October 2000
123 528M
Processes
MIG (GMAW) Welding Flux Cored (FCAW) Welding
Description
Wire Feeder
S-22A
www.MillerWelds.com
Working as hard as you do every power source from Miller is backed by the most hassle-free warranty in the business.
Miller offers a Technical Manual which provides more detailed service and parts information for your unit. To obtain a Technical Manual, contact your local distributor. Your distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMAW-P.
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 catalog sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.
TABLE OF CONTENTS
SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Additional Symbols for Installation, Operation, and Maintenance . . . . . . . . . . . . . . . . . . . . . . 1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . 1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Dangers relatifs au soudage larc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. Principales normes de scurit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Information sur les champs lectromagntiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Rating Label For CE Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Site Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Gun Recommendation Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. Equipment Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5. Connecting 14-Pin Plug, Shielding Gas And Optional Volt Sense Lead . . . . . . . . . . . . . . . . . 3-6. 14-Pin Plug Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7. Connecting Welding Gun And Weld Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8. Setting Time Range For Optional Spot Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9. Installing And Aligning Wire Guide And Drive Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10. Installing And Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Optional Side Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONS AND ACCESSORIES WARRANTY 1 1 1 3 3 4 5 5 5 7 8 8 9 9 10 10 11 11 11 11 12 12 12 13 13 14 15 16 16 16 17 17 17 18 19 21
OM-1570M
S-22A
Directives Low Voltage Directive: 73/23/EEC Electromagnetic Compatibility (EMC) Directive: 89/336/EEC
Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC Standards Arc Welding Equipment Part I: Welding Power Sources: IEC 974-1 (April 1995 Draft Revision) Arc Welding Equipment: Wirefeed Systems: IEC 974-4 (May 1995 Draft Revision) Degrees of Protection Provided By Enclosures (IP Code): IEC 529:1989 Insulation Coordination For Equipment With Low-Voltage Systems: Part I: Principles, Requirements and Tests: IEC 664-1: 1992 Electromagnetic Compatibility, (EMC): EN 50199
European Contact:
Mr. Luigi Vacchini, Managing Director MILLER Europe S.P.A. Via Privata Iseo 20098 San Giuliano Milanese, Italy 39(02)98290-1 39(02)98281-552
Telephone: Fax:
dec_con1 1/96
D If earth grounding of the workpiece is required, ground it directly with a separate cable. D Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. D Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. D Wear a safety harness if working above floor level. D Keep all panels and covers securely in place. D Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. D Insulate work clamp when not connected to workpiece to prevent contact with any metal object. D Do not connect more than one electrode or work cable to any single weld output terminal.
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D Pacemaker wearers keep away. D Wearers should consult their doctor before going near arc welding, gouging, or spot welding operations.
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D D D D
D D
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. Signifie NOTA ; nest pas relatif la scurit. 1-2. Dangers relatifs au soudage larc
Y Les symboles prsents ci-aprs sont utiliss tout au long du prsent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant et suivez les directives mentionnes afin dviter tout danger. Les consignes de scurit prsentes ci-aprs ne font que rsumer linformation contenue dans les normes de scurit numres la section 1-4. Veuillez lire et respecter toutes ces normes de scurit. Y Linstallation, lutilisation, lentretien et les rparations ne doivent tre confis qu des personnes qualifies. Y Au cours de lutilisation, tenir toute personne lcart et plus particulirement les enfants.
D Nutiliser quun matriel en bon tat. Rparer ou remplacer sur-lechamp les pices endommages. Entretenir lappareil conformment ce manuel. D Porter un harnais de scurit quand on travaille en hauteur. D Maintenir solidement en place tous les panneaux et capots. D Fixer le cble de retour de faon obtenir un bon contact mtal-mtal avec la pice souder ou la table de travail, le plus prs possible de la soudure.
D Isoler la pince de masse quand pas mis la pice pour viter le contact avec tout objet mtallique.
Il y a DU COURANT CONTINU IMPORTANT dans les convertisseurs aprs la suppression de lalimentation lectrique.
D Arrter les convertisseurs, dbrancher le courant lectrique, et dcharger les condensateurs dalimentation selon les instructions indiques dans la partie entretien avant de toucher les pices.
