Miller KD420835 Owner's manual

Millerﬁ

July

1993

Form:

OM-1586C

Effective

With

Serial

No.

KD420835

OWNERS

MANUAL

SS-64M

(12)

And

(16)

Foot

Boom

Mounted

Wire

Feeder

U

Read

and

follow

these

instructions

and

all

U

Give

this

manual

to

the

operator.



U

safety

blocks

carefully.

Have

only

trained

and

qualified

persons

install,

operate,

or

service

this

unit.

Call

your

distributor

if

you

do

not

understand

the

directions.



U

For

help,

call

your

distributor

or:

MILLER

Electric

Mfg.

Co.,

P.O.

Box

1079,

Appleton,

WI

54912

414-734-9821



Microprocessor

Controlled

Constant

Speed

Wire

Feeder



For

Use

With

Maxtron

450

Welding

Power

Source

U

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

ipm

(1.3

To

19.8

mpm)



Programmable

Pulse

Weld

Parameters

cove,

6/93



ST~157

388

PRINTED

IN

USA

MILLERS

TRUE

BLUEIM

LIMITED

WARRANTY

Effective

January

1,

1992

(Equipment

with

a

serial

number

preface

of

KC

or

newer)

This

limited

wsrrsnty

supersedes

all

werrenties

end

is

exclusive

with

no

other

guarantees

or

warranties

espressed

or

implied.

1.1

LIMITED

WARRANTY



Subject

to

the

terms

and

conditions

below.

MILLER

Electric

MIg.

Co..

Appleton.

Wisconsin.

warrants

to

its

original

retail

purchaser

that

new

MILLER

equipment

sold

after

the

effective

date

ol

this

limited

warranty

is

tree

of

de

tects

in

materiel

and

workmanship

at

the

time

it

is

shipped

by

MILLER.

TIllS

WAR

RANTY

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTHER

WARRANTIES.

EXPRESS

OR

IMPLIED.

INCLUDING

THE

WARRANTIES

OF

MERCHANTABIUTY

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

notified

in

writing

within

thirty

(30)

days

of

such

detect

or

failure,

at

which

lime

MILLER

will

provide

instructions

on

the

warranty

claim

procedures

to

be

followed.

MILLER

shall

honor

warranty

claims

on

warranted

equipment

listed

below

in

the

event

of

such

a

failure

within

the

warranty

time

periods.

All

warranty

time

periods

start

on

the

date

that

the

equipment

was

delivered

to

the

original

retail

purchaser,

or

one

year

after

the

equipment

is

sent

to

the

distributor.

1.

5YearsParts3YearsLabor



Original

main

power

rectifiers

2.

3

Years



Parts

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

sre

warranted

separately

by

the

engine

manufacturer.)



Air

Compressors

4.

1

Year



Parts

and

Labor



Motor

Driven

Guns



Process

Controllers



Water

Coolant

Systems



HF

Units



Grids



Spot

Welders

*

Load

Banks



SDX

Transformers



Running

Gear/Trailers



Field

Options

(NOTE:

Field

options

are

covered

under

True

Blue

nu

for

the

remaining

warranty

period

of

the

product

they

are

installed

in,

or

for

a

minimum

of

one

year



whichever

is

greater.)

6

Months



Batteries

90

Days



Parts

and

Labor



MIG

Guns/TIG

Torches



Plasma

Cutting

Torches

*

Remote

Controls



Accessory

Kits



Replacement

Parts

MILLERS

True

Blue

TM

Limited

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

warrsnty.

if

any.

2.

Consumable

components:

such

as

contact

tips,

cutting

nozzles,

contactors

and

relays

or

parts

that

fail

due

to

normal

wear.

3.

Equipment

that

has

been

modified

by

any

party

other

than

MILLER,

or

equip

ment

that

has

been

improperly

installed,

improperly

operated

or

misused

based

upon

industry

standards,

or

equipment

which

has

not

had

reasonable

and

necessary

maintenance,

or

equipment

which

has

been

used

for

operation

outside

of

the

specifications

for

the

equipment.

MILLER

PRODUCTS

ARE

INTENDED

FOR

PURCHASE

AND

USE

BY

COMMER

CIALIINDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

IN

THE USE

AND

MAINTENANCE

OF

WELDING

EGUIPMENr

In

the

event

of

a

warranty

claim

covered

by

this

warranty,

the

exclusive

remedIes

shall

be.

at

MILLERS

opt

ion:

(1)

repair:

or

(2)

replacement:

or,

where

authorized

in

writing

by

MILLER

in

appropriate

cases.

