Processes Pulsed MIG Miller MIG (GMAW-P) (GMAW) Flux Cored (FCAW) (Gas- and Self-Shielded) The Power ofBlue.
to YOu From . Thank you and you can congratulations on choosing Miller. Now get the job done and get it done right. We know you dont Thats have time to do it any other way. when Neils Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldnt afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.
TM Front Panel Features Description 2-line Put the benefits of technology to work on the production line. The SS-64M represents a major advancement in wire feed technology, and delivers the ultimate in versatility, simplicity, programmability and performance. The SS-64M feeder includes special features for pulsed MIG (GMAW-P) welding that requires the use of inverter-type power sources.
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1. Read Before Using Safety Precautions 1.1 Symbol Usage OM-1586K -2/97, 11/96 Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. 4A A safety_som Marks a special safety This group ELECTRIC message. of symbols Wamingl Watch means SHOCK, MOVING PARTS, Out! possible and HOT PARTS hazards.
CYLINDERS can if explode damaged H F RADIATION can cause interference High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. Shielding only qualified persons familiar with equipment perform this installation.
NOISE can Noise from FLYING METAL or DIRT can damage hearing some processes or equipment Wear can with side shields or face shield. damage hearing. Wear safety glasses injure eyes. approved ear protection if noise level is high. FALLING UNIT STATIC (ESD) Put grounded on handling can boards Use proper store, move, Use damage PC boards wrist strap injury lifting eye to lift unit only, NOT running cylinders, or any other accessories.
1. Consignes de SØcuritØ pour le Soudage a Iarc 1 1 Signification OM-1 586K/cfr a ~ des symboles Attention! Ce mode opØratoire peut en garde! Signifie presenter des dangers! Les dangers possibles sont indiques par Mise les divers symboles. message de sØcuritØ A Indique ~ Signifie NOTA; pas un special. ilØ a Ia sØcuritØ Ce groupe de symboles signifie Mise en garde! Attention!, risque de CHOCS ELECTRIQUES, dangers prØsentØs par les PI¨CES MOBILES et les PI¨CES CHAUDES.
LES VAPEURS ET LES FUMEES peuvent Œtre dangereuses pour Ia sante. Le soudage produit des vapeurs dangereux de respirer. 1. 2. et des fumØes Garder Ia tŒte a lextØrieur des vapeurs et des fumØes et les respirer. quil ne Ne travaillerdans un espace confine que sil est bien ventilØ, ou en portant un appareil respiratoire a adduction dair pur. Demandera un observateur ayant recu Ia bonne formation de toujours se tenir 5. est a proximitØ.
LELECTRICITE STATIQUE peutendom mager les piŁces des circuits imprimØs. 1. Mettre un bracelet antistatique AVANT de mani puler les cartes de circuits imprimØs ou les piŁces. 2. Utiliser des sacs et boltes antistatiques adequats pour ranger, dØplacer ou expedier les cartes de circuits imprimØs. LES CHAMPS MAGNETIQUES PRO DUITS PAR LES COU RANTS ELEVES peuvent nuire au fonctionnement du sti mulateur cardiaque 1. Les personnes qui portent un slimulateurcardiaque doivent se tenir Øloignees du paste de soudage.
2. Introduction 21 Specifications Type of Input Power 24 Volts AC Single-Phase 10 Amperes 50/60 Hertz Welding Power Source Type Wire Feed Range Range Constant Voltage (CV) DC For GMAW Or Constant Voltage (CV) / Constant Current (CC) DC For GMAW-P All Need 14-Pin And Contactor Control Standard: 50 To 780 ipm (1.3 To 19.8 mpm) To 3.2 Optional High Speed: 92 To 1435 ipm (2.3 To 36.5 mpm) 12 ft Height Maximum With 4 ft (1.2 in) Post (3.7 m) .
32 Installing Boom and Reel Support ST-142 596-C ______ 3 1 Swivel Plates 2 Yoke 7 Remove hardware plates and yoke. 3 swivel Boom Set boom into swivel 4 from as shown. Yoke Pin 5 pin through yoke. Install pin and spread ends. Install ter 5 4 cot 2 6 Bolt *0 Install bolt, tighten hardware, and back bolt off one half tum. 6 Locking Install Knob locking knob but do not tighten. 7 Reel Support Install reel support. Tools Needed: ~ 3/8, 3/4 in 3.
