Miller KD348472 Owner's manual

Category
Welding System
Type
Owner's manual

This manual is also suitable for

Millerfi
January1993
Form:
OM-1586B
Effective
With
Serial
No.
KD348472
OWNERS
MANUAL
SS-64M
Boom
Mounted
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.
Mia~oprocessor
Contro4led
Constant
Speed
Wire
Feeder
For
Use
With
Maxtron
450
Welding
Power
Source
For
GMAW,
GMAW-P,
And
FCAW
Welding
For
.023
To
1/8
Inch
(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
Give
this
manual
to
the
operator.
For
help,
call
your
distributor
or:
MILLER
ELECTRIC
Mfg.
Co.,
P.O.
Box
1079,
Appleton,
WI
54912
414-734-9821
cover
8/92
ST-i
57388
PRINTED
IN
USA
F
MILLERS
TRUE
BLUE1M
LIMITED
WARRANTY
Effective
January
1,1992
(Equipment
with
a
serial
number
preface
of
KC
or
newer)
This
limited
werrenty
supersedes
all
previoss
MILLER
werrenties
end
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
I
ii
LIMITED
WARRANTY
Subjectto
the
terms
snd
conditions
below.
MILLER
Electric
Mtg.
Co..
Appleton,
Wisconsin.
warrants
to
its
original
retail
purchaser
that
new
MILLER
equipment
sold
aher
the
effective
date
of
this
limited
warranty
is
tree
of
de
tects
in
material
snd
workmanship
at
lhe
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
wilt
repair
or
replace
any
war
ranted
parts
or
components
that
tail
due
to
such
detects
in
material
or
workmanship.
MILLER
must
be
notihed
in
writing
within
thirty
(30)
days
of
such
defect
or
failure,
at
which
time
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
Ihat
Ihe
equipment
was
delivered
to
the
original
retail
purchaser,
and
are
as
tollows:
1.
5
Years
Parts
3
Years
Labor
Original
main
power
rectihers
2.
3
Yearn
Parts
and
Labor
Transformer/Rectifier
Power
Sources
Plasma
Arc
Cusing
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
manufacturer)
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
BluenM
for
the
remaining
warranty
period
of
the
product
they
are
installed
in.
or
for
a
minimum
ot
one
yesr
whichever
is
greater.)
5.
6
Months
Baseries
6.
90
Days
Parts
and
Labor
*
MIG
Gunn/TIG
Torches
*
Plasma
Cusing
Torches
Remote
Controls
*
Accessory
Kits
*
Replacement
Parts
MILLERS
True
BluerM
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
warranty,
if
any.
2
Consumable
components;
such
as
contact
tips,
cutting
nozzles,
contactors
and
relays.
3.
Equipment
that
has
been
moditied
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
eouipment.
MILLER
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USE
BY
COMMER
CIAL/INDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT.
In
the
event
of
a
warranty
claim
covered
by
this
warranty,
the
esclusive
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
stan
authorized
MILLER
service
station:
or
(4)
payment
ofor
credit
for
the
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
customers
risk
and
eepense.
MILLERS
option
of
repair
or
replacement
will
be
FO
B..
Factory
at
Appleton,
Wisconsin.
or
FOB.
at
a
MILLER
authorized
ser
vice
facility
as
determined
by
MILLER.
Therefore
no
compensation
or
reimburse
ment
for
transportation
costs
of
any
kind
will
be
allowed.
TO
THE
EXTENT
PERMfTTED
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
CONSEOUENTIAL
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
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,
WtTH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
Some
states
in
the
U.S.A.
do
not
allow
limitations
of
how
long
an
implIed
warranty
lasts,
or
the
eaclusion
of
incidental,
indirect,
special
or
consequential
damages,
so
the
above
limitation
or
esclusion
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
for
certain
additional
warrantIes
or
remedies
other
than
as
stated
herein,
and
to
the
extent
thst
they
may
not
be
waived,
the
limitations
and
eaclusions
set
out
above
may
not
apply.
This
Limited
Warranty
provides
specific
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
province
to
province.
RECEIVING-HANDLING
Before
Unpacking
equipment,
check
carton
for
any
damage
that
may
have
occurred
during
shipment.
File
any
c)aims
for
loss
or
damage
with
the
delivering
carrier.
Assistance
for
filing
or
sett)ing
c)aims
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
St-y)e
Number.