(3)

the

reasonable

cost

ol

repair

or

replace

ment

at

an

authorized

MILLER

service

station:

or

(4)

payment

of

or

credit

for

the

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

return

of

the

goods

at

customers

risk

and

expense.

MILLERS

option

of

repair

or

replacement

will

be

FOB.,

Factory

at

Appleton.

Wisconsin,

or

FOB.

ala

MILLER

authorized

ser

vice

facility

as

determined

by

MILLER.

Therefore

no

compensation

or

reimburse

ment

for

transportation

costs

of

any

kind

will

be

allowed.

TO

THE

EXTENT

PERMItTED

BY

LAW.

THE

REMEDIES

PROVIDED

HEREIN

ARE

THE

SOLE

AND

EXCLUSIVE

REMEDIES.

IN

NO

EVENT

SHALL

MILLER

BE

LIABLE

FOR

DIRECT,

INDIRECT,

SPECIAL.

INCIDENTAL

OR

CONSEGUENTIAL

DAMAGES

(INCLUDING

LOSS

OF

PROFID,

WHETHER

BASED

ON

CON

TRACt

TORT

OR

ANY

OTHER

LEGAL

THEORY.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WAR

RANTY,

GUARANTY

OR

REPRESENTATION

AS

TO

PERFORMANCE.

AND

ANY

REMEDY

FOR

BREACH

OF

CONTRACT

TORT

OR

ANY

OTHER

LEGAL

THEORY

WHICH,

BUT

FOR

THIS

PROVISION,

MIGHT

ARISE

BY

IMPLICATION,

OPERATION

OF

LAW.

CUSTOM

OF

TRADE

OR

COURSE

OF

DEALING,

IN

CLUDING

ANY

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OR

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

TO

ANY

AND

ALL

EOUIPMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

AND

DISCLAIMED

BY

MILLER.

Some

states

in

the

U.S.A.

do

not

allow

limitations

of

how

long

an

implied

wsrranty

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

aome

provinces

provides

for

certain

additional

warrsntIaa

or

remedies

other

than

as

stated

herein.

and

to

the

extent

that

they

may

not

be

waived,

the

limitations

and

exclusions

set

out

above

mey

not

apply.

This

Limited

Warranty

provides

specific

legal

rights,

and

other

rights

may

be

available,

but

may

vary

hom

province

to

province.

S.

6.

72\

r.

I

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

manufacturers

Transportation

Department.

When

requesting

information

about

this

equipment,

always

provide

Model

Designation

and

Serial

or

Style

Number,

Use

the

following

spaces

to

record

Model

Designation

and

Serial

or

Style

Number

of

your

unit.

The

information

is

located

on

the

rating

label

or

nameplate.

Model

_________

Serial

or

Style

No,

Date

of

Purchase

miller

5/93a

ERRATA

SHEET

September

20,

1993

FORM:

OM-1586C

Use

above

FORM

number

when

ordering

extra

manuals.

NOTE

~

Effective

with

Serial

No.

K0494695,

the

reed

relay

is

a

field

installation

only

option.

CHANGES

TO

SECTION

3INSTALLATION

Replace

Section

3-7.

Control

Connection

1

17-Pin

Receptacle

2

Keyway

To

connect

interconnecting

cord

to

receptacle,

align

keyway,

insert

plug,

and

tighten

threaded

collar.

3

Reed

Relay

Receptacle

(See

Section

3-6)

4

35

ft

(10.6

m)

Voltage

Sens

ing

Lead

Connect

to

workpiece

(see

Figure

3-10).

5

Threaded

Collar

6

14-Pin

Plug

To

connect

plug

to

matching

recep

tacle

on

welding

power

source,

align

keyway,

insert

plug,

and

tight

en

threaded

collar.

Signals

Supplied

To

Welding

Power

Source

Through

14-Pin

Plug:

Contactor

Control

A

24

volts

ac.

B

Contact

closure

to

A

completes

the

24

volts

ac

contactor

con

trol

circuit.

G

Circuit

common

for

24

volts

ac

circuit.

Voltage

Control

C

Command

signal;

+10

volts dc.

D

Control

circuit

common.

E

Remote

power

source

voltage

command

signal

from

feeder

(potentiometer

wiper

or

0

to

+10

volts

dc).

