Miller
June
1994
Form:
OM-1587A
Effective
With
Serial
No.
KE648703
OWNERS
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
________________
________________
MILLERS
TRUE
BLUETM
LIMITED
WARRANTY
Effective
January
1,
1992
(Equipment
with
a
serial
number
preface
of
KC
or
newer)
This
limited
warranty
supersedes
all
previous
MILLER
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
MILLERS
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
manufacturers
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
MILLERS
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
customers
risk
and
expense.
MILLERS
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
manufacwrers
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
Mkps.
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
Owners
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
next
page.
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
manufacturers
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
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
LARC
ISE
EN_GARDE
PROTEGEZ-VOUS,
AINSI
QUE
LES
AUTRES,
CONTRELES
BLESSURES
GRAVES
POSSIBLES
OU
LA
MORT.
NE
LAiSSEZ
PAS
LES
ENFANTS
SAPPROCHER,
NI
LES
PORTEURS
DE
STIMULATEUR
CARDIAQUE
(A
MOINS
QUILS
NAIENT
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
Iinformation
contenue
dans
les
normes
ØnumØrØes
ci-aprŁs.
Lisez
et
respectez
toutes
ces
riormes.
SEULES
DES
PERSONNES
QUALIFEES
DOIVENT
FAIRE
DES
TRAVAUX
DINSTALLATION,
DE
REPARATION,
DENTRETIEN
ET
DESSAI
La
SOUDAGE
peut
causer
un
Incendie
ou
une
explosion.
Carc
pioduit
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
Iarc,
ou
couvroz-Ies
soigneusomont
avec
des
bches
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.
Noublioz
pas
quune
soudure
sur
un
plafond,
un
plancher,
une
cloison
ou
une
paroi
peut
en
enflammer
Iautre
ctO.
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
tle
de
soudage
pour
empOcher
le
courant
do
suivro
un
parcours
long
et
inconnu,
et
prØvenir
ainsi
les
risques
dØlectrocution
et
dincendie.
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
LARC
est
dangereux.
LELECTROCUTION
peut
Œtre
mortelle.
Une
dØcharge
Ølectrique
peut
vous
tuerou
vous
brQler
gravernent.
LØloctrode
et
le
circuit
de
soudage
sont
sous
tension
au
dØmarrage.
Le
circuit
dentrØo
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
dentrainement
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
tle
a
souder
et
de
Ia
mise
a
Ia
terre
au
moyen
de
petits
tapis
isclants
ou
autres.
4.
DØconnectez
Ia
prise
dentrØe
des
matØriels
ou
arrŁtez
leur
moteur
avant
de
les
installer
ou
den
faire
lentretien.
5.
Veillez
a
installer
ces
matOnels
et
a
les
mottre
a
Ia
terre
solon
le
manuel
dutilisation
et
les
codes
nationaux,
provinciaux
et
locaux
applicables.
6.
ArrŒtez
tous
los
matØriels
apres
utilisation.
7.
Nutilisez
pas
de
cables
uses,
endommages,
mal
Øpisses
ou
do
calibre
trop
petits.
8.
Nenroulez
pas
de
cables
autour
do
votre
corps.
9.
Mettez
ala
terre
Ia
tle
a
souder
au
moyen
dune
bonne
prise
do
terre.
10.
Ne
touchez
pas
a
IØlectrode
Si
vous
Œtes
en
contact
avec
le
circuit
de
soudage
(terre).
11.
Nutilisez
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
LARC
peut
brQler
les
yeux
at
Ia
peau;
le
BRUIT
peut
endommager
Iouie.
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
louie.
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
IexØcution
dune
soudure.
2.
Portez
des
lunettes
do
sØcuritØ
approuvØes.
Des
Øcrans
latØraux
sont
recommandØes.
3.
Entourez
laire
do
soudage
do
rideaux
ou
do
cloisons
do
protection
contro
los
coups
darc
ou
lØblouissement;
avertissez
los
observateurs
do
no
pas
rogarder
larc.
4.
Portoz
dos
vOtements
en
tissus
ignifugo
durable
(lame
et
cuir)
et
des
chaussuros
do
sØcuritØ.
5.
Portoz
un
casque
antibruit
ou
des
bouchons
dorellle
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
quiI
=L~w
~!
ost
dangereux
de
respirer.
1.
Ecartez
le
visage
pour
Øviter
do
respirer
los
fumØes.
2.
A
IintØrieur,
assuroz-vous
quo
Iaire
do
soudage
ost
bien
ventilØe
ou
que
les
fumØes
ot
los
vapeurs
sont
aspirØes
a
Iarc.
