
des
effets
sur
Iorganisme
et
mŒme
y
produire
des
transformations.
MŒme
sil
5.
Reliez
Ia
pince
de
masse
le
plus
prŁs
possible
de
Ia
zone
de
sagit
de
travaux
de
trØs
grande
qualite,
les
rØsultats
sont
soudure.
complexes.
Cette
dØmarche
scientifique
ne
nous
permet
pas
detablir
un
tableau
densemble
coherent.
Pire
encore,
elle
ne
nous
Consignes
relatives
aux
stimulateurs
cardiaques
pemlet
pas
de
tirer
des
conclusions
finales
concemant
les
nsques
Les
consignes
mentionnØes
precØdemment
font
partie
de
celles
Øventuels,
ni
doffrir
des
conseils
sur
les
mesures
a
prendre
pour
destinØesauxpersonnesayantrecoursaunstimulateurcardiaque.
rØduire
sinon
Øliminer
es
nsques
Øventuels.
(Traduction
libre)
Veuillez
consulter
votre
mØdecin
pour
obtenir
plus
de
details.
OM-1
588
Page
6
SECTION
2-INSTALLATION
2-1.
Installing
Swivel
Into
Pipe
Post
5
4
1
Swing
pak
Base
or
CBC
Cart
2
Pipe
Post With
Base
3
Steel
Bolt
Secure
as
shown
using
as
a
mini
mum
1/2
in
diameter
SAE
grade
5
steel
bolts.
4
Swivel
Assembly
2
3
Tools
Needed:
~=
3/4
in
Insert
into
pipe
post.
Lubricate
swivel.
5
Safety
Collar
A
Do
not
remove
instructed
to.
until
2-2.
Installing
Control
Box
And
Adjusting
Tilt
ST-152
382
1
1
Weld
Control
2
Bracket
3
Screw
Bracket
and
screws
are
installed
onto
bottom
of
control
at
factory.
4
Swivel
Loosen
screws.
Place
control
on
swivel
and
slide
forward.
Tighten
screws.
6
5
Tilt
Bracket
6
Rear
Pivot
Screw
7
Front
Screw
Loosen
rear
pivot
screw.
Remove
front
screw.
Pivot control
down
ward
to
desired
viewing
angle.
Re
place
and
tighten
front
screw.
Tighten
pivot
screw.
Tools
Needed:
ST-800
174!
ST-801
278
3
4
OM-1588
Page
7
2-5.
Equipment
Connection
Diagram
1
300/400
Ampere
Model
CCICV
Inverter
Welding
Power
Source
Use
switch
settings
shown
for
pulse
welding.
Change
switch
to
CV
for
other
wire
feed
weld
ing
processes.
2
450
Ampere
Model
CC/CV
Inverter
Welding
Power
Source
Use
switch
settings
shown
for
all
wire
feed
welding
pro
cesses.
3
17-Pin
Cord
4
14-Pin
Cord
5
Positive
(+)
Weld
Cable
6
Negative
()
Weld
Cable
Be
sure
weld
cables
are
sized
properly
for
peak
amperage
if
pulse
welding
(see
welding
power
source
Owners
Manual).
7
Workpiece
8
Voltage
Sensing
Lead
9
Gun
Be
sure
gun
is
rated
for
peak
am
perage
if
pulse
welding.
Install
ac
cording
to
its
Owners
Manual.
10
Wire
Feeder
For
connections
see
Section
2-6.
11
Shielding
Gas
Supply
12
Supplied
V
Adapter
13
Gas
Hose
From
Boom
ST-800
173-Al
Ref.
ST-154
197
IST-146
127-C/Ref.
ST-163
420-Al
Ref.
ST-153
175-A
OM-1588
Page
9
2-6.
Control
Box
Connections
2-7.
14-Pin
Plug
Information
*The
remaining
pins
are
not
used.
I~J
REMOTE
14
~j~*
Pin
Information
A
24
volts
ac
with
respect
to
socket
G.
B
Contact
closure
to
A
completes
24
volts
ac
contactor
control
circuit.
G
Circuit
common
for
24
volts
AC
circuit.
C
+10
volts
dc
output
to
remote
control
with
respect
to
socket
D.
D
Remote
control
circuit
common.
E
0
to
+10
volts
dc
input
command
signal
from
remote
control
with
respect
to
socket
D.
H
Voltage
feedback;
0
to
+10
volts
dc,
1
volt
per
10
arc
volts.
F
Current
feedback;
0
to
+10
volts
dc,
1
volt
per
100
amperes.
