Page 1
OM-169 571
September 1995
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Adaptive Pulsed MIG (GMAW-P)
Description
Automatic Welding
Computer Interface II
Visit our website at
www.MillerWelds.com
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EMF INFORMATION
NOTE
The following is a quotation from the General Conclusions Section
of the U.S. Congress, Office of Technology Assessment, Biological
Effects of Power Frequency Electric & Magnetic Fields −
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
Government Printing Office, May 1989): “. . . there is now a very
large volume of scientific findings based on experiments at the
cellular level and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible
risk or t o o f fer clear science-based advice on strategies to minimize
or avoid potential risks.”
Considerations About Welding And The Effects Of Low Frequency Electric And
Magnetic Fields
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around the body.
4. Keep welding power source and cables as far away as
practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your doctor for
complete information.
TABLE OF CONTENTS
SECTION 1 − SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mod10.1 4/93
SECTION 2 − INSTALLATION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Connection Diagram 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Rear Panel Connections 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − OPERATIONAL TERMS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − OPERATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INTRODUCTION TO PROGRAMMING 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Programs 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Pulse Panel Microprocessor Push Buttons 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Selecting Welding Process 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − TEACHING A PULSE WELDING PROGRAM 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Pulse Waveform Explained 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Teach Points Explained 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Teaching A Pulse Welding Program 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − USING THE OPTIONAL DATA CARD 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Installing Data Card 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Using The Data Card 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − SETUP 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Setup Flow Chart 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Using Setup Displays 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Selecting Welding Power Source Range 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Selecting Security Lock 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Selecting Or Changing Access Code 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Selecting Voltage Correction 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-169 571 − 9/95
Page 4
8-7. Selecting Inductance 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8. Selecting Purge Time 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-9. Selecting Voltage Sensing Method 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-10. Selecting Regular Or Hot Arc Start 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-11. Resetting Arc Time 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-12. Selecting Units For Wire Feed Speed And Motor Type 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-13. Selecting Wire Type 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-14. Selecting Display 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-15. Resetting Memory 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-16. Selecting Arc Start/Volt Sense Error Shutdown 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-17. Selecting Program Name Feature 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-18. Remote Program Select 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-19. Stick Check Selection 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-20. Arc Voltage Error Selection 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-21. Software Version Number 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − MAINTENANCE & TROUBLESHOOTING 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Routine Maintenance 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Overload Protection 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Front Panel Error Displays 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − ELECTRICAL DIAGRAMS 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − PARTS LIST 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-1. Case Section w/Components 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-2. Panel, Center w/Components 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-3. Panel, Front w/Components 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 11-4. Panel, Rear w/Components 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page 5
3
1
5
6
7
SECTION 1 − SAFETY INFORMATION
Read all safety messages throughout this manual.
Obey all safety messages to avoid injury.
Learn the meaning of WARNING and CAUTION.
2
WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Disconnect input power before
installing or servicing.
WARNING
NOTE
Turn Off switch when using high frequency.
3
4
READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.
2
CAUTION
MOVING PARTS can injure.
• Keep away from moving parts.
• Keep all panels and covers closed
when operating.
mod1.1 2/9
1 Safety Alert Symbol
2 Signal Word
WARNING means possible death
or serious injury can happen.
CAUTION means possible minor
injury or equipment damage can
happen.
3 Statement Of Hazard And
Result
4 Safety Instructions To Avoid
Hazard
5 Hazard Symbol (If Available)
6 Safety Banner
Read safety blocks for each sym-
bol shown.
7 NOTE
Special instructions for best oper-
ation − not related to safety.
Figure 1-1. Safety Information
OM-169 571 Page 1
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SECTION 2 − INSTALLATION
2-1. Connection Diagram
2
1
3
1 Robot (Will Vary According To
Application)
2 Motor/Drive Assembly
3 Positive (+) Voltage Sensing
Lead
4 Gas Cylinder
5 Gas Hose
6 Robot Control
7 Fiber Optic Cable
8 Remote Program Select
Cable
9 Gas And Motor Control Cable
10 Interface Unit
6
4
5
11 Welding Power Source
12 17-Socket Plug And Intercon-
necting Cord
13 14-Socket Plug And Intercon-
necting Cord
14 Negative (−) Weld Cable
15 Workpiece
16 Negative (−) Voltage Sensing
Lead
17 Positive (+) Weld Cable
15
16
17
14
13
12
7
8
9
10
11
OM-169 571 Page 2
ST-801 354
Figure 2-1. Connection Diagram
Page 7
2-2. Rear Panel Connections
WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn Off robot, welding power source, and interface unit, and disconnect input power before inspecting or installing.
2
1
7
6
3
5
swarn1.1* 2/93
Select proper cord for connection.
To make connections, align keyway, insert plug into receptacle,
and tighten threaded collar.
1 Current Sensing Connection
This is used only when an older
Deltaweld welding power source is
used in the welding system.
2 Voltage Sensing Connection
3 Fiber Optic Connection
See Robot Owner’s Manual for
connection information if the Computer Interface is not factory
installed.
4 14-Pin Welding Power
Source Receptacle
5 17-Pin Welding Power
Source Receptacle
Choose correct cord or cords for
welding power source.
6 Gas And Motor Control
Receptacle
Connect remaining end of cord to
receptacle at base of robot.
7 Remote Program Select
Connection
4
Connect remnaining end of cord to
receptacle on robot controller.
Figure 2-2. Rear Panel Connections
Ref. S-0003-A / ST-801 353 / Ref. ST-801 146
OM-169 571 Page 3
Page 8
SECTION 3 − OPERATIONAL TERMS
The following is a list of terms and their definitions as they apply to this interface unit:
General Terms:
Adaptive Pulse Welding When the “adaptive pulse” welding process is selected, the unit will automati-
cally regulate pulse frequency in order to maintain a constant arc length, regardless of change in welding wire stickout.
Abk (Background
Amperage)
Apk (Peak Amperage) Apk is the high pulse of welding current. Peak current melts the welding wire
Inductance In short circuit GMAW welding, an increase in inductance will decrease the
PPS (Pulses Per Second) PPS, pulse rate, and frequency (Hz) are used interchangeably. A PPS or pulse
PWms (Pulse Width in
Milliseconds)
Synergic Synergic refers to the unit’s ability to use preprogrammed pulse parameters to
Trim Term used to represent arc length adjustments in pulse programs. Increasing
Abk is the low weld current. Background current preheats welding wire and
maintains the arc. When background current is too low, the arc is unstable and
hard to maintain.
and forms a droplet. The droplet is forced into the weld puddle.
number of short circuit metal transfers per second (provided no other changes
are made) and increase the arc-on time. The increased arc-on time makes the
pool more fluid.
rate of 60 Hz means 60 pulses of current are produced each second.
PWms is the time spent at peak current (1.2 ms is .0012 seconds). This time
must be long enough to form a droplet of welding wire. The stiffness or fluidity
of the molten weld puddle is controlled by PWms.
determine the actual pulse settings of Peak Amperage, Background Amperage,
Pulse Frequency and Pulse Width at any specific wire feed speed setting.
trim increases the actual arc length. Likewise, decreasing trim shortens arc
length. Trim is replaced by volts in MIG programs.
Pulse Panel Terms:
Card Mode Is used to select use of the optional data card storage and retrieval capabilities.
Process Mode Is used to select the type of process to be used, including Pulse, Adaptive
Pulse, or Mig.
Setup Screen Terms:
Access Code NOTE: The optional Data Card is required to activate this feature. With code
off, access to the setup displays is not restricted. With code on, the operator
must know and enter the access code to access or change any of the setup
displays.
To use code, press Parameter Select button to enter access code. When the
correct letter is entered, the indicator automatically moves to the next character.
When the final access code letter is entered, the display automatically changes
to the initial setup display.
Arc Start NOTE: Do not use the Hot Start setting for .035 in (9 mm) or smaller wire. Use
the Hot Start mode for pulse welding with 450 Ampere Inverter Model when
high initial weld current is necessary to start large diameter welding wires.
When in Hot Start, the 450 Ampere Inverter Model starts the arc in the CV
mode and switches to CC once the arc is started. Do not use Hot Start unless
using 450 Ampere Inverter Model
Arc Time Allows actual arc time up to 9,999.99 hours and weld cycles up to 999,999 to
be accumulated and displayed on the digital display, and can be reset to zero
as required.
OM-169 571 Page 4
.
Page 9
Mig Type (Voltage
Correction)
With DVC Voltage Correction On, the unit uses closed-loop feedback from the
17-pin cord or voltage sensing leads to maintain set voltage parameters. With
DVC Voltage Correction Off, feedback from the arc is not used for closed-loop
feedback to maintain voltage parameters. Feedback from the arc is still used for
other functions.
