Miller D-64M WIRE FEEDER Owner's manual

Miller

June

1994

Form:

OM-1587A

Effective

With

Serial

No.

KE648703

OWNERS

MANUAL

D-64M

Wire

Feeder



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.



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



Give

this

manual

to

the

operator.



For

help,

call

sour

distributor



or:

MILLER

Electric

Mfg.

Co.,

P.O.

Box

1079,

Appleton,

WI

54912

414-734-9821

cover

1/94



ST-800

179

'

1994

MILLEA

EleCtriC

141g.

Co.

PRINTED

IN

USA

I

________________

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

Effective

January

1,

1992

(Equipment

with

a

serial

number

preface

of

KC

or

newer)

This

limited

warranty

supersedes

all

warranties

and

is

exclusive

with

no

other

guarantees

or

warranties

expressed

or

implied.

LIMITED

WARRANTY



Subject

to

the

terms

and

conditions

below,

MILLER

Electric

Mtg.

Co.,

Appleton,

Wisconsin,

warrants

to

its

original

retail

purchaser

that

new

MILLER

equipment

sold

after

the

effective

date

of

this

limited

warranty

Is

tree

of

de

tects

in

material

and

workmanship

at

the

time

it

is

shipped

by

MILLER.

THIS

WAR

RANTY

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTHER

WARRANTIES,

EXPRESS

OR

IMPLIED,

INCLUDING

THE

WARRANTIES

OF

MERCHANTABILITY

AND

FIT

NESS.

Within

the

warranty

periods

listed

below,

MILLER

will

repair

or

replace

any

war

ranted

parts

or

components

that

tail

due

to

such

detects

in

material

or

workmanship.

MILLER

must

be

notitied

in

writing

within

thirty

(30)

days

of

such

defect

or

failure,

at

which

time

MILLER

wilt

provide

instructions

on

the

warranty

claim

procedures

to

be

followed.

MILLER

shall

honor

warranty

claims

on

warranted

equipment

listed

below

in

the

event

ot

such

a

failure

within

the

wsrrenty

time

periods.

All

warranty

time

periods

start

on

the

date

that

the

equipment

wee

delivered

to

the

original

retail

purchaser,

or

one

year

after

the

equipment

is

sent

to

the

distributor.

1.

5YearaParta-aYearsLabor

Original

main

power

rectifiers

2.

3

Years



Pans

and

Labor



Transformer/Rectifier

Power

Sources



Plasma

Arc

Cutting

Power

Sources



Semi-Automatic

and

Automatic

Wire

Feeders



Robots

3.

2

Years



Parts

and

Labor



Engine

Driven

Welding

Generators

(NOTE;

Engines

are

warranted

separately

by

the

engine

manutecturer

for

a

period

of

two

years.)



Air

Compressors

4,

1

Year



Parts

end

Labor

*

Motor

Driven

Guns



Process

Controllers

*

Water

Coolant

Systems



HFUnits



Grids



Spot

Welders



Lcod

Banks



SDX

Transtormers



Running

Gear/Trailers



Field

Options

(NOTE;

Field

options

are

covered

under

True

BIueTM

tor

the

remaining

warranty

period

of

the

product

they

are

installed

in,

or

br

a

minimum

of

one

year



whichever

is

greater.)

6

Months



Banenea

90

Days



Pans

end

Labor



MIG

Guns/TIG

Torches



Plasma

Cutting

Torches



Remote

Controls



Accessory

Kits



Replacement

Parts

MILLERS

True

BIueTM

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

manufacturers

wsrranty,

if

any.

2.

Consumable

components;

such

as

contact

tips,

cutting

nozzes,

contaclors

and

relays

or

parts

that

tall

due

to

normal

wear.

3.

Equipment

that

has

been

modified

by

eny

party

other

than

MILLER,

or

equip

ment

that

has

been

improperly

installed,

improperly

operated

or

misused

based

upon

industry

standards,

or

equipment

which

has

not

had

reasonable

end

necessary

maintenance,

or

equipment

which

has

been

used

tor

operation

outside

of

the

specifications

br

the

equipment.

MILLER

PRODUCTS

ARE

INTENDED

FOR

PURCHASE

AND

USE

BYCOMMER

CIALJINDUSTRIAL

USERS

AND PERSONS

TRAINED

AND

EXPCRtENCED

IN

THE USE

AND

MAINTENANCE

OF

WELDING

EQUIPMENT.

In

the

event

of

a

warranty

claim

covered

by

this

warranty,

the

exciesive

remedies

shall

be,

at

MILLERS

option;

(1)

repair;

or

(2)

replacement;

or,

where

authorized

in

writing

by

MILLER

in

appropriate

cases,

(3)

the

reasonable

cost

of

repair

or

replace

ment

at

an

authorized

MILLER

service

station;

or

(4)

payment

of

orciodit

tor

the

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

return

ot

the

goods

at

customers

risk

and

expense.

MILLERS

option

ot

repair

or

replacement

will

be

FOB.,

Factory

at

Appleton,

Wisconsin,

or

FOB.

ate

MILLER

authorized

ser

vice

tacility

as

determined

by

MILLER.