D D D D
D Couper lalimentation ou arrter le moteur avant de procder linstallation, la rparation ou lentretien de lappareil. Dverrouiller lalimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de scurit). D Installer et mettre la terre correctement cet appareil conformment son manuel dutilisation et aux codes nationaux, provinciaux et municipaux. D Toujours vrifier la terre du cordon dalimentation Vrifier et sassurer que le fil de terre du cordon dalimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccorde une prise correctement mise la terre. D En effectuant les raccordements dentre fixer dabord le conducteur de mise la terre appropri et contre-vrifier les connexions. D Vrifier frquemment le cordon dalimentation pour voir sil nest pas endommag ou dnud remplacer le cordon immdiatement sil est endommag un cble dnud peut provoquer une lectrocution. D Mettre lappareil hors tension quand on ne lutilise pas. D Ne pas utiliser des cbles uss, endommags, de grosseur insuffisante ou mal pisss. D Ne pas enrouler les cbles autour du corps. D Si la pice soude doit tre mise la terre, le faire directement avec un cble distinct. D Ne pas toucher llectrode quand on est en contact avec la pice, la terre ou une lectrode provenant dune autre machine.
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LES RAYONS DE LARC peuvent provoquer des brlures dans les yeux et sur la peau.
Le rayonnement de larc du procd de soudage gnre des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brlures dans les yeux et sur la peau. Des tincelles sont projetes
pendant le soudage.
D Porter un casque de soudage muni dun cran de filtre appropri pour protger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 numr dans les normes de scurit). D Porter des protections approuvs pour les oreilles si le niveau sondre est
trop lev.
D Utiliser des crans ou des barrires pour protger des tiers de lclair et de lblouissement; demander aux autres personnes de ne pas regarder larc. D Porter des vtements de protection constitu dans une matire durable, rsistant au feu (cuir ou laine) et une protection des pieds.
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D D D D D
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Consignes relatives aux stimulateurs cardiaques : Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur. Si vous tes dclar apte par votre docteur, il est alors recommand de respecter les consignes cidessus.
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SECTION 2 DEFINITIONS
2-1. Warning Label Definitions
Warning! Watch Out! There are possible hazards as shown by the symbols. Drive rolls can injure fingers Welding wire and drive parts are at welding voltage during operation keep hands and metal objects away. 1 Electric shock can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1.2 Protect yourself from electric shock by insulating yourself from work and ground. 1.3 Disconnect input plug or power before working on machine. 2 Breathing welding fumes can be hazardous to your health. 2.1 Keep your head out of the fumes. 2.2 Use forced ventilation or local exhaust to remove the fumes. 2.3 Use ventilating fan to remove fumes. 3 Welding sparks can cause explosion or fire. 3.1 Keep flammables away from welding. Do not weld near flammables. 3.2 Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it. 3.3 Do not weld on drums or any closed containers. 4 Arc rays can burn eyes and injure skin. 4.1 Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection. 5 Become trained and read the instructions before working on the machine or welding. 6 Do not remove or paint over (cover) the label.
S-178 936
1.1
1.2
1.3
2.1
2.2
2.3
3.1
3.2
3.3
4.1
+
5
+
6
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S/N:
U1 24 V = I1= 7.0 A
50/60 Hz IP 21
U2 100 V =
I2= 500 A
X 100 %
ST-178 794-A
NOTE
On
Off
Input
Output
A IP
Jog
V Hz U1
Volts
Alternating Current
Duty Cycle
Hertz
Wire Feed
Primary Voltage
Line Connection
Purge
Spot Weld
Continuous Weld
Burnback Time
Preflow Time
Postflow Time
Read Instructions
U2
Load Voltage
I1
Primary Current
I2
Rated Current
U1
Primary Voltage
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SECTION 3 INSTALLATION
3-1. Specifications
Type of Input Power Welding Power Source Type
Constant Voltage (CV) DC With 14-Pin And Contactor Control
IP Rating
Overall Dimensions
Length: 22-1/2 in (572 mm)
Weight
IP 21
32 lb (14.5 kg)
Choose slot that allows all rubber feet to sit securely on top of welding power source. 5 6 7 Wire Spool/Reel Gas Cylinder (Customer Supplied) Welding Power Source
5 1 7
Y Do not put feeder where welding wire hits cylinder. Y Do not move or operate equipment when it could tip.