Be sure voltage sensing leads are connected or voltage feedback is available
through the 17-pin receptacle via the welding power source.
Name Feature When using the optional Data Card and turning the name feature on, programs
written to the card can be identified by name, number, job number, etc.
Program Reset By selecting program reset in the memory reset mode, the unit defaults to origi-
nal factory program settings for the program last active. All other program and
setup information remains the same.
Range The interface requires that the voltage and amperage range of the welding
power source be entered. Obtain this information from the welding power
source Owner’s Manual.
Security NOTE: The optional Data Card is required to activate this feature. Is used to
limit what the operator can control. This includes accessing the number of the
program, 1 through 8, and the range of welding parameters within the program.
Software Screen Selection of this function will display the software version of the unit. When talk-
ing with factory service personnel, this number may be required.
System Reset By selecting system reset in the memory reset mode, the unit defaults to origi-
nal factory settings for all programs and all set up excluding System, Arc Time,
and Model Type.
Voltage (Control Feedback) Allows voltage to be monitored at the output terminals by two methods. This
can be selected through the 17-pin cord connection if the welding power source
has a 17-pin receptacle, or through the unit’s external voltage sense lead.
If the 17 Pin setting is used, it is recommended that the voltage sensing terminals on the welding power source be used to monitor arc voltage at the workpiece.
When using the V. Sense setting, arc voltage feedback is through the voltage
sense leads connected to the feeder. Use this setting when there is more than
50 ft (15 m) of weld cable used.
Arc Start/Volt Sense
Shutdown
When this feature is on, the system immediately shuts down if no arc voltage is
sensed. An error message is displayed. When this feature is off, wire feeds
even when there is no arc voltage sensed.
Wire Feed Mode Allows the selection of inches per minute or meters per minute for wire feed
speed. This mode is also used to select motor type; standard speed, low
speed, or high speed. High speed motor is available as factory option.
OM-169 571 Page 5
Page 10
SECTION 4 − OPERATION
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 (MSDSs) 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 handling.
123
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.
• Keep away from pinch points such as drive rolls.
• Keep all doors, panels, covers, and guards closed
and securely in place.
MAGNETIC FIELDS FROM HIGH CURRENTS 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 basic welding safety information.
Wear the following while welding:
1 Dry, Insulating Gloves
2 Safety Glasses With Side
Shields
3 Welding Helmet With Correct
Shade Of Filter (See ANSI
Z49.1)
wfwarn3.1 8/92
Tools Needed:
Figure 4-1. Safety Equipment
1
Figure 4-2. Work Clamp
sb3.1 1/94
1 Work Clamp
Connect work clamp to a clean,
paint-free location on workpiece,
as close to weld area as possible.
Use wire brush or sandpaper to
clean metal at weld joint area. Use
chipping hammer to remove slag
after welding.
sb4.1* 2/93
OM-169 571 Page 6
Page 11
Front Panel
1 Display
2 Reset Button
After clearing an error, press this
button to reset the display.
3 Contactor On Light
Lights when welding power source
contactor is energized.
4 Wirefeed On Light
Lights when wirefeed motor is On.
5 Gas On Light
Lights when gas flow is On.
6 Purge Button
Push to energize gas valve. If a
purge time value is programmed,
the gas will flow for the programmed length of time. If a value
is not programmed, the gas flows
until the Purge button is released.
This button allows purging of air
from gun shielding gas line, and
adjusting shielding gas regulator
without energizing the welding
circuit.
7 Advance Button
Push to feed welding wire without
energizing welding circuit or
shielding gas valve.
Pulse Panel
8 Display
9 Data Card Slot
Insert optional data card here. See
Section 7 for information on using
the data card.
10 Increase Button
11 Decrease Button
12 Parameter Select Button
13 Mode Select Button
See Section 5 for information on
using pulse panel controls.
Rear Panel
14 Power Switch
User power switch to tun unit On
and Off.
14
2
Front Panel
Pulse Panel
34
8
9
10
11
12
13
1
7
6
5
Rear Panel
ST-801 352 / ST-801 353
Figure 4-3. Controls
OM-169 571 Page 7
Page 12
WARNING
BUILDUP OF SHIELDING GAS can harm health or kill.
• Shut off shielding gas supply when not in use.
2
1
Figure 4-4. Shielding Gas
warn1.1 9/91
1 Shielding Gas Cylinder
2 Valve
Open valve on cylinder just before
welding.
Close valve on cylinder when fin-
ished welding.
sb5.1* 6/92 − S-0621-C
Install & Connect
Interface Into
Welding System
Figure 4-5. Sequence Of Gas Metal Arc (GMAW), Gas Metal Arc - Pulse (GMAW-P),
Personal Safety
Adjust Weld
Parameters
As Needed
Put On
Equipment
Welding System
Equipment
Begin
Welding
Turn On
Turn On Shielding
Gas
And Flux Cored Arc Welding (FCAW)
Set switches as shown for all
welding processes when using
this interface unit.
Set All Controls
And Verify
Program Selection
Perform Test
Weld
ssb6.1* 9/92
Figure 4-6. Setting Switches On 450 Ampere Inverter Model Welding Power Source
OM-169 571 Page 8
Ref. ST-150 171-C / Ref. SC-154 197
Page 13
SECTION 5 − INTRODUCTION TO PROGRAMMING
5-1. Programs
A. General
1 Interface Unit
The interface unit is designed for
1
use in pulse MIG welding (adaptive
or standard), or MIG welding.
The unit is factory-equipped with
eight programs for pulse MIG welding (see Figure 5-2). The programs
contain parameters that maximize
welding performance for each
combination of wire and shielding
gas.
B. Pulse MIG Programs
Program
1
2
3
4
5
6
7 3/64” 5356, Argon
8 .035” SIB, Argon
.045” Steel, 309, Argon − CO2
Hardwire Selected*
.035” Steel, Argon − Oxy
.045” Steel, Argon − Oxy
.035” Steel, Argon − CO2
.045” Steel, Argon − CO2
.035” 309, Argon − CO2
Figure 5-1. Interface Unit
Softwire Selected*
.045” 4043, Argon
.045” 5356, Argon
.035” 4043, Argon
.035” 5356, Argon
1/16” 4043, Argon
1/16” 5356, Argon
.045” Steel, Argon − CO2
.045” Steel, Argon − Oxy
ST-801 351
The eight pulse programs are
shown in the table. Each program
can be used in standard pulse MIG
or adaptive pulse MIG.
In an adaptive pulse MIG program,
the unit manipulates certain weld
variables to hold arc voltage
constant.
The factory-set parameters for
each program can be changed to
customize them for an application
(see Section 6).
Selecting hardwire or softwire is
done during setup (see Section 8)
Figure 5-2. Pulse MIG Programs
OM-169 571 Page 9
Page 14
5-2. Pulse Panel Microprocessor Push Buttons
WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Control circuit and interface operational power are
On when using or changing the microprocessor
settings.
Pulse Panel
1
WELDING WIRE can cause puncture
wounds.
• Do not point gun towards any part of the body, other
people, or any metal when programming.
The welding wire can be electrically live and move out
of the gun during programming.
1 Mode Display
2 Mode Select Button
Press Mode Select button to move
indicator in left window display.
Go to Figure 5-4.
Process
>C a r d
OM-169 571 Page 10
>P r o c e s s
Ca rd
2
Figure 5-3. Mode Select Button
>Prg 1
Pu l s e
03 5 ” S t e e l
Ar gon − Oxy
Ref. ST-154 109
Page 15
Pulse Panel
1 Parameter Display
2 Moving Line
Moving line is under value that can
be changed.
3 Pulse Panel Parameter Se-
lect Button
Press pulse panel parameter select button to move indicator in
right window display.
1
>P r o c e s s
Ca rd
3
>Prg 1
Pu l s e
03 5 ” S t e e l
Ar g on − O x y
2
Prg 1
u l s e
>P
035”Steel
A r g on − O x y
Pu lse
035”Steel
A r g on − O x y
>T e a c h Off
Figure 5-4. Pulse Panel Parameter Select Button
Ref. ST-154 109
OM-169 571 Page 11
Page 16
Pulse Panel
Use mode select button to select
mode to be changed (see
Figure 5-3).
Use pulse panel parameter select
button to select parameter to be
changed (see Figure 5-4).
1 Increase Button
Press button to increase value that
is underlined by the moving line.
2 Decrease Button
Press button to decrease value
that is underlined by the moving
line.