.
.
2-8.
1
7-Socket
Receptacle
Information
Socket
Information
CC/CV
select;
+13
to
+24
volts
dc
is
CV,
0
volts
dc
is
CC.
Arc
controliinductance
control;
0
to
+10
volts
dc.
Actual
weld
amperage
output
signal;
+1
volt
dc
is
100
amps.
Actual
weld
voltage
output
signal;
+1
vottdc
is
10
volts
dc.
Circuit
common.
*The
remaining
sockets
are
not
used.
.
OM-1
588
Page
10
2-9.
-Removing
Safety
Collar
And
Adjusting
Boom
1
Locking
Knob
Tighten
knob
to
prevent
boom
movement.
Loosen
knob
to
allow
boom
movement.
Change
knob
position
to
limit
upward
movement.
Pull
boom
down
slightly
and
re
move
safety
collar.
Boom
should
balance
in
any
position
from
hon
zontal
to
60
degrees
above
hori
zontal.
If
necessary,
adjust
boom
as
follows:
2
Threaded
Rod
3
Jam
Nut
Loosen
jam
nut
and
tum
threaded
rod
until
boom
balances.
Tighten
jam
nut.
Be
sure
several
full
threads
are
through
yoke
to
pre
vent
boom
falling.
4
Yoke
Retain
safety
collar
for
use
in
dis
assembling
or
moving
boom.
Increasing
Spring
Pressure
For
A
Heavy
Gun
2
Decreasing
Spring
Pressure
For
A
Lighter
Gun
Tools
Needed:
1-1/8
in
2-10.
Gun
Recommendation
Table
ST-i
42
599-B
Process
Gun
GMAW-P
Hard
or
Cored
Wires
GW-500
Or
GW-600
GMAW
Hard
or
Cored
Wires
M25,
M40,
Or
GA-50C
FCAW
Self-Shielding
Wires
GA-4OGL
Or
GA-5OGL
2-11.
Wire
Type,
Size,
And
Feed
Speed
Capability
Table
Motor
Speed
Wire
Type
Wire
Size
Feed
Speed
Capability
Standard
All
.023
To
5/64
in
(0.6
To
2
mm)
50
To
780
pm
(1.3
To
19.8
mpm)
Standard
All
3/32
To
7/64
in
(2.4
To
2.8
mm)
50
To
700
1pm
(1.3
To
17.8
mpm)
Standard
All
1/8
in
(3.2
mm)
50
To
300
ipm
(1.3
To
7.6
mpm)
Optional
High
All
.023
To
5/64
in
(0.6
To
2
mm)
92
To
1440
ipm
(2.3
To
35.6
mpm)
1
3
2
E
0
t
Rod
4
OM-1
588
Page
11
2-12.
Installing
And
Threading
Welding
Wire
Install
wire
spooi.
Adjust
tension
nut
in
hub
so
wire
is
taut
when
wire
feed
stops.
Install
wire
guide.
Install
drive
rolls.
Lay
gun
cable
out
straight.
Cut
oft
end
of
wire.
Push
wire
through
guides
up
to
drive
rolls;
continue
to
hold
wire.
Press
Jog
button
to
feed
wire
out
gun.
To
adjust
drive
roll
pressure,
press
gun
trigger
to
feed
wire
against
wood
surface.
Tighten
knob
so
wire
does
not
slip.
Cut
wire
off.
Close
cover.
Repeat
for
other
side.
Tools
Needed:
3/16,5/64
in
15/16,3/8in
ST-i
52564-B!
Ref.
ST-i
56
929
I
Ref.
SC-i
50
922
I
Ref.
ST-i
56
930
I
S-0627-A
OM-1
588
Page
12
3-1.
Operational
Terms
SECTION
3-
OPERATION
The
wire
feeder
automatically
regulates
pulse
frequency
to
maintain
a
constant
arc
length,
regardless
of
change
in
welding
wire
stickout.
When
weld
amperage
is
not
present,
wire
feeds
for
about
three
seconds
at
set
wire
feed
speed.
Then
the
welding
power
source
contactor
deenergizes
and
wire
continues
to
feed
at
the
wire
jog
speed.
As
inductance
increases,
arc
on
time
increases,
and
the
weld
puddle
becomes
more
fluid.
Arc
length
adjustment
in
pulse
welding.
Increasing
trim
increases
the
actual
arc
length.
Trim
is
replaced
by
volts
in
MIG
programs.
The
operator
programs
pulse
parameters
for
a
specific
wire
feed
speed.
