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Miller Electric DS-64M Swingarc manual

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Table of contents for the manual

  • Page 1

    DS-64M Swingarc Processes 12 and 16 Foot ™ MIG (GMA W) W elding Pulsed MIG (GMAW -P) Flux Cored (FCA W ) Welding OM-1588 161 875S 2006 − 05 Description Wire Feeder (Use with CC/CV Power Sources) Visit our website at www.MillerWelds.com File: MIG (GMA W)[...]

  • Page 2

    Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

  • Page 4

    T ABLE OF CONTENTS SECTION 10 − S T ANDARD PULSE WELDING PROGRAMS FOR PHOENIX/INVISION 456 INVERTER WELDING POWER SOURCES 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1. Program 1 − Steel 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 5

    OM-1588 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety messa[...]

  • Page 6

    OM-1588 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching (s[...]

  • Page 7

    OM-1588 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. F [...]

  • Page 8

    OM-1588 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American W elding Society Standard A WS [...]

  • Page 9

    OM-1588 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION som _3/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symbo les ut ilisés Sy mbole graphique d’avert iss ement ! Att ention ! Cette pro - cédur e comporte d es r i sques poss ibles[...]

  • Page 10

    OM-1588 Page 6 Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RA YONS D’ARC peuvent entraî- ne r des brûlures aux yeux et à la peau.[...]

  • Page 11

    OM-1588 Page 7 2-3 . Dange rs suppléme ntaire s en r e lation avec l’installa tion, le f onctionne ment et l a maintena nce Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur , au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger l?[...]

  • Page 12

    OM-1588 Page 8 2-5. Princi pales no rmes de sécurit é Safety in W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www .global.ihs.com). Recommended Safe Practices fo r the Preparati on for W elding and Cut- ting of Containers and Piping , American W eldin[...]

  • Page 13

    OM-1588 Page 9 SECTION 3 − INTRODUCTION 3-1. Specifications T ype of Input Power W elding Power Source T ype Wire Feed Speed Range Wire Diameter Range W elding Circuit Rating W eight 24 V olts AC Single-Phase 10 Amperes 50/60 Hertz Constant V oltage (CV) DC For GMAW Or Constant V oltage (CV) / Constant Current (CC) DC For GMAW -P All Need 14-Pin [...]

  • Page 14

    OM-1588 Page 10 4-2. Installing Control Box And Adjusting T ilt ST-800 174 / ST -801 278 1 Weld Control 2 Bracket 3 Screw Bracket and screws are installed onto bottom of control at factory . 4 Swivel Loosen screws. Place control on swivel and slide forward. Tighten screws. 5 T ilt Bracket 6 Rear Pivot Screw 7 Front Screw Loosen rear pivot screw. Re[...]

  • Page 15

    OM-1588 Page 1 1 4-4. Installing Wire Guide Extension ST-152 383 1 Wire Guide Fitting 2 Bolt 3 Monocoil Liner 4 Wire Guide Extension T ighten bolt to secure liner in wire guide fitting. Do not overtighten bolt and crush liner . Repeat procedure for opposite side. T ools Needed: 1 2 3 4 3/8 in[...]

  • Page 16

    OM-1588 Page 12 4-5. Equipment Connection Diagram ST-801 806 / Ref. ST -175 086 / Ref. ST-180 31 1-B 1 300/400 Ampere Model CC/CV Inverter W elding Power Source . Use settings shown for both pulse MIG welding and MIG welding. 2 45 0 Ampere Model CV Inverter Welding Power Source 3 14-Pin Cord 4 Positive (+) Weld Cable 5 Negative ( − ) Weld Cable B[...]

  • Page 17

    OM-1588 Page 13 4-6. Connecting Weld Cables And Gas Hoses Ref. ST-801 806 / Ref. ST -152 800-A T ools Needed: 5/8 in The weld cables and shielding gas hoses extend 10 ft (3 m) from the boom. Route weld cables from boom through reed relays, if applicable. If the welding power source or gas supply are further from the boom, extend cables or hoses as [...]

