Miller A1-2 Owner's manual

Millerﬁ

OWNERS

MANUAL

Al

Motor/Drive

Assemblies



Read

and

follow

these

instructions

and

all



Give

this

manual

to

the

operator.



safety

blocks

carefully.

Have

only

trained

and

qualified

persons

install,

operate,

or

service

this

unit.

Call

your

distributor

if

you

do

not

understand

the

directions.



-

U

For

help,

call

your

distributor



or:

MILLER

Electric

Mfg.

Co.,

P.O.

Box

1079,

Appleton,

WI

54912

414-734-9821

April

1994

Form:

OM-1538C

Effective

With

Style

No.

KE-17



115

Volts

DC

Motor

And

Wire

Drive

Assembly



For

Automatic

Weld

Control



For

GMAW,

FCAW

And

SAW

Welding



Two-

And

Four-Drive

Roll

Models

Available



Adjustable

Mounting

Bracket



Interconnecting

Cord

To

Weld

Control

Needed

cover

1/94



ST-070

885-B

'

1994

MILLER

Electric

Mfg.

Co.

PRINTED

IN

USA

I

Kt2~

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

Effective

January

1.

1992

(Equipment

with

a

serial

number

preface

of

KC

or

newer)

This

limited

warranty

supersedes

all

marranties

and

is

exclusive

with

no

other

guarantees

or

warranties

expressed

or

implied

LIMITED

WARRANTY



Subjecttolhe

terms

and

conditions

below.

MILLER

Electric

MIg

Co..

Appleton.

Wisconsin.

warrants

to

its

original

retail

purchaser

that

new

MILLER

equipment

sold

after

the

effective

dale

01 this

limited

warranty

is

tree

01

de

fects

in

material

and

workmanship

at

the

time

ills

shipped

by

MILLER

TNIS

WAR

RANTY

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTNER

WARRANTIES.

EXPRESS

OR

IMPLIED,

INCLUDING

TNE

WARRANTIES

OF

MERCHANTABILITY

AND

FIT

NESS.

Within

the

warranty

periods

listed

below.

MILLER

will

repair

or

replace

any

war

ranted

parts

or

components

thaI

tail

due

to

such

detects

in

rnalerial

or

workmanship.

MILLER

must

be

notilied

in

writing

within

thirty

(30)

days

of

such

detector

failure,

at

which

time

MILLER

will

provide

instructions

on

the

warranty

claim

procedures

to

be

tollowed.

MILLER

shall

honor

warranty

claims

on

warranted

equipment

listed

below

in

the

event

of

such

a

tailure

within

the

warranty

lime

periods

All

warranty

lime

periods

start

on

the

date

that

the

equipment

was

delivered

lathe

original

retail

purchaser,

or

one

year

aher

the

equipment

is

sent

to

the

distributor

1.

5

Years

Pans



3

Years

Labor

Original

main

power

rectifiers

2.

3

Years



Parts

and

Labor

*

Transformer/Rectifier

!ower

Sources



Plasma

Arc

Cutting

Power

Sources



Semi-Automatic

and

Automatic

Wire

Feeders



Robots

3

2

Years



Parts

and

Labor



Engine

Driven

Welding

Generators

(NOTE

Engines

are

warranted

separately

by

the

engine

manutaclurer

tar

a

period

01

two

years.)

*

Air

Compressors

4.

1

Year



Parts

and

Labor

*

Motor

Driven

Guns



Process

Controllers



Waler

Coolant

Systems



HF

Units

*

Grids



Spot

Welders



Load

Banks



SDX

Transformers



Running

Gear/Trailers



Field

Options

(NOTE:

Field

options

are

covered

under

True

BluerM

br

the

remaining

warranty

period

ot

the

product

they

are

installed

in,

or

br

a

minimum

01

one

year



whichever

rs

greater.)

6

Months



Batteries

90

Days



Pans

and

Labor



MIG

Guns/rIG

Torches



Plasma

Cutting

Torches



Remote

Controls



Accessory

Kits



Replacement

Parts

MILLERS

True

BluerM

Limited

Warranty

shall

not

apply

to:

1

Items

furnished

by

MILLER,

but

manufactured

by

others,

such

as

engines

or

trade

accessories,

These

items

are

covered

by

the

manufacturers

warranty.

if

any

2.

Consumable

components:

such

as

contact

tips.

cuning

nozzles.

contactors

and

relays

or

parts

that

fail

due

to

normal

wear.