Therefore

no

compensation

or

reimburse

ment

for

trsnsportation

costs

of

any

kind

wilt

be

allowed.

TO

THE

EXTENT

PERMITTED

BY

LAW,

THE

REMEDIES

PROVIDED

HEREIN

ARE

THE SOLE

AND

EXCLUSIVE

REMEDIES.

IN

NO

EVENT

SHALL

MILLER

BE

LIABLE

FOR

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

AND

ANY

IMPLIED

WAR

RANTY,

GUARANTY

OR

REPRESENTATION

AS TO

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

OF

CONTRACT

TORT

OR

ANY

0

~HER

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

MERCHANTABILtTY

OR

FITNESS

FDR

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

ot

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

spe

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

extent

that

they

may

not

be

waived,

the

limitations

end

exclusions

set

out

above

may

not

apply.

This

Limited

Warranty

provides

specific

legal

rights,

and

other

rights

may

be

available,

but

mey

vary

from

province

to

province.

.1-

-1~

5.

6.

RECEIVING-HANDLING

Before

unpacking

equipment,

check

carton

for

any

damage

that

may

have

occurred

during

shipment.

File

any

claims

for

loss

or

damage

with

the

delivering

carrier.

Assistance

for

filing

or

settling

claims

may

be

obtained

from

distributor

and/or

equipment

manufacwrer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

Number

of

your

unit.

The

information

is

located

on

the

rating

label

or

nameplate.

Model

_________

Serial

or

Style

No.

Date

of

Purchase

miller

9/93

ERRATA

SHEET

November

15,

1994

FORM:

OM-1587A

Use

above

FORM

number

when

oroering

extra

manuals.

After

this

manual

was

printed,

refinements

in

equipment

design

occurred.

This

sheet

lists

exceptions

to

data

appearing

later

in

this

manual.

CHANG

ES

TO

SIECTION

16

PARTS

LIST

Change

Parts

List

as

follows:

Dia.

Part

Mkps.

No.

Replaced

With

Description

Quantity

84-35

.

PLG1O,24

...

155

022

170

980

..

CABLE,

ribbon

34

posn

12.000

in

1

86-2

150

147 172

075

..

CARRIER,

drive

roll

w/components

24

pitch

(Eff

w/KE754598)

4



87-40

133

530

168

825

.

DRIVE,

pinion

40T

24P

.376

bore

(Eff

w/KE754598)

1

**First

digit

represents

page

no



digits

following

dash

represent

item

no.

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

ARC

WELDING

SAFETY

PRECAUTIONS

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

wald~ng,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

touchin9

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

191

0.147

(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

ARC

WELDING

can

be

hazardous.

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.

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

Read

and

follow

all

Safety

Standards.

HAVE

ALL

INSTALLATION,

OPERATION,

MAINTENANCE,

AND

REPAIR

WORK

PERFORMED

ONLY

BY

PEOPLE.

(4~

..



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

oft

piece~s

of

metal

or

slag.

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.

NOISE

5.

Wear

protective

clothing

made

from

durable,

flame-resistant

1.

Use

appr

oved

ear

plugs

or

ear

muffs

if

noise

level

is

high.

material

(wool

and

leather)

and

foot

protection.

FUMES

AND

GASES

can

be

hazardous

to

yoi~r

health.

~

J

Welding

produces

fumes

and

gases.

Breathing

these

fumes

and

gases

can

be

hazardous

to

your

health..

1.

Keep

your

head

cut

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

de~lreasers.

5.

6.

7.

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.

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.

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.

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

gas

cylinders

are

normally

part

of

the

welding

process,

be

sure

to treat

them

carefully.

5.

6.

7.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

Never

weld

on

a

pressurized

cylinder



explosion

will

result.

Use

only

correct

shielding

gas

cylinders,

regulators.

hoses,

and

fittings

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.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

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

associatedequipment,andCGApublicationP-1

listed

in

Safety

circuits.

Standards.

Sri

.1.1

2194

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,

unlessthey

are

properly

prepared

according

toAWS

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.

ii.

Wearoil-free

protective

garments

such

as

leather

gloves,

heavy

shirt,

cuff

less

trousers,

high

shoes,

and

a

cap.

12.

Removeany

combustibles,

such

as

a

butane

lighteror

matches,

from

your

person

before

doing

any

welding.

ENGINE

EXHAUST

GASES

can

kill.

1.

Use

equipment

outside

in

open,

well-ventilated

areas.

Engines

produce

harmful

exhaust

gases.

2.

If

used

in

a

closed

area,

vent

engine

exhaust

outside

and

away

from

any

building

air

intakes.

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

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.

3.

Have

only

qualified

people

remove

guards

or

covers

for

maintenance

and

tioubleshooting

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

1.

Always

wear

a

face

shield

when

working

on

a

battery.

TO

EXPLODE;

BATTERY

ACID

can

2.

Stop

engine

before

disconnecting

or

connecting

battery

burn

eyes

and

skin,

cables.