  • Page 18

    OM-1588 Page 14 4-7. Control Box Connections ST-800 177-A / Ref. ST -800 175 1 Optional Reed Relay Connection 2 Wire Feed Motor And Gas V alve Control Receptacle 3 Wire Feed Motor And Gas V alve Control Plug From Boom 4 14-Pin Cord 5 V olt Sense Lead (Optional Use) 6 Gun Trigger Plug From Boom 4 1 5 3 2 2 6 4-8. 14-Pin Plug Information Pin* Pin Inf[...]

  • Page 19

    OM-1588 Page 15 4-9. Removing Safety Collar And Adjusting Boom ST-142 599-B 1 Locking Knob T ighten knob to prevent boom movement. Loosen knob to allow boom movement. Change knob po- sition 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- z[...]

  • Page 20

    OM-1588 Page 16 4-12. Installing And Threading W elding Wire Install wire spool. Ad - just tension nut so wire is taut when wire feed stops. Install wire guide. Pressure Indicator Scale Pressure Adjust Install drive rolls. NONCONDUCTIVE SURF ACE NONCONDUCTIVE SURF ACE No Wire Slip Wire Slips ST-152 564-B / Ref. ST -156 929 / Ref. SC-150 922 / Ref. [...]

  • Page 21

    OM-1588 Page 17 SECTION 5 − OPERA TION 5-1. Operational T erms See Menu Guide for detailed programming steps. Note The following is a list of terms and their definitions as they apply to this wire feeder: General T erms: Adaptive Pulse W elding The wire feeder automatically regulates pulse frequency to maintain a constant arc length, regardless o[...]

  • Page 22

    OM-1588 Page 18 5-3. Front Panel Controls ST-162 127 1 Display 2 Parameter Select Button Press button to move > (the cursor) on the display . 3 Display Control Turn control to change value pointed to by > . T urning control one click causes Trim (arc length) to increase/decrease by one or V olts to increase/decrease by 0.1. When IPM is select[...]

  • Page 23

    OM-1588 Page 19 SECTION 6 − SETTING SEQUENCE P ARAMETERS 6-1. Sequence Parameters In A Program . See Menu Guide for detailed programming steps. Trim is arc length. If set to zero, arc length is short. If set to 99, arc length is long. If time is set to zero in W eld sequence, welding continues until gun trigger is released. If time is set to zero[...]

  • Page 24

    OM-1588 Page 20 SECTION 7 − SETTING DUAL SCHEDULE P ARAMETERS 7-1. Selecting Dual Schedule Pair Dual Schedule is used with two consecutive weld programs 1 & 2, 3 & 4, 5 & 6, or 7 & 8. Any program type (MIG, Adaptive Pulse, or Pulse) can be combined in dual schedule. 1 Side Panel Display Use side panel to turn feature on. See Menu [...]

  • Page 25

    OM-1588 Page 21 7-2. Optional Dual Schedule Switch Diagrams 1 Momen 2P (Momentary-Contact 2-Pole Switch) 2 Maint 2P (Maintained-Contact 2-Pole Switch) 3 Maint 1P (Maintained-Contact 1-Pole Switch) 4 T rigger Allows dual scheduling after establishing a welding arc. 5 Momen 1P (Momentary-Contact 1-Pole Switch) . If trigger is used for dual sched- ule[...]

  • Page 26

    OM-1588 Page 22 SECTION 8 − USING THE OPTIONAL DA T A CARD 8-1. Data Card T erms SA-158 435 >W r i t e R ead De l e t e D one READ Programs From Card WRITE Programs T o Card CARD SCREEN TERMS PULSE MIG TERMS PPS (Pulses Per Second) Apk (Peak Amperage) PWms (Pulse Width In Milliseconds) Abk (Background Amperage) T ime Amperage 8-2. Installing D[...]