Use
the
fo)lowing
spaces
to
record
Model
Designation
and
Serial
or
Sty)e
Number
of
your
unit.
The
information
is
located
on
the
rating
(abel
or
nameplate.
Model
_________
Serial
or
Style
No,
Date
of
Purchase
miller
5/92
ERRATA
SHEET
May
3,
1993
FORM:
OM-1586B
Use
above
FORM
number
when
ordering
extra
manuals.
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
CHANGES
TO
SECTION
14-
MAINTENANCE
&
TROUBLESHOOTING
Replace
Section
14-4.
Error
Screens
Figure
14-4.
Error
Screens
CHANGES
TO
SECTION
15
ELECTRICAL
DIAGRAMS
NOTE
I~
Use
Serial
Number
to
select
correct
diagram.
Replace
Figure
15-1.
Circuit
Diagram
For
Wire
Feeder
(see
Pages
2
through
5
on
this
Errata
Sheet)
Replace
Figure
15-2.
Wiring
Diagram
For
Wire
Feeder
(see
Pages
6
through
9
on
this
Errata
Sheet)
I
Release
Trigger
2
No
Volt
Sensed
3
Error
Prg
1
Er
ror
Prg
1
Er
ror
Memory
CRC
~ILI1
4
I
Release
Trigger
Error
Screen
This
appears
if
the
trigger
is
closed
when
the
unit
power
is
turned
on,
or
if
the
trigger
is
stuck
or
defective.
2
No
Volt
Sensed
Error
Screen
The
arc
voltage
sense
circuit
Is
not
receiving
feedback.
Check
voltage
sensing
connections.
Check
con
nections
at
17-position
plugs/recep
tacles
at
the
unit
and
welding
power
source.
Turn
unit
off
and
back
on
after
cor
recting
problem.
3
Memory
CRC
Error
Screen
The
data
in
the
program
indicated
is
not
the
same
data
that
was
saved.
Perform
a
system
reset.
4
Memory
Range
Error
Screen
The
data
in
the
program
indicated
is
out
of
usable
range.
Perform
a
system
reset.
Memory
Range
00
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With
Serial
No.
KD403197
I~PDNT
PC
0
MIcR~g~ES&p
OCAPO
PC
10/PIG
10
PC Il/PIG
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PC
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PC
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5
L
2
OM-1586B
Page
4
r
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RCGO/PLGGO
RCRI/PLG5I
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RCG3/P1.G7S
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PC
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A
CQ#ECI
TO
POWER
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C
L
SO-160
544
OM-15856B
Page
5
Figure
15-2.
Wiring
Diagram
For
Wire
Feeder
Effective
With
Serial
No.
KD383724
Thru
KD403196
OM-1
586B
Page
6
P020
FRONT
DISPLAY
PC
MOTOR
BOARD
PLG37
5C42
0
Pt-
IT~
I
PC
15/
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to
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51*
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OM-15856B
Page
7
Pc~
MOTOR
BOARD
PC23/PLG23
TRIGGER
II
P020
FRONT
DISPLAY
PL033
PLG28
Figure
15-2.
Wiring
Diagram
For
Wire
Feeder
Effective
With
Serial
No.
KD403197
OM-1586B
Page
8
(I
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z
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__________________
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CHANGES
TO
SECTION
16
PARTS
LIST
Change
Parts
List
as
follows:
Dia.
Part
Replaced
Mkgs.
No.
With
Description
Quantity
Model
12
16
73-3
139597
..
159992
..
CABLE,
interconnecting
(Effw/KD412179)
(consisting
of)
1
CABLE,
interconnecting
(Eff
w/KD41
2179)
(consisting
of)
1
047 636
....
CONNECTOR
&
PINS,
(consisting
of)
1
.
.
.
1
079
535
CONNECTOR,
circ
pin
push-in
14-l8ga
Amp
66359-6
158
734
. . . .
CABLE,
port
No.
18-14
9/c
(order
by
ft)
079
739
. . . .
CONNECTOR,
circ
clamp
str
rlf
sz
17-20
Amp
206322-2
1
. . .
1
73-
...
PLG33
...
Added
..
135
409
..
CONNECTOR
&
PINS,
(Eff
w/KD41
2179)
(consisting
of)
1
..
.
1
CONNECTOR,
rect
pin
24-l8ga
Molex
39-00-0040
8
. .
.
8
73-
...
RC37....
Added
..
047
637
..