1
>P r g 1
Pu lse
035”Steel
Argon−Oxy
>P r g 2
Pu lse
045”Steel
A r g on − O x y
Increase
Increase
>P r g 3
2
Pu lse
052”Steel
A r g on − O x y
Decrease
>P r g 2
Pu lse
045”Steel
A r g on − O x y
OM-169 571 Page 12
Ref. ST-154 109
Figure 5-5. Pulse Panel Parameter Increase And Decrease Buttons
Page 17
5-3. Selecting Welding Process
Mode Select
1 Pulse Panel Display
Default display when unit is first
turned On, at other times use mode
select button to select Process.
1
>P r o c e s s
Ca rd
>P r o c e s s
Ca rd
>P r o c e s s
Ca rd
>P r g 1
Pu lse
035”Steel
Argon−Oxy
Parameter
Select
Prg 1
>P u l s e
035”Steel
Argon−Oxy
Increase/
Decrease
Prg 1
>A d a p tPu lse
035”Steel
Argon−Oxy
>P r o c e s s
Ca rd
Increase/
Decrease
Prg 1
>M I G
Figure 5-6. Selecting Process
OM-169 571 Page 13
Page 18
Mode Select
1 Pulse Panel Display
Default display when unit is first
turned On, at other times use mode
select button to select Process.
1
>P r o c e s s
Ca rd
>P r o c e s s
Ca rd
>P r g 1
Pu lse
035”Steel
Argon−Oxy
Parameter
Prg 1
>P u l s e
035”Steel
Argon−Oxy
Increase/
Decrease
Select
>P r o c e s s
Ca rd
Prg 1
>M
I G
OM-169 571 Page 14
Page 19
SECTION 6 − TEACHING A PULSE WELDING PROGRAM
WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Control circuit and interface operational power are
On when using or changing the microprocessor
settings.
All sequence times are controlled by the robot controller, not the interface unit.
Start time is set to 20 ms. Start speed and voltage are set by Hot Start parameters in robot controller weld
parameter menu.
Weld Time
Weld Speed
Wire Speed
Preflow Time
Weld
Start
Start Time
Start
Speed
Arc
Start
Crater Time
Weld
Stop
WELDING WIRE can cause puncture
wounds.
• Do not point gun towards any part of the body, other
people, or any metal when programming.
The welding wire can be electrically live and move out
of the gun when programming.
Burnback Time
Crater
Speed
Arc
Out
Postflow Time
Time
NOTE
Ref. S-0271
See GMAW-P (Pulsed MIG) Process Guide supplied with unit for more
information.
OM-169 571 Page 15
Page 20
6-1. Pulse Waveform Explained
3
Amps (Current)
2 41
Time
The interface, not the welding power source, controls weld output for
pulsed welds.
1 ApK − Peak Current Of
100-565 Amperes
ApK is the high pulse of welding
current. Peak current melts the
welding wire and forms a droplet.
The droplet is forced into the weld
puddle.
2 AbK − Background Current
Of 10-200 Amperes
AbK is the low weld current. Background current preheats welding
wire and maintains the arc. When
background current is too low, the
arc is unstable and hard to
maintain.
3 PPS − Pulses Per Second Of
20-400
PPS, pulse rate, and frequency
(Hz) are used interchangeably. A
PPS or pulse rate of 60 Hz means
60 pulses of current are produced
each second.
4 PWms − Pulse Width Of
1.0-5.0 Milliseconds
PWms is the time spent at peak
current (1.2 ms is .0012 seconds).
This time must be long enough to
form a droplet of welding wire. The
stiffness or fluidity of the molten
weld puddle is controlled by
PWms.
OM-169 571 Page 16
Ref. S-0259
Figure 6-1. Pulse Waveforms And Explanation Of Terms
Page 21
6-2. Teach Points Explained
IPM
780
750
700
650
600
550
500
450
400
350
300
250
200
150
100
50
150 180 210 240 270 300 330 360 370 420 450 480 510 540 565 ApK
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 AbK
30 55 80 105 130 160 185 210 235 260 290 315 340 365 400 PPS
1 3 5 PWms24
Example Of A Synergic
Setting For 425 IPM With
All Teach Points Set At
50 IPM Increments
ApK
AbK
PPS
PWms
The teach mode allows the user to create
custom pulse MIG welding programs. The
teach mode has 15 teach points. At each
teach point, the user can adjust four parameters: peak amperage (ApK), background
amperage (AbK), pulses per second (PPS),
and pulse width in milliseconds (PWms) to
shape the pulse waveform of the weld
output.
Wire feed speed teach points can range
from the minimum to the maximum wire feed
speed of the feeder . When using a standard
speed motor, wire feed speed teach points
typically range from 50 to 750 ipm. The feeder uses pulse parameters at teach points to
establish the pulse parameters at any wire
feed speed setting.
Below the wire feed speed of the lowest
Figure 6-2. Typical Teach Point Settings And Resulting Synergic Setting
teach point, and above the wire feed speed
of the highest teach point, the unit may limit
wire feed speed settings in pulse MIG to
maintain all pulse parameters within the
capability of the unit.
Pulse MIG programs made by the manufacturer have pulse waveform information entered for all 15 teach points. The operator
can relocate and modify the setting of one, or
any number of the 15 teach points if the factory set information is not appropriate for a
specific application.
After the parameters for each teach point are
established, an arc must be struck and maintained for at least 5 seconds in teach mode.
This allows the wire feeder to learn the arc
voltage length associated with the taught
pulse parameters. To ensure a proper arc
length reading, electrode stick-out must be
carefully maintained.
The taught arc length represents a Trim (arc
length) setting of 50. Increasing the value of
Trim, increases the actual arc length. Likewise, decreasing the value of Trim will
decrease actual arc length.
In the Pulse mode, the unit does not maintain a constant arc length with variations in
electrode stick-out. In the Adaptive Pulse
mode, the unit adjusts pulse frequency to
maintain a constant arc length regardless of
variations in electrode stick-out.
Proceed to next section to teach a pulse MIG
program.
OM-169 571 Page 17
Page 22
6-3. Teaching A Pulse Welding Program
WARNING
NOTE
A. Selecting Teach Point Wire Feed Speed
>P r o c e s s
Ca rd
Mode
Select
Welding param e t e r s a r e t h e s am e for both a Pulse and an Adaptive Pulse welding
program. While welding adaptively, the unit uses feedback to attempt to maintain a
constant arc length. To change to Adaptive Pulse welding, refer to Section 5-3.
>P r g 1
Pu lse
035”Steel
3
Teach On
>4 0 0 IPM
340 Apk
70 Abk
READ SAFETY BLOCKS at start of
Section 6 before proceeding.
1 Process Display
When unit is first turned On, Pro-
cess is the default screen, at other
1
Parameter
Select
Pu lse
035”Steel
>T e a c h O
Increase/
Decrease
>T e a c h O
400 IPM
340 Apk
70 Abk
2
n
times use mode select button to
select Process.
2 Teach Display
Use parameter select button to se-
lect Teach.
Use increase/decrease buttons to
select On.
f f
3 IPM (Teach Point)
The parameters associated with
this wire feed speed teach point
can be modified. The wire feed
speed value itself cannot be
changed from this unit.
To set or adjust teach point
parameters, go to Figure 6-4.
Parameter
Select
Figure 6-3. Selecting Teach Point Wire Feed Speed
OM-169 571 Page 18
Page 23
B. Setting Teach Point Parameters On The Pulse Panel
Increase/
Decrease
>P r o c e s s
Ca rd
343 Apk
92 Abk
>2 8 0 PPS
1.9 PWms
Parameter
Select
>4
Increase/
Decrease
Teach On
5 0 IPM
340 Apk
70 Abk
343 Apk
92 Abk
>1 6 0 PPS
1.9 PWms
3
Parameter
Select
Parameter
Select
Teach On
450 IPM
>3 4 0 Apk
70 Abk
1
450 IPM
343 Apk
2 Abk
>9
160 PPS
Or
Increase/
Decrease
Teach On
450 IPM
4 3 Apk
>3
70 Abk
Parameter
Select
450 IPM
343 Apk
>70 Abk
160 PPS
2
Increase/
Decrease
343 Apk
92 Abk
280 PPS
. 9 PWm s
>1
4
When the Process Teach mode is On, and
one of the following pulse parameters is selected: ApK, AbK, PPS, or PWms, the pulse
panel displays the selected pulse parameter
instead of Trim (arc length). When the pulse
parameter is selected, the value can be
changed with the pulse panel controls as follows:
1 ApK Display
343 Apk
92 Abk
280 PPS
>3 . 6 PWms
Weld for
5 seconds
2 AbK Display
3 PPS Display
4 PWms Display
When values have been set for a teach
point, strike and maintain an arc for five seconds. Repeat procedure at each teach point
until custom program is complete (see
Figure 6-2).
Parameter
Select
>T e a c h On
450 IPM
343 Apk
92 Abk
Pu lse
035”Steel
Argon-Oxy
>T e a c h O f f
Increase/
Decrease
Parameter
Select
Prg1 C
Pu lse
035”Steel
Argon-Oxy
Turn Teach mode Off.