  • Page 27

    OM-1588 Page 23 8-3. Card Displays . See Menu Guide for detailed programming steps. Security mode only functions with a data card. 1 Card Display 2 Moving Line Moving line is under value that can be changed. 3 W rite T ransfers program data from unit to card. The program card can hold u p to 32 programs. When writing to the card, the next available[...]

  • Page 28

    OM-1588 Page 24 8-4. Entering Access Code 1 Security Display 2 Program Lock Display 3 Access Code Display With a code set, this display appears when trying to turn off a program lock. Pressing Mode Select button will exit the access code display . . If any character is incorrect during code entry , pressing side panel Parameter Select button will c[...]

  • Page 29

    OM-1588 Page 25 8-5. Security The security feature allows a mini- mum and maximum range limit to be defined for Trim, inches per min- ute (IPM), and ShpArc (see Section 12 ). When the security lock is Of f, the full range of values is available for each parameter . When the security lock is On, the range of values available for each parameter is t [...]

  • Page 30

    OM-1588 Page 26 SECTION 9 − SYSTEM SETUP 9-1. Accessing The Setup Menu 1 Setup Panel 2 Power Switch Press and hold down both buttons while turning On unit. 3 Main Display Main display during setup. 4 Setup Display Follow this procedure any time access is required. Once in the setup displays, use the Mode Select button to select a particular displ[...]

  • Page 31

    OM-1588 Page 27 9-2. System Setup Display Parameters See Menu Guide for detailed programming steps. Note DISPLA Y SETTING NOTES >System Select the process the welding power source is able to do. >Model For the Invision 456 and XMT 304 selections, pulse data and welding power source minimum and maximum voltage values are automatically loaded i[...]

  • Page 32

    OM-1588 Page 28 SECTION 10 − ST ANDARD PULSE WELDING PROGRAMS FOR PHOENIX/INVISION 456 INVERTER WELDING POWER SOURCES Apk = Peak Amperage, Vpk = Peak V oltage, Abk = Background Amperage, PPS = Pulses Per Second, PWms = Pulse Width (milliseconds). The following eight pulse welding programs are in the memory of the wire feeder . Use this informatio[...]

  • Page 33

    OM-1588 Page 29 10-4. Program 4 − Steel Wire Size/T ype: .062” Gas: Ar - CO 2 or Ar - Oxy / 40 CFH (19 L/m) IPM / MPM Apk Vpk Abk PPS PWms COMMENTS 400 / 10.2 550 36.8 200 195 4.1 300 / 7.6 510 36.3 145 175 3.8 200 / 5.1 480 31.6 11 0 155 3.2 100 / 2.5 460 28.7 69 94 2.6 10-5. Program 5 − Stainless Steel Wire Size/T ype: .035” Gas: Ar - He [...]

  • Page 34

    OM-1588 Page 30 SECTION 1 1 − ST ANDARD PULSE WELDING PROGRAMS FOR XMT 304 INVERTER WELDING POWER SOURCES Apk = Peak Amperage, Vpk = Peak V oltage, Abk = Background Amperage, PPS = Pulses Per Second, PWms = Pulse Width (milliseconds). The following eight pulse welding programs are in the memory of the wire feeder . Use this information if it is n[...]

  • Page 35

    OM-1588 Page 31 1 1-4. Program 4 − Stainless Steel Wire Size/T ype: .030” Gas: Ar - He - CO 2 / 40 CFH (19 L/m) IPM / MPM Apk Vpk Abk PPS PWms COMMENTS 700 / 17.8 350 34.1 102 130 1.8 400 / 10.2 315 31.7 70 94 1.7 200 / 5.1 280 30.1 50 46 1.5 100 / 2.5 265 29.9 26 25 1.4 1 1-5. Program 5 − Stainless Steel Wire Size/T ype: .035” Gas: Ar - He[...]