CONNECTOR
&
SOCKETS,
(Eff
w/KD41
2179)
(consisting
of)
079
534
..
..
CONNECTOR,
circ
skt
14-l8ga
Amp
66358-6
020
279
..
Deleted
..
Eff
w/KD41
2179
150998
..
157295
..
GUIDE,
monocoil
1
..
.1
604612
..
604612..
SCREW,
(qtychg)
146
544
. .
159
646
. .
CLAMP,
motor
base
(Eff
w/KD372904)
Added
..
159
647
..
INSULATOR,
motor
clamp
(Eff
w/KD372904)
74-
Added
..
159
360
..
INSULATOR,
screw
machine
(Eff
w/KD372904)
77-30
110
015
..
158
735
..
CABLE,
port
No.
18/14
7c
(order
by
if)
78-44
144
842
..
153 169
..
ACTUATOR,
switch
81-2
139
338
..
159
991
..
BOOM,
single
(Eff
w/KD41
2179)
1
81-2
139643
..
159989
..
BOOM,
single
(Effw/KD412179)
1
~First
digit
represents
page
no
digits
following
dash
represent
item
no.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
73-3
139598
..
159990
PLG37,38
114656
14..
14
l7ft
.2lft
73-22
73-28
73-29
74-34
74-
1
...1
14..
14
2...2
1
...1
1
...1
4.4
l2ft
.l2ft
8...8
OM~1586B
Page
10
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
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.
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
next
page.
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;
ARC
RAYS
~
NOISE
can
damage
hearing.
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
Arc
rays
from
the
welding
process
produce
intense
eyes
when
welding
or
watching.
heat
and
strong
ultraviolet
rays
that
can
burn
eyes
3.
Wear
approved
safety
glasses.
Side
shields
recommended
and
skin.
Noise
from
some
processes
can
damage
hearing.
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
approved
ear
plugs
or
ear
muffs
if
noise
level
is
high.
material
(wool
and
leather)
and
foot
protection.
I
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
I
I
Welding
produces
fumes
and
gases.
Breathing
welding
can
displace
air
causing
injury
or
death.
Be
sure
the
~
I
these
fumes
and
gases
can
be
hazardous
to
your
breathing
air
is
safe.
I
health.
I
6.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
1.
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
fumes.
form
highly
toxic
and
irritating
gases.
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
3.
If
ventilation
is
poor,
use
an
approved
air-supplied
respirator.
cadmium
plated
steel,
unless
the
coating
is
removed
from
the
4.
Read
the
Material
Safety
Data
Sheets
(MSDSs)
and
the
weld
area,
the
area
is
well
ventilated,
and
if
necessary.
while
manufacturers
instruction
for
metals,
consumables,
coatings,
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
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
contact
of
electrode
or
welding
wire
to
metal
objects
can
cause
sparks,
overheating,
or
fire.
7.
8.
Do
not
weld
on
closed
containers
such
as
tanks
or
drums
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
tire
1.
Protect
yourself
and
others
from
flying
sparks
and
hot
metal.
hazards.
2.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
9.
Do
not
use
welder
to
thaw
frozen
pipes.
3.
Remove
all
flammables
within
35
ft
(10.7
m)
of
the
welding
arc.
10.
Remove
stick
electrode
from
holder
or
cut
off
welding
wre
at
If
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
easily
go
through
small
cracks
and
openings
to
adjacent
areas.
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap
4
FLYING
SPARKS
AND
HOT
METAL
can
I
cause
Injury,
I
Chipping
and
grinding
cause
flying
metal.
As
welds
cool,
they
can
throw
off
slag.
1.
2.
Wear
approved
face
shield
or
safety
goggles.
Side
sr,eids
recommended.
Wear
proper
body
protection
to
protect
skin.
~.
i,:
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.
I.
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.
a
WARNING
A
I
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.
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.
Safe
Handling
of
Compressed
Gases
in
Cylinders.
CGA
Pampriiet
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
kigh.
way,
Suite
501,
Arlington,
VA
22202.
Code
for
Safety
in
Welding
and
Cutting,
CSA
Standard
Wi
1
7
2
f~Om
Canadian
Standards
Association,
Standards
Sales,
178
Pe~daie
Bou
levard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
Safe
Practices
For
Occupation
And
Educational
Eye
And
Face
Potec
tion,
ANSI
Standard
Z87.1,
from
American
National
Stancaros
Institute,
1430
Broadway,
New
York,
NY
10018.