5 Custom Pulse Screen
The letter C will appear in the upper right cor-
ner of all customized programs.
Customized programs can be reverted back
to factory-set values through memory reset
(see Section 8-15).
5
Figure 6-4. Setting Teach Point Parameters On The Pulse Panel
OM-169 571 Page 19
Page 24
NOTE
Program # Wire Size/Type Gas
Program Name Card #
Gun Model Flowrate CFM
IPM ApK AbK PPS PWms COMMENTS
Make copies of this chart for future use.
Preflow: Sec.
Run-In Trim: IPM: Sec.:
Crater Trim: IPM: Sec.:
Postflow: Sec.
OM-169 571 Page 20
Page 25
SECTION 7 − USING THE OPTIONAL DATA CARD
7-1. Installing Data Card
14
11
7
8
9
4
5
6
1
2
3
10
12
13
Data cards are compatible with
the 60M wire feeder and the
Robotic Interface.
THIS SIDE UP
1 Label
Peel backing from label and apply
to data card with THIS SIDE UP by
metal pins.
Write the names of the programs
stored on the card on the label.
Write the name of the piece of
equipment the card is used with on
the label.
2 Data Card
3 Card Slot
Insert card into slot. To format card,
60-M Data Card
turn On power to the unit. Select
Card from menu. Data card formats when unit enters Card mode.
3
Exit Card mode and turn Off power .
2
1
ST-156 266-B / Ref. S-155 823
7-2. Using The Data Card
Process
>C a r d
2
3
4
>Wr i t e
Read
De l e te
Done
5
Figure 7-1. Installing Data Card
1
Press
Be low
Parameter
Select Once
#1Pul se
035”Steel
Argon−Oxy
Press
6
Use Mode Select button to select
Card.
1 Card Display
2 Write
Used to transfer program data from
unit to card. The program card can
hold up t o 3 2 programs. When writing to the card, the next available
program number is automatically
assigned.
3 Read
Used to transfer program data from
card to unit.
4 Delete
Used to delete program data from
card.
5 Done
Used to exit card display.
6 Moving Line
Moving line is under value that can
be changed.
Figure 7-2. Card Displays
OM-169 571 Page 21
Page 26
NOTE
All program types (Pulse, Adaptive Pulse, and MIG) can be stored on a data card
and retrieved.
Process
>C a r d
>Wr i t e
Read
De l e te
Done
3
Press
Be low
2
Pu lse
#1
035”Steel
Argon−Oxy
Press
1
Parameter
Select
Allowable characters include: 0 thru 9, :, ;, <, = ,
>, ?, @, A thru Z, [,
%, &, ’, (, ), *, +, −, ., /,
1 Card Display
Use Mode Select button to select
Card.
2 Moving Line
Moving line is under value that can
be changed. Use increase or
decrease button to change value.
3 Name Display
If no name is desired, press
Parameter Select button to continue the write procedure.
Ψ, ], ^, _,‘, a thru z, !, ”, #, $,
Name? No
035”Steel
Argon−Oxy
Press
No
Parameter
Select
Wr i t eDone
Prg 1 to
Ca rdP rg 1
Press
Parameter
Select
#1 Pu lse
035”Steel
Argon−Oxy
Press
Parameter
Yes
Select
Increase
Name? Ye s
035”Steel
Argon−Oxy
Press
Wr i t eDone
Prg1 to
Ca rd Pr g1
Press
Parameter
Select
#1 Pu lse
5007992
Frame
Press
Parameter
Select
Parameter
Select
Name? Yes
35”Steel
0
Argon−Oxy
⇒Press
Name? No
5007992
Frame
Press
Increase/
Decrease
Increase
Name? Yes
5007992
Frame _
⇒Press
Parameter
Select
Name? Ye s
5007992
Frame
Press
OM-169 571 Page 22
Figure 7-3. Naming Programs And Writing To Card
Page 27
Process
>C a r d
Mode
Select
Twice
Press
Be low
Parameter
Select Once
1
2
3
Use Mode Select button to select
Card.
1 Card Display
2 Moving Line
Moving line is under value that can
be changed. Use increase or decrease button to select program
number to read from card to feeder.
3 Read Display
Use increase or decrease button to
select feeder program number
where the card program goes.
Wr i t e
>Read
De l e te
Done
WA R N I N G : Prg1 Will
#1Pul se
035”Steel
Argon−Oxy
Press
Be Los t
Lose? Y
Press
Parameter
Select
Read Done
Ca rd Pr g1
to Prg 1
Press
Read Card
to Feeder
Prg 1
Press
Parameter
Select
Prg1 Will
Be Los t
Lose? N
Press
#1Pul se
035”Steel
Argon−Oxy
Press
Yes
e s
No
Increase
Parameter
Select
Figure 7-4. Reading From Card
Parameter
Select
o
Parameter
Select
#1Pul se
035”Steel
Argon−Oxy
Press
Wr i t e
>Read
De l e te
Done
Wr i t e
Read
De l e te
>Done
1
WA R N I N G :
Ca rdEmp t y
Press
Be low
Parameter
Select Once
>P r o c e s s
Ca rd
Press
Parameter
Select
Figure 7-5. Reading (Or Deleting) From An Empty Card
1 Warning Display
If there are no programs on the
card, this series of displays appear.
>P r g 2
MIG
OM-169 571 Page 23
Page 28
Process
>C a r d
Mode
Select
Twice
Press
Be low
Select Once
Parameter
Use Mode Select button to select
Card.
1 Card Display
1
2 Moving Line
Moving line is under value that can
be changed.
3 Delete Display
Select program number to be de-
leted from card.
Wr i t e
Read
>D e l e t e
Done
De l e te
Ca rd Pr g2
Yes
e s
Parameter
Select
Lose? Y
Press
Ca rd Pr g2
De l e ted
Press
No
2
3
#2MIG
Press
Increase
#3 MIG
Parameter
De l e te
Ca rd Pr g2
Lose? N
Press
Press
Select
o
Parameter
Select
WA R N I N G :
#2 MIG
Press
OM-169 571 Page 24
Parameter
Select
Figure 7-6. Deleting Programs From Card
Page 29
8-1. Setup Flow Chart
SECTION 8 − SETUP
1
>Range
Secu r i t y
Access
Mig Type
Example Of Pulse Panel Setup Display
Vo l t Mi n
10.0 Vol t
Display Features Settings Section
Selection
>Range Volt Min 0.0 - 25.0 V 8-3
Volt Max 25.0 - 99.9 V
Amp Min 0 - 50 A
Amp Max 50 - 999 A
Press Mode Se-
lect To Go To Next
Setup Display
>Security Program Number 8-4
Lock Off/On
1 Display Selections
2 Features
2
3
3 Settings
To set up features that customize
operation, use the setup displays.
Features that can be customized
are as follows:
Display Features Settings Section
Selection
>Wire Feed Display IPM/MPM 8-12
Motor Type Standard
>Wiretype Wire Type Hardwire/Softwire 8-13
In Feeder
>Display Actual 8-14
Low Speed
High Speed
Amps
Command
>Access Code Off/On 8-5
>Mig Type Voltage DVC On/Off 8-6
Correction
>Inductance Level 0.0 - 99 8-7
>Purge Button 0.0 - 25.0 8-8
Timer
>Voltage Control 17-Pin 8-9
Feedback Volt Sense
>Arc Start Arc Start Type Standard 8-10
Hot Start
Soft Start
>Arc Time Run Hours 0−9999.99 Hours 8-11
0−999,999 Cycles
No Reset
Reset
>Memory No Reset 8-15
Program Reset
Memory Reset
>Shutdown Arc Start/ Off/On 8-16
Volt Sense
>Name Card Programs Off/On 8-17
>Program Remote Off/On 8-18
Program
>Stick Stick Check Off/On 8-19
>Monitor Arc Volt Error Off/On 8-20
Range 0.1 - 9.9
>Software Version Number 8-21
Figure 8-1. Setup Flow Chart
OM-169 571 Page 25
Page 30
8-2. Using Setup Displays
Mode
Select
Set up
Front Panel Display
Parameter
1
Select
1 Front Panel Setup Display
2
3
>Range
Secu r i t y
Access
Mig Type
Front panel display during setup.
2 Pulse Panel Mode And Para-
meter Select Buttons
3 Power Switch On Rear Panel
Press and hold down both buttons
while turning On unit.
4 Pulse Panel Setup Display
Follow this procedure any time ac-
cess is required. Once in the setup
displays, use the Mode Select button to select a particular display.
To save any or all of the changes
made while in the setup displays,
and/or to exit the setup displays,
turn power to the unit Off and back
On.