The
wire
feeder
determines
the
pulse
parameters
between
these
wire
feed
speed
increments.
Side
Panel
Terms
Card
Mode
Dual
Schedule
Mode
Process
Mode
Sequence
Mode
Is
used
to
select
use
of
the
optional
data
card
storage
and
retrieval
capabilities.
Is
used
to
select
a
pair
of
programs
that
can
be
used
together.
Is
used
to
select
the
type
of
process
to
be
used,
including
Pulse,
Adaptive
Pulse,
or
Mig.
Is
used
to
select
and
program
the
weld
sequences
which
include
weld,
crater,
burnback,
postf
low,
preflow,
and
run-in.
3-2.
Pulse
Welding
Terms
NOTE
iri~
See
Menu
Gw~e
for
detailed
programming
steps.
The
following
is
a
list
of
terms
and
their
definitions
as
they
apply
to
this
wire
feeder:
General
Terms
Adaptive
Pulse
Welding
Cold
Wire
Jog
Inductance
Trim
Synergic
/\
3
Amps
1
Apk
=
Peak
Amperage
Increasing
Apk
increases
penetra
tion.
2
Abk
Background
Amperage
Maintains
arc
between
pulses.
3
PPS
=
Pulses
Per
Second
Increasing
PPS
increases
travel
speed.
4
PWms
=
Pulse
Width
In
Milliseconds
Increasing
PWms
increases
bead
width.
2
$
Time
\
/
OM-1588
Page
13
3-3.
Front
Panel
Controls
1
Display
2
Parameter
Select
Button
Press
button
to
move
>
on
display.
3
Display
Control
Turn
control
to
change
value
pointed
to
by
>.
Turning
control
one
click
causes
Trim
(arc
length)
to
increase/decrease
by
one
or
Volt
to
increase/decrease
by
0.1.
When
1PM
is
selected,
turning
control
one
click
causes
wire
feed
speed
(1PM)
to
in
crease/decrease
by
one.
When
MPM
is
selected,
turning
control
three
clicks
causes
wire
feed
speed
(MPM)
to
increase
by
0.1.
When
Prg
#
is
selected,
turning
control
one
click
causes
program
number
(Prg
#)
to
in
creaseldecrease
by
one.
The
program
number
cannot
be
changed
while
welding,
with
exception
of
Dual
Schedule
Mode
(see
Section
5).
Pulse
is
a
default
setting.
To
change
type
of
process
(Pulse,
Adaptive
Pulse,
or
MIG)
use
side
panel
controls
(see
Section
3-4).
4
Active
Side
Indicator
Light
5
Trigger
Hold
Button
And
Indicator
Light
To
weld
without
holding
gun
trigger
through
out
weld
cycle,
press
and
release
button
to
turn
feature
on
(indicator
light
turns
on).
To
start
weld
cycle,
press
and
release
gun
trigger
within
three
seconds
after
an
arc
has
been
struck.
To
end
weld
cycle,
press
and
release
gun
trigger.
6
Side
Select
Button
The
feeder
remernbers
the
last
used
pro
gram
for
each
side
and
returns
to
that
pro
gram
when
the
active
side
is
changed.
I~1
2
The
gun
tngger
maybe
used
to
change
active
side
of
the
feeder~
7
Jog
Button
Push
to
momentarily
feed
welding
wire
with
out
energizing
welding
circuit
or
shielding
gas
valve.
Jog
speed
is
varied
using
the
Display
Con
trol
while
Jog
button
is
pressed.
Default
set
ting
is
200
1PM.
8
Purge
Button
Push
to
momentarily
energize
gas
valve
without
energizing
the
welding
circuit.
~
Jog
and
Purge
only
work
on
the
active
side
of
the
feeder.
Holding
the
Jog
and
Purge
buttons
atthe
same
time
displays
pulse
parameters
on
the
side
panel
display
and
voltage
on
front
panel
display.
II
Jll~i~
8
..
3
2~f
c\o~
o/p~~o
1
ST-162
127
OM-1
588
Page
14
3-4.
Side
And
Rear
Panel
Controls
1
Mode
Display
2
Mode
Select
Button
Press
button
to
move>
in
display.
3
Parameter
Display
4
Parameter
Select
Button
Press
button
to
move>
in
display.
5
Parameter
Increase
Button
6
Parameter
Decrease
Button
7
Power
Switch
8
Circuit
Breaker
CB1
CB1
protects
the
wire
feeder
from
overload.