Signals

Supplied

To

Welding

Power

Source

Through

17-Pin

Receptacle:

Remote

Output

Control

C

CC/CV

select;

+13

thru

+24

volts

dc

=

CV,

0

volts

dc

=

CC.

G

Arc

control/inductance

control;

0

to

+10

volts

do.

Signals

Supplied

By

Welding

Power

Source:

Remote

Metering

E

Actual

weld

current

output

signal;

+1

volt

dc

=

100

amps.

M

Actual

weld

voltage

output

signal;

+1

volt

dc

=

10

volts dc.

Feedback

Signals

F

Current

feedback

0-10

volts

dc;

1

volt

per

100

amperes.

I-I

Voltage

feedback

0-10

volts

dc:

I

volt

per

10

arc

voltage.

The

remaining

pins

are

not

used.

ST-157

433-A

/

Ret

S-05i2

/

S-0003-A

I

S-0628

After

this

manual

was

printed,

refinements

in

equipment

design

occurred.

This

sheet

lists

exceptions

to

data

appearing

later

in

this

manual.

1

2

o~o

Figure

3-9.

Control

Connections

With

Information

CHANGES

TO

SECTION

15

ELECTRICAL

DIAGRAMS

NOTE

~

Use

Serial

Number

to

select

correct

diagram.

Replace

Figure

15-1.

Circuit

Diagram

For

Wire

Feeder

INCPEMENT

OPENENT

 

o

0 0

0

P941

P942

P943

P944

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o

0 0 0

NODE

PAPAMETEP

____________

SELECT

PAR

A

NE

I

ER

SELECT

V3~3

~

PC36~

___________

0

)>

P036

0p931

)>

P036

P5

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P/W

)>

P036

E

OR~

)

P036

>>

PC36

061

)>

RC36

TRIGGEP

064

)

PC36

JOG

OLD

PURGE

063

)

RC36

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DB~

)

RC36

RC33 P029

DRA

)

RC36

PC

30

CABLE

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)>

RC36

PC3I

COMMON

CABLE

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I

CORDUCTOR

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RC26

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Serial

No.

KD463564

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OM-1586C

Page

3

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OM-1586C

Page

5

Replace

Figure

15-2.

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Diagram

For

Wire

Feeder

Figure

15-2.

Wiring

Diagram

For

Wire

Feeder

Eftective

With

Serial

No.

KD463564

Thru

KD494694

OM-1586C

Page

6



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KD494695

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SECTION

16

PARTS

LIST

Change

Parts

List

as

follows:

77-28

PC8O,RC8O

159

477

77-30

158735

77-

..

PLG19

...

Added

+164475..

+164

474..

163519..

Deleted..

164842..

163917..



164713..



164709..



163519..



158719..

**First

digit

represents

page

no



digits

following

dash

represent

item

no.

OPTIONAL

+All

components

remain

the

same

with

listed

exceptions.

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

73-3.

73-

73-6.

77-1

77-8.

77-9.

Dia.

Part

Replaced

Mkgs.

No.

With

Description

12

16

155992

159990

158734

REED

.

140

789

155024

PC5O

...

158817

PC1O

...

158921

147995..

CABLE,

interconnecting

(consisting

of)

1

CABLE,

interconnecting

(consisting

of)

1

CABLE,

port

No.

18

8/c

(order

by

ft)

l7ft

.

2lft

Available

as

Field

Kit

Option

Only

METER

LENS,

w/gasket

(Eff

w/KD494695)

2

...

2

CIRCUIT

CARD,

interface

(Eff

w/KD494695)

1

...

1

CIRCUIT

CARD,

processor

w/proms

(Eff

w/KD494695)

1

...

1

CIRCUIT

CARD,

HF

filter

(Eff

w/KD494695)

1

..

.

1

CABLE,

port

No.

18

8/c

(order

by

ft)

1

2ft

.

1

2ft

CONNECTOR

&

PINS,

(consisting

of)

1

...

1

CONNECTOR,

rect

skt

22-1

8ga

Amp

770904-3

2

...

2

OM-1586C

Page

10

ARC

WELDING

SAFETY

PRECAUTIONS

a

WARNING

ARC

WELDING

can

be

hazardous.

PROTECT

YOURSELF

AND

OTHERS

FROM

POSSIBLE

SERIOUS

INJURY

OR

DEATH.

KEEP

CHILDREN

AWAY.