3

Esuipment

that

has

been

moditied

by

any

party

other

than

MILLER.

or

equip

ment

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

br

operation

outside

of

the

specilications

br

the

equipment

MILLER

PRODUCTS

ARE

INTENDED

FOR

PURCHASE

AND

USE

BY

COMMER

CIALJINDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

IN

THE

USE

AND

MAINTENANCE

OF

WELDING

EQUIPMENT.

In

the

event

ot

a

warranty

claim

covered

by

this

warranty,

the

esclusive

remedies

shall

be.

at

MILLERS

option.

(1)

repair:

or

(2)

replacement,

or.

where

authorized

in

writing

by

MILLER

in

appropriate

cases.

(3)

the

reasonable

cast

of

repair

or

replace

ment

alan

authorized

MILLER

service

station:

or

(4)

payment

of

or

credit

for

the

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

return

of

the

goods

at

customers

risk

and

espense.

MILLERS

option

01

repair

or

replacement

will

be

F

0

B

.Factory

at

Appleton.

Wisconsin.

or

FOB.

ate

MILLER

authorized

ser

vice

tacility

as

determined

by

MILLER.

Therefore

no

compensation

or

reimburse

ment

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

CON

TRACT.

TORT

OR

ANY

OTHER

LEGAL

THEORY.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WAR

RANTY.

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,

IN

CLUDING

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

ol

how

long

an

implied

warranty

lasts.

or

the

esclusion

of

incidental.

indirect,

special

or

consequential

damages,

so

the

above

limilatron

or

esclusion

may

nol

apply

to

you.

This

warranty

provides

spa

citic

legal

rights,

and

other

rights

may

be

available,

but

may

vary

trom

state

to

state.

In

Canada.

legislation

in

some

provinces

provides

tor

certain

additional

warranties

or

remedies

other

than

as

slated

herein,

and

to

the

estent

that

they

may

not

be

waived,

the

limitations

and

esclusions

set

out

above

may

not

apply.

This

Limited

Warranly

provides

specitic

legal

righls.

and

other

rights

may

be

available,

but

may

vary

from

province

to

province.

1

ti

l

5.

6.

r

RECEIVING-HANDLING

Befor

unpacking

equipment.

chBck

carton

for

any

damage

that

may

have

occurred

during

shipment.

File

any

claims

for

loss

or

damage

with

the

delivering

carrier.

Assistance

for

filing

or

settling

claims

may

be

obtained

from

distributor

and/or

equipment

manufacturers

Transportation

Department.

When

requesting

information

about

this

equipment,

always

provide

Model

Designation

and

Serial

or

Style

Number.

Use

the

following

spaces

to

record

Model

Designation

and

Serial

or

Style

Number

of

your

unit.

The

information

is

located

on

the

rating

label

or

nameplate.

Model

_________

Serial

or

Style

No.

Date

of

Purchase

miller

9/93

ERRATA

SHEET

January

4,

1995

FORM:

OM-1538C

Use

above

FORM

number

when

ordering

extra

manuals.

After

this

manual

was

printed,

refinements

in

equipment

design

occurred.

This

sheet

lists

exceptions

to

data

appearing

later

in

this

manual.

CHANGES

TO

SECTION

6

PARTS

LIST

Change

Paris

List

as

follows:

Part

**

No.

Replaced

With

Description

Quantity

**First

digit

r~presents

page

no



digits

following

dash

represent

item

no.

+When

ordering

a

component

originally

displaying

a

precautionary

label,

the

label

should

also

be

ordered.

*Recommended

Spare

Parts.

BE

SURE

TO

PROVIDE

STYLE

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

14-1

046967

+172

998

14-2

047636

079

535

14-3

079739

14-4

007826

14-5

+172807

153491

153492

~153493

14-7

153631



14-10

132611

14-

131

203

114656

MOTOR,

gear

(A1D-4)

(Eff

w/KE-51)

(consisting

of)

1

CONNECTOR

&

PINS,

(consisting

of)

1

CONNECTOR,

circ

push-in

14-lBga

14

CONNECTOR,

circ

clamp

str

rlf

sz

17-20

1

CABLE,

port

No.

183/c

(order

by

ft)

2ft

MOTOR,

gear

1/8

hp

115V

2000RPM

(consisting

of)

1

KIT,

brush

replacement

(consisting

of)

1

CAP,

brush

2

BRUSH,

carbon

2

CIRCUIT

CARD,

digital

tach

1

OPTICAL

ENCODER

DISC

1

CONNECTOR

&

PINS,

(consisting

of)

1

CONNECTOR,

rect

24-l8ga

3

ARC

WELDING

SAFETY

PRECAUTIONS

ELECTRIC

SHOCK

can

kill.

