Miller SS-64M SWINGARC Owner's manual

September

1992

Form:

OM-1586

Effective

With

Serial

No.

KC296026

OWNERS

MANUAL



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.

SS-64M

Boom

Mounted

Wire

Feeder



Microprocessor

Controlled

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

57

388

PRINTED

IN

USA

S

I

MILLERS

TRUE

BLUEIM

LIMITED

WARRANTY

Effective

January

I,

1992

(Equipment

with

a

serial

number

preface

of

XC

or

newer)

This

limited

warranty

supersedes

all

warranties

and

is

exclusive

with

no

other

guarantees

or

warranties

espressed

or

implied.

1

.1

LIMITED

WARRANTY



Subject

to

the

terms

and

conditions

below.

MILLER

Electric

Mlg.

Co..

Appleton.

Wisconsin,

watrants

to

its

original

retail

purchaser

that

new

MILLER

equipment

sold

aher

the

effective

date

of

this

limited

warranty

is

tree

of

de

fects

in

material

and

workmanship

at

the

time

ills

shipped

by

MILLER.

THIS

WAR

RANTY

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTHER

WARRANTIES.

EXPRESS

DR

IMPLIED.

INCLUDING

THE

WARRANTIES

OF

MERCHANTABILITY

AND

FIT

NESS.

Within

the

warranty

periods

listed

below,

MtLLER

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

ot

such

detect

or

failure,

at

which

lime

MILLER

will

provide

instructions

on

the

warranty

ctainr

procedures

to

be

followed.

MILLER

shalt

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,

and

are

as

tolloieg:

1

5

Years

Parts



3

Years

Labor

Original

main

power

rectitiers

2.

3

Years



Parts

and

Labor



Transtormer/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

manutacturer)

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

tom

a

minimum

of

one

year



whichever

is

greater.)

5.

6

Months



Batteries

B.

aS

Days



Parts

and

Labor



MIG

Guns/TIG

Torches

*

Plasma

Cutting

Torches



Remote

Controls



Accessory

Kits

*

Replacement

Parts

MILLERS

True

Btuere

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,

it

any.

2.

Consumable

components;

such

as

contact

tips,

cutting

nozzles,

contactora

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

tor

operation

outside

of

the

specifications

for

the

equipment.

MILLER

PRDDUCTS

ARE

INTENDED

FDR

PURCHASE

AND

USE

BY

COMMER

CIALJINDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

IN

THE

USE

AND

MAINTENANCE

OF

WELDING

EQUIPMENT

In

the

event

01

a

warranty

claim

covered

by

this

warranty,

the

exclusive

remedies

shall

be,

at

MILLERS

option:

(I)

repair:

or

(2)

replacement:

or,

where

authorIzed

in

writing

by

MILLER

inappropriate

cases,

(3)

the

reasonable

cost

ot

repair

or

replace

ment

at

an

authorized

MILLER

service

station,

or

(4)

payment

of

or

credIt

tor

the

pur

chase

price

(lena

reasonable

depreciation

based

upon

actual

uee)

upon

return

of

the

goods

at

customers

risk

and

eapense.

MILLERS

option

ot

repair

or

replacement

will

be

F.D

B..

Factory

at

Appleton,

Wisconsin.

or

F

D.B.

at

a

MILLER

authorized

ser

vice

facility

as

determined

by

MtLLER

Theretore

no

compensation

or

reimburse

ment

tor

transportation

costs

of

any

kind

will

be

allowed.

TD THE

EXTENT

PERMITTED

BY

LAW,

THE

REMEDIES PROVIDED

HEREIN

ARE

TNE

SOLE

AND

EXCLUStVE

REMEDIES.

IN

ND

EVENT

SHALL

MILLER

BE

LIABLE

FOR

DIRECT,

INDIRECt

SPECIAL.

INCIDENTAL

DR

CONSEQUENTIAL

DAMAGES

(INCLUDING

LOSS

OF

PROFIT),

WHETHER

BASED

ON

CON

TRACT,

TDRT

GR

ANY

OTHER

LEGAL

THEDRY.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WAR

RANTY,

GUARANTY

DR

REPRESENTATION

AS

TO

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

OF

CONTRACT

TORT

OR

ANY

GTNER

LEGAL

THEORY

WHICH.