PACEMAKER

WEARERS

KEEP

AWAY

UNTIL

CONSULTING

YOUR

DOCTOR.

In

welding,

as

in

most

jobs,

exposure

to

certain

hazards

occurs.

Welding

is

safe

when

precautions

are

taken.

The

safety

information

given

below

is

only

a

summary

of

the

more

complete

safety

information

that

will

be

found

in

the

Safety

Standards

listed

on

the

Read

and

follow

all

Safety

Standards.

HAVE

ALL

INSTALLATION,

OPERATION,

MAINTENANCE,

AND

REPAIR

WORK

PERFORMED

ONLY

BY

QUALIFIED

PEOPLE.

ARC

RAYS

can

burn

eyes

and

skin;

~

NOISE

can

damage

hearing.

Arc

rays

from

the

welding

process

produce

intense

heat

and

strong

ultraviolet

rays

that

can

burn

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

NOISE

1.

Use

approved

ear

plugs

or

ear

muffs

if

noise

level

is

high.

ARC

RAYS

2.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

(see

ANSI

Z49.

1

listed

in

Safety

Standards)

to

protect

your

face

and

eyes

when

welding

or

watching.

3.

Wear

approved

safety

glasses.

Side

shields

recommended.

4.

Use

protective

screens

or..barriers

to

protect

others

from

flash

and

glare;

warn

others

not

to

watch

the

arc.

5.

Wear

protective

clothing

made

from

durable,

flame-resi~tant

material

(wool

and

leather)

and

foot

protection.

FUMES

AND

GASES

can

be

hazardous

5.

Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

to

your

health.

wearing

an

air-supplied

respirator.

Shielding

gases

used

for

Welding

produces

fumes

and

gases.

Breathing

these

fumes

and

gases

can

be

hazardous

to

your

health.

:~

6.

welding

can

displace

air

causing

injury

or

death.

Be

sure

the

breathing

air

is

safe.

Do

not

weld

in

locations

near

degreasing,

cleaning,

or

spraying

1.

Keep

your

head

out

of

the

fumes.

Do

not

breathe

the

fumes.

.

2.

If

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

operations.

The

heat

and

rays

of

the

arc

can

react

with

vapors

to

.

form

highly

toxic

and

irritating

gases.

remove

welding

fumes

and

gases.

7.

Do

not

weld

on

coated

metals,

such

as

galvanized,

lead,

or

3.

If

ventilation

is

poor,

use

an

approved

air-supplied

respirator.

cadmium

plated

steel,

unless

the

coating

is

removed

from

the

4.

Read

the

Material

Safety

Data

Sheets

(MSDS5)

and

the

weld

area,

the

area

is

well

ventilated,

and

if

necessary,

while

manufacturers

instruction

for

metals,

consumables,

coatings,

wearing

an

air-supplied

respirator.

The

coatings

and

any

metals

and

cleaners,

containing

these

elements

can

give

off

toxic

fumes

if

welded:

WELDING

can

cause

fire

or

explosion.

5.

Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.

Sparks

and

spatter

fly

off

from

the

welding

arc.

The

flying

sparks

and

hot

metal,

weld

spatter,

hot

6.

Be

aware

that

welding

on a

ceiling,

floor,

bulkhead,

or

partition

can

cause

fire

on

the

hidden

side.

workpiece,

and

hot

equipment

can

cause

fires

and

burns.

Accidental

contactof

electrode

orwelding

wire

7.

.

Do

not

weld

on

closed

containers

such

as

tanks

or

drums.

to

metal

objects

can

cause

sparks,

overheating,

or

fire.

8.

Connect

work

cable

to

the

work

as

close

to

the

welding

area

as

practical

to

prevent

welding

current

from

traveling

long,

possibly

.

1.

Protect

yourself

and

others

from

flying

sparks

and

hot

metal.

2.

Do

not

weld

where

flying

sparks

can

strike

flammable

material.

9.

unknown

paths

and

causing

electric

shock

and

fire

hazards.

Do

not

use

welder

to

thaw

frozen

pipes.

3.

Remove

all

flammables

within

35

ft

(10.7

m)

of

the

welding

arc.

If

10.

Remove

stick

electrode

from

holder

or

cut

oft

welding

wire

at

this

is

not

possible,

tightly

cover

them

with

approved

covers,

contact

tip

when

not

in

use.

4.