Touching

live

electrical

parts

can

cause

fatal

shocks

or

severe

burns.

The

electrode

and

work

circuit

is

electrically

live

whenever

the

output

is

on.

The

input

power

circuit

and

machine

internal

circuits

are

also

live

when

power

is

on.

In

semiautomatic

or

automatic

wire

welding,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live.

Incorrectly

installed

or

improperly

grounded

equipment

is

a

hazard.

Do

not

tcuch

live

electrical

parts.

Wear

dry,

hole-free

insulating

gloves

and

body

protection.

Insulate

yourself

from

work

and

ground

using

dry

insulating

mats

or

covers.

4.

Disconnect

input

power

or

stop

engine

before

installing

or

servicing

this

equipment.

FLYING

SPARKS

AND

HOT

METAL

can

cause

injury.

Chipping

and

grinding

cause

flying

metal.

As

welds

cool,

they

can

throw

off

slag.

5.

Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual

and

national,

state,

and

local

codes.

6.

When

making

input

connections,

attach

proper

grounding

conductor

first.

7.

Turn

off

all

equipment

when

not

in

use.

8.

Do

not

use

worn,

damaged,

undersized,

or

poorly

spliced

cables.

9.

Do

not

wrap

cables

around

your

body.

10.

Ground

the

workpiece

to

a

good

electrical

(earth)

ground.

11.

Do

not

touch

electrode

if

in

contact

with

the

work

or

ground.

12.

Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

13.

Wear

a

safety

harness

if

working

above

floor

level.

14.

Keep

all

panels

and

covers

securely

in

place.

1.

Wear

approved

face

shield

or

safety

goggles.

Side

shields

recommended.

2.

Wear

proper

body

protection

to

protect

skin.

a

WARNING

ARC

WELDING

can

be

hazardous.

PROTECT

YOURSELF

AND

OTHERS

FROM

POSSIBLE

SERIOUS

INJURY

OR

DEATH.

KEEP

CHILDREN

AWAY.

PACEMAKER

WEARERS

KEEP

AWAY

UNTIL

CONSULTING

YOUR

DOCTOR.

In

welding,

as

in

most

jobs,

exposure

to

certain

hazards

occurs.

Welding

is

safe

when

precautions

are

taken.

The

safety

information

given

below

is

only

a

summary

of

the

more

complete

safety

information

that

will

be

found

in

the

Safety

Standards

listed

on

the

Read

and

follow

all

Safety

Standards.

HAVE

ALL

INSTALLATION,

OPERATION,

MAINTENANCE,

AND

REPAIR

WORK

PERFORMED

ONLY

BY

QUALIFIEID

PEOPLE.

-

1.

2.

3.

ARC

RAYS

can

burn

eyes

and

skin;

~

NOISE

can

damage

hearing.

Arc

rays

from

the

welding

process

produce

intense

.-.

heat

and

strong

ultraviolet

rays

that

can

burn

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

NOISE

ARC

RAYS

2.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

(see

ANSI

Z49.

1

listed

in

Safety

Standards)

to

protect

your

face

and

eyes

when

welding

or

watching.

3.

Wear

approved

safety

glasses.

Side

shields

recommended.

4.

Use

protective

screens

or

barriers

to

protect

others

from

flash

and

glare:

warn

others

not

to

watch

the

arc.

5.

Wear

protective

clothing

made

from

durable,

flame-resistant

1.

Use

appioved

ear

plugs

or

ear

muffs

if

noise

level

is

high.

material

(wool

and

leather)

and

foot

protection.

~,.

~IPW

~

~

~

FUMES

AND

GASES

can

be

hazardous

to

your

health.

Welding

produces

fumes

and

gases.

Breathing

these

fumes

and

gases

can

be

hazardous

to

your

health.

5.

Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

wearing

an

air-supplied

respirator.

Shielding

gases

used

far

welding

can

displace

air

causing

injury

or

death.

Be

sure

the

breathing

air

is

safe.

a.

6.

Do

not

weld

in

locations

near

degreasing,

cleaning,

or

spraying

1.

Keep

your

head

out

of

the

fumes.

Do

not

breathe

the

fumes.

2.

If

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

operations.