BUT

FOR

THIS

PROVISION,

MIGHT

ARISE

BY

IMPLICATION,

OPERATtON

OF

LAW,

CUSTOM

OF

TRADE

DR

COURSE

OF

DEALING,

IN

CLUDING

ANY

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OR

F1TNE5S

FOR

PARTICULAR

PURPOSE.

WITH

RESPECT

TO

ANY

AND

ALL

EQUIPMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

AND

DISCLAIMED

BY

MILLER.

Some

stales

in

the

U.S.A.

do

not

allow

limitations

of

how

long

an

implIed

warranty

lasts,

or

the

exclusion

oI

incidental,

indirect,

special

or

consequential

damages,

so

the

above

limitation

or

eaclunion

may

not

apply

to

you.

This

warranty

provides

ape

ciSc

legal

righta,

and

other

rights

may

be

available,

but

may

vary

from

stale

to

slate.

In

Canada,

legislation

in

aome

provinces

provides

for

certain

additional

warranllea

or

remedies

other

than

as

elated

herein,

and

to

the

estent

that

they

may

not

be

waived.

the

limitations

and

eaclusions

set

out

above

may

not

apply.

This

Limited

Warranty

provides

specilic

legal

rights,

and

other

rights

may

be

available.

but

may

vary

from

province

to

province.

r

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

bB

obtained

from

distributor

and/or

equipment

manufacturers

Transportation

Department.

When

requesting

information

about

this

equipment,

always

provide

Mode)

Designation

and

Serial

or

Style

Number.

Use

the

fol)owing

spaces

to

record

Mode)

Designation

and

Serial

or

Sty)e

Number

of

your

unit.

The

information

is

)ocated

on

the

rating

label

or

nameplate.

Model

__________

Serial

or

Style

No-

Date

of

Purchase

miller

5/92

ERRATA

SHEET

December

1,

1992

FORM:

OM-1586

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

9

PARTS

LIST

Change

Parts

List

as

follows:

Quantity

Replaced

Model

With

Description

12

16

600

324

..

CABLE,

weld

cop

strd

No.

4/0

(order

by

ft)

....

26ft

..

30ft

157818

..

CIRCUIT

CARD,

interface

1

....

1

**First

digit

represents

page

no



digits

following

dash

represent

item

no.

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

Dia.

**

Mkgs.

51-5

55-9

...

PC5O

Part

No.

600

323

156

742

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.

Do

not

touc~

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.

Turn

off

all

equipment

when

not

in

use.

Do

not

use

worn,

damaged,

undersized,

or

poorly

spliced

cables.

Do

not

wrap

cables

around

your

body.

Ground

the

workpiece

to

a

good

electrical

(earth)

ground.

Do

not

touch

electrode

while

in

contact

with

the

work

(ground)

circuit.

11.

Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

12.

Wear

a

safety

harness

to

prevent

falling

if

working

above

floor

level.

13.

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

Read

and

follow

all

Safety

Standards.

HAVE

ALL

INSTALLATION,

OPERATION,

MAINTENANCE,

AND

REPAIR

WORK

PERFORMED

ONLY

BY

QUALIFIED

PEOPLE.

I.

6.

7.

8.

9.

10.

._~

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.

1.

2.

3.

4.

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.

Wear

approved

safety

glasses.

Side

shields

recommended.

Use

protective

screens

or

barriers

to

protect

others

from

flash

and

glare;

warn

others

not

to

watch

the

arc.

Wear

protective

clothing

made

from

durable,

flame-resistant

material

(wool

and

leather)

and

foot

protection.

5.

Use

approved

ear

plugs

or

ear

muffs

if

noise

level

is

high.

..

~

FUMES

AND

GASES

can

be

hazardous

to

your

health.

Welding

producesfumes

and

gases.

Breathing

these

fumes

and

gases

can

be

hazardous

to

your

health.

5.

Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

wearing

an

air-supplied

respirator.

Shielding

gases

used

for

welding

can

displace

air

causing

injury

or

death.

Be

sure

the

breathing

air

is

safe.

a...,.~

6.

Do

not

weld

in

locations

near

degreasing,

cleaning,

or

spraying

1.

Keep

your

head

out

of

the

fumes.

Do

not

breath

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

(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

tire

or

explosion.

5.

Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.

Sparks

and

spatter

fly

off

from

the

welding

arc.