3.

Do

not

allow

tools

to

cause

sparks

when

working

on

a

battery.

Batteries

contain

acid

and

generate

explosive

4.

Do

not

use

welder

to

charge

batteries

or

jump

start

vehicles.

gases.

5.

Observe

correct

polarity

(+

and

)

on

batteries.

STEAM

AND

PRESSURIZED

HOT

1.

If

the

engine

is

warm

and

checking

is

needed,

follow

steps

2

COOLANT

can

burn

face,

eyes,

and

3.

skin.

2.

Wear

safety

glasses

and

gloves

and

put

a

rag

over

cap.

It

is

best

to

check

coolant

level

when

engine

is

cold

3.

Turn

cap

slightly

and

let

pressure

escape

slowly

before

to

avoid

scalding.

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

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

Electrical

Code,

NFPA

Standard

70,

from

National

Fire

Pro

tection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

srl.1.1

2/94

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,

GSA

Standard

Wi

17.2,

from

Canadian

Standards

Association,

Standards

Sales,

178

Rexdale

Bou

levard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

Safe

Practices

ForoccupationAnd

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

51

B,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

£~

WARNING

ENGINES

can

be

hazardous.

ENGINE

FUEL

can

cause

fire

or

explosion.

Engine

fuel

is

highly

flammable.

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.

PRECAUTIONS

DE

SECURITE

EN

SOUDAGE

A

LARC

ISE

EN_GARDE



PROTEGEZ-VOUS,

AINSI

QUE

LES

AUTRES,

CONTRELES

BLESSURES

GRAVES

POSSIBLES

OU

LA

MORT.

NE

LAiSSEZ

PAS

LES

ENFANTS

SAPPROCHER,

NI

LES

PORTEURS

DE

STIMULATEUR

CARDIAQUE

(A

MOINS

QUILS

NAIENT

CONSULTE

UN

MEDE~1N).

Le

soudage,

comme

Is

plupart

des

activitØs

Industrielles,

expose

a

certains

risques.

Le

soudage

nest

pas

dangereux

lorsquon

prend

des

precautions.

Les

consignes

de

sØcuritØ

suivantes

ne

font

que

rØsumer

Iinformation

contenue

dans

les

normes

ØnumØrØes

ci-aprŁs.

Lisez

et

respectez

toutes

ces

riormes.

SEULES

DES

PERSONNES

QUALIFEES

DOIVENT

FAIRE

DES

TRAVAUX

DINSTALLATION,

DE

REPARATION,

DENTRETIEN

ET

DESSAI

La

SOUDAGE

peut

causer

un

Incendie

ou

une

explosion.

Carc

pioduit

des

Øtincelles

et

des

projections.

Avec

Ia

chaleui

intense

degagee

par

Ia

tOle

et

Ies

matØriels,

elles

pouvent

causer

un

incendie

et

des

brOlures.

Le

contact

accidentel

de

lØlectrode

avec

un

objet

metallique

peut

provoquer

des

Øtincelles,

un

Øchauffemont

ou un

incendie.

1.

ProtØgoz-vous,

ainsi

que

los

autres,

contre

les

Øtincelles

et

les

projections.

2.

Ne

soudez

pas

dans

un

endroit

o

des

Øtincelles

peuvent

atteindre

des

matØriaux

inflammables.

3.

Enlevoz

toutes

los

matiŁros

inflammables

dans

un

rayon

de

10,7

metres

autour

de

Iarc,

ou

couvroz-Ies

soigneusomont

avec

des

bches

approuvØes.

4.

MØfiez-vous

des

Øtincelles

et

des

Øc~ats

brOlants,

susceptib~es

de

pØnØtrer

dans

des

aires

adjacentes

par

de

petites

ouvertures

ou

fissures.

5.

MØfiez-vous

des

incendies

et

gardez

un

extincteur

a

portØe

de

Ia

main.

6.

Noublioz

pas

quune

soudure

sur

un

plafond,

un

plancher,

une

cloison

ou

une

paroi

peut

en

enflammer

Iautre

ctO.

7.

Ne

soudez

pas

un

recipient

fermØ,

comme

un

reservoir

ou

un

tonneau.

8.

Connectez

le

cable

de

soudage

le

plus

prŁs

possible

de

Ia

tle

de

soudage

pour

empOcher

le

courant

do

suivro

un

parcours

long

et

inconnu,

et

prØvenir

ainsi

les

risques

dØlectrocution

et

dincendie.

Ne

faites

pas

degeler

des

tuyaux

avec

un

chalumeau.

Videz

votre

carquois

porte-electrodes

ou

coupez

le

fil

au

tube-contact

apres

le

soudage.

It.

Portez

des

vØtements

protecteurs

non

huileux,

tels

des

gants

en

cuir,

une

chemise

epalsse,

un

pantalon

sans

revers,

des

chaussures

montantes

et

un

casque.

LE

SOUDAGE

A

LARC

est

dangereux.

LELECTROCUTION

peut

Œtre

mortelle.

Une

dØcharge

Ølectrique

peut

vous

tuerou

vous

brQler

gravernent.