34 Adjusting Control 1 Tht Bracket 2 Rear Pivot Screw 3 Front Screw Tilt Bracket ST-801 279 Loosen rear pivot screw. Remove front screw. Pivot control down ward to desired viewing angle. Re place and tighten front screw. Tighten pivot screw.
/ ST-801 805/ Ref. ST-175 086 / Ref. ST-180 311-B 1 . 300/400 Ampere Model CC/CV Inverter Welding Power Source Use settings shown for both pulse MIG welding and MIG welding. 2 Ampere Model DC Welding Power 450 Inverter Source 3 14-Pin Cord 4 Positive 5 Negative () Be sure (+) weld Weld Cable Weld Cable for are peak properly pulse welding (see welding source Owners Manual).
3.6 CoflnectingWeId Cabtes And Gas Hoses Ref. ST-801 805/ Ref. ST-152 800-A The weld cable and shielding gas hose extend 10 ft (3 m) from the boom. Route weld through reed cable from boom if applicable. relay, If the welding power source or gas supply are further from the boom, extend cable or 1 Weld Cable 2 Insulated Bolt hose as follows: Sleeving cables from together welding power weld Use electrical tape and insulated sleeving 3 source and boom. to cover connection.
Control Box Connections 37 ~ ~ Optional 1 Reed ST-i 57433-B / Ref. ST-i 57434 Relay Connection 2 Wire Feed Motor And Gas Valve Control Receptacle 3 Wire Feed Motor And Gas Valve Control Plug From Boom 4 14-Pin Cord 5 Volt Sense Lead (Optional Use) 6 Gun Trigger Plug From Boom 4 3.8 14-Pin Plug Information pin. Pin Information A 24 volts B Contact closure to A G Circuit C +10 volts dc D Remote control circuit common.
Motor Start Control: 3,9 ST-157 480-A I Ref. SB-146 862-D change wire feed starting speed proceed as follows: To Turn Off unit and welding power source. Remove wrapper. 1 Front Panel Remove screw ner, and open from upper left cor front panel. hinged 2 Motor Board PCi 3 Motor Start Control Potentiometer R70 Rotate potentiometer clockwise to increase time it takes the motor to ramp up to speed. Remove protec rubber white tive cap before making adjustment.
Gun Recommendation Table 311 Gun Process GMAW-P GMAW Hard Hard or or Self-Shielding 312 Wire Speed M25, M40, Or GA-50C Cored Wires FCAW Motor GW-500 Or GW-600 Cored Wires GA-4OGL Or GA-5OGL Wires Type, Size, Wire Type and Feed Speed Capability Wire Size Feed mm) Standard All .023 To 5/64 in (0.6 To 2 Standard All 3/32 To 7/64 in (2.4 To 2.8 Standard All 1/8 in Optional High Speed All .023 To 5/64 in 14 Table mm) (3.2 mm) (0.
Installing and Threading Welding Wire 3.13 ST-152 648-A / Ref. ST-i 57432 / Ref. ST-i 37391-A / ST-i42 597-A/ Ref. S-0627-A I Ref. ST-i 50 922 For soft wire that outlet cable has proper size welding wire size. When installing gun, position linerextending fro moutlet wire guide as close as possible to drive rolls without touching. Be sure Install gun. Lay gun cable out straight. Cutoff end of wire. Push wire through guides up to drive rolls; continue to hold wire. Press Jog button to feed wire out gun.
4. Operation 41 Operational Note ~ The following is a Terms / See Menu Guide for detailed list of terms and their definitions as programming steps. they apply to this wire feeder: General Terms Pulse Adaptive The wire feeder Welding less of Cold Wire change automatically regulates pulse frequency welding wire stickout. to maintain a constant length, regard arc in When weld amperage is not present, wire feeds for about three seconds at set wire feed speed.
FrOnt. Pane! Controls 4.3 Ref. ST-155 222 crease/decrease 1 Display 2 Parameter Select Button Press button to move > on display. Display Control 3 Turn control to to by>. Turning control one click causes Trim (arc length) to increase/decrease by one or Volt to increase/decrease by 0.1. click causes selected, turning control one wire feed speed (1PM) to in crease/decrease by one. When MPM is selected, clicks causes wire feed crease by 0.1. ule Mode valve.