The

6.

Be

aware

that

welding

on

a

ceiling,

floor,

bulkhead,

or

partition

flying

sparks

and

hot

metaf,

weld

spatter,

hot

can

cause

fire

on

the

hidden

side.

workpiece,

and

hot

equipment

can

cause

fires

and

burns.

Accidental

contactof

electrodeorweldingwire

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

.

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.

Removeallflammableswithin35tt(10.7m)oftheweldingarc.lf

10.

Remove

stick

electrode

from

holder

or

cut

off

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,

cuffless

trousers,

high

shoes,

and

a

cap.

FLYING

SPARKS

AND

HOT

METAL

can

cause

injury,

1.

Wear

approved

face

shield

or

safety

goggles.

Side

shields

recommended.

Chipping

and

grinding

cause

flying

metal.

As

welds

cool,

they

can

throw

off

slag.

2.

Wear

proper

body

protection

to

protect

skin.

Sri

9i91

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

Safely

Standards.

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.

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

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.

Do

not

remove

radiater

cap

when

engine

is

hot.

Allow

engine

COOLANT

can

burn

face,

eyes,

and

to

cool.

skin.

.

2.

Wear

gloves

and

put

a

rag

over

cap

area

when

removing

cap.

The

coolant

in

the

radiator

can

be

very

hot

and

under

pressure.

3.

Allow

pressure

to

escape

before

completely

removing

cap.

PRINCIPAL

SAFETY

STANDARDS

Safety

in

We!ding

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,

Amen.

can

Welding

Society

Standard

AWS

F4.

1,

from

American

Welding

So

ciety,

550

N.W.

LeJeune

Ad,

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

Pamphlet

P-i,

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.

178

Rexdale

Bou

levard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

Protec

tion,

ANSI

Standard

Z87.1,

from

American

National

Standards

Insti

tue,

1430

Broadway,

New

York,

NY

10018.

Cutting

And

Welding

Processes,

NFPA

Standard

51

B,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

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.

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.

Sri

9f91

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.

~1otor

Start

Control

10

3-12.

Threading

Welding

Wire

11

SECTION

4OPERATION

4-1.

Front

Panel

Controls

12

4-2.

Side

Panel

Controls

14

4-3.

Rear

Panel

Controls

14

SECTION

5

PROGRAMMING

THE

MICROPROCESSOR

5-1.

Front

Panel

Microprocessor

Controls

16

5-2.

Side

Panel

Microprocessor

Push

Buttons

17

5-3.

Setting

Sequence

Welding

Parameters

On

Side

Panel

Display

19

5-4.

Setting

Dual

Schedule

Parameters

23

5-5.

Card

Screens

24

5-6.

Setting

MIG

Welding

Process

Parameters

28

5-7.

Pulse

MIG

Welding

29

SECTION

6

SECURITY

&

SETUP

6-1.

Security/Setup

Flow

Chart

33

6-2.

Using

Security/Setup

Screens

34

6-3.

Selecting

Security

Lock

35

6-4.

Selecting

Or

Changing

Access

Code

36

6-5.

Selecting

Type

Of

Dual

Schedule

Switch

37

6-6.

Selecting

Trigger

Program

Select

38

6-7.

Selecting

Remote

Increase/Decrease

Capability

38

6-8.

Using

SelfTest

39

6-9.

Resetting

Memory

40

6-10.

Selecting

Program

Name

Feature

40

6-11.

Selecting

Units

For

Wire

Feed

Speed

And

Motor

Type

40

6-12.

Selecting

Voltage

Sensing

Method

41

6-13.

Selecting

Voltage

Error

Shutdown

41

6-14.

ResettingArcTime

41

6-15.

Software

Version

Number

41

SECTION

7

MAINTENANCE

&

TROUBLESHOOTING

7-1.

Routine

Maintenance

42

7-2.

Replacing

The

Hub

Assembly

42

7-3.

Overload

Protection

43

7-4.

Error

Screens

43

7-5.

Diagnostic

Indicator

LEDs

44

7-6.

Troubleshooting

45

OM.1586



9/92

SECTION

8



ELECTRICAL

DIAGRAMS

.

46

SECTION

9

PARTS

LIST

Figure

9-1.

Main

Assembly

50

Figure

9-2.