2 4 3
Gun
M25 Or M40 GA-40GL OM-1570 Page 11
4 6
3 2 115VAC Contactor 4
3-5. Connecting 14-Pin Plug, Shielding Gas And Optional Volt Sense Lead
1 Gas Hose With 5/8-18 Righthand Thread Fittings (Customer Supplied) 14 Pin Plug PLG2
2 4 3
Use plug to make connection to welding power source. 3 Optional Volt Sense Lead (Part Of Meter Option) Power Switch
Pin Information
L C M D E
Loosen knob, insert gun into block. Position outlet wire guide as close as possible to drive rolls without touching. Tighten knob. 4 5 6 7 Gun Trigger Plug Gun Trigger Receptacle Weld Cable Terminal Weld Cable From Welding Power Source
Tools Needed:
1/4 in
ST-801 694 / Ref. SA-125 969-C
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Installation
Alignment
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If necessary, move hub on support for use of different size wire spool. Remove retaining ring, and install spool so hub pin fits spool hole. Reinstall retaining ring. Adjust tension nut so wire is taut when wire feed stops. 3 Pressure Assembly Adjustment Knob
Lay gun cable out straight. Open pressure assembly, hold wire tightly, and cut off end. Push wire through guides into gun. Close and tighten pressure assembly. Press JOG button until wire comes out gun. To adjust drive roll pressure, press gun trigger to feed wire against wood surface. Tighten knob so wire does not slip. Cut off wire. Close door.
Tighten
WOOD
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SECTION 4 OPERATION
4-1. Front Panel Controls
1 2 Optional Voltage/Wire Speed Meter Optional Voltage/Wire Speed Switch
Use to choose volts or wire feed speed display. 1 2 3 Optional Remote Voltage Control
Use to set welding power source voltage at the wire feeder. Numbers are for reference only. 4 5 Wire Speed Control Jog/Purge Switch
Use Jog position to momentarily feed welding wire at speed set on Wire Speed control without energizing welding circuit or shielding gas valve. 5 4 Use Purge position to momentarily energize gas valve to purge air from gun or adjust gas regulator. Power switch is on rear panel (see Section 3-5)
ST-801 692
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3 Months
Replace Unreadable Labels Repair Or Replace Cracked Weld Cable Clean And Tighten Weld Terminals
6 Months
Clean Drive Rolls Blow Out Or Vacuum Inside, During Heavy Service, Clean Monthly
OR
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5-3. Troubleshooting
Trouble
Wire does not feed, unit completely inop- Turn Power switch On. erative.
Remedy
Check fuse F1 and replace if necessary (see Section 5-2). Check 14pin plug PLG2 connections. Check input power. Wire does not feed. Check circuit breaker CB1 and fuse F1. (see Section 5-2) Check gun trigger connection at wire feeder. Check gun trigger leads and trigger switch. See gun Owners Manual. Have Factory Authorized Service Agent check drive motor and control board PC1. Wire feeds erratically. Readjust hub tension and drive roll pressure (see Section 3-10). Use correct size drive roll (see Parts List). Clean or replace dirty or worn drive roll (see Section 3-9). Remove weld spatter around nozzle opening. Replace contact tube or liner. See gun Owners Manual. Have Factory Authorized Service Agent check drive motor and control board PC1. Wire feeds when Jog switch is pressed Check gun trigger connection at wire feeder. Check gun trigger leads and trigger switch. See gun Owners but not when gun trigger is pressed. Manual. Wire feeds as soon as power is applied. Check gun trigger. See gun Owners Manual. Wire does not feed until trigger is Check for short between gun trigger leads and weld cable. Repair or replace gun trigger leads. pressed but continues to feed after trigger is released. Gas valve rattles loudly and wire feeds Check for short between gun trigger leads and weld cable. Repair or replace gun trigger leads. slowly or erratically. Gas does not flow; wire feeds. Check gas valve and flowmeter.
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SC-182 776
Figure 6-1. Circuit Diagram For Wire Feeder With Optional Equipment
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Notes
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Quantity
1 1 1 1 1 1 2 2 1 1 4 1 1 1 1 1 1
5 6 7 8 Fig 7-2 1 9 8 7 2
10
11
12
ST-801 693
Figure 7-1. Main Assembly OPTIONAL +When ordering a component originally displaying a precautionary label, the label should also be ordered. To maintain the factory original performance of your equipment, use only Manufacturer s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.