LØloctrode

et

le

circuit

de

soudage

sont

sous

tension

au

dØmarrage.

Le

circuit

dentrØo

et

los

circuits

internes

des

matØriels

sont

aussi

sous

tension

des

Ia

mise

en

marche.

En

soudage

automatique

ou

semi-automatique

avec

f

ii,

ce

dernier,

le

support

de

roquette,

le

logement

des

galets

dentrainement

et

toutes

les

piŁces

metalliques

en

contact

avec

10

fil

de

soudacpe

sont

sous

tension.

Des

matØriels

mal

install~s

ou

mal

mis

a

Ia

terre

sont

dangereux.

1.

Ne

touchez

pas

a

des

piŁces

sous

tension.

2.

Portez

des

gants

et

des

vŒtements

isolants,

secs

et

non

trouØs.

3.

lsolez-vous

de

Ia

tle

a

souder

et

de

Ia

mise

a

Ia

terre

au

moyen

de

petits

tapis

isclants

ou

autres.

4.

DØconnectez

Ia

prise

dentrØe

des

matØriels

ou

arrŁtez

leur

moteur

avant

de

les

installer

ou

den

faire

lentretien.

5.

Veillez

a

installer

ces

matOnels

et

a

les

mottre

a

Ia

terre

solon

le

manuel

dutilisation

et

les

codes

nationaux,

provinciaux

et

locaux

applicables.

6.

ArrŒtez

tous

los

matØriels

apres

utilisation.

7.

Nutilisez

pas

de

cables

uses,

endommages,

mal

Øpisses

ou

do

calibre

trop

petits.

8.

Nenroulez

pas

de

cables

autour

do

votre

corps.

9.

Mettez

ala

terre

Ia

tle

a

souder

au

moyen

dune

bonne

prise

do

terre.

10.

Ne

touchez

pas

a

IØlectrode

Si

vous

Œtes

en

contact

avec

le

circuit

de

soudage

(terre).

11.

Nutilisez

que

des

matØriels

en

bon

Otat.

Reparez

ou

remplacez

sur-le-champ

los

piŁces

endommagØes.

12.

Portez

un

hamais

de

sØcuritØ

si

vous

travaillez

en

hautour.

13.

Fermez

solidement

touS

10

panneaux

et

los

capots.

La

RAYONNEMENT

DE

LARC

peut

brQler

les

yeux

at

Ia

peau;

le

BRUIT

peut

endommager

Iouie.

Larc

de

soudage

produit

une

chaleur

et

des

rayons

ultraviclets

intenses,

susceptibles

de

brOler

los

yeux

et

Ia

poati.

Le

bruit

cause

par

certains

procØdØs

peut

endom

rnager

louie.

1.

Protez

un

casquce

de

soudeur

avec

Acran

filtrant

do

teinte

appropriØe

(consultez

Ia

norme

ANSI

Z49

indiquØe

ci-apres),

pour

vous

protØger

to

visage

et

les

yeux

Iorsque

vous

soudez

ou

que

vous

observez

IexØcution

dune

soudure.

2.

Portez

des

lunettes

do

sØcuritØ

approuvØes.

Des

Øcrans

latØraux

sont

recommandØes.

3.

Entourez

laire

do

soudage

do

rideaux

ou

do

cloisons

do

protection

contro

los

coups

darc

ou

lØblouissement;

avertissez

los

observateurs

do

no

pas

rogarder

larc.

4.

Portoz

dos

vOtements

en

tissus

ignifugo

durable

(lame

et

cuir)

et

des

chaussuros

do

sØcuritØ.

5.

Portoz

un

casque

antibruit

ou

des

bouchons

dorellle

approuvØs

5~

10

nivoau

do

bruit

est

ØlevØ.

m.

Las

VAPEURS

ET

LES

FUMEES

sont

~

dangareuses

pour

Ia

sante.

I

Le

soudago

dØgage

des

vapeurs

ot

des

fumØes

quiI

=L~w

~!

ost

dangereux

de

respirer.

1.

Ecartez

le

visage

pour

Øviter

do

respirer

los

fumØes.

2.

A

IintØrieur,

assuroz-vous

quo

Iaire

do

soudage

ost

bien

ventilØe

ou

que

les

fumØes

ot

los

vapeurs

sont

aspirØes

a

Iarc.

3.

Si

Ia

ventilation

est

mauvaise,

portez

un

rospirateur

a

adduction

dair

approuvØ.

4.

Lisez

los

fiches

signaletiques

et

los

consignes

du

fabricant

relatives

aux

mØtaux,

aux

produits

consummables,

aux

rovŒtements

et

aux

produits

nettoyants

5.

Ne

travailloz

dans

un

espace

confine

quo

slI

est

bien

ventilO;

sinon,

portez

un

respirateur

a

adduction

dair.

Los

gaz

protecteurs

do

soudago

peuvent

dØplacer

Ioxygene

do

Iair

et

causer

des

blossures

ou

Ia

mort.

Assurez-vous

quo

lair

est

propre

a

Ia

respiration.