Support,

Hub

&

Reel

53

Figure

9-3.

Control

Box

54

Figure

9-4.

Wire

Drive

Assembly

57

Figure

9-5.

Boom

Assembly

58

Table

9-1.

Drive

Roll

And

Wire

Drive

Kits

60

SECTION

1



SAFETY

IN

FORMATION



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

mcdl

I

892

1

2

a

WARNING

2

\

3

ELECTRIC

SHOCK

can

kill.

I



Do

not

touch

live

electrical

parts.



Disconnect

input

power

before

4

installing

or

servicing.

a

CAUTION

/

5

MOVING

PARTS

can

injure.

S

KeeP

away

from

moving

parts.

I



Keep

all

panels

and

covers

closed

I

when

operating.

I

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

READ

SAFETY

BLOCKS

at

start

of]

~

Section

3-1

before

proceeding

NOTE

~

Turn

OFF

switch

when

using

high

frequency.

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.

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

Description

Wire Diameter

Range

Welding

Process

Input

Power

Cord

100

Volts,

750

Amperes,

100%

Duty

Cycle

Constant

Voltage

(CV)

DC,

With

Contactor

Standard:

50

To

780

pm

(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

Thru

1/8

in.

(0.6

To

3.2

mm)

Gas

Metal

Arc

(GMAW),

Gas

Metal

Arc-

Pulse

(GMAW-P),

Flux

Cored

Arc

Welding

(FCAW)

lOft.

(3.1

m)

Maximum

Height

With

4

ft.

(1.2

m)

Post

Weight

12

ft.

(3.7

m)

Boom

17

ft.

(5.2m)

Vertical

Lift

Of

Boom

16

ft.

(4.9

m)

Boom

Net:

160

lbs.

(73

kg)

Ship:

280

lbs.

(127

kg)

21

ft.

(6.4

m)

Horizontal

To

600

Above

Horizontal

Net:

210

lbs.

(95

kg)

Ship:

350

lbs.

(159

kg)

Horizontal

To

600

Above

Horizontal

OM-1586

Page

1

SECTION

3INSTALLATION

3-1.

Installing

Swivel

Into

Pipe

Post

A

WARNING

IL

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

do

so.

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

2

Secure

as

shown

using

as

a

mini

mum

1/2

in.

diameter

SAE

grade

5

steel

bolts.

4

Sw

ivel

Assembly

Insert

into

pipe

post.

Lubricate

swivel.

5

Safety

Collar

._-~.

3

Do

~

not

remove

until

inst

ructed

to.

a

WARNING

Tools

Needed:

.~:

-:

3/4in.

ST-~52

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

FA

before

LLING

BOOM

HAZARDS.

Read

safety

infor

proceeding.

1

Swivel

Plates

2

Yoke

Remove

hardware

from

swivel

plates

and

yoke.

3

Boom

Set

boom

into

swivel

as

shown.

4

Yoke

Install

through

yoke.

Install

cot

ter

and

spread

ends.

2

5

Bolt

Tools

Ne

eded:

~-I~

3/4

in.,

3/8

in.

Install

bolt,

tighten

back

bolt

off

one

h

hardware,

and

alt

turn.

6

Locking

Knob

Install

locking

knob

but

do

not

tighten.

7

Reel

Support

Install

reel

support.

Figure

3-2.

Boom

Installation

ST-142

596-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

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.1

9/91

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:

11111JtJ

3/8

in.

Sr-152

323

A.

Wire

Guide

Installation

When

changing

wire

size

or

type,

check

guide

size

(see

Table

9-1).

1

Drive

Rolls

Remove

drive

rolls

before

installing

wire

guides

(see

Figure

3-5).

2

Wire

Guide

Securing

Screws

Loosen

wire

guide

screws.

3

InletWire

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-E

/

ST-137 377.0

Figure

3-4.

WIre

Guide

Installation

OM-1586

Page

3

B.

Drive

Roll

Installation

Figure

3-5.

Drive

Roll

Installation

3-5.

Weding

Gun

Connections

a

WARNING

wfwarnl.I

9/91

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.

4



When

changing

wire

size

or

type,

check

drive

roll

size

(see

Table

9-1).

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

2 3

6

5

4

3

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

8

Weld

Control

Trigger

Receptacle

Insert

plug

into

receptacle

and

tighten

threaded

collar.