5. Setting Sequence Parameters Setting Sequence 5 1 Parameters in a Program ~ See Menu Guide for detailed programming steps. length. If set to zero, is short. If set to 99, Thm is arc length length is arc arc long. If time is set to zero in Weld se quence, welding continues until gun trigger is released. If time is set to zero in any timed se the Weld, except quence sequence is skipped. Pulse Weld 1. Trim Volts Inductance 1PM 0-99 10.0-38.0 0-99% 50-780 X MIG Pulse Crater 2.
G. Setting Dual Schedule Parameters Selecting 6.1 Dual Schedule Pair : rti~ . Dual Schedule is used with two consecutive weld programs 1 & 2, 3 & 4, 5 & 6, or 7 & 8. Any program type (MIG, Pulse) can Adaptive Pulse, or be combined in dual schedule. 1 Display Side Panel Use side panel to turn feature on. See Menu Guide for detailed pro gramming steps. 2 Front Panel Press front Display panel parameter select button to select program number.
Dual Schedule Switch 62 1 / Momen2P (Momentary-Contact Switch Or DSS-1O) 2 Diagrams Maint 2P 2-Pole 1 (Maintained-Contact DSS-9M) 3 Maint 1 P (Maintained-Contact 1-Pole Switch, Or DSS-8) 4 Trigger lishing a ~ If trigger is used schedule switch, is disabled. for > > A 3 4 B 4 3 0 2 > > A scheduling afterestab welding arc. > 2 2 > Allows dual > > 2 2-Pole Switch Or 1 1 1 > 2 1 dual 0- Trigger Hold \~B p p 4 3 Adapter 1 > ___________ 3 7.
7.2 Installing Data Card ST-156 266-B Label 1 to data card. Write pro gram information on label. Apply label 2 Data Card 3 Card Slot 3 For Blank Data Card: Insert card into slot. To format card, turn On power. Select Card from menu. Data card formats when unit enters Card mode. 1 For Power Source Data Card: Insert card into slot. Tum On pow Push Parameter Select button er. within 3 seconds and the 8 pro grams and setup information are read into the wire feeder memory.
a. System Setup 8 1 Display Settings Note ~ DISPLAY SETTING >System >Range * See Menu Guide for detailed programming steps. NOTES Select the process the welding power source is able to do. Welding power source minimum and maximum voltage values are always needed. Amperage for pulse welding. Set values to match welding power source ranges. * of setup >Access When on, restricts >Mig Type Default is Off. Set to On >Voltage Default is use only values are required screens.
0. Standard Pulse Welding Programs Note ~ Apk = PPS = Peak Amperage, Vpk factory set programs. interpolations from the 9.1 Wire Program SizelType: 1 = Peak Pulses Per Second, PWms = Voltage, If selection is set for 4 Abk Background Amperage, (milliseconds). Four teach points were used for fifteen teach points, the remaining points are = Pulse Width taught points. Steel .035 Gas: Ar - CO2 or Ar- Oxy /40 CFH (19 Urn) 1PM / MPM Apk Vpk Abk PPS PWrns 700/17.
Program 95 Wire Size/Type: Stainless 5 Gas: Ar .035 - He - C02140 CFH (19 1/rn) 1PM! MPM Apk Vpk Abk PPS PWms 700/17.8 403 339 132 191 2.8 400 /10.2 318 316 87 146 2.4 200/5.1 295 285 53 94 1.9 100/2.5 280 260 32 45 1.8 9,6 Wire Program S Gas: Ar - He - C02/40 CFH (19 Urn) 1PM! MPM Apk Vpk Abk PPS PWms 700/17.8 480 390 200 227 3.2 400/10.2 425 324 155 185 2.5 200/5.1 360 280 100 115 2.0 100/2.5 350 262 40 70 2.
10. Teach Points / TeachUsingl5Points 101 The teach mode allows the user to create cus tom pulse programs. The teach mode selec tion for 15 teach points gives a more defined curve the for a specific range. At each teach point, adjust five parameters to shape user can pulse waveform of the weld output. The six parameters are: 1PM (MPM), Apk, Vpk, Abk, PPS, and PWms.