Be

alert

that

welding

sparks

and

hot

materials

from

welding

can

11.

Wear

oil-free

protective

garments

such

as

leather

gloves,

heavy

easily

go

through

small

cracks

and

openings

to

adjacent

areas.

shirt,

cuftless

trousers,

high

shoes,

and

a

cap.

FLYING

SPARKS

AND

HOT

METAL

can

cause

injury.

Chipping

and

grinding

cause

flying

metal.

As

welds

cool,

they

can

throw

off

slag.

ELECTRIC

SHOCK

can

kill.

~

Touching

live

electrical

parts

can

cause

fatal

shocks

or

severe

burns.

The

electrode

and

work

circuit

is

electrically

live

whenever

the

output

is

on.

The

input

power

circuit

and

machine

internal

circuits

are

also

live

when

power

is

on.

In

semiautomatic

or

automatic

wire

welding,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live.

Incorrectly

installed

or

improperly

grounded

equipment

is

a

hazard.

1.

Do

not

touch

live

electrical

parts.

2.

Wear

dry,

hole-free

insulating

gloves

and

body

protection.

3.

Insulate

yourself

from

work

and

ground

using

dry

insulating

mats

or

covers.

4.

Disconnect

input

power

or

stop

engine

before

installing

or

servicing

this

equipment.

5.

Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual

and

national,

state,

and

local

codes.

6.

When

making

input

connections,

attach

proper

grounding

conductor

first.

7.

Turn

off

all

equipment

when

not

in

use.

8.

Do

not

use

worn,

damaged,

undersized,

or

poorly

spliced

cables.

9.

Do

not

wrap

cables

around

your

body.

10.

Ground

the

workpiece

to

a

good

electrical

(earth)

ground.

11.

Do

not

touch

electrode

if

in

contact

with

the

work

or

ground.

12.

Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

13.

Wear

a

safety

harness

if

working

above

floor

level.

14.

Keep

all

panels

and

covers

securely

in

place.

1.

Wear

approved

face

shield

or

safety

goggles.

Side

shields

recommended.

2.

Wear

proper

body

protection

to

protect

skin.

sri

9/92

CYLINDERS

can

explode

if

damaged.

Shielding

gas

cylinders

contain

gas

under

high

pressure.

If

damaged,

a

cylinder

can

explode.

Since

gas

cylinders

are

normally

part

of

the

welding

process,

be

sure

to

treat

them

carefully.

1.

Protect

compressed

gas

cylinders

from

excessive

heat.

mechanical

shocks,

and

arcs.

2.

Install

and

secure

cylinders

in

an

upright

position

by

chaining

them

to

a

stationary

support

or

equipment

cylinder

rack

to

prevent

falling

or

tipping.

3.

Keep

cylinders

away

from

any

welding

or

other

electrical

circuits.

4.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

5.

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

in

good

condition.

6.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

7.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

in

use

or

connected

for

use.

8.

Read

and

follow

instructions

on

compressed

gas

cylinders.

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

Standards.

ENGINE

FUEL

can

cause

fire

or

1.

Stop

engine

before

checking

or

adding

fuel.

explosion.

2.

Do

not

add

fuel

while

smoking

or

if

unit

is

near

any

sparks

or

open

flames.

3.

Allow

engine

to

cool

before

fueling.

If

possible,

check

and

add

Engine

fuel

is

highly

flammable,

fuel

to

cold

engine

before

beginning

job.

4.

Do

not

overfill

tank



allow

room

for

fuel

to

expand.

5.

Do

not

Spill

fuel.

If

fuel

is

spilled,

clean

up

before

Starting

enciine.

3.

Have

only

qualified

people

remove

guards

or

covers

for

maintenance

and

troubleshooting

as

necessary.

4.

To

prevent

accidental

starting

during

servicing,

disconnect

negative

()

battery

cable

from

battery.

5.

Keep

hands,

hair,

loose

clothing,

and

tools

away

from

moving

parts.

6.

Reinstall

panels

or

guards

and

close

doors

when

servicing

is

finished

and

before

starting

engine.

SPARKS

can

cause

BATTE

TO

EXPLODE;

BATTERY

RYGASES

ACID

can

1.

2.

Always

wear

Stop

engine

a

faces

before

hield

when

working

on

a

battery.

disconnecting

or

connecting

battery

burn

eyes

and

skin,

cables.

3.

Batteries

contain

acid

and

generate

explosive

4.