3.
Si
Ia
ventilation
est
mauvaise,
portez
un
rospirateur
a
adduction
dair
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
slI
est
bien
ventilO;
sinon,
portez
un
respirateur
a
adduction
dair.
Los
gaz
protecteurs
do
soudago
peuvent
dØplacer
Ioxygene
do
Iair
et
causer
des
blossures
ou
Ia
mort.
Assurez-vous
quo
lair
est
propre
a
Ia
respiration.
6.
Ne
soudoz
pas
a
proximitØ
doperations
de
dØgraissage,
do
nettoyage
ou
de
pulvØrisation.
La
chaleur
et
les
rayons
de
larc
pouvent
reagir
avec
des
vapeurs
et
former
des
gaz
hautement
toxiques
et
irritants.
7.
Ne
soudez
pas
do
tles
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
dune
bonne
ventilation
et
portez
un
respirateur.adduction
dair
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
dŒtre
renversØes.
3.
Eloignoz
les
bouteilles
de
tout
circuit
electrique
ou
do
soudage.
4.
EmpŒchez
tout
contact
entre
une
bouteille
et
une
electrode.
5.
Nutilisez
que
des
bouteilles
do
gaz
protecteur,
des
dØtondeurs,
des
flexibles
et
des
raccords
conus
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
Iouvrant.
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
dun
radiateur
pout
Otre
brUlant
et
sous
pression.
Les
MOTEURS
peuvent
Œtre
dangereux.
1.
Ntez
pas
le
bouchon
do
radiateur
tant
que
le
moteur
na
pas
refroidi.
Mettez
des
gants
et
posez
un
torchon
sur
le
bouchon
pour
lter.
Laissez
Ia
pression
sechapper
avant
dter
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
DECHAPPEMENT
D
PEU
VENT
ETRE
MORTELS.
ES
MOTEURS
1.
Utilisez
des
machines
a
IextØrieur
dans
dos
aires
ouvertes
et
bien
ventilØes.
-
Les
moteurs
produisent
des
gaz
nocifs.
dechappement
2.
Si
vous
utilisez
des
machines
dans
un
endroit
confine,
les
fumØes
dØchappement
doivent
Œtre
envoyØes
a
iextØrieur,
loin
des
prises
dair
du
btiment.
Le
CARBURANT
peut
causer
un
incendie
ou
une
explosion,
3.
Si
cest
possible,
laissez
lo
moteur
refroidir
avant
do
faire
le
plein
de
carburant
ou
den
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
dune
source
d~~~~
~
dune
flamme
nue.
Le
carburant
est
hautement
inflammable.
4.
No
les
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
lentretion
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
dun
systŁme
pendant
lentretien,
dØbranchez
le
cAble
daccumulateur
a
Ia
borne
negative.
Napprochez
pas
les
mains
ou
los
cheveux
de
piŁces
en
mouvement;
elles
peuvent
aussi
accrocher
des
vŒtements
amples
et
des
outils.
2.
Avant
dinstaller
ou
de
connecter
un
systŁme,
arrŒtez-en
le
moteur.
6.
RØinstallez
les
capots
ou
les
protecteurs
et
fermez
les
portes
aprŁs
dos
travaux
dentrotien
et
avant
do
faire
dØmarror
le
motour.
1.
Des
ETINCELLES
oeuvent
FAIRE
EXPLOSER
UNACCUMULATEIJR;
LELECTROLYTE
DUN
ACCUMULATEUR
peut
brOler
Ia
peau
et
Ies
yeux.
Les
accumulateurs
contiennent
do
iØloctrolyte
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
daccumulateur.
Nutilisez
que
des
outils
anti-Otincelles
pour
travailler
sur
un
accumulateur.
Nutilisez
pas
un
poste
de
soudage
pour
charger
un
accumulateur
ou
connecter
provisoirement
un
vØhicule.
Utilisez
Ia
polarite
correcte
(+
et
-)
de
laccumulateur.
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
1
2
2
3
4
5
5
6
7
9
11
13
15
17
18
20
21
22
23
23
25
28
SECTION
10TEACHING
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
related
to
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
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
Pin
information
REMOTE
14
Pin*
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
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
Pin
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
manufacturers
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.
wam4.19/91
/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
Owners
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
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
Pin
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
pin
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
Pin
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
pin
into
wire
retainer.
Slide
wire
reel
assembly
onto
hub,
and
turn
assembly
until
hub
pin
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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