10.2 Teach Using 4 Points The teach mode allows the userto create custorn pulse programs. The teach mode selec- points gives the whole welding quickly. At each teach point, the user adjust five parameters to shape the pulse tion for 4 teach range can waveform of the weld output. The six parame(MPM), Apk, Vpk, Abk, PPS, and Apk, Vpk, Abk, PPS, and PWms acting together provide the energy necessary to bum oft welding wire at a set wire feed speed.
103 Redefining Teach Points Ref. S-0259 / Ref. ST-154 109 Redefining 1PM Teach Point 1PM determines the weld metal de position rate. Trim 50 Redefining 1PM is notnoimally required unless special wire or unusual is joint design ~ needed. /~ Use front panel parameter select button to move> to select 1PM. Use Display Control to select teach point Purge I Pu se QAL~ Li value. Press and hold Purge button while turning Display Control to redefine the 1pm teach point.
Wire Program Number_ Date Sizefrype. Flowrate - Gas Equipment Used Power Source__ Serial Number_ Serial Number Wire Feeder Gun Model_________________ Weld Cable Wire Manufacturer_________________ 1PM! MPM CFH(Umin) Apk Abk ~If.. Positive______ Negative fl~*~ PPS PWms Vpk COMMENTS .
11. Maintenance and Troubleshooting 11 1 Routine Maintenance , ~ it~j1~ A Disconnect power before maintaining. 3 Months Replace Repair Or Replace Unreadable Labels Cracked Weld Cable 14-Pin Replace Cracked Parts ~ Co~~ Gas Hose And Gun Cable Fittings 6 Months Blow Out Or Vacuum Inside.
11.2 Error Displays r!1~H~ Ref. 5T-155 222 EEJ R e I e a s e I 2 00 No Volt 1Er ror 3 1 Memory Prg _CRC Er ror Release Error Trigger Display This appears if the trigger is closed when the unit power is turned on, or if the 2 trigger is stuck or defective. No Volt Sensed Error Display The Memory Prg Er Range ror arc voltage sense circuit is not receiving feedback. Check voltage connections.
11 3 Troubleshooting ~ A Trouble Wire feeds, shielding gas flows, but energized. Wire feeder is on, meter(s) do not light up, motor does not run, gas valve and welding power not pull in. source contactor Electrode wire feeding stops erratically dunng welding. or Check interconnecting cord connections. If secure, check cord for (see Sections 3.5 and 3.7). Check and reset CB1 feeds trigger Check gun trigger.
12.
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13. Parts List 13 1 Main Assembly ST-i 57 507-G ~ Hardware is common and not available unless listed. or 0) U, 0) LI~ . Co Co N N C,) a LL N N C,) N 0~ C) 0) .
I Quantity Item No. 1 1 2 3 3 Dia. Model Part No. Mkgs. Description 12 149 251 CABLE, trigger (consisting of) 149 252... CABLE, trigger (consisting of) PLG23.... 079 878 CONNECTOR & PINS 079 531 CONNECTOR, circ clamp str rlf sz 11 Amp 206358-2 605 156 CABLE, port No. 184/c (order by ft) PLG28.... 080 328 CONNECTOR w/SOCKETS, free hanging See Note... CONTROL BOX, (Fig 13.2) 164475... CABLE, interconnecting (consisting of) 164 474...
132 Control Box (Fig 131 Item 2) ST-157 508-0 ~ Hardware is common and not available unless listed. cJ N cJ Co Cj U, C.) CJ .
Item No. Part No. Dia. Mkgs. 1 147139 2 155024 144844 PC4O 5....PLG16,41 ..6 158160 ... 155023 PC6O 156623 PLG6O 153 501 RC7O 048282 079 532 079 535 079531 154938 8 PC5O 163917 PLG51 .... 158720 PLG52 .... 158719 PLG53 .... 131 204 PLG54 .... 148439 PLG55 10 12 .. ... 115092 PC1O 184775 PLG11 115092 PLG15 11 .... .... .... 153501 PLG17 .... 115093 PLG18 .... 162382 ... 170980 ...
13.2 Item No (Continued) Dia. Part No. Mkgs. 37 38 :1 145948 PC2O,30. PLG25 169502 164899 Quantity Description BRACKET, mtg control box CIRCUIT CARD, display front CONNECTOR & SOCKETS (RC25) ext .625 shaft grv 1 1 1 .O45thk E 39 159264 RING, retaining 40 167633 41 167698 42 010291 WASHER, shldr .612 ID PANEL, front WASHER, flat .