Pel.

ST-152

466(51-152

321

/

Ret

ST-157

434

6

Figure

3-6.

Gun

And

Trigger

Lead

Connections

OM-1586

Page

4

3-6.

Wire

Feed

Motor,

Gas

Valve,

And

Reed

Relay

Connections

A.

Wire

Feed

Motor,

Gas

Valve,

And

Reed

Relay

Connections

B.

Shielding

Gas

Connections

To

Regulator/Flowmeter

3

1

Wire

Feed

Motor

And

Gas

Valve

Control

Receptacle

2

Plug

From

Boom

3

Cord

From

Boom

Insert

plug

from

boom

cord

into

re

ceptacle

on

rear

of

control,

and

tighten

threaded

collar.

4

Reed

Relay

Receptacle

Insert

plug

from

reed

relay

mounted

on

swivel

into

receptacle,

and

tighten

threaded

collar.

ST-i

57

433

/

Ret.

ST-157

434

Figure

3-7.

Boom

Connections

2

3

CO2

Flowmeter/Regulator

Obtain

gas

cylinder

and

chain

to

running

gear,

wall,

or

other

station

ary

support

so

cylinder

cannot

fall

and

break

off

valve.

1

Cap

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

CO2

Washer

5

Regulator

Install

onto

gas

cylinder

so

that

face

is

vertical.

6

Gas

Hose

Connection

7

Flowmeter

Fitting

has

5/8-18

right-hand

threads.

Obtain

gas

hose

with

fittings,

and

install

between

flow-

meter

and

welding

power

source.

8

Flow

Adjust

Typical

flow

rate

is

20

cfh

(cubic

feet

per

hour).

7

6

5

3

Argon

Or

Mixed

Gas

F(owmeter/Regulator

Tools

Needed:

~r

1-I/Sin.,

5/8

in.

Figure

3-8.

Gas

Supply

Connections

ssb3.1

2/92



SB-log

492-A

OM-1586

Page

5

3-7.

Control

Connection

I

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

conrlect

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

con

tactor

control

circuit.

G

Circuit

common

for

24

volts

ac

circuit.

Contactor

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).

H

Nonfunctional

at

this

time.

The

remaining

pins

are

not

used.

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

dc.

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.

The

remaining

pins

are

not

used.

ST-I

56

931

/

Ref.

S.051

2

/

5-0003-A

/

S-0628

Figure

3-9.

Control

Connections

With

Information

4

6

2

OM-1586

Page

6

3-8.

Shielding

Gas

And

Weld

Cable

Connections

a

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.

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.

I

BUILDUP

OF

SHIELDING

GAS

can

harm

health

or

kill.



Shut

off

shielding

gas

supply

when

not

in

use.

warn4

19/91

Figure

3-10.

Shielding

Gas

And

Weld

Cable

Connections

The

weld

cable

and

shielding

gas

hose

extend

10

ft.

(3

m)

from

the

boom.

Route

weld

cable

from

boom

through

reed

relay.

If

the

welding

power

source

or

gas

supply

are

further

from

the

boom,

extend

cable

or

hose

as

follows:

I

Weld

Cable

2

Insulated

Sleeving

Bolt

together

weld

cables

from

welding

power

source

and

boom.

Use

electrical

tape

and

insulated

sleeving

to

cover

connection.

3

Shielding

Gas

Hose

Connect

hose

to

gas

supply

or

ex

tension

hose.

The

hose

from

the

boom

has

5/8-18

right-hand

threads.

Tools

Needed:

~

5/Bin.

ST-152

800-A

OM-1586

Page

7

3-9.

Removing

Safety

Collar

And

Adjusting

Boom

a

WARNING

1+

RELEASE

OF

SPRING

PRESSURE

WITHOUT

BOOM

ATTACHED

can

cause

serious

personal

injury.



Do

riot

remove

safety

collar

untU instructed

to

do

so.

FALLING

BOOM

can

cause

serious

personal

injury

and

equipment

damage.



Adjustment

yoke.

rod

must

be

threaded

fully

through

3-10.

Welding

Wire

Installation

A.

Installation

Of

Spool-Type

Wire

Figure

3-11.

Boom

Adjustments

Figure

3-12.

Installation

Of

Spool-Type

Wire

3

1

Locking

Knob

Tighten

knob

to

prevent

boom

movement.