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OM-1570 Page 22 64 63 62 61 60
2 3
4 5
7 8 9 10 18 11 12 13 59 14 15 16 17 19 22 23 24 25
20 21
26 58 57 56 55
27
28
29
30 54 53 33 32 31 34 35
36
48 47 39 52 51 50 49 46 45 43 44 40 41 38 37
42
Item No.
Dia. Mkgs.
Part No.
Quantity
. . . 1 . . . . . . . . . . . . . 602 009 . . . SCREW, .250-20 x 1.250 soc hd hex gr 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 2 . . . . . . . . . . . . . 166 072 . . . SPACER, gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 3 . . . . . . . . . . . . . 151 828 . . . PIN, cotter hair .054 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 4 . . . . . . . . . . . . . 166 071 . . . LEVER, mtg pressure gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 5 . . . . . . . . . . . . . 079 634 . . . PIN, hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 6 . . . . . . . . . . . . . 085 243 . . . KNOB, adjustment tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 7 . . . . . . . . . . . . . 089 477 . . . SPRING, cprsn .770 OD x .105 wire x 1.225 . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 8 . . . . . . . . . . . . . 085 244 . . . WASHER, cupped stl .328 ID x .812 OD x .125 . . . . . . . . . . . . . . . . . . . . . . 1 . . . 9 . . . . . . . . . . . . . 085 242 . . . FASTENER, pinned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 10 . . . . . . . . . . . . . 048 449 . . . WASHER, shldr nyl .363 OD x .194 ID x .703 . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 11 . . . . . . . . . . . . . 010 224 . . . PIN, spring CS .187 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 12 . . . . . . . . . . . . . 079 624 . . . SCREW, cap stl hexhd slflkg .375-16 x 2.250 . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 13 . . . . . . . . . . . . . 130 365 . . . INSULATOR, housing drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 14 . . . . . . . . . . . . . 178 937 . . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 15 . . . . . . . . . . . . . 010 291 . . . WASHER, flat nylafil .625 ID x 1.250 OD x 1.000 . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . 601 880 . . . NUT, stl hex jam .500-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 16 . . . . F1 . . . . *011 116 . . . FUSE, mintr gl slo-blo 7A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 17 . . . . . . . . . . . . . 046 432 . . . HOLDER, fuse mintr .250 x 1.250 panel mtg . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 18 . . . . . . . . . . . . . 010 494 . . . BUSHING, snap-in nyl 1.375 ID x 1.750mtg hole . . . . . . . . . . . . . . . . . . . . . 1 . . . 19 . . . . . . . . . . . . . 131 181 . . . WIRE GUIDE & NUT, inlet (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . 039 796 . . . . NUT, term jack rcpt black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . 131 182 . . . . GUIDE, wire inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 20 . . . . . . . . . . . . . 180 634 . . . PLATE, ident control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 21 . . . . . . . . . . . . . 134 834 . . . HOSE, SAE .187 ID x .410 OD (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . 2ft . . . 22 . . . . GS1 . . . . 125 785 . . . VALVE, 24VAC 2 way custom port 1/8 orf . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 23 . . . . . . . . . . . . . 089 572 . . . CATCH, link-lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . 089 573 . . . PLATE, keeper link-lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 24 . . . . . . . . . . . . . 134 464 . . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 24 . . . . . . . . . . . . . 178 936 . . . LABEL, warning general precautionary CE . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 25 . . . . . . . . . . . . +152 725 . . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . 126 873 . . . BUMPER, polyurethane polymer .500sq adh back . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . 090 439 . . . LABEL, warning electric shock can kill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 26 . . . . CB1 . . . . 123 745 . . . CIRCUIT BREAKER, man reset 1P 4A 250VAC . . . . . . . . . . . . . . . . . . . . . . 1 . . . 27 . . . . S1 . . . . . 111 997 . . . SWITCH, rocker SPST 10A 250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 28 . . . . . . . . . . . . . 605 227 . . . NUT, nyl hex jam .750NPST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 29 . . . . . . . . . . . . . 182 270 . . . CABLE, power 10 ft 8 in (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . 182 271 . . . . CABLE, port No. 18 3/c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11ft . . . . . . . . . PLG2 . . . 