Professional Documents
Culture Documents
October 2000
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Wire Feeder
S-22A
OM-1570M
Declaration of Conformity for
European Community (CE) Products
NOTE This information is provided for units with CE certification (see rating label on unit).
Directives
Standards
Telephone: 39(02)98290-1
Fax: 39(02)98281-552
dec_con1 1/96
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_4/98
Y Marks a special safety message. This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
. Means “Note”; not safety related. to avoid the hazards.
OM-1570 Page 1
ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill.
Arc rays from the welding process produce intense D Shut off shielding gas supply when not in use.
visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use
that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator.
weld.
D Wear a welding helmet fitted with a proper shade of filter to protect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards). HOT PARTS can cause severe burns.
D Wear approved safety glasses with side shields under your
helmet. D Do not touch hot parts bare handed.
D Use protective screens or barriers to protect others from flash and D Allow cooling period before working on gun or
glare; warn others not to watch the arc. torch.
D Wear protective clothing made from durable, flame-resistant mate-
rial (leather and wool) and foot protection.
MAGNETIC FIELDS can affect pacemakers.
WELDING can cause fire or explosion.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks going near arc welding, gouging, or spot
can fly off from the welding arc. The flying sparks, hot welding operations.
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding. NOISE can damage hearing.
D Protect yourself and others from flying sparks and hot metal.
Noise from some processes or equipment can
D Do not weld where flying sparks can strike flammable material. damage hearing.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers. D Wear approved ear protection if noise level is
high.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can CYLINDERS can explode if damaged.
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes, Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
unless they are properly prepared according to AWS F4.1 (see gas cylinders are normally part of the welding
Safety Standards). process, be sure to treat them carefully.
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly D Protect compressed gas cylinders from excessive heat, mechani-
unknown paths and causing electric shock and fire hazards. cal shocks, slag, open flames, sparks, and arcs.
D Do not use welder to thaw frozen pipes. D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use. D Keep cylinders away from any welding or other electrical circuits.
D Wear oil-free protective garments such as leather gloves, heavy D Never drape a welding torch over a gas cylinder.
shirt, cuffless trousers, high shoes, and a cap. D Never allow a welding electrode to touch any cylinder.
D Remove any combustibles, such as a butane lighter or matches, D Never weld on a pressurized cylinder – explosion will result.
from your person before doing any welding.
D Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
FLYING METAL can injure eyes.
D Turn face away from valve outlet when opening cylinder valve.
D Welding, chipping, wire brushing, and grinding D Keep protective cap in place over valve except when cylinder is in
cause sparks and flying metal. As welds cool, use or connected for use.
they can throw off slag.
D Read and follow instructions on compressed gas cylinders,
D Wear approved safety glasses with side associated equipment, and CGA publication P-1 listed in Safety
shields even under your welding helmet. Standards.
OM-1570 Page 2
1-3. Additional Symbols For Installation, Operation, And Maintenance
OM-1570 Page 3
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them.
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator.
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17 3. Do not coil or drape cables around your body.
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the 4. Keep welding power source and cables as far away from opera-
committee’s judgment, has not demonstrated that exposure to power- tor as practical.
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be 5. Connect work clamp to workpiece as close to the weld as possi-
examined. Until the final conclusions of the research are reached, you ble.
may wish to minimize your exposure to electromagnetic fields when
welding or cutting. About Pacemakers:
To reduce magnetic fields in the workplace, use the following Pacemaker wearers consult your doctor first. If cleared by your doctor,
procedures: then following the above procedures is recommended.
OM-1570 Page 4
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT
UTILISATION
som _nd_fre 4/98
OM-1570 Page 5
LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris-
voquer des brûlures dans les yeux et quent de provoquer des blessures ou
sur la peau. même la mort.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses D Fermer l’alimentation du gaz protecteur en cas de
(ultraviolets et infrarouges) susceptibles de provoquer non utilisation.
des brûlures dans les yeux et sur la peau. Des étincelles sont projetées D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-
pendant le soudage. rateur d’adduction d’air homologué.
D Porter un casque de soudage muni d’un écran de filtre approprié pour
protéger votre visage et vos yeux pendant le soudage ou pour regar-
der (voir ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
D Porter des protections approuvés pour les oreilles si le niveau sondre est DES PIÈCES CHAUDES peuvent pro-
trop élevé. voquer des brûlures graves.
D Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair
et de l’éblouissement; demander aux autres personnes de ne pas re- D Ne pas toucher des parties chaudes à mains nues
garder l’arc. D Prévoir une période de refroidissement avant
D Porter des vêtements de protection constitué dans une matière dura- d’utiliser le pistolet ou la torche.
ble, résistant au feu (cuir ou laine) et une protection des pieds.
OM-1570 Page 6
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance
OM-1570 Page 7
1-4. Principales normes de sécurité
Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C. Règles de sécurité en soudage, coupage et procédés connexes, norme
20402. CSA W117.2, de l’Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
Recommended Safe Practice for the Preparation for Welding and Cut-
ting of Containers That Have Held Hazardous Substances, norme AWS Safe Practices For Occupation And Educational Eye And Face Protec-
F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL tion, norme ANSI Z87.1, de l’American National Standards Institute,
33126 1430 Broadway, New York, NY 10018.