Cutting
And
Welding
Processes,
NFPA
Standard
51B,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269
ENGINES
can
be
hazardous.
ENGINE
EXHAUST
GASES
can
kill.
1.
Use
equipment
outside
in
open,
well-ventilated
areas.
Engines
pr
oduce
harmful
exhaust
gases.
2.
If
used
in
a
closed
area,
vent
engine
exhaust
outside
and
away
from
any
building
air
intakes.
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.
,
Engine
fuel
is
highly
flammable.
3.
4.
5.
Allow
engine
to
cool
before
fueling.
If
possible,
check
and
add
fuel
to
cold
engine
before
beginning
job.
Do
not
overfill
tank
allow
room
for
fuel
to
expand.
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
troubleshooting
as
necessary.
Moving
parts,
such
as
fans,
rotors,
and
belts
can
cut
fingers
and
hands
and
catch loose
clothing,
4.
To
prevent
accidental
starting
during
servicing,
disconnect
negative
()
battery
cable
from
battery.
1.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
5.
Keep
hands,
hair,
loose
clothing,
and
tools
away
from
moving
parts.
securely
in
place.
6.
Reinstall
panels
or
guards
and
close
doors
when
servicing
is
2.
Stop
eng
ne
before
installing
or
connecting
unit.
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
lump
start
vehicles
~ases.
5.
Observe
correct
polarity
(+
and
)
on
batteries.
(.
~
STEAM
AND
COOLANT
can
skin.
The
coolant
in
the
under
pressure.
PRESSURIZED
HOT
burn
face,
eyes,
and
radiator
can
be
very
hot
and
1.
2.
3.
Donotremoveradiatorcapwhenengineishot.Allowengune
to
cool.
Wear
gloves
and
put
a
rag
over
cap
area
when
removing
cap
Allow
pressure
to
escape
before
completely
removing
cap
sr~
9/92
TABLE
OF
CONTENTS
SECTION
1
SAFETY
INFORMATION
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.
Motor
Start
Control
10
3-12.
Threading
Welding
Wire
11
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
GETFING
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
-
SElliNG
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
SECTION
13
SECURITY
&
SETUP
13-1.
Security/Setup
Flow
Chart
52
13-2.
Using
Security/Setup
Screens
53
13-3.
Selecting
Security
Lock
54
OM-15868-
b93
SECTION
13
SECURITY
&
SETUP
(Continued)
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
And
Wire
Drive
Kits
82
SECTION
1
-
SAFETY
INFORMATION
Read
all
safety
messages
throughout
this
manual.
U
Obey
all
safety
messages
to
avoid
injury.
Learn
the
meaning
of
WARNING
and
CAUTION.
SECTION
2-
SPECIFICATIONS
Table
2-1.
Wire
Feeder
modl.l
8~2
12
ft.
(3.7
m)
Boom
16
ft.
(4.9
m)
Boom
1
2
rr~~t~
I~Il~eU
2
ELECTRIC
SHOCK
can
klii.~
Do
r~t
touch
live
electrical
parts.
Dls~nne~
Input
p~et
before
4
installing
or
servicing.
a
CAUTION
/
5
MOVING
PARTS
can
Inlure.
Keep
away
from
n~1ng
parts.
Keep
all
panels
and
c~eie
crioeed
when
operating.
0
READ
SAFETY
BLOCKS
et
start
of
SectIon
3-1
before
proceeding.
1
Safety
Alert
Symbol
2
SignaiWord
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.
NOTE
CY
flrn
OFF
switch
when
using
high
frequency.
SpecIficatIon
Type
Of
Input
Power
From
Welding
Power
Source
Maximum
Weld
Circuit
Rating
Welding
Power
Source
Type
Wire
Feed
Speed Range
Single-Phase
24
Volts
AC,
10
Amperes.
50(60
Hertz
D.ecrlption
Wire
Diameter
Range
Welding
Process
Input
Power
Cord
100
Volts,
750
Amperes,
100%
Duty Cycle
Constant
Voltage
(CV)
DC.
With
Cont~
Standard:
5OTo
780
ipm
(1.3
To
l9en~m)
High
Speed:
92
To
1435
ipm
(2.3
To
36.5
mpm)
Low
Speed:
13
To
213
ipm
(0.34
To
5.3S
rn~m)
.023
Thru
1/8
in.