4
Vo l t Mi n
10.0 Vol t
Pulse Panel Display
Figure 8-2. Accessing Setup Displays
OM-169 571 Page 26
Page 31
8-3. Selecting Welding Power Source Range
NOTE
Access
Setup
Display
Welding power source minimum and maximum voltage values are always
required. Amperage values are required for pulse welding.
>Range
Secu r i t y
Access
Mig Type
Press Mode
Select
Default values are for 450 Ampere Inverter Model.
Do not change values if using 450 Ampere
Inverter Model.
1
o l t M i n
>V
10.0Vo l t
Parameter
Select
Vo l t Mi n
0 . 0 Vo l t
>1
2
Increase/Decrease
1 Range Display
See welding power source Own-
er’s Manual for voltage and amperage ranges. Set values to match
welding power source ranges.
2 Minimum Voltage Display
Range is 0 to 25.0 volts.
3 Maximum Voltage Display
Range is 25.0 to 99.9 volts.
4 Minimum Amperage Display
(Available When System Set
For Pulse/Mig)
Range is 0 to 50 amperes.
5 Maximum Amperage Display
(Available When System Set
For Pulse/Mig)
Range is 150 to 999 amperes.
*Use Parameter Select button to
select voltage or amperage.
Use Increase/Decrease buttons
to change value.
5*
>Am p Ma x
565 Amp
Vo l t Mi n
. 0 Vol t
>8
Parameter
Increase
>V o l t M a x
38.0Vo l t
Parameter
>Am p M i n
10 Amp
Select
3*
Select
4*
Parameter
Select
Figure 8-3. Range Display
OM-169 571 Page 27
Page 32
8-4. Selecting Security Lock
NOTE
Access
Setup
Display
Press Mode
Select
Prog 2
>L o c k O
Trim 0
IPM 0
Security lock works only when a data card is inserted (see Section 7-1).
1 Security Display
Use this display to lock a program’s
weld parameters so that changes
can not be made using pulse panel
controls.
12
Range
>S e c u r i t y
Access
Mig Type
n
Increase
Prog 2
>L o c k O f f
>P r o g 1
Lock Of f
Parameter
Select
Increase
>P r o g 2
Lock Of f
3
2 Program Number
Choose the program number (1
through 8) to be locked.
3 Program Lock Display
When lock is off a program, the op-
erator can change all weld parameters of that program without
restriction.
With lock on a program, the operator can change parameters of that
program but the range of change is
restricted.
In the example displays in this figure, the operator could change the
value of trim
speed
values. If the settings are left at 0,
the operator cannot change values
from those programmed.
±10% and wire feed
±100 ipm from programmed
Parameter
Select
Prog 2
Lock On
>T r i m 0
IPM 0
>P r o g 3
Lock Of f
Increase/
Decrease
Increase
Prog 2
Lock On
>T r i m 1
IPM 0
>P r o g 2
Lock On
Trim 10
IPM 100
0
Parameter
Select
Parameter
Select
Prog 2
Loc k O n
Trim 10
>I PM 0
Increase/
Decrease
Prog 2
Lock On
Trim 10
>I PM 1
0 0
OM-169 571 Page 28
Figure 8-4. Security Display
Page 33
8-5. Selecting Or Changing Access Code
NOTE
Press Mode
Access
Setup
Display
Select
Access code works only when a data card is inserted (see Section 7-1).
1 Code Display
With code off, access to the setup
displays is not restricted.
With code on, the operator must
know and enter the access code to
access or change any of the setup
displays.
2 Access Display
With a code set, this display ap-
pears when power is turned on
while holding the pulse panel Mode
and Parameter Select buttons.
Press Parameter Select button to
enter access code. When the correct letter is entered, the indicator
automatically moves to the next
character. When the final access
code letter is entered, the display
automatically changes to the initial
setup display.
Range
Secu r i t y
>A c c e s s
Mig Type
Co d e
f f
>O
Code
n
>O
AAA
1
Increase
Parameter
Select
Co d e
On
AA
>A
⇒Press
Increase/Decrease
To Set Code
Parameter Select
To Move
Indicator
Co d e
On
>ZWX
⇒Press
Turn Power Off And Back On
And Access Security Display
2
Ent er
Access
Code
>Code A
⇒Press
Figure 8-5. Access Code Display
AA
OM-169 571 Page 29
Page 34
8-6. Selecting Voltage Correction
Access
Setup
Display
Press
Mode Select
Secu r i t y
Access
>M i g T y p e
Induc t .
Figure 8-6. Mig Type Display
Vol tage
Co r r e c t i o n
VC O n
>D
1 Mig Type Display
With DVC Voltage Correction On,
the unit uses closed-loop feedback
from the 17-pin cord or voltage
sensing leads to maintain set voltage parameters.
With DVC Voltage Correction Off,
feedback from the arc is not used
for closed-loop feedback to maintain voltage parameters. Feedback from the arc is still used for
other functions.
1
Increase
Be sure voltage sensing leads are
connected or voltage feedback is
available through the 17-pin receptacle via the welding power source.
Vol tage
Co r r e c t i o n
VC O f f
>D
8-7. Selecting Inductance
Press
Access
Setup
Display
Mode Select
8-8. Selecting Purge Time
Use Purge only when a weld
program is not running.
Ac c e s s
Mig Type
>Induc t .
Pur ge
Le v e l
Figure 8-7. Inductance Display
30
1 Inductance Display
1
1
The inductance level can be varied
between 0 (zero) and 99.
Increase
Le v e l
99
1 Purge Display
The purge time can be varied be-
tween 0.0 (zero) and 25.0 seconds.
Access
Setup
Display
OM-169 571 Page 30
Press
Mode Select
Mig Type
Induc t .
>P u r g e
Vol tage
Figure 8-8. Purge Display
Bu t t o n
Ti me r
0.0
Increase
Bu t t o n
Ti me r
25.0
Page 35
8-9. Selecting Voltage Sensing Method
1 Voltage Feedback Display
When using the 17 Pin setting, arc
voltage feedback is through the
welding power source and the
feedback signal is sent through the
17-pin cord to the feeder.
If the 17 Pin setting is used, it is recommended that the voltage sensing terminals on the welding power
source be used to monitor arc voltage at the workpiece.
When using the V. Sense setting,
arc voltage feedback is through the
voltage sense leads connected to
the interface. Use this setting when
there is more than 50 ft (15 m) of
1
weld cable used.
Access
Setup
Display
Press
Mode Select
Induc t .
Pur ge
>Vol tage
ArcStar t
Figure 8-9. Voltage Feedback Display
8-10. Selecting Regular Or Hot Arc Start
NOTE
Access
Setup
Display
Press
Mode Select
Arc Start selection is not used when welding in non-pulsed MIG.
Do not use the Hot Start setting for .035 in (9 mm) or smaller wire.
Pur ge
Vol tage
>A r c S t a r t
Arc Time
Co n t r o l
Feedback
7 P i n
>1
Ar c S t a r t
Ty p e
t a n d a r d
>S
Increase
1
Co n t r o l
Feedback
. S e n s e
>V
1 Arc Start Display
Use the Hot Start mode for pulse
welding with 450 Ampere Inverter
Model when high initial weld current is necessary to start large diameter welding wires. When in Hot
Start, the 450 Ampere Inverter
Model starts the arc in the CV
mode and switches to CC once the
arc is started. Do not use Hot Start
unless using 450 Ampere Inverter
Model.
Ar c S t a r t
Ty p e
o t S t a r t
>H
Figure 8-10. Arc Start Display
Increase
Ar c S t a r t
Ty p e
o f t S t a r t
>S
OM-169 571 Page 31
Page 36
8-11. Resetting Arc Time
1 Arc Time Display
The unit accumulates arc hours up
to 9999.99 hours or 999999 weld
cycles before rolling over to zero
(0). The arc timer can be reset using this display.
1
Access
Setup
Display
Press
Mode Select
Vol tage
Arc Start
>A r c T i m e
Wi refeed
0.00Hrs
o R e s e t
>N
0Cyc l
Figure 8-11. Arc Time Display
8-12. Selecting Units For Wire Feed Speed And Motor Type
Increase
0.00Hrs
0Cyc l
e s e t
>R
Press
1 Wire Feed Display
The displayed unit of wire speed
(IPM or MPM) can be changed
along with the wire feed motor type
(Standard, Low Speed, or High
Speed).