National Electrical Code, NFPA Standard 70, de la National Fire Protec- Cutting and Welding Processes, norme NFPA 51B, de la National Fire
tion Association, Batterymarch Park, Quincy, MA 02269. Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-1570 Page 8
SECTION 2 – DEFINITIONS
S-178 936
OM-1570 Page 9
2-2. Rating Label For CE Products
S/N:
U1 24 V 1 50/60 Hz
=I1= 7.0 A IP 21
ST-178 794-A
A Amperes
V Volts Alternating Current
X Duty Cycle
IP Degree Of
Protection Hz Hertz Circuit Breaker Wire Feed
OM-1570 Page 10
SECTION 3 – INSTALLATION
3-1. Specifications
Welding Wire Welding
Type of Input Wire Feed IP Overall
Power Diameter Circuit Weight
Power Speed Range Rating Dimensions
Source Type Range Rating
1 Wire Feeder
2 Lifting Eye
3 Rubber Feet
4 Slot
Choose slot that allows all rubber
feet to sit securely on top of welding
power source.
5 Wire Spool/Reel
6 Gas Cylinder (Customer
Supplied)
7 Welding Power Source
6
5 Y Do not put feeder where
welding wire hits cylinder.
1 Y Do not move or operate
equipment when it could tip.
7
2
4
3
OM-1570 Page 11
3-4. Equipment Connection Diagrams
1 CV Welding Power Source
With 24 VAC Power
2 CV Welding Power Source
Without 24 VAC Power
3 115 Volts AC /24 Volts AC
Power Adapter
4 14-Pin Control Cord
5 Weld Cable
1
6 Work
3
5
2
115VAC
4
Contactor
6
3-5. Connecting 14-Pin Plug, Shielding Gas And Optional Volt Sense Lead
1 Gas Hose With 5/8-18 Right-
hand Thread Fittings (Cus-
tomer Supplied)
2 14 Pin Plug PLG2
4 Use plug to make connection to
welding power source.
3 3 Optional Volt Sense Lead
(Part Of Meter Option)
Connect to work.
4 Power Switch
1
Tools Needed:
5/8, 11/16 in
ST-801 688
OM-1570 Page 12
3-7. Connecting Welding Gun And Weld Cable
1 Gun Securing Knob
2 Gun Block
3 Gun Outlet Wire Guide
Loosen knob, insert gun into block.
Position outlet wire guide as close
1
as possible to drive rolls without
2 touching. Tighten knob.
3
4 Gun Trigger Plug
5 Gun Trigger Receptacle
6 Weld Cable Terminal
7 Weld Cable From Welding
Power Source
5 4
Tools Needed:
6
9/16, 5/8 in
ST-801 689
Long Spot
Time
0.25-5 Seconds
Short Spot
Time
0.12-2.5 Seconds
Tools Needed:
1/4 in
ST-801 694 / Ref. SA-125 969-C
OM-1570 Page 13
3-9. Installing And Aligning Wire Guide And Drive Roll
Install and secure wire guide. Install
drive rolls and turn drive roll nut one
click.
Only drive gear is adjustable. Turn
adjustment screw in or out until
groove in drive roll lines up with wire
guide as shown.
Remove drive rolls, and clean
grooves using a wire brush.
Installation
Alignment
Tools Needed:
3/16 in
3/8 in
ST-801 690 / S-0856
OM-1570 Page 14
3-10. Installing And Threading Welding Wire
1 Retaining Ring
2 Hub Tension Adjustment Nut
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.
1 2 3 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 assem-
bly. 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
OM-1570 Page 15
SECTION 4 – OPERATION
ST-801 692
1 Preflow Control
Control sets time gas flows before
welding wire is energized.
5 4 2 Postflow Control
1
Control sets time gas flows after
3 completion of burnback.
2
3 Burnback Control
Control adjusts time welding wire is
energized after wire feed stops.
4 Spot Continuous Switch
Switch selects an untimed continu-
ous weld or a timed spot weld.
5 Spot Time Control
Factory set for 0.25 to 5 seconds of
spot time. If 0.12 to 2.5 seconds is
desired, see Section 3-8.
Close side door.
OM-1570 Page 16
SECTION 5 – MAINTENANCE & TROUBLESHOOTING
3 Months
Replace
Cracked
Parts
14-Pin Cord Gun Cable Gas Hose
6 Months
OM-1570 Page 17
5-3. Troubleshooting
Trouble Remedy
Wire does not feed, unit completely inop- Turn Power switch On.
erative.
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 Owner’s
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).
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 Owner’s
but not when gun trigger is pressed. Manual.
Wire feeds as soon as power is applied. Check gun trigger. See gun Owner’s 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 trig-
ger 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.