6.

Ne

soudoz

pas

a

proximitØ

doperations

de

dØgraissage,

do

nettoyage

ou

de

pulvØrisation.

La

chaleur

et

les

rayons

de

larc

pouvent

reagir

avec

des

vapeurs

et

former

des

gaz

hautement

toxiques

et

irritants.

7.

Ne

soudez

pas

do

tles

galvanisØes

ou

plaquees

en

plÆmb

ou

on

cadmium

sans

los

avoir

grattees

a

fond,

car

ces

mØtaux,

et

tout

revOtoment

qui

en

contient,

peuvent

alors

dØgager

des

tumØes

toxiques.

Assurez-vous

dune

bonne

ventilation

et

portez

un

respirateur.adduction

dair

si

cest

nØcessairo.

9.

10.

>

LES

ETINCELLES

ET

LES

PROJECTIONS

1.

Protez

un

Øcran

facial

ou

des

lunottes

a

coques

approuvØes.

Des

BRULANTES

peuvent

causer

des

blessures.

Øcrans

latOraux

sont

recommandØs.

Le

piqu

age

et

le

meulage

produisent

des

Øclats

de

metal.

2.

Portez

des

vØtements

de

protection

indivlduelle

apropriØs.

En

refroidissant,

Ia

soudure

pout

projeter

du

laltier.

srl.1.2

5191

Lea

BOUTEILLES

endommagees

peuvent

exploser.

Les

bouteilles

contiennent

des

gaz

protecteurs

sous

haute

pression.

Des

bouteilles

endommagØes

peuvent

exploser.

Comme

les

bouteilles

font

normalement

partie

du

procØdØ

de

soudage,

traitez-les

avec

soin.

1.

Les

bouteilles

doivent

Œtre

protegees

contre

les

sources

de

chaleur

intense,

les

chocs

et

les

arcs

de

soudage.

2.

EnchaInez

verticalement

les

bouteillss

a

un

support

ou

a

un

cadre

fixe

pour

les

empŒcher

do

tomber

ou

dŒtre

renversØes.

3.

Eloignoz

les

bouteilles

de

tout

circuit

electrique

ou

do

soudage.

4.

EmpŒchez

tout

contact

entre

une

bouteille

et

une

electrode.

5.

Nutilisez

que

des

bouteilles

do

gaz

protecteur,

des

dØtondeurs,

des

flexibles

et

des

raccords

conus

pour

chaquo

application

spØcifique;

ces

matØriels

et

les

piŁces

connexes

doivent

Œtro

en

bon

Øtat.

6.

Ne

mettez

pas

le

visage

devant

le

robinet

de

bouteiUe

en

Iouvrant.

7.

Remettez

le

chapeau

do

bouteille

aprŁs

utilisation.

8.

Lisez

et

respectez

los

consignes

relatives

aux

bouteilles

do

gaz

comprime

et

aux

matØriels

connexes,

ainsi

que

Ia

publication

P-i

do

Ia

CGA,

ØnumØrØes

dans

les

normes

ci-dessous.

I

e

La

VAPEUR

ET

LE

LIQUIDE

DE

REFROIDISSEMENT

BRULANT

SOUS

PRESSION

peuvent

brOler

Ia

peau

et

les

yeux.

Le

liquide

do

refroidissement

dun

radiateur

pout

Otre

brUlant

et

sous

pression.

Les

MOTEURS

peuvent

Œtre

dangereux.

1.

Ntez

pas

le

bouchon

do

radiateur

tant

que

le

moteur

na

pas

refroidi.

Mettez

des

gants

et

posez

un

torchon

sur

le

bouchon

pour

lter.

Laissez

Ia

pression

sechapper

avant

dter

compiŁtement

10

bouchon.

PRINCIPALES

NORMES

DE

SECURITE

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

P-i,

from

Compressed

Gas

Association,

1235

Jefferson

Davis

Highway,

Safetyand

Health

Standards,

OSHA29

CFR

1910,

from

Superintendent

Suite

501,

Arlington,

VA

22202.

of

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

Code

for

Safety

in

Welding

and

Cutting,

norme

CSA

Wi

17.2,

Associa

20402.

tion

canadienne

do

normalisation,

Standards

Sales,

176

Rexdale

Boule

Recommended

Safe

Practices

for

the

Preparation

for

Welding

and

Cut-

yard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

ting

of

Containers

That

Have

Held

Hazardous

Substances,

norme

Am-

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

Protec

erican

Welding

Socioty

AWS

F4.i,from

American

Welding

Society,

550

tion,

norme

ANSI

Z87.i,

from

American

National

Standards

Institute,

N.W.

LeJeune

Rd.

Miami,

FL

33128.

1430

Broadway,

New

York,

NY

10018.

---4

a

MISE

EN

GARDE

Les

GAZ

DECHAPPEMENT

D

PEU

VENT

ETRE

MORTELS.

ES

MOTEURS

1.

Utilisez

des

machines

a

IextØrieur

dans

dos

aires

ouvertes

et

bien

ventilØes.