Do

not

allow

tools

to

cause

sparks

when

working

on

a

battery.

Do

not

use

welder

to

charge

batteries

or

jump

start

vehicles.

gases.

5.

Observe

correct

polarity

(+

and

)

on

batteries.

PRINCIPAL

SAFETY

STANDARDS

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.1,

from

American

Welding

Society,

550

NW.

LeJeune

Ad,

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.

Sri

9/92

Safe

Handling

of

Compressed

Gases

in

Cylinders.

CGA

Pamphlet

P.1,

from

Compressed

Gas

Association,

1235

Jefferson

Davis

High.

way,

Suite

501,

Arlington,

VA

22202.

Code

for

Safety

in

Welding

and

Cutting,

CSA

Standard

Wi

17.2,

from

Canadian

Standards

Association,

Standards

Sales,

i

78

Rexdale

Bou

levard.

Rexdale,

Ontario,

Canada

M9W

1

R3.

Safe

Practices

For

OccupationAnd

Educational

EyeAnd

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.

a

WARNING

ENGINES

can

be

hazardous.

ENGINE

EXHAUST

GASES

can

kill.

1.

Use

equipment

outside

in

open,

well-ventilated

areas.

2.

If

used

in

a

closed

area,

vent

engine

exhaust

outside

and

Engines

produce

harmful

exhaust

gases.

away

from

any

building

air

intakes.

MOVING

PARTS

can

cause

injury.

Moving

parts,

such

as

fans,

rotors,

and

belts

can

cut

fingers

and

hands

and

catch

loose

clothing.

1.

Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

2.

Stop

engine

before

installing

or

connecting

unit.

~.

~

.

(~\

~

L

STEAM

AND

COOLANT

can

skin.

The

coolant

in

the

under

pressure.

PRESSURIZED

burn

face,

eyes,

radiator

can

be

very

h

HOT

and

ot

and

1.

2.

3.

Do

not

remove

radiator

cap

when

engine

is

hot.

Allow

engine

to

cool.

Wear

gloves

and

put

a

rag

over

cap

area

when

removing

cap.

Allow

pressure

to

escape

before

completely

removing

cap.

TABLE

OF

CONTENTS

SECTION

1



SAFETY

IN

FORMATION

1

SECTION

2

SPECIFICATIONS

1

SECTION

3

INSTALLATION

3-1.

Installing

Swivel

Into

Pipe

Post

2

3-2.

Installing

Boom

And

Reel

Support

2

3-3.

Installing

Wire

Guide

Extension

3

3-4.

Wire

Guide

And

Drive

Roll

Installation

3

3-5.

Welding

Gun

Connections

4

3-6.

Wire

Feed

Motor,

Gas

Valve,

And Reed

Relay

Connections

5

3-7.

Control

Connection

6

3-8.

Shielding

Gas

And

Weld

Cable

Connections

7

3-9.

Removing

Safety

Collar

And

Adjusting

Boom

8

3-10.

Welding

Wire

Installation

8

3-11.

MotorStartControl

10

3-12.

Threading

Welding

Wire

10

SECTION

4

GLOSSARY

12

SECTION

5OPERATION

5-1.

Front

Panel

Controls

14

5-2.

Side

Panel

Controls

16

5-3.

Rear

Panel

Controls

16

SECTION

6

STEPPING

THROUGH

THE

MICROPROCESSOR

CONTROLS

6-1.

Front

Panel

Microprocessor

Controls

18

6-2.

Side

Panel

Microprocessor

Push

Buttons

20

SECTION

7

STANDARD

PULSE

WELDING

PROGRAMS

22

SECTION

8

GETTING

STARTED

8-1.

Welding

With

Only

Front

Panel

Controls

32

8-2.

Setting

Sequence

Pulse

Welding

Parameters

On

Side

Panel

Display

33

SECTION

9

TEACHING

A

PULSE

WELDING

PROGRAM

9-1.

Pulse

Waveform

Explained

37

9-2.

Teach

Points

Explained

38

9-3.

Teaching

A

Pulse

Welding

Program

39

9-4.

Changing

To

Adaptive

Pulse

Welding

41

SECTION

10-TEACHING

A

MIG

WELDING

PROGRAM

42

SECTION

11



SETTING

DUAL

SCHEDULE

PARAMETERS

46

SECTION

12

USING

THE

DATA

CARD

12-1.

Installing

Data

Card

48

12-2.