141 162 . . . . HOUSING PLUG & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 29 . . . . . . . . . 182 758 . . . CABLE, power 10 ft 8 in (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . . . 182 475 . . . . CABLE, port No. 18 6/c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11ft . . . . . . . . . PLG2 . . . 141 162 . . . . HOUSING PLUG & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 30 . . . . . . . . . . . 601 222 . . . CLAMP, univ 50A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 31 . . . . . . . . . . . 601 225 . . . INSULATOR, vinyl clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 32 . . . . . . . . . . . 600 399 . . . LEAD, sensing (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15ft . . . 33 . . . . . . . . . . . . . 115 104 . . . CONNECTOR, clamp cable .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 34 . . . . . . . . . . . . . 087 111 . . . CLAMP, capacitor 1.375dia clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 35 . . . . C1 . . . . . 048 504 . . . CAPACITOR, elctlt 5000uf 50V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 36 . . . . PC1 . . . . 183 047 . . . CIRCUIT CARD, motor speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . PLG1 . . . 115 093 . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . PLG3 . . . 115 092 . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . PLG4 . . . 115 091 . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 37 . . . . . . . . . . . . . 134 201 . . . STAND-OFF SUPPORT, PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 38 . . . . PC2 . . 139 897 . . . CIRCUIT CARD, meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . PLG15 . 115 092 . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . PLG16 . 131 055 . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . . . 115 443 . . . STAND-OFF, 6-32 x .750 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . . . . . . 136 339 . . . COVER, opening meter (not used when unit has Meter Kit) . . . . . . . . . . . . 1 . . . 39 . . . . . . . . . . . . . 134 201 . . . STAND-OFF SUPPORT, PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OM-1570 Page 23
Item No.
Dia. Mkgs.
Part No.
Quantity
. . . 40 . . . . . . . . . . . . . 605 308 . . . RING, retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 . . . . . . . . . . . . . 092 865 . . . KEY, stl .1215/.1230 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 . . . . M1 . . . . 122 741 . . . MOTOR, gear 24VDC 122RPM (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *136 745 . . . . BRUSH & SPRING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 . . . . . . . . . . . . . 079 625 . . . WASHER, spring stl .500 shakeproof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 . . . . S2 . . . . . 134 846 . . . SWITCH, tgl SPTT 6A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 . . . . . . . . . . . . . 035 897 . . . POTENTIOMETER, CP std slot 1T 2W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 . . . . R1 . . . . . 073 562 . . . POTENTIOMETER, C sltd sft1/T 2W 10K ohm . . . . . . . . . . . . . . . . . . . . . . . . . 47 . . . . . . . . . . . . . 152 728 . . . CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 . . . . . . . . . . . . . 090 440 . . . INSULATOR, cover housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE (order by model and serial number) . . . . . . . . . . . . . . . . . . . . . . . 50 . . . . . . . . . . . . . 097 922 . . . KNOB, pointer .875dia x .250 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 . . . . . . . . . . 097 922 . . . KNOB, pointer .875dia x .250 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 . . . . . . . . . . . . . 107 983 . . . BLANK, snap-in nyl .500mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 . . . . RC2 . . . . 048 282 . . . CONNECTOR w/SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 . . . . . . . . . . . . . 057 084 . . . BUSHING, snap-in nyl .250 ID x .375mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . 55 . . . . . . . . . . . . . 172 391 . . . HOUSING, adapter gun/feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 . . . . . . . . . . . . . 144 172 . . . FITTING, hose brs barbed 3/16tbg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 . . . . . . . . . . . . . 604 538 . . . WASHER, flat stl SAE .312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 . . . . . . . . . . . . . 124 778 . . . KNOB, plstc T 1.000 lg x .312-18 x 2.000 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 . . . . . . . . . . . . . 010 910 . . . WASHER, flat stl SAE .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 . . . . . . . . . . . . . 