Loosen

knob

to

allow

boom

movement.

Change

knob

position

to

limit

upward

movement.

Pull

boom

down

slightly

and

re

move

safety

collar.

Boom

should

balance

in

any

position

from

hori

zontal

to

60

degrees

above

hori

zontal.

If

necessary,

adjust

boom

as

follows:

2

Threaded

Rod

3

Jam

Nut

V

Tools

Needed:

E

:~

1-1/Bin.

Loosen

jam

nut

and

turn

threaded

rod

until

boom

balances.

Tighten

jam

nut.

Be

sure

several

full

threads

are

through

yoke

to

pre

vent

boom

falling.

4

Yoke

Increasing

Spring

Pressure

For

A

Heavy

Gun

Retain

safety

collar

for

use

in

dis

assembling

or

moving

boom.

Decreasing

Spring

Pressure

ForA

Light

Gun

~ei.

ST-~52

380

1

Retaining

Ring

2

Wire

Spool

3

Hub

Remove

retaining

ring

and

slide

spool

onto

hub.

4

Hub

Turn

spool

until

hub

fits

hole

in

spool.

Reinstall

retaining

ring.

E

1

ST-152

648-A

2

OM-1

586

Page

8

B.

Installation

Of

Optional

Wire

Reel

And

Reel

Type

Wire

C.

Adjusting

Hub

Tension

Figure

3-13.

Installation

Of

Optional

Wire

Reel

And

Reel

Type

Wire

7

6

4~

1

Retaining

Ring

2

Spanner

Nut

3

Wire

Retainer

4

Wire

Reel

5

Nub

6

Hub

7

Reel

Support

Remove

retaining

ring

and

wire

reel

assembly

(wire

reel,

wire

re

tainer,

and

spanner

nut)

from

hub.

8

Wire

Installation

Lay

wire

reel

assembly

on

flat

sur

face,

and

install

wire

as

shown.

Slide

wire

reel

assembly

onto

hub,

and

turn

assembly

until

hub

is

seated

in

hole

in

reel.

Reinstall

re

taining

ring.

ST-143

478

f

ST-~52

463

3

2

1

HH

Figure

3-14.

Adjusting

Hub

Tension

OM-1586

Page

9

3-11.

Motor

Start

Control

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.

To

change

wire

feed

starting

speed

proceed

as

follows:

Turn

OFF

unit

and

wetding

power

source.

Figure

3-15.

Motor

Start

Control

On

Motor

Control

Board

PCi

Remove

screw

from

upper

left

cor

ner,

and

open

hinged

front

panel.

2

Motor

Board

PCi

3

Motor

Start

Control

Poten

tiometer

R70

Rotate

potentiometer

clockwise

to

increase

time

it

takes

the

motor

to

ramp

up

to

speed.

Remove

protec

tive

white

rubber

cap

before

making

adjustment.

Adjust

poten

tiometer

R70

using

a

small

non-

conductive

screwdriver.

Close

and

secure

front

panel,

and

reinstall

wrapper.

ST-157

480/

Ret.

58-146

862

4~

WARNING

STATIC

ELECTRICITY

can

damage

parts

on

circuit

boards.



Put

on

grounded

wrist

strap

BEFORE

handling

boards

or

parts.

wfwarnl.19/91

Remove

wrapper.

1

Front

Panel

2

Tools

Needed:

1/4

in.

OM-1586

Page

10

3-12.

Threading

Welding

Wire

A

WARNING

Tools

Needed:

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.

WELDING

WIRE

can

cause

puncture

wounds.



Do

not

press

gun

trigger

until

instructed

to

do

so.



Do

not

point

gun

toward

any

part

of

the

body,

other

people,

or

any

metal

when

threading

welding

wire.

HOT

SURFACES

can

burn

skin.



Allow

gun

to

cool

before

touching.

wtwarn2.i

/wiwarnl,i

9/91

1

Wire

Spool/Reel

Loosen

wire

from

spool/reel,

cut

off

bent

wire,

and

pull

6

in.

(150

mm)

of

wire

off

spool/reel.

2

Wire

Tube

Manually

feed

wire

through

tube,

over

pulley

and

into

monocoil

liner

at

wire

inlet

guide.