-

Les

moteurs

produisent

des

gaz

nocifs.

dechappement

2.

Si

vous

utilisez

des

machines

dans

un

endroit

confine,

les

fumØes

dØchappement

doivent

Œtre

envoyØes

a

iextØrieur,

loin

des

prises

dair

du

btiment.

Le

CARBURANT

peut

causer

un

incendie

ou

une

explosion,

3.

Si

cest

possible,

laissez

lo

moteur

refroidir

avant

do

faire

le

plein

de

carburant

ou

den

verifier

le

niveau

au

debut

du

soudago.

1.

ArrŒtez

le

moteur

avant

do

verifier

le

niveau

do

carburant

ou

de

faire

le

plein.

5.

Faites

attention

de

ne

pas

renverser

do

carburant.

Nettoyez

tout

carburant

renversØ

avant

de

faire

dØmarrer

le

moteur.

2.

No

faites

pas

le

plein

en

fumant

ou

proche

dune

source

d~~~~

~



dune

flamme

nue.

Le

carburant

est

hautement

inflammable.

4.

No

les

faites

pace

p

pas

le

plein

de

carburant

a

ras

bord:

prevoyez

de

our

son

expansion.

Des

PIECES

EN

MOUVEMENT

peuvent

causer

des

blessures.

3.

Seules

des

personnes

qualifiees

doivont

dØmontor

des

protecteurs

ou

des

capots

pour

faire

lentretion

ou

le

depannage

nØcessaire.

1.

Des

piŁces

en

mouvement,

telles

des

ventilateurs,

des

rotors

et

des

courroies

pouvent

couper

los

doigts

et

les

mains,

ou

accrocher

des

vØtemonts

amples.

Assurez-vous

quo

los

portes,

los

panneaux,

les

capots

et

los

protecteurs

sont

bien

fermØs.

4.

5.

Pour

empŒcher

un

demarrago

accidentel

dun

systŁme

pendant

lentretien,

dØbranchez

le

cAble

daccumulateur

a

Ia

borne

negative.

Napprochez

pas

les

mains

ou

los

cheveux

de

piŁces

en

mouvement;

elles

peuvent

aussi

accrocher

des

vŒtements

amples

et

des

outils.

2.

Avant

dinstaller

ou

de

connecter

un

systŁme,

arrŒtez-en

le

moteur.

6.

RØinstallez

les

capots

ou

les

protecteurs

et

fermez

les

portes

aprŁs

dos

travaux

dentrotien

et

avant

do

faire

dØmarror

le

motour.



1.

Des

ETINCELLES

oeuvent

FAIRE

EXPLOSER

UNACCUMULATEIJR;

LELECTROLYTE

DUN

ACCUMULATEUR

peut

brOler

Ia

peau

et

Ies

yeux.

Les

accumulateurs

contiennent

do

iØloctrolyte

et

dØgagent

des

vapeurs

explosives.

Portez

toujours

un

Øcran

facial

en

travaillant

sur

un

accumulateur.

2.

~

5.

ArrOtez

le

moteur

avant

de

connecter

ou

do

dØconnecter

des

cAbles

daccumulateur.

Nutilisez

que

des

outils

anti-Otincelles

pour

travailler

sur

un

accumulateur.

Nutilisez

pas

un

poste

de

soudage

pour

charger

un

accumulateur

ou

connecter

provisoirement

un

vØhicule.

Utilisez

Ia

polarite

correcte

(+

et

-)

de

laccumulateur.

2.

3.

Safelyin

WeldingandCutting,

norme

ANSI

Z49.1

,from

American

Weld

ing

Society,

550

NW.

LeJeune

Rd,

Miami

FL

33128.

National

Elect

rical

Code,

norme

NFPA

70,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

Cuffing

And

Welding

Processes,

norme

NFPA

51

B,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

Sri

.1.2

9/91

EMF

INFORMATION

TABLE

OF

CONTENTS

SECTION

1



SAFETY

INFORMATION

SECTION

2

SPECIFICATIONS

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.

Moltor

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.

WeJlding

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

OM-1587A-5194

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



Backgmund

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

frec~uency

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

riot

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.

modloi

4193

1

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

48

10-1.

Changing

to

MIG

Welding

48

10-2.

Setting

Sequence

MIG

Welding

Parameters

On

Side

Panel

Display

49

SECTION

11



SETtiNG

DUAL

SCHEDULE

PARAMETERS

52

SECTION

12

USING

THE

OPTIONAL

DATA

CARD

54

12-1.

Installing

Data

Card

54

12-2.

Using

The

Data

Card

54

SECTION

13

SETUP

58

13-1.

Setup

Flow

Chart

58

13-2.

Using

Setup

Displays

59

13-3.

Selecting

Process

Capability

59

13-4.

Selecting

Welding

Power

Source

Range

60

13-5.

Selecting

Security

Lock

61

13-6.

Selecting

Or

Changing

Access

Code

62

13-7.

Selecting

Voltage

Correction

63

13-8.

Selecting

Voltage

Sensing

Method

63

13-9.