602 213 . . . WASHER, lock stl split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 . . . . . . . . . . . . . 601 872 . . . NUT, stl hex full .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 . . . . . . . . . . . . . 172 076 . . . CARRIER, drive roll w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 . . . . . . . . . . . . . 121 271 . . . SCREW, .250-20 x .500 soc hd hex gr 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 . . . . . . . . . . . . . 172 075 . . . CARRIER, drive roll w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 285 . . . ROLL, drive V groove .035/.045 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 994 . . . GUIDE, wire inlet .045 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 304 . . . BLANK, snap-in nyl .250mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 6
*Recommended Spare Parts. +When ordering a component originally displaying a precautionary label, the label should also be ordered. Part of 152 212 Optional Digital Meter V/WFS Part of 121 569 Optional Remote Voltage To maintain the factory original performance of your equipment, use only Manufacturer s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1570 Page 24
NOTE
Base selection of drive rolls upon the following recommended usages: 1. V-Grooved rolls for hard wire. 2. U-Grooved rolls for soft and soft shelled cored wires. 3. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). 4. V-Knurled rolls for hard shelled cored wires. 5. Drive roll types may be mixed to suit particular requirements (example: V-Knurled roll in combination with U-Grooved). Drive Roll Part No. Type 087 130 053 695 053 700 053 697 053 698 053 699 072 000 053 701 053 702 053 706 053 704 132 958 132 957 132 956 132 955 132 959 132 960 083 489 083 490 053 708 053 710 V-Grooved V-Grooved V-Grooved V-Grooved V-Grooved V-Grooved U-Grooved U-Grooved U-Grooved U-Grooved U-Grooved V-Knurled V-Knurled V-Knurled V-Knurled V-Knurled V-Knurled U-Cogged U-Cogged U-Cogged U-Cogged Inlet Wire Guide 056 192 056 192 056 192 056 193 056 193 056 195 056 192 056 193 056 193 056 195 056 195 056 192 056 193 056 193 056 195 056 195 056 195 056 193 056 193 056 195 056 195
S-0157-C
Wire Diameter Fraction Decimal .023/.025 in. .030 in. .035 in. .045 in. .052 in. 1/16 in. .035 in. .045 in. .052 in. 1/16 in. 5/64 in. .035 in. .045 in. .052 in. 1/16 in. .068-.072 in. 5/64 in. .045 in. .052 in. 1/16 in. 5/64 in. .023/.025 in. .030 in. .035 in. .045 in. .052 in. .062 in. .035 in. .045 in. .052 in. .062 in. .079 in. .035 in. .045 in. .052 in. .062 in. .068-.072 in. .079 in. .045 in. .052 in. .062 in. .079 in.
Metric 0.6 mm 0.8 mm 0.9 mm 1.2 mm 1.3 mm 1.6 mm 0.9 mm 1.2 mm 1.3 mm 1.6 mm 2.0 mm 0.9 mm 1.2 mm 1.3 mm 1.6 mm 1.8 mm 2.0 mm 1.2 mm 1.3 mm 1.6 mm 2.0 mm
Kit No. 087 131 079 594 079 595 079 596 079 597 079 598 044 749 079 599 079 600 079 601 079 602 079 606 079 607 079 608 079 609 089 984 079 610 083 318 083 317 079 614 079 615
OM-1570 Page 25
Notes
OM-1570 Page 26
* * * * * *
APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts (No labor) Spoolmate 185 & Spoolmate 250 Canvas Covers
Millers True Blue Limited Warranty shall not apply to: 1. Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear. 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. 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.
2.
3.
* *
2.
Original main power rectifiers Inverters (input and output rectifiers only) Transformer/Rectifier Power Sources Plasma Arc Cutting Power Sources Semi-Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Engine Driven Welding Generators (NOTE: Engines are warranted separately by the engine manufacturer.) DS-2 Wire Feeder Motor Driven Guns (w/exception of Spoolmate 185 & Spoolmate 250) Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems HF Units Grids Maxstar 140 Spot Welders Load Banks Miller Cyclomatic Equipment Running Gear/Trailers Plasma Cutting Torches (except APT & SAF Models) Field Options (NOTE: Field options are covered under True Blue for the remaining warranty period of the product they are installed in, or for a minimum of one year whichever is greater.)
* * * * * *
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 Millers 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.
miller_warr 7/00
3.
* * * * * * * * * * * * * * * * *
4. 5.
* *
Owners Record
Please complete and retain with your personal records.
Model Name Purchase Date Distributor Address City State Zip Serial/Style Number
(Date which equipment was delivered to original customer.)
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you.
PRINTED IN USA
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