OM-1570 Page 18
SECTION 6 – ELECTRICAL DIAGRAM
SC-182 776
Figure 6-1. Circuit Diagram For Wire Feeder With Optional Equipment
OM-1570 Page 19
Notes
OM-1570 Page 20
SECTION 7 – PARTS LIST
Item Part
No. No. Description Quantity
3
. Hardware is common and
not available unless listed.
4
5
6
7 2
8
Fig 7-2
1 9
8
7
10
11
12
ST-801 693
1 2 3 4 5 6
7
64 8
9
23
10
18 19 24
63 22 25
62 11 12 13 14 15 16 17
61
60
59 20 21
Figure 7-2. Control Box
26 27 28 29
58 57 56 55
30
54 35
53
33 32 31
34
36
42
Item Dia. Part
No. Mkgs. No. Description Quantity
OM-1570 Page 24
Table 7-1. Drive Roll And Wire Guide Kits
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).
OM-1570 Page 25
Notes
OM-1570 Page 26
Effective January 1, 2000
(Equipment with a serial number preface of “LA” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
Warranty Questions? guarantees or warranties expressed or implied.
Call LIMITED WARRANTY – Subject to the terms and conditions * APT, ZIPCUT & PLAZCUT Model Plasma Cutting
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants Torches
1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold
* Remote Controls
for your local after the effective date of this limited warranty is free of defects
* Accessory Kits
in material and workmanship at the time it is shipped by Miller.
Miller distributor. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER * Replacement Parts (No labor)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS. * Spoolmate 185 & Spoolmate 250
Within the warranty periods listed below, Miller will repair or * Canvas Covers
Your distributor also gives replace any warranted parts or components that fail due to
you ... Miller’s True Blue Limited Warranty shall not apply to:
such defects in material or workmanship. Miller must be
Service notified in writing within thirty (30) days of such defect or 1. Consumable components; such as contact tips,
failure, at which time Miller will provide instructions on the cutting nozzles, contactors, brushes, slip rings,
You always get the fast, warranty claim procedures to be followed.
reliable response you relays or parts that fail due to normal wear.
need. Most replacement Miller shall honor warranty claims on warranted equipment
2. Items furnished by Miller, but manufactured by others,
parts can be in your listed below in the event of such a failure within the warranty
such as engines or trade accessories. These items are
time periods. All warranty time periods start on the date that
hands in 24 hours. the equipment was delivered to the original retail purchaser, or
covered by the manufacturer’s warranty, if any.
Support one year after the equipment is sent to a North American 3. Equipment that has been modified by any party other
Need fast answers to the distributor or eighteen months after the equipment is sent to an than Miller, or equipment that has been improperly
International distributor. installed, improperly operated or misused based upon
tough welding questions?
Contact your distributor. 1. 5 Years Parts – 3 Years Labor industry standards, or equipment which has not had
The expertise of the reasonable and necessary maintenance, or equipment
* Original main power rectifiers which has been used for operation outside of the
distributor and Miller is specifications for the equipment.
* Inverters (input and output rectifiers only)
there to help you, every
step of the way. 2. 3 Years — Parts and Labor MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
* Transformer/Rectifier Power Sources PERSONS TRAINED AND EXPERIENCED IN THE USE
* Plasma Arc Cutting Power Sources AND MAINTENANCE OF WELDING EQUIPMENT.
* Semi-Automatic and Automatic Wire Feeders In the event of a warranty claim covered by this warranty, the
* Inverter Power Supplies exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
* Intellitig appropriate cases, (3) the reasonable cost of repair or
* Engine Driven Welding Generators replacement at an authorized Miller service station; or (4)
(NOTE: Engines are warranted separately by payment of or credit for the purchase price (less reasonable
the engine manufacturer.) depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
3. 1 Year — Parts and Labor replacement will be F.O.B., Factory at Appleton, Wisconsin, or
* DS-2 Wire Feeder F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
* Motor Driven Guns (w/exception of Spoolmate transportation costs of any kind will be allowed.
185 & Spoolmate 250)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Process Controllers PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
* Positioners and Controllers REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
* Automatic Motion Devices DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* RFCS Foot Controls PROFIT), WHETHER BASED ON CONTRACT, TORT OR
* Induction Heating Power Sources ANY OTHER LEGAL THEORY.
* Water Coolant Systems ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
* HF Units AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
* Grids REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* Maxstar 140 OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
* Spot Welders OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
* Load Banks OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
* Miller Cyclomatic Equipment MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
* Running Gear/Trailers EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
* Plasma Cutting Torches (except APT & SAF DISCLAIMED BY MILLER.
Models) Some states in the U.S.A. do not allow limitations of how long
* Field Options an implied warranty lasts, or the exclusion of incidental,
(NOTE: Field options are covered under True indirect, special or consequential damages, so the above
Blue for the remaining warranty period of the limitation or exclusion may not apply to you. This warranty
product they are installed in, or for a minimum of provides specific legal rights, and other rights may be
one year — whichever is greater.) available, but may vary from state to state.
miller_warr 7/00
Owner’s Record
Please complete and retain with your personal records.
Distributor
Address
City
State Zip
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.
Contact the Delivering Carrier for: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.