133 Hub & Reel Support, (Fig 131 Item 12) ST-146 339-B IJ~ Hardware is common and not available unless fisted. 3 5 4 3 2 11 12 13 14 includes Item 8 8 Item No. Part No. 1 142399.. 2 010191 3 058628.. 4 058428 5 108 008 6 124900 7 +168 104 8 166594.. 9 168103.. 10 057971 11 010233 12 605941 13 136684.. 14 058427.. Description SUPPORT, reel WASHER, fbr .656 ID x 1.500 OD x .
134 Drive Assembly, Wire (Fig 13 1 Item 25) ST-801 456-A IrT Hardware is common and not available unless listed. See Section 13.
Item No. Part No. Dia. Mkgs. Description Quantity 4 10 SCREW, cap stl sch .250-20 x 1.500 CARRIER, drive roll w/components 24 pitch 149 962 SPACER, carrier drive roll 149 486 PIN, rotation arm rocker 163 282 NUT, .250-28 stl 165 798 SPRING, pressure arm retaining 165 799 WASHER, flat .257 ID stl 132750...ARM, pressure 150 520 SPACER, rotation pin 133493... RING, retaining ext .250 shaft x .O25thk 11 133350... 1 1 010 668 ... 2 172 075 ... 3 2 ... 5 2 ... 6 2 ... 7 2 ...
135 Boom Assembly (Fig 131 Item 15) ST-142 601-E \ \ 0) \ \~_ Co Co 0)~ ~ \ \ \ \ \ to cJ Co C%J N cJ IE? Hardware is common and not available unless listed.
Quantity 1 010493 2 159991 2 159989 3 079665 3 080811 4 079664 5 139633 6 073742 7 073741 8 079029 9 075462 10 602250 11 079020 12 149858 12 080723 13 150258 14 024605 15 075101 16 079030 17 +174754 18 174688 080157 142804 134327 073666 19 047224 602246 22 079667 22 080812 23 079632 24 010910 ...25 079622 ...26 010313 27 079621 ...28 139336 149322 +When Model Part No. Item No. ordering a Description 12 BUSHING, snap-in nyl .625 ID x .
13,~6; Drive.RoII& Wire Guide Kits S-0549-C 0 a 0 WureSuze V-GROOVE U-GROOVE VK-GROOVE UC-GROOVE ~ w ~w 4 RoIl Drive 4 Roll Drive 4 Roll Drive 4 RoIl Drive Kit Roll Kit Roll Kit Roll Kit Roll 149518 151024 087130 150993 149518 151025 053695 0.9mm 150993 149518 151026 053700 151036 072000 151052 132958 .045in. 1.1 mm 150994 149519 151 027 053697 151 037 053701 151 053 132957 151 070 083489 .052in. 1.
Options and Accessories SS-60M A Skill Level Index The box to the right of the options contains a stock number of field-installed letter and number. The letter indicates the skill level required to install the option. The number indicates the approximate time required for installation (see legend). C Easy. No previous experience needed. Average. Requires removal of service panels. Mechanical ability is helpful. Difficult.
and Accessories Continued Options One of the is following required for mounting Swingarc~ booms: the SS-60M and DS-60M Swingpak Base pipe post with base plate CBC Cart (for use with 12 ft 3.7 ml model only) the 6 ft (1.8 m) pipe post without base plate (ordered separately) Pipe The Post Bases Swingpak~ Swingpak-1 2 base to mount a 12 ft Swingpak-16 base is for use witha l6ft(4.9m)boom. Order a (3.7 m) boom.
fi (Equipment with This limited warranty Effective January 1, 1997 serial number preface of KH supersedes previous alt guarantees or Subject to the terms and conditions Mtg. 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.
Owners Record S Please complete and retain with your personal records. Serial/Style Number Model Name Purchase Date (Date when equipment wae delivered to original cuetomer.) Distributor Address City State lip Resources Available Always provide Model Name and Serial/S tyle Number. Contact your Distributor for: Welding Supplies Options To locate the distributor nearest you, call and Consumables and Accessories Personal Safety Equipment 1-800-4-A-Miller.