Selecting

Regular

Or

Hot Arc

Start

64

13-10.

Selecting

Type

Of

Dual

Schedule

Switch

64

13-11.

Selecting

Trigger

Program

Select

65

13-12.

Selecting

Remote

Increase/Decrease

Capability

66

13-13.

Resetting

Arc

Time

66

13-14.

Using

Self

Test

67

13-15.

Selecting

Units

For

Wire

Feed

Speed

And

Motor

Type

68

13-16.

Selecting

Bench

Or

Boom

Model

Type

68

13-17.

Resetting

Memory

69

13-18.

Selecting

Voltage

Error

Shutdown

69

13-19.

Selecting

Program

Name

Feature

70

13-20.

Software

Version

Number

70

SECTION

14

MAINTENANCE

&

TROUBLESHOOTING

71

14-1.

Routine

Maintenance

71

14-2.

Replacing

The

Hub

Assembly

72

14-3.

Overload

Protection

72

14-4.

Error

Screens

73

14-5.

Troubleshooting

74

SECTION

15-

ELECTRICAL

DIAGRAMS

76

SECTION 16

PARTS

LIST

80

Figure

16-1.

Main

Assembly

80

Figure

16-2.

Control

Box

82

Figure

16-3.

Panel,

Front

w/Components

85

Figure

16-4.

Drive

Assembly,

Wire

86

Figure

16-5.

Panel,

Side

w/Components

88

Table

16-1.

Drive

Roll

And

Wire

Guide

Kits

89

SECTION

1

-

SAFETY

INFORMATION

Figure

1-1.

Safety

Information

modl.1

2/93

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

sym

bol

shown.

7

NOTE

Special

Instructions

for

best

oper

ation



not

safety.

SECTION

2

SPECIFICATIONS

Table

2-1.

Wire

Feeder

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-1587

Page

1



Read

all

safety

messages

throughout

this

manual.



Obey

all

safety

messages

to

avoid

injury.



Learn

the

meaning

of

WARNING

and

CAUTION.

2

CAUTION

/

5

__

_____

3

_________



Do

riot

touch

live

etectflc~

pam.



Keep

away

troth

moving

pans.

~

ELECTRIC

SHOCK

can

kill

~

MOVING

PARTS

can

Injure



Disconnect

Input

power

beforeJj

~



Keep

all

panels

and

covers

closed

nstsLlling

or

servicing.

when

operating.

6

a

WA

7H

NOTE

Er

:I~II~~

READ

SAFETY

BLOCKS

at

start

of

SectIon

3-1

before

proceedIng.

Turn

Off

switch

when

using

high

frequency.

SpecIfication

DescrIptIon

Type

Of

Input

Power

Maximum

Weld

CircuiI~

Rating

Welding

Power

Source

Type

Wire

Feed

Speed

Range

Wire

Diameter

Range

Welding

Processes

Input

Power

Cord

Overall

Dimensions

Weight

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

For

GMAW

Welding

Constant

Current

(CC)

DC,

With

Contactor

For

GMAW-P

Welding

Standard:

50

To

780

1pm

(1.3

To

19.8

mpm)

High

Speed:

92

To

1435

ipm

(2.3

To

36.5

mpm)

Low

Speed:

13

To

213

ipm

(0.34

To

5.38

mpm)

.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)

lOft

(3.1

m)

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

a

WARNING

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.

Do

not

put

feeder

where

welding

wire

hits

cylinder.

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.

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.

Figure

3-1.

Installing

Wire

Feeder

OM-1587

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

ST-162

129

N

OTE

~j~

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.

8

Gun

9

Wire

Feeder

10

Gas

Hose

With

Y~

Adapter

11

Gas

Cylinder

2.

3

4

8

Figure

3-2.

Connection

Diagram

OM-1587

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

Figure

3-3.

Wire

Guide

Installation

Figure

3-4.

Drive

Roll

Installation

wtwaml.1

2/93

When

changing

wire

size

or

type,

check

guide

size

(see

Table

16-1).

1

Drive

Rolls

Remove

drive

rolls

before

installing

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.

Tools

Needed:

4

Inlet

Wire

Guide

5/64

in

Install

inlet

guide

so

wire

guide

screw

is

centered

in

groove

in

guide.

1

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

1258

/

ST-137

377.0

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

377-0

4

OM-1

587

Page

4

3-4.

Welding

Gun

Connections

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.

wlwaml.1

2/93

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.

3-5.

Motor

Start

Control

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.

STATIC

ELECTRICITY

can

damage

parts

on

circuit

boards.



Put

on

grounded

wrist

strap

BEFORE

handling

boards

or

parts.

wtwaml.r2/93

Figure

3-5.

Gun

And

Trigger

Lead

Connections

ST-162

183

/

Ref.

ST-187

703

Tools

Needed:

1/4

in

_____

3

Non-conductive

To

change

wire

feed

starting

speed

proceed

as

follows:

Turn

Off

wire

feeder

and

welding

power

source.

Remove

wrapper.