(0.6
To
3.2
mm)
Gas
Metal
Arc
(GMAW),
Gas
Ms~
Arc
-
Puls
(GMAW-P),
Flux
Cored
Arc
Welding
(FCAW)
lOft.
(3.1
m)
Maximum
Height
With
4
ft.
(1.2
m)
Post
Weight
17
ft.
(5.2
m)
Vertical
Lift
Of
Boom
21
ft.
(6.4
m)
Net:
160
lbs.
(73
kg)
Ship:
280
lbs.
(127
kg)
Horizontal
To
600
Above
Horizontal
Net:
210
lbs.
(95
kg)
Ship:
350
lbs.
(159
kg)
Horizontal
To
600
Above
Horizontal
OM-1
586
Page
1
SECTION
3INSTALLATION
3-1.
installing
Swivel
into
Pipe
Post
AA
WARNING
RELEASE
OF
SPRING
PRESSURE
FALLING
BOOM
can
cause
serious
WITHOUT
BOOM
ATTACHED
can
cause
personal
Injury
and
equipment
damage.
serIous
personal
Injury.
Securely
mount
pipe
post
to
base
that
can
support
Do
not
remove
safety
collar
until
instructed
to
dose.
weight
of
unit
with
boom
in
horizontal
position.
Use
proper
equipment
for
lifting
swivel
and
boom
into
place.
5
1
Swingpak
Base
or
CBC
Cart
2
Pipe
Post With
Base
3
Steel
Bolt
4
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
3
Do
not
remove
until
instructed
to.
A~
WARNING
Tools
Needed:
r~
3/4
in.
ST~152
268
FIgure
3-1.
Swivel
Installation
3-2.
Installing
Boom
And
Reel
Support
RELEASE
OF
SPRING
PRESSURE
A
mation
at
beginning
of
Section
3-1
ND
FALLING
BOOM
HAZARDS.
Read
safety
Infor
before
proceeding.
3
1
Swivel
Plates
2
Yoke
Remove
hardware
from
swivel
plates
and
yoke.
3Boom
Set
boom
into
swivel
as
shown.
4
Yoke
Pin
Install
pin
through
yoke.
Install
cot
ter
pin
and
spread
ends.
2
5
Bolt
Tools
Needed:
3/4
in.,
3/8
in.
Install
bolt,
tighten
hardwa
back
bolt
off
one
half
turn.
re,
and
6
Locking
Knob
Install
locking
knob
but
tighten.
do
not
7
Reel
Support
Install
reel
support.
ST-142
596-8
Figure
3-2.
Boom
Installation
OM-1586
Page
2
3-3.
Installing
Wire
Guide
Extension
3-4.
Wire
Guide
And
Drive
Roll
Installation
4~
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.
Figure
3-4.
Wire
Guide
Installation
wfwaml.1
~91
1
Wire
Guide
Fitting
2
Bolt
3
Monocoil
Liner
4
4
Wire
Guide
Extension
flghten
bolt
to
secure
liner
in
wire
guide
fitting.
Do
not
overtighten
bolt
and
crush
liner.
Tools
Needed:
C~ZJ===1]
3/8
in.
ST-152
323
FIgure
3-3.
Wire
Guide
Extension
installation
A.
Wire
Guide
instaiiation
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:
R~.
ST-137
391.E
I
ST-137
377.0
OM-1586
Page
3
B.
Drive
Roll
Installation
Figure
3-5.
Drive
Roll
Installation
4
When
changing
wire
size
or
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
dick
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
dick.
5
Drive
Assembly
Cover
Close
cover.
ST-142
597-A
2
3
3-5.
WeldIng
Gun
Connections
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.
I
Drive
Assembly
Cover
2
Gun
Securing
Knob
3
Gun
Connector
3
Loosen
securing
knob.
Insert
gun
connector
until
it
bottoms
against
drive
assembly.
Tighten
knob.
4
Gun
Trigger
Plug
5
Gun
Trigger
Receptade
lnsertplug
into
free-hanging
recep
tacle
and
tighten
threaded
collar.
6
Trigger
Cord
7
Tngger
Plug
8
Weld
Con~ol
Trigger
Receptacle
Insert
plug
into
receptacle
and
tighten
threaded
collar.
6
Figure
3-6.
Gun
And
Trigger
Lead
Connections
R&.
ST-152
486/ST-i
52
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Miller KD348472 Owner's manual

Category
Welding System
Type
Owner's manual
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