Access
Setup
Display
Di s p l a y
IPM
Mo t o r T y p e
i g h S p d
>H
OM-169 571 Page 32
Press
Mode Select
Increase
ArcStar t
Arc Time
>Wi r e f e e d
Wi retype
Di s p l a y
IPM
Mo t o r T y p e
o w S p d
>L
Figure 8-12. Wire Feed Display
Increase
Di s p l a y
PM
>I
Mo t o r T y p e
Standard
Di s p l a y
IPM
Mo t o r T y p e
t a n d a r d
>S
1
Parameter
Select
Decrease
Increase
Di s p l a y
PM
>M
Mo t o r T y p e
Standard
Page 37
8-13. Selecting Wire Type
NOTE
Access
Setup
Display
Press
Mode Select
If wire type is changed, perform a memory reset (see Section 8-15) immediately
after selecting wire type to bring up the correct welding programs.
1 Wire Type Display
Select soft wire when using alumi-
num wire in the wire feeder. Select
hard wire when using any other
kind of wire.
1
Arc Time
Wi refeed
>Wi r e t y p e
Display
Wi re Type
In Feeder
>H a r d w i r e
Wi re Type
In Feeder
>S o f t w i r e
Increase
Figure 8-13. Wire Type Display
8-14. Selecting Display
Press
Access
Setup
Display
Mode Select
Wi refeed
Wi retype
>Di s p l a y
Memo r y
Command
Actua l
1
Increase
Increase
1 Display Select Display
The display can show amps, actual
reading or print out command.
Amp s
Figure 8-14. Display Select
OM-169 571 Page 33
Page 38
8-15. Resetting Memory
Press
Access
Setup
Display
>P r o c e s s
Ca rd
Mode Select
4
>P r g 1
Pu lse
035”Steel
Argon Oxy
Wi retype
Display
>Me m o r y
Shu tdown
Parameter
Select
o
>N
Re s e t
>P r o g r a m 1
Rese t
Press
Increase/
Decrease
Increase/
Decrease
1 No Reset
Memory cannot be reset.
1
2 Program Reset
Press Parameter Select button to
reset last active program to original
factory program settings. All other
program and setup information remains the same.
3 System Reset
Press Parameter Select button to
reset programs and setup to original factory settings. System, Arc
Time, and Model Type settings are
not affected by the system reset.
4 Reset (Default) Displays
2
>S y s t em
Rese t
Parameter
Select
Figure 8-15. Resetting Memory
8-16. Selecting Arc Start/Volt Sense Error Shutdown
3
Press
1 Voltage Shutdown Display
With Arc Start/Volt Sense on, the
unit shuts down when no arc voltage is sensed. If the unit shuts
down, an error message appears
(see Section 9-3).
With Arc Start/Volt Sense off, the
unit continues to feed wire even
when there is no arc voltage
sensed.
1
Access
Setup
Display
OM-169 571 Page 34
Press
Mode Select
Display
Memo r y
>S h u t d o w n
Name
Ar c S t a r t /
Vo l t S e n s e
n
>O
Figure 8-16. Voltage Shutdown Display
Increase
Ar c S t a r t /
Vo l t S e n s e
f f
>O
Page 39
8-17. Selecting Program Name Feature
Press
Access
Setup
Display
Mode Select
Memo r y
Shu tdown
>N a m e
Program
Figure 8-17. Naming Card Programs
Ca r d
Pr o g r ams
n
>O
1
Increase
1 Name Display
When a data card is used, the pro-
grams written from the unit to the
card can be named.
Ca r d
Pr o g r ams
f f
>O
8-18. Remote Program Select
NOTE
Access
Setup
Display
Press
Mode Select
Remote Program Select is in binary code, with “A” the least significant bit, and “C”
the most significant bit.
Shu tdown
Name
>P r o g r a m
St ick
Rem o t e
Pr o g r am
ff
>O
1
Increase
1 Program Display
When Program is On, a remote de-
vice may be used to select programs. When Off, program selection must be done from robot Teach
Pendant or interface pulse panel.
Rem o t e
Pr o g r am
n
>O
Figure 8-18. Program Display
OM-169 571 Page 35
Page 40
8-19. Stick Check Selection
Press
Access
Setup
Display
Mode Select
Name
Program
>S t i c k
Mo n i t o r
Figure 8-19. Stick Check Display
8-20. Arc Voltage Error Selection
Access
Setup
Display
Mode Select
Program
St ick
>Mo n i t o r
Sof twa re
Press
When a system reset is done, Monitor is set to Off.
Ar c Vo l t s
n
>O
2.0 Volts
1.0 Sec
1 Stick Check Display
1
St i c k
Ch e c k
n
>O
Increase
1
Arc Vol ts
f f
>O
Increase
When stick check is On, a stick
check routine is performed at the
end of each weld. When Off, no
stick check is done.
St i c k
Ch e c k
ff
>O
1 Monitor Display
Provides a means to enable/dis-
able the arc voltage error feature
and to set an acceptable range of
deviation from set arc voltage or
arc length (trim) before the error
will actuate.
When this feature is off, arc voltage
or arc length variations will not
cause an error or shut the unit
down.
When this feature is on and a range
of deviation is set (±0.1 − 9.9 volts
from desired weld voltage), arc
voltage or arc length variations ou t side of the range for a period of
time longer than that set by the Arc
Error timer, causes either the error
relay to energize or the unit to shut
down depending on the Arc Start/
Volt Sense shutdown error setting.
8-21. Software Version Number
Access
Setup
Display
OM-169 571 Page 36
Press
Mode Select
Program
St ick
Mo n i t o r
>S o f t w a r e
Figure 8-21. Version Number Display
Figure 8-20. Monitor Display
Ve r s i o n
#123456Z
1 Example Version Number
Display
When talking with service person-
1
nel, this number may be required.
(Check actual unit display for number.) The factory keeps this number on file with the serial number of
the unit.
Page 41
SECTION 9 − MAINTENANCE & TROUBLESHOOTING
WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn Off robot, interface, and welding power
source, and disconnect input power before
inspecting, maintaining, or servicing.
MOVING PARTS can cause injury.
• Keep away from moving parts.
• Keep away from pinch points such as drive rolls.
9-1. Routine Maintenance
Turn Off all power before maintaining.
3 Months
Replace
Unreadable
Labels
Replace
Cracked
Parts
Tape Or
Replace
Cracked
Weld
Cable
14-Pin Cord
HOT PARTS can cause severe burns.
• Allow cooling period before servicing gun or unit.
Maintenance to be performed only by qualified
persons.
wfwarn4.1 8/92
6 Months3 Months
OR
During Heavy Service,
Clean Monthly
Blow Out
Or
Vacuum
Inside
9-2. Overload Protection
WARNING
2
Gas Hose Gun Cable
Figure 9-1. Maintenance Schedule
READ SAFETY BLOCKS at start of
Section 9 before proceeding.
1
Turn Off robot, interface, and welding power source.
1 Fuse F1
F1 protects the interface from
overload. If F1 opens, the unit
shuts down.
Replace F1 with fuse of the same
type, size, and rating.
2 Circuit Breaker CB1
CB1 protects the interface from
overload. If CB1 trips, the unit
shuts down.
Allow cooling period and manually
reset breaker.
ST-801 353
Figure 9-2. Overload Protection
OM-169 571 Page 37
Page 42
9-3. Front Panel Error Displays
1
Memo r y
CRC
2
Memo r y
Range
3
No Vo l t
Sensed Er ror
4
No Tach
Sensed Er ror
5
Arc
Stop Error
6
Arc
Start Error
Prg X
Error
Prg X
Error
1 Memory CRC Error Display
Corrupted program data has been
detected or loaded. The “X” value indicates the program number.
May be caused by incompatible information on the data card or bad
memory.
2 Memory Range Error Display
Improper welding power source
range is selected. The “X” value indicates the program number.
May be caused by improper range
settings or improper data loaded into
the interface unit.
3 No Volt Sensed Error Display
The arc voltage sense circuit did not
receive feedback within the required
time after an arc was established.
May be caused by an inability to establish an arc in the pulse schedule,
or a lack of voltage feedback.
4 No Tach Sensed Error Display
The motor tachometer feedback is
not reaching the control.
May be caused by obstructions in the
wire feed system or a faulty wire
drive system.
5 Arc Stop Error Display
Trouble is occurring at arc end.
May be caused by obstructions in the
wire feed system or a faulty wire
drive system.
6 Arc Start Error Display
Trouble is occurring at arc start.
May be caused by obstructions in the
wire feed system or a faulty wire
drive system.
OM-169 571 Page 38
Figure 9-3. Error Displays
Page 43
1
Stop Weld
Error Detected
2
Error
Car d
3
Robo t
E−St op
4
Ground
De tec t
5
Cur r en t
Error
Wi re
St ick
6
Arc Fai l
Cyc l e
Read
Error
1 Stop Weld Cycle Error Display
An error has been detected and the
robot hasn’t stopped the weld cycle,
causing the interface unit to stop the
weld cycle and wait for the robot to
stop.
2 Error Card Read Display
The card reader is not working
properly.