Using

The

Data

Card

48

12-3.

Naming

Programs

50

OM.1586C

7193

SECTION

13

SECURITY

&

SETUP

13-1.

Security/Setup

Flow

Chart

52

13-2.

Using

Security/Setup

Screens

53

13-3.

Selecting

Security

Lock

54

13-4.

Selecting

Or

Changing

Access

Code

55

13-5.

Selecting

Type

Of

Dual

Schedule

Switch

56

13-6.

Selecting

Trigger

Program

Select

57

13-7.

Selecting

Remote

Increase/Decrease

Capability

57

13-8.

Using

Self

Test

58

13-9.

Resetting

Memory

59

13-10.

Selecting

Program

Name

Feature

59

13-11.

Selecting

Units

For

Wire

Feed

Speed

And

Motor

Type

60

13-12.

Selecting

Voltage

Sensing

Method

60

13-13.

Selecting

Voltage

Error

Shutdown

61

13-14.

Resetting

Arc

Time

61

13-15.

Selecting

Bench

Or

Boom

Model

Type

61

13-16.

Selecting

Regular

Or

Hot Arc

Start

62

13-17.

Selecting

Voltage

Correction

62

13-18.

Software

Version

Number

62

SECTION

14

MAINTENANCE

&

TROUBLESHOOTING

14-1.

Routine

Maintenance

63

14-2.

Replacing

The

Hub

Assembly

63

14-3.

Overload

Protection

64

14-4.

Error

Screens

64

14-5.

Diagnostic

Indicator

LEDs

65

14-6.

Troubleshooting

66

SECTION

15

ELECTRICAL

DIAGRAMS

68

SECTION

16

PARTS

LIST

Figure

16-1.

Main

Assembly

72

Figure

16-2.

Support,

Hub

&

Reel

75

Figure

16-3.

Control

Box

76

Figure

16-4.

Wire

Drive

Assembly

79

Figure

16-5.

Boom

Assembly

80

Table

16-1.

Drive

Roll

&

Wire

Guide

Kits

82

SECTION

1



SAFETY

INFORMATION

modl.l

2/93



Read

all

safety

messages

throughout

this

manual.



Obey

all

safety

messages

to

avoid

injury.



Learn

the

meaning

of

WARNING

and

CAUTION.

!S~t~;1~II~eU

Figure

1-1.

Safety

Information

SECTION

2

SPECIFICATIONS

Table

2-1.

Wire

Feeder

Specification

.

Description

Type

Of

Input

Power From

Welding

Power

Source

Single-Phase

24

Volts

AC,

10

Amperes,

50/60

Hertz

Maximum

Weld

Circuit

Rating

100

Volts,

750

Amperes,

100%

Duty

Cycle

Welding

Power

Source

Type

Constant

Voltage

(CV)

DC,

With

Corttactor

Wire

Feed

Speed

Range

Standard:

50

To

780

ipm

(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)

Wire

Diameter

Range

.023

Thru

1/8

in

(0.6

To

3.2

mm)

Welding

Process

Gas

Metal

Arc

(GMAW),

Gas

Metal

Arc

-

Pulse

(GMAW-P).

Flux

Cored

Arc

Welding

(FCAW)

Input

Power

Cord

Maximum

Height

With

4

ft

(1.2

m)

Post

10

ft

(3.1

m)

12

ft

(3.7

m)

Boom

16

ft

(4.9

m)

Boom

17

ft

(5.2

m)

21

ft

(6.4

m)

Weight

Net:

160

lb

(73

kg)

Net:

210

lb

(95

kg)

Ship:

280

lb

(127

kg)

Ship:

350

lb

(159

kg)

Vertical

Lift

Of

Boom

Horizontal

To

60

Above

Horizontal Horizontal

To

60

Above

Horizontal

1

2

\.

2

\.

/

a

CAUTION

L

~

ELECTRIC

SHOCK

can

kill

i?

~

_____________________________



MOVING

PARTS

can

Injure.



Do

not

touch

live

electrical

parts

~



Keep

away

from

moving

parts.



Disconnect

input

power

before

installing

or

servicing.

Jj

~



Keep

all

panels

and

covers

closed

when

operating.

5

6

a

WARNING

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.

READ

SAFETV

BLOCKS

at

start

of

Section

3-1

before

proceeding.

N

OTE

~

Turn

Off

switch

when

using

high

frequency.

OM-1586

Page

1

SECTION

3INSTALLATION

3-1.