3

Wire

Guides

4

Drive

Rolls

Manually

feed

wire

through

wire

guide(s),

up

to

drive

rolls.

Turn

wire

feeder

and

welding

pow

er

source

ON

(see

Figure

4-9),

and

place

OUTPUT/CONTACTOR

switch

on

welding

power

source

in

REMOTE

position,

if

applicable.

5

Jog

Button

6

Gun

Conduit

Cable

Lay

gun

conduit

cable

out

straight.

Press

JOG

button

to

feed

welding

wire.

Apply

enough

hand

pressure

to

wire

to

allow

drive

rolls

to

grab

wire

to

start

jogging.

Release

switch

when

approximately

I

in.

(25

mm)

of

wire

extends

out

end

of

gun.

7

Pressure

Adjustment

Knob

8

Drive

Roll

Pressure

Indicator

Scale

9

Adjusting

Pressure

Check

drive

roll

pressure

by

feed.

ing

wire

against

a

wood

board

or

concrete

surface;

wire

should

feed

steadily

without

slipping.

Increase

drive

roll

pressure

by

turning

pres.

sure

adjustment

knob

clockwise.

The

drive

roll

pressure

indicator

scale

is

for

reference

only.

ST-i

57432

/

ST-i

53073

/

Ref.

S0827-A

/

Ref.

Sc-i

50922

FIgure

3-16.

ThreadIng

Welding

Wire

2

6

3

4

7

OM.1586

Page

11

SECTION

4

OPERATION

a

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Always

wear

dry

insulating

gloves.



Insulate

yourself

from

work

and

ground.



Keep

all

panels

and

covers

securely

in

place

FUMES

AND

GASES

can

be

hazardous

to

your

health.



Keep

your

head

out

of

the

fumes.



Ventilate

area,

or

use

breathing

device.



Read

Material

Safety

Data

Sheets

(MSDS5)

and

manufacturers

instructions

for

material

used.

WELDING

can

cause

fire

or

explosion.



Do

not

weld

near

flammable

material.



Watch

for

fire;

keep

extinguisher

nearby.

%Do

not

locate

unit

over

combustible

surfaces.



Do

not

weld

on

closed

containers.



Allow

work

and

equipment

to

cool

before

handtng.

Tools

Needed:

1

Work

Clamp

Use

wire

brush

or

sandpaper

to

clean

metal

at

weld

joint

area.

Use

chipping

hammer

to

remove

slag

after

welding.

Connect

work

clamp

to

a

clean,

paint-free

location

on

workpiece,

as

close

to

weld

area

as

possible.

2

Voltage

Sensing

Clamp

Connect

to

workpiece

(see

Section

Figure

3-10).

Ref.

SD.144

451A

Figure

4-2.

Work

And

Voltage

Sensing

Clamps

4-1.

Front

Panel

Controls

1

Display

2

Parameter

Select

Button

2

3

Jog

Button

:

4

Display

Control

Knob

5

Trigger

I-bId

Button

And

Indi

cator

Light

6

PurgeButton

See

Section

5

for

programming.

Ref.

Sr-155

222

Figure

4-3.

Front

Panel

Controls

=~w

~

,~

~

~~-

ARC

RAYS

can

burn

eyes

and

skin;

NOISE

can

damage

hearing.



Wear

welding

helmet

with

correct

shade

of

filter.



Wear

correct

eye,

ear,

and

body

protection.

'

~

MOVING

PARTS

can

cause

injury.

S

Keep

away

from

pinch

points

such

as

drive

rolls.



Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

I

~\

...

MAGNETIC

FIELDS

FROM

HIGH

CUR

RENTS

can

affect

pacemaker

operation.



Pacemaker

wearers

keep

away.



Wearers

should

consult

their

doctor before

gOing

near

any

welding

operations.

See

Safety

Precautions

at

beginning

of

manual

for

ba

sic

welding

safety

information.

-

~arn3.1

10/91

1

2

3

/

~

Figure

4-1.

Safety

Equipment

1

Insulating

Gloves

2

Safety

Glasses

With

Side

Shields

3

Welding

lielmet

Wear

dry

insulating

gloves,

safety

glasses

with

side

shields,

and

a

welding

helmet

with

a

correct

shade

of

filter

(see

ANSI

Z49.1).

sb3.1

10/91

OM-1586

Page

12

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