1

Motor

Board

PCi

2

Motor

Start

Control

Poten

tiometer

R70

Turn

potentiometer

clockwise

to

In

crease

time

it

takes

the

motor

to

ramp

up

to

speed.

Remove

protec

tive

white

rubber

cap

before

mak

ing

adjustment.

Adjust

potentiome

ter

R70

using

a

small

nonconduc

tive

screwdriver.

Reinstall

wrapper.

ST-162

132/

Ref.

5B148

882-D

Figure

3-6.

Motor

Start

Control

On

Motor

Control

Board

PCi

OM-1

587

Page

5

3-6.

Control

Connections

Table

3-1.

Remote

17

Socket

Information

REMOTE

17

Socket*

Socket

Information

E

/

~

C

G

E

M

CCICV

select;

+13

to

+24

volts

dc

is

CV,

0

volts

dc

is

CC.

Arc

control/inductance

control;

0

to

+10

volts

dc.

Actual

weld

current

output

signal;

+1

volt

dc

is

100

amps.

Actual

weld

voltage

output

signal;

+1

volt

dc

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

OUTPUT

(CONTACTOR)

A

Al

AMPERAGE

MIV

VOLTAGE

A

B

G

C

D

E

24

volts

ac.

Contact

closure

to

A

completes

24

volts

ac

contactor

control

circuit.

Circuit

common

for

24

volts

ac

circuits.

+10

volts

dc

input

to

remote

control.

Remote

control

circuit

common.

0

to

+10

volts

dc

output

command

signal

from

feeder

voltage

control.

*The

remaining

pins

are

not

used.

OM-1

587

Page

6

1

7-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

workpiece

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.

S-162

132

/

Ref.

S-o512

/

S-0003-A

/

S-0628

Figure

3-7.

Control

Connections

With

Information

3-7.

Shielding

Gas

And

Weld

Cable

Connections

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

Obtain

gas

cylinder

and

chain

to

running

gear,

wall,

or

other

station

ary

support

so

cylinder

cannot

fall

and

break

off

valve.

1

Cap

Tools

Needed:

~

1-1/8,5/8

in

F-



OR

Argon

Gas

L

1

.2

3

CO2

Gas

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

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

adapter

with

0-ring

between

regulator/flowmeter

and

CO2

cylinder.

3

Figure

3-8.

TypIcal

Regulator/Flowmeter

Installation

ssb3.V

5/94

-ST-158

697-A

~

E



LECTRIC

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.

H

BUILDUP

OF

SHIELDING

GAS

can

harm

health

or

kill.



Shut

off

shielding

gas

supply

when

not

in

use.

wam4.19/91

/wtwaml.1

2/93

4

7

8

OM-1587

Page

7

B.

Shielding

Gas

And

Weld

Cable

Connections

At

Feeder

Tools

Needed:

~

9/16,5/8

in

1

V

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

priate

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.

Ref.

5T-152

567-A

Figure

3-9.

Shielding

Gas

And

Weld

Cable

Connections

1

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)

OM-1

587

Page

8

3-8.

Welding

Wire

Installation

A.

Positioning

Spool

Support

Arm

B.

Installation

Of

Spool-Type

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

spoov

reel

is

to

be

used,

reposition

spool

support

arm

as

instructed.

1

Base

2

SpoolSupport

Arm

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

spool/reel,

through

the

drive

rolls,

Tools

Needed:

~

3/8in

ST-152

565

Figure

3-10.

Positioning

The

Spool

Support

Arm

8

7

6

2

1

Hex

Nut

Remove

hex

nut.

2

HubSupportShaft

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

3-16).

Turn

spool

until

hub

fits

hole

in

spool.

Reinstall

retaining

ring.

9

Hub

Bracket

Repeat

procedure

using

hub

bracket

to

install

spool-type

wire

onto

right

side

of

wire

feeder.

ST-152

564-A

Tools

Needed:

15/Thin

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

3-12.

Installation

Of

Optional

Wire

Reel

And

Reel

Type

Wire

Figure

3-13.

Adjusting

Hub

Tension

12

.9

7

6

5

1

Hub

SupportShaft

2

Hex

Nut

Remove

hex

nut.

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

without

touching

the wire

feeder

or

gas

cylinder.

Reinstall

hex

nut.

4

Spacer

5

Hub

6

Hub

7

Wire

Reel

8

Wire

~

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.

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).

Tighten

spanner

nut

until

lock

is

in

position

over

hole

in

wire

retainer.

Pull

lock

and

turn

to

insert

locking

into

wire

retainer.

Slide

wire

reel

assembly

onto

hub,

and

turn

assembly

until

hub

is

seated

in

hole

in

reel.

Reinstall

re

taining

ring.

13

Hub

Bracket

Repeat

procedure

using

hub

bracket

to

install

reel-type

wire

onto

right

side

of

wire

feeder.

ST-i

52

563-B

1ST-i

52

463/

Ret.

ST-i

57 999-A

Tools

Needed:

/

15/l6in

Wire

Installation

Tools

Needed:

r

15/l6in

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-i52

562-A

OM-1

587

Page

10

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