  • Page 36

    OM-1588 Page 32 SECTION 12 − SETTING SharpArc E CONTROL 12-1. Selecting And Adjusting SharpArc E Control Ref. S-0259 1 Arc SharpArc ™ is “Arc” on the display . It is used to adjust arc cone width and arc characteristics. Use front panel parameter select button to move > to select Arc. Use Display Control to adjust Arc setting. SharpArc ?[...]

  • Page 37

    OM-1588 Page 33 SECTION 13 − TEACH POINTS 10 18 21 24 27 30 33 36 37 42 45 48 51 54 56 Vpk 10 20 30 40 50 60 70 80 90 100 1 10 120 130 140 200 Abk 20 55 80 105 130 160 185 210 235 260 290 315 340 365 400 PPS 1 3 5 PWms 24 Vpk Abk PPS PWms 100 180 210 240 270 300 330 360 370 420 450 480 510 540 565 Apk Apk 13-1. T each Using 15 Points The teach mo[...]

  • Page 38

    OM-1588 Page 34 13-2. Redefining T each Points Ref. S-0259 / Ref. ST-154 109 1 IPM IPM determines the weld metal de- position rate. . Redefining IPM is not normally required unless special wire or unusual joint design is needed. Use front panel parameter select button to move > to select IPM. Use Display Control to select teach point value. Pres[...]

  • Page 39

    OM-1588 Page 35 Date Program Number Wire Size/T ype Wire Manufacturer Mfg. Date Gas Flowrate CFH(L/min) Equipment Used − Power Source Serial Number Wire Feeder Serial Number Gun Model Weld Cable − Negative Positive IPM / MPM Vpk Apk Abk PPS PWms COMMENTS Preflow Seconds: Run In IPM: Ramps/Start: Crater: Start T rim/V olts: IPM / MPM: Seconds: C[...]

  • Page 40

    OM-1588 Page 36 SECTION 14 − MAINTENANCE AND TROUBLESHOOTING 14-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. Clean and tighten weld terminals. Repair or replace cracked weld cable. Check 14-pin cord. Check gas hose and fittings. Check gun cable. Replace cracked parts. 6 Months Blow out or vacuu[...]

  • Page 41

    OM-1588 Page 37 14-3. Error Displays Ref. ST-155 222 1 Release T rigger Error Display This appears if the trigger is closed when the unit power is turned on, or if the trigger is stuck or defective. 2 No V olt Sensed Error Display The arc voltage sense circuit is not receiving feedback. Check voltage sensing connections. Check connections at 14-pos[...]

  • Page 42

    OM-1588 Page 38 14-4. T roubleshooting Y Disconnect power before troubleshooting T rouble Remedy Wire feeds, shielding gas flows, but elec- trode wire is not energized. Check interconnecting cord connections. If secure, check cord for continuity and repair or replace (see Sections 4-5 and 4-7). Wire feeder is on, meter(s) do not light up, motor doe[...]

  • Page 43

    OM-1588 Page 39 Notes[...]

  • Page 44

    OM-1588 Page 40 SECTION 15 − ELECTRICAL DIAGRAM Figure 15-1. Circuit Diagram[...]

  • Page 45

    OM-1588 Page 41 SD-184 792-B[...]

  • Page 46

    OM-1588 Page 42 SECTION 16 − P ARTS LIST 800 272-D 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 1 3 Fig 16-8 Fig 16-4 24 23 26 29 30 Fig 16-5 Fig 16-2 20 22 25 27 28 31 32 33 Fig 16-5 . Hardware is common and not available unless listed. 34 34 Figure 16-1. Main Assembly[...]

  • Page 47

    OM-1588 Page 43 12 Description Part No. Dia. Mkgs. Item No. Model Quantity 16 Figure 16-1. Main Assembly 1 149 251 CABLE, trigger (consisting of) 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 149 252 CABLE, trigger (consisting of) 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 48

    OM-1588 Page 44 Description Part No. Item No. Quantity Figure 16-2. Support, Hub & Reel (Fig 16-1 Item 12) 1 058 427 RING, retaining spool 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 136 684 NUT , stl slflkg hex reg .625-1 1 w/nyl insert 2 . . . . . . . . . . . [...]