Installing

Swivel

Into

Pipe

Post

a

WARNING

I,

RELEASE

OF

SPRING

PRESSURE

WITHOUT

BOOM

ATTACHED

can

cause

serious

personal

injury.



Do

not

remove

safety

coltar

until

instructed

to

do

so.

FALLING

BOOM

can

cause

serious

personal

injury

and

equipment

damage.



Securely

mount

pipe

post

to

base

that

can

support

weight

of

unit

with

boom

in

horizontal

position.



Use

proper

equipment

for

lifting

swivel

and

boom

into

place.

Figure

3-1.

Swivel

Installation

READ

SAFETY

BLOCKS

at

start

of

Section

3-1

before

proceeding.

Figure

3-2.

Boom

Installation

5

4

3

1

Swingpak

Base

or

CBC

Cart

2

Pipe

Post

With

Base

3

Steel

Bolt

Secure

as

shown

using

as

a

mini

mum

1/2

in

diameter

SAE

grade

5

steel

bolts.

4

Swivel

Assembly

Insert

into

pipe

post.

.

Lubricate

swivel.

5

Safety

Collar

Do

not

remove

until

instructed

to.

Tools

Needed:

~

3/4

in

ST-152

268

3-2.

Installing

Boom

And

Reel

Support

2

5

Bolt

Install

bolt,

tighten

hardwa

re,

and

back

bolt

off

one

half

turn.

6

Locking

Knob

Install

locking

knob

but

do

not

tighten.

7

Reel

Support

Tools

Needed:

.

Install

reel

support.

3/8,3/4

in

ST.142

598-B

OM-1586

Page

2

3-3.

Installing

Wire

Guide

Extension

Figure

3-3.

Wire

Guide

Extension

Installation

3-4.

Wire

Guide

And

Drive

Roll

Installation

a

WARNING

1

Wire

Guide

Fitting

2

Bolt

3

Monocoil

Liner

4

Wire

Guide

Extension

Tighten

bolt

to

secure

liner

in

wire

guide

fitting.

Do

not

overtighten

bolt

and

crush

liner.

Tools

Needed:

~

3/8

in

ST-i

52

323

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.

wfwami.i

2/93

A.

Wire

Guide

Installation

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

3-5).

2

Wire

Guide

Securing

Screws

Loosen

wire

guide

screws.

3

Inlet

Wire

Guide

4

Intermediate

Wire

Guide

Insert

intermediate

guide

until

flange

on

guide

rests

against

cast

ing,

and

secure

with

guide

screw.

Install

drive

rolls

(see

Figure

3-5).

Tools

Needed:

Ref.

ST-137

391-F

/

ST-142

591-A

Figure

3-4.

Wire

Guide

Installation

OM-1586

PageS

B.

Drive

Roll

Installation

Figure

3-5.

Drive

Roll

Installation

3-5.

Welding

Gun

Connections

A

WARNING

4

3

6

2

3

When

changing

wire

size

ov

type,

check

drive

roll

size

(see

Table

16-1).

1

Spring

Shaft

Carrier

Close

spring

shaft

carrier.

2

Drive

Roll

Nut

3

Drive

Roll

Carrier

Turn

all

nuts

one

click

until

lobes

of

nut

line

up

with

lobes

of

drive

roll

carrier.

Open

spring

shaft

carrier.

4

Drive

Roll

Slide

drive

rolls

onto

drive

roll

carri

ers.

Close

spring

shaft

carrier.

Turn

nut

one

click.

5

Drive

Assembly

Cover

Close

cover.

ST-142

597-A

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.

wfwarnl.l

2/93

1

Drive

Assembly

Cover

2

Gun

Securing

Knob

3

Gun

Connector

Loosen

securing

knob.

Insert

gun

connector

until

it

bottoms

against

drive

assembly.

Tighten

knob.

4

Gun

Trigger

Plug

5

Gun

Trigger

Receptacle

Insert

plug

into

free-hanging

recep

tacle

and

tighten

threaded

collar.

6

Trigger

Cord

7

Trigger

Plug

$

Weld

Control

Trigger

Receptacle

Insert

plug

into

receptacle

and

tighten

threaded

collar.

Ref.

ST.I

52

466

/

ST-i

52

321

/

Ref.

ST-I

57

434

Figure

3-6.

Gun

And

Trigger

Lead

Connections

OM-1586

Page

4

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