The

heat

and

rays

of

the

arc

can

react

with

vapors

to

form

highly

toxic

and

irritating

gases.

remove

welding

fumes

and

gases.

7.

Do

not

weld

on

coated

metals,

such

as

galvanized,

lead,

or

3.

If

ventilation

is

poor,

use

an

approved

air-supplied

respirator.

cadmium

plated

steel,

unless

the

coating

is

removed

from

the

4.

Read

th~

Material

Safety

Data Sheets

(MSDSs)

and

the

weld

area,

the

area

is

well

ventilated,

and

if

necessary,

while

manufacturers

instruction

for

metals,

consumables,

coatings,

wearing

an

air-supplied

respirator.

The

coatings

and

any

metals

and

cleai~ers.

containing

these

elements

can

give

off

toxic

fumes

if

welded.

WELDING

can

cause

fire

or

explosion.

5.

Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.

Sparks

and

spatter

fly

off

from

the

welding

arc.

The

flying

sparks

and

hot

metal,

weld

spatter,

hot

workpiece,

and

hot

equipment

can

cause

fires

and

burns.

Accidental

contact

of

electrode

orwelding

wire

6.

7.

Be

aware

that

welding

on

a

ceiling,

floor,

bulkhead,

or

partition

can

cause

fire

on

the

hidden

side.

Do

not

weld

on

closed

containers

such

as

tanks

or

drums.

to

metal

objects

can

cause

sparks,

overheating,

or

fire,

8.

Connect

work

cable

to

the

work

as

close

to

the

welding

area

as

practical

to

prevent

welding

current

from

traveling

long,

possibly

1.

Protect

yourself

and

others

from

flying

sparks

and

hot

metal.

2.

Do

not

weld

where

flying

sparks

can

strike

flammable

material.

3.

Removeallflammableswithin35ft(10.7m)oftheweldiflgarC.lf

this

is

net

possible,

tightly

cover

them

with

approved

covers,

9.

10.

unknown

paths

and

causing

electric

shock

and

fire

hazards.

Do

not

use

welder

to

thaw

frozen

pipes.

Remove

stick

electrode

from

holder

or

cut

off

welding

wire

at

contact

tip

when

not

in

use.

4.

Be

alert

that

welding

sparks

and

hot materials

from

welding

can

11.

Wear

oil-free

protective

garments

such

as

leather

gloves,

heavy

easily

go

through

small

cracks

and

openings

to

adjacent

areas.

shirt,

cuffless

trousers,

high

shoes,

and

a

cap.



Sri

9/i)2

CYLINDERS

can

explode

if

damaged.

Shielding

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.

I.

Protect

compressed

gas

cylinders

from

excessive

heat,

mechanical

shocks,

and

arcs.

2.

Install

and

secure

cylinders

in

an

upright

position

by

chaining

them

to

a

stationary

support

or

equipment

cylinder

rack

to

prevent

falling

or

tipping.

-___________________________

3.

Keep

cylinders

away

from

any

welding

or

Other

electrical

circuits.

4.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

5.

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

fittings

designed

for

the

specific

application:

maintain

them

and

associated

parts

in

good

condition.

6.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

7.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

in

use

or

connected

for

use.

8.

Read

and

follow

instructions

on

compressed

gas

cylinders.

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

Standards.

a

WARNING

ENGINE

EXHAUST

GASES

can

kill.

1.

Use

equipment

outside

in

open,

well-ventilated

areas.

2.

If

used

in

a

closed

area,

vent

engine

exhaust

outside

and

Engines

produce

harmful

exhaust

gases.

away

from

any

building

air

intakes.

ENGINE

FUEL

can

cause

fire

or

1.

Stop

engine

before

checking

or

adding

fuel.

explosion.

2.

Do

not

add

fuel

while

smoking

or

if

unit

is

near

any

sparks

or

open

flames.

3.

Allow

engine

to

cool

before

fueling.

If

possible,

check

and add

Engine

fuel

is

highly

flammable,

fuel

to

cold

engine

before

beginning

job.

4.

Do

not

overfill

tank



allow

room

for

fuel

to

expand.

5.

Do

not

spill

fuel.

If

fuel

is

spilled,

clean

up

before

starting

engine.

MOVING

PARTS

can

cause

injury.

3.

Have

only

qualified

people

remove

guards

or

covers

for

maintenance

and

troubleshooting

as

necessary.

Moving

parts,

such

as

fans,

rotors,

and

belts

can

cut

fingers

and

hands

and

catch loose

clothing.