May be caused by a bad data card,
a bad data card reader, a faulty microprocessor circuit board, or a wiring problem.
3 Robot E-Stop Display
The robot E-Stop is active. The inter-
face unit will remain in a locked
stated until the E-Stop is released.
4 Ground Current Detect Error
Display
Weld current has been detected in
the earth ground connection.
May be caused by a conductor making connection to the unit chassis.
5 Wire Stick Error Display
The welding wire has stuck to the
workpiece at the end of the weld.
May be caused by poor weld
conditions.
6 Arc Fail Time Out Error Display
An arc was not established within the
allotted time.
May be caused by an inoperable
wire drive, absence of shield gas, or
improperly operating welding power
source.
Time Out Error
Figure 9-4. Error Displays (Continued)
OM-169 571 Page 39
Page 44
1 Diagnostic LED’s Cover
Remove cover.
2 Interface Board PC5
Diagnostic LED’s are visible inside
unit, located on edge of Interface
Board PC5 facing front of unit.
Refer to Table 9-1 for information on
diagnostic LED’s.
1
Reinstall cover after checking diagnostic LED’s.
LED5
LED4
LED3
LED6
LED7
LED8
LED9
LED2
LED1
2
ST-801 352 / ST-801 094
Figure 9-5. Location Of Diagnostic LED’s
Table 9-1. Diagnostic LED’s On Interface Board PC5
LED Status Diagnosis
1 On Indicates +15 volts dc present on interface board PC5 with respect to power source common.
Off If LED 1 is off and LED’s 2 thru 5 are on, replace interface board PC5. If LED 1 is off and LED’s 2 thru
2 On Indicates −15 volts dc present on interface board PC5 with respect to power source common.
Off If LED 2 is off and LED’s 1, 3, 4, and 5 are on, replace interface board PC5. If LED 2 is off and LED’s 1,
3 On Indicates +15 volts dc present on interface board PC5 with respect to dc circuit common.
5 are off, check Power switch S1, integrated rectifier SR1, and motor board PC3. Replace S1, SR1, and
PC1 if necessary.
3, 4, and 5 are off, check Power switch S1, integrated rectifier SR1, and motor board PC3. Replace S1,
SR1, and PC1 if necessary.
4 On Indicates −15 volts dc present on interface board PC5 with respect to dc circuit common.
5 On Indicates +5 volts dc present on interface board PC5 with respect to dc circuit common.
6 On Indicates contactor is not energized, normal standby mode.
7 On Indicates CV mode is selected.
8 On Indicates gas valve GS1 is not energized, normal standby mode.
9 On Indicates wire feed motor M1 is not running, normal standby mode.
OM-169 571 Page 40
Off If LED 3 is off and LED’s 1, 2, 4, and 5 are on, replace interface board PC5. If LED 3 is off and LED’s 1,
2, 4, and 5 are off, check Power switch S1, integrated rectifier SR1, and motor board PC3. Replace S1,
SR1, and PC1 if necessary.
Off If LED 4 is off and LED’s 1, 2, 3, and 5 are on, replace interface board PC5. If LED 4 is off and LED’s 1,
2, 3, and 5 are off, check Power switch S1, integrated rectifier SR1, and motor board PC3. Replace S1,
SR1, and PC1 if necessary.
Off If LED 5 is off and LED’s 1 thru 4 are on, replace interface board PC5. If LED 5 is off and LED’s 1 thru
4 are off, check Power switch S1, integrated rectifier SR1, and motor board PC3. Replace S1, SR1, and
PC1 if necessary.
Off Indicates contactor is energized.
Off Indicates CC mode is selected.
Off Indicates gas valve GS1 is energized.
Off Indicates wire feed motor M1 is running.
Page 45
NOTES
OM-169 571 Page 41
Page 46
SECTION 10 − ELECTRICAL DIAGRAMS
OM-169 571 Page 42
Figure 10-1. Circuit Diagram For Robotic Interface Unit
Page 47
SD-166 165-A
OM-169 571 Page 43
Page 48
OM-169 571 Page 44
Figure 10-2. Circuit Diagram For Microprocessor Board PC1
Page 49
SD-161 039-A
OM-169 571 Page 45
Page 50
OM-169 571 Page 46
Figure 10-3. Circuit Diagram For Motor Board PC3
Page 51
SD-083 388-B
OM-169 571 Page 47
Page 52
OM-169 571 Page 48
Figure 10-4. Circuit Diagram For Robot Interface Board PC4
Page 53
SD-165 458
OM-169 571 Page 49
Page 54
OM-169 571 Page 50
Figure 10-5. Circuit Diagram For Interface Board PC5
Page 55
SD-165 466
OM-169 571 Page 51
Page 56
Figure 10-6. Circuit Diagram For Filter Board PC6
SB-159 412
OM-169 571 Page 52
Page 57
Figure 10-7. Circuit Diagram For Display Board PC7
SC-165 462-A
OM-169 571 Page 53
Page 58
Figure 10-8. Circuit Diagram For Data Card Board PC8
SA-156 626-A
OM-169 571 Page 54
SA-158 163
Figure 10-9. Circuit Diagram For Pulse Display Board PC8
Page 59
NOTES
OM-169 571 Page 55
Page 60
25
SECTION 11 − PARTS LIST
2
1
7
3
26
4
6
5
13
8
9
10
11
12
14
22
21
23
24
15
16
17
18
2
19
20
ST-801 355
Figure 11-1. Case Section w/Components
OM-169 571 Page 56
Page 61
Part
Dia.
Item
ty
No.
Mkgs.
No.
Description
Figure 11-1. Case Section w/Components
1 PC3 071 642 CIRCUIT CARD ASSEMBLY, motor speed control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 098 691 STAND-OFF, No. 6-32 x .500 lg 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 C1 031 692 CAPACITOR, elctlt 750uf 200VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 006 426 CLAMP, capacitor 2.000dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 R3 079 497 RESISTOR, WW fxd 25W 2K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 605 741 CLIP, mtg resistor 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 R2 030 941 RESISTOR, WW fxd 100W 5 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 R1 030 651 RESISTOR, WW fxd 25W 10 ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 166 357 CASE SECTION, bottom/sides 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
+166 512 COVER, top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
134 327 LABEL, warning general precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 PLG7 165 897 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
111 030 CONNECTOR, edge skt 20-18ga 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 PC4 165 455 CIRCUIT CARD, isolation 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG1,3 164 899 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
147 995 CONNECTOR, rect skt 22-18ga 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG2 163 467 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
147 995 CONNECTOR, rect skt 22-18ga 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG4 152 249 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
147 995 CONNECTOR, rect skt 22-18ga 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG5 148 439 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
147 995 CONNECTOR, rect skt 22-18ga 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG6 115 092 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
113 746 CONNECTOR, rect skt 24-18ga 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 155 022 CABLE, ribbon 34posn 12.000 in 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 169 923 CABLE, ribbon 24posn 14.000 in 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 PC1 171 438 CIRCUIT CARD ASSEMBLY, processor w/prom 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG11 115 092 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
113 746 CONNECTOR, rect skt 24-18ga 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG13 163 467 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
147 995 CONNECTOR, rect skt 22-18ga 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG15 153 501 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
147 995 CONNECTOR, rect skt 22-18ga 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG17 115 093 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
113 746 CONNECTOR, rect skt 24-18ga 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG18 162 382 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
113 746 CONNECTOR, rect skt 24-18ga 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 155 629 CABLE, ribbon 14posn 3.000 in 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 126 689 STAND-OFF, No. 6-32 x 1.500 lg 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 PC5 165 463 CIRCUIT CARD ASSEMBLY, I/O interface 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG51 158 720 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
147 995 CONNECTOR, rect skt 22-18ga 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG52,58 158 719 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
147 995 CONNECTOR, rect skt 22-18ga 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG53 131 204 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
113 746 CONNECTOR, rect skt 24-18ga 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG54 148 439 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
147 995 CONNECTOR, rect skt 22-18ga 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG55 115 092 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
113 746 CONNECTOR, rect skt 24-18ga 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG56 115 093 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
113 746 CONNECTOR, rect skt 24-18ga 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG57 164 900 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
147 995 CONNECTOR, rect skt 22-18ga 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 009 335 STAND-OFF, No. 4-40 x .625 lg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 134 201 STAND-OFF SUPPORT, PC card 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 019 663 MOUNT, nprn 15/16 OD x 3/8rec 3/16 x 3/8 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 T2 090 465 TRANSFORMER, signal 115V 24VCT 4A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 T1 169 063 TRANSFORMER, control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 SR1,SR2 035 704 RECTIFIER, integ 40A 800V 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-169 571 Page 57
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Figure 11-1. Case Section w/Components (Continued)
24 C2 169 080 CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 1T 157 169 BLOCK, term 20A 16 pole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
108 023 LINK, jumper term blk 10A 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 CR1 109 006 RELAY, encl 24VAC DPDT 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
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Figure 11-2. Panel, Center w/Components
1 PC2 152 145 PCB, auto II 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG21,31 165 884 CONNECTOR & SOCKETS, (consisting of) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
125 748 CONNECTOR, rect skt 22-18ga 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG22,24 165 885 CONNECTOR & SOCKETS, (consisting of) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
125 748 CONNECTOR, rect skt 22-18ga 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG23 165 886 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
125 748 CONNECTOR, rect skt 22-18ga 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 099 037 EDGE TRIM, style 62-1/16 black w/clips (order by ft) 2ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 134 201 STAND-OFF SUPPORT, pc card 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 2T 157 169 BLOCK, term 20A 16 pole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
108 023 LINK, jumper term blk 10A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 C3 169 062 CAPACITOR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 PS1 166 352 POWER SUPPLY, switching 85−264VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 166 354 PANEL, mtg cmpts 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