3
\~/~
it
lilt
II
Ref.
ST-162
128/
Ref.
ST-162
133
OM-1
588
Page
15.
SECTION
4-
SETTING
SEQUENCE
PARAMETERS
A
f~
See
Menu
Guide
for
detailed
programming
steps.
Trim
is
arc
length.
If
set
to
zero,
arc
length
is
short.
If
set
to
99,
arc
length
is
long.
If
time
is
set
to
zero
in
Weld
se
quence,
welding
continues
until
gun
tngger
is
released.
If
time
is
set
to
zero
in
any
timed
se
quence
except
Weld,
the
sequence
is
skipped.
Trim
0-99
Volts
10.0-38.0
Inductance
0-99%
1PM
50-780
Seconds
1.
Weld
Pulse
X
x
0-25.0
MIG
X
X
X
2.
Crater
Pulse
X
X
0-2.50
MIG
X
X
3.
Bumback
Pulse
or
x
0-0.25
4.
&
5.
Postflow/
Preflow
Pulse
or
MIG
0-9
9
.
6.
Run-In
Pulse
X
X
0-2.50
MIG
X
X
X
=
Setting
Available
.
a
a
a.
U)
a
Weld
Time
025sec.
Cl)
U
C,
U
c
Run-In
I
Time
Preflow
Time
Crater
~,
Time
U
a
Cs
0
Bumback
/
Time
/
/
Time
Preflow
Run-In
Arc
Strike
Trigger
Pressed
Weld
Time
Burnback
Crater
Trigger
Released
Postflow
Sequence
End
OM-1588
Page
16
SECTION
5-
SETTING
DUAL
SCHEDULE
PARAMETERS
5-1.
Selecting
Dual
Schedule
Pair
24.
OV
250
1PM
Display
Control
1
Dual
Schedule
is
used
with
two
consecutive
weld
programs
1
&
2,
3
&
4,
5
&
6,
or
7
&
8.
Any
program
type
(MIG,
Adaptive
Pulse,
or
Pulse)
can
be
combined
in
dual
schedule.
1
Side
Panel
Display
Use
side
panel
to
turn
feature
on.
See
Menu
Guide
for
detailed
pro
gramming
steps.
2
Front
Panel
Display
Press
front
panel
parameter
select
button
to
select
program
number.
3
Front
Panel
Display
Control
4
Dual
Schedule
Switch
(See
Section
5-2)
~
Switch
type
is
set
in
System
Setup.
See
Section
7.
5
Welding
Gun
Trigger
Selecting
dual
schedule
program
A
or
B
is
done
by
using
Display
Con
trol,
dual
schedule
switch,
or
gun
trigger
(depending
on
system
set
up).
When
program
B
is
active,
turn
Display
Control
one
click
clock
wise
to
select
another
pair
of
dual
schedule
programs.
~
Programs
can
be
rearranged
in
desired
order
using
the
data
card.
See
Section
6.
CM-i
588
Page
17
2
4
3
Display
Control
5-2.
Dual
Schedule
Switch
Diagrams
A
3
0
>
(
4
p
A
3
0
>
B
4
p
1
Momen2P
(Momentary-Contact
2-Pole
Switch
or
DSS-1O)
2
Maint
2P
(Maintained-Contact
2-Pole
Switch
or
DSS-9M)
3
Maint
1
P Or
Trigger
(Maintained-Contact
1-Pole
Switch,
DSS-9,
Or
DSS-8)
lET
If
tngger
is
used
for
dual
schedule
switch,
turn
off
Thg
ger
Program
Select
in
system
setup.
1
1
>
>
2 2
>
>
1
1
>
>
2
2
>
>
1
2
.
1
3
2
2
3
A~>S~$
~0
TR
___________
I
3
A\~~
1
Adapter
1
>~
>
2
2
>
>
3
3
>
>
4
SE
CTION
6-
USING
THE
OPTIONAL
DATA
CARD
6-1.
Data
Card
Terms
CARD
SCREEN
TERMS
WRITE
Programs
To
Card
~
READ
Programs
From
Card
PULSE
MIG
TERMS
PPS
Amperage
(Pulses
Per
Second)
PWms
~
(Pulse
Width
In
Milliseconds)
~k=~e)
J~\J\J\
Abk
lime
(Background
Amperage)
sA-1~~s
.
OM-1588
Page
18
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Miller DS-64M Swingarc Owner's manual

Miller
Brand
Miller
Model
DS-64M Swingarc
Category
Welding System
Type
Owner's manual
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