  • Page 49

    OM-1588 Page 45 Description Part No. Dia. Mkgs. Item No. Quantity Figure 16-3. Panel, Front w/Components (Fig 16-4 Item 28) 1 NAMEPLA TE, (order by model and serial number) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 167 697 P ANEL, front 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 50

    OM-1588 Page 46 ST-800 273-B 1 2 3 4 56 89 1 0 11 71 2 13 14 15 16 17 18 19 20 21 22 23 24 2 25 26 27 28 29 30 31 32 33 34 35 36 37 Fig 16-7 Fig 16-3 29 PC40 PC10 PC50 PC1 PC80 . Hardware is common and not available unless listed. Figure 16-4. Control Box[...]

  • Page 51

    OM-1588 Page 47 Description Part No. Dia. Mkgs. Item No. Quantity Figure 16-4. Control Box (Fig 16-1 Item 2) 1 162 253 P ANEL, side lower 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 RC30,40 047 637 CONNECTOR & SOCKETS 2 . . . . . . . . . . . . . . . . . . [...]

  • Page 52

    OM-1588 Page 48 2 3 4 8 10 11 17 18 19 20 21 22 29 32 33 34 35 36 38 1 9 13 14 16 30 27 28 37 12 26 39 2 1 ST-801 456 − A 5 6 7 42 15 23 25 24 31 41 40 See T able 16-1 For Drive Roll & Wire Guide Kits . Hardware is common and not available unless listed. Figure 16-5. Drive Assembly , Wire[...]

  • Page 53

    OM-1588 Page 49 Description Part No. Item No. Quantity Dia. Mkgs. Figure 16-5. Drive Assembly , Wire (Fig 16-1 Items 29 & 33) 1 010 668 SCREW , cap stl sch .250-20 x 1.500 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 172 075 CARRIER, drive roll w/components 24 pitch 4 . . . . . . . . . . [...]

  • Page 54

    OM-1588 Page 50 T able 16-1. Drive Roll and Wire Guide Kits .023-.025 in. 0.6 mm 151 024 087 130 .030 in. 0.8 mm 151 025 053 695 .035 in. 0.9 mm 151 026 053 700 151 036 072 000 151 052 132 958 .045 in. 1.1/1.2 mm 151 027 053 697 151 037 053 701 151 053 132 957 151 070 083 489 .052 in. 1.3/1.4 mm 151 028 053 698 151 038 053 702 151 054 132 956 151 0[...]

  • Page 55

    OM-1588 Page 51 Description Part No. Dia. Mkgs. Item No. Quantity Figure 16-6. Panel, Side w/Components (Fig 16-4 Item 37) 1 147 139 T APE, adh acrylic double sided .010 x .500 x 3.000 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 155 024 LENS, clear anti-glare 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 56

    OM-1588 Page 52 ST-142 306-G 1 23 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 28 29 14 13 23 24 25 18 26 27 4 . Hardware is common and not available unless listed. Figure 16-7. Boom Assembly[...]

  • Page 57

    OM-1588 Page 53 Quantity Description Part No. Item No. Model 12 16 Figure 16-7. Boom Assembly (Fig 16-1 Item 15) 1 010 313 PIN, cotter hair .072 x 1.437 4 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 010 910 WASHER, flat stl SAE .375 6 6 . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 58

    OM-1588 Page 54 Notes[...]

  • Page 59

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2006 − 01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expe[...]

  • Page 60

    PRINTED IN USA © 2006 Miller Electric Mfg. Co. 2006 − 01 Miller Elect ric Mfg. Co. An Illinois T ool W orks Compa ny 1635 West S pencer S treet Applet on, WI 5 4914 US A International He adquarters − US A USA Phone: 920-735-4505 Aut o-At tended USA & Canada F A X: 9 20-735-4134 Int ernati onal F AX : 920-735-4125 European Headqua rters −[...]