3
2
5
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Figure 11-2. Panel, Center w/Components
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-169 571 Page 58
ST-801 356
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Figure 11-3. Panel, Front w/Components
1 DSPL1 165 459 CIRCUIT CARD ASSEMBLY, display 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 166 355 PANEL, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
057 359 BLANK, snap-in nyl .375mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 164 757 GASKET, meter lens 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 169 419 COVER, troubleshooting lights 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 154 109 PLATE, ident inner control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 155 024 LENS, clear anti glare 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 168 337 PANEL, control inner 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 PC8 156 623 CIRCUIT CARD ASSEMBLY, data card 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG60 153 501 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
147 995 CONNECTOR, rect skt 22-18ga 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 DSPL2 158 160 CIRCUIT CARD ASSEMBLY, side display 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 144 844 STAND-OFF, No. 6-32 x .875 lg 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 NAMEPLATE, (order by model and serial No.) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 168 459 DOOR, access 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 089 899 LATCH, slide 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 153 169 ACTUATOR, switch 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 089 032 LENS, LED 4341 red 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
107 983 BLANK, snap-in nyl .500mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
3
7
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1
2
15
14
6
9
5
10
11
13
12
Figure 11-3. Panel, Front w/Components
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-169 571 Page 59
ST-801 143-A
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OM-169 571 Page 60
ST-801 357
Figure 11-4. Panel, Rear w/Components
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Figure 11-4. Panel, Rear w/Components
1 FL1 084 171 FILTER, line pwr 115/250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 166 356 PANEL, rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 S1 111 997 SWITCH, rocker SPST 10A 250VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 046 432 HOLDER, fuse mintr .250 x 1.250 panel mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 F1 012 655 FUSE, mintr cer 10A 250V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 155 601 CABLE, fiber optic 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 149 923 MOUNTING BLOCK, insulator fiber optic cable 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 RC19 174 316 RECEPTACLE, w/components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 057 360 BLANK, snap-in nyl 1.375mtg hole black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 RC13 035 523 CONNECTOR, circ 5skt rcpt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 RC14 174 317 RECEPTACLE, w/components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 3T 038 772 BLOCK, term 20A 6 pole screw term 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 RC8 039 718 CONNECTOR, circ 10skt sz 18 rcpt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 CR3 168 978 SWITCH, reed 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 CB1 011 991 CIRCUIT BREAKER, man reset 1P 1.5A 250VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 PC6 174 325 CIRCUIT CARD ASSEMBLY, HF filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG89 131 204 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
113 746 CONNECTOR, rect skt 24-18ga 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG82 158 720 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
147 995 CONNECTOR, rect skt 22-18ga 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 073 756 STAND-OFF, No. 6-32 x .625 lg .250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 RC9 152 492 CONNECTOR w/PINS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
134 731 CONNECTOR, circ pin 14-18ga 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
158 373 CABLE, interconnecting power 10ft (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
097 868 CONNECTOR, circ 17skt plug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
116 964 CONNECTOR, circ clamp str rlf 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
600 343 CABLE, port No. 16 5/c (order by ft) 10ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
097 866 CONNECTOR, circ 17 pin plug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
175 115 CABLE, interconnecting 10ft (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
141 162 CONNECTOR & PINS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
134 731 CONNECTOR, circ pin 14-18ga 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
079 739 CONNECTOR, circ clamp str rlf 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
121 274 CABLE, port No. 18 12/c (order by ft) 10ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
152 370 CONNECTOR & SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
079 534 CONNECTOR, circ skt 14-18ga 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
079 739 CONNECTOR, circ clamp str rlf 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
133 866 CABLE, volt sense 35ft (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
073 686 CONNECTOR, circ 4skt plug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
039 828 CONNECTOR, circ clamp str rlf 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
133 859 CABLE, shld No. 18ga 1/c (order by ft) 70ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
134 308 CABLE, interconnecting (order by ft) 23ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
174 349 CABLE, remote program select (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
039 273 CONNECTOR, circ 5 pin plug 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
039 685 CONNECTOR, circ str rlf sz 16 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
600 343 CABLE, port No. 16 5/c (order by ft) 20ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-169 571 Page 61
Page 66
Page 67
MILLER’S TRUE BLUE LIMITED WARRANTY
(Equipment with a serial number preface of “KD” or newer)
This limited warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions below, MILLER Electric
Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new
MILLER equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by MILLER. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, MILLER will repair or replace any warranted parts or components that fail due to such defects in material or workmanship.
MILLER must be notified 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 that the equipment was delivered to the original retail purchaser, o r
one year after the equipment is sent to a North American distributor or eighteen
months after the equipment is sent to an International distributor.
1. 5 Years Parts − 3 Years Labor
* Original main power rectifiers
* Inverters (input and output rectifiers only)
2. 3 Years — Parts and Labor
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Supplies
* Intellitig
* Robots
3. 2 Years — Parts and Labor
* Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the engine manufacturer.)
* Air Compressors
4. 1 Year — Parts and Labor
* Motor Driven Guns
* Process Controllers
* IHPS Power Sources
* Water Coolant Systems
* HF Units
* Grids
* Spot Welders
* Load Banks
* SDX Transformers
* Running Gear/Trailers
* Plasma Cutting Torches (except APT, ZIPCUT & PLAZCUT Models)
* Tecumseh Engines
* Deutz Engines (outside North America)
* Field Options
(NOTE: Field options are covered under True Blue
warranty period of the product they are installed in, or for a minimum of
one year — whichever is greater.)
Effective January 1, 1995
for the remaining
5. 6 Months — Batteries
6. 90 Days — Parts and Labor
* MIG Guns/TIG Torches
* APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches
* Remote Controls
* Accessory Kits
* Replacement Parts
MILLER’S True Blue 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 or parts that fail due to normal wear.
3. Equipment that has been modified by any party other than MILLER, or equipment 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 COMMERCIAL/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 exclusive 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 replacement at an authorized MILLER service station; or (4) payment of or credit for the purchase 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 F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a MILLER authorized service facility as determined by MILLER. Therefore no compensation or reimbursement 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 CONSEQUENTIAL
DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, 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, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an implied warranty
lasts, or the exclusion of incidental, indirect, special or consequential damages, so
the above limitation or exclusion may not apply to you. This warranty provides specific 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 that they may not be
waived, the limitations and exclusions 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.
For help,
H contact your distributor
For additional information, such as
Technical Manuals (Service And Parts)
Engine Manuals
Circuit And Wiring Diagrams
Process Handbooks
User’s Guides
Distributor Directories
H contact your distributor
Always provide Model Name and Serial or Style Number
WHO DO I CONTACT?
To file a claim for loss or damage during
shipment,
H contact the delivering carrier
For assistance in filing or settling claims,
H contact your distributor and/or equipment
manufacturer’s Transportation
Department
Miller Electric Mfg. Co.
H CALL:
414-735-4505
H FAX:
800-637-2348 (in USA), or
414-735-4136 (outside USA)
H WRITE:
Miller Electric Mfg. Co.
P.O. Box 1079
Appleton, WI 54912 USA
miller_war1 6/95
Page 68
Owner’s Record
Please complete and retain with your personal records.
Model Name Serial/Style Number
Purchase Date (Date which equipment was delivered to original customer.)
Distributor
Address
City
State Zip
Resources Available
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
To locate distributor nearest you call
1-800-4-A-Miller.
Contact the Delivering Carrier
for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Owner’s Manuals
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
Welding Process Handbooks
File a claim for loss or damage during shipment.
Miller Electric Mfg. Co.
An Ill inoi s Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters−USA
Phone: 920-734-9821
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters −
United Kingdom
Phone: 44 (0) 1625-525556
FAX: 44 (0) 1625-537553
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.
PRINTED IN USA 1995 Miller Electric Mfg. Co.
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