SPARKS

can

cause

BATTERY

GASES

TO

EXPLODE;

BATTERY

ACID

can

burn

eyes

and

skin.

The

coolant

in

the

radiator

can

be

very

hot

and

under

pressure.

5.

Keep

hands,

hair,

loose

clothing,

and

tools

away

from

moving

parts.

6.

Reinstall

panels

or

guards

and

close

doors

when

servicing

is

finished

and

before

starting

engine.

PRINCIPAL

SAFETY

STANDARDS

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.i,

from

American

Welding

Society,

550

NW.

LeJeune

Rd.

Miami

FL

33126

Safety

and

Health

Standards,

OSHA

29

CFR

1910,

from

Superinten

dent

of

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

Recommended

Sate

Practices

for

the

Preparation

for

Welding

and

Cutting

of

Containers

That

Have

Held

Hazardous

Substances,

Ameri

can

Welding

Society

Standard

AWS

F4.1

,from

American

Welding

So

ciety,

550

N.W.

LeJeune

Ad, Miami,

FL

33126

National

Electrical

Code,

NFPA

Standard

70,

from

National

Fire

Pro

tection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

P-i,

from

Compressed

Gas

Association,

1235

Jefferson

Davis

High

way,

Suite

501,

Arlington,

VA

22202.

Code

for

Safety

in

Welding

and

Cutting,

CSA

Standard

Wi

17.2,

from

Canadian

Standards

Association,

Standards

Sales,

178

Rexdale

Bou

levard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

SafePractices

For

OccupationAnd

Educational

EyeAnd

Face

Protec

tion,

ANSI

Standard

Z87.1,

from

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

Cutting

And

Welding

Processes,

NFPA

Standard

51

B,

from

National

Fire

Protection

Association,

Bafterymarch

Park,

Quincy,

MA

02269.

ENGINES

can

be

hazardous.

2.

Stop

en

1.

Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

ne

before

installing

or

connecting

unit.

4.

To

prevent

accidental

starting

during

servicing,

disconnect

negative

()

battery

cable

from

battery.

Batteries

contain

acid

and

generate

explosive

ases.

STEAM

AND

PRESSURIZED

HOT

COOLANT

can

burn

face,

eyes,

and

skin.

1.

Always

wear

a

face

shield

when

working

on a

battery.

2.

Stop

engine

before

disconnecting

or

connecting

battery

cables.

3.

Do

not

allow

tools

to

cause

sparks

when

working

on

a

battery.

4.

Do

not

use

welder

to

charge

batteries

or

jump

start

vehicles.

5.

Observe

correct

polarity

(+

and

)

on

batteries.

1.

Do

not

remove

radiator

cap

when

engine

is

hot.

Allow

engine

to

cool.

2.

Wear

gloves

and

put

a

rag

over

cap

area

when

removing

cap.

3.

Allow

pressure

to

escape

before

completely

removing

cap.

srI

9/92

EMF

INFORMATION

NOTE

~

Considerations

About

Welding

And

The

Effects

Of

Low

Frequency

Electric

And

____________________

Magnetic

Fields

The

following

is

a

quotation

from

the

General

Conclusions

Section

To

reduce

magnetic

fields

in

the

workplace,

use

the

following

of

the

U.S.

Cc

ngress,

Office

of

Technology

Assessment,

Biological

procedures:

Effects

of

Power

Frequency

Electric

&

Magnetic

Fields



1.

Keep

cables

close

together

by

twisting

or

taping

them.

Background

Paper,

OTA-BP-E-53

(Washington,

DC:

U.S.

Government

Printing

Office,

May

1989):

.

. .

there

is

now

a

very

2.

Arrange

cables

to

one

side

and

away

from

the

operator.

large

volume

of

scientific

findings

based

on

experiments

at

the

3.

Do

not

coil

or

drape

cables

around

the

body.

cellular

level

and

from

studies

with

animals

and

people

which

clearly

4.

Keep

welding

power

source

and

cables

as

far

away

as

establish

that

low

frequency

magnetic

fields

can

interact

with,

and

~ractical

produce

changes

in,

biological

systems.

While

most

of

this

work

is

of

very

high

quality,

the

results

are

complex.

Current

scientific

5.

Connect

work

clamp

to

workpiece

as

close

to

the

weld

as

understandinq

does

not

yet

allow

us

to

interpret

the

evidence

in

a

pOssible.

single

coherent

framework.

Even

more

frustrating,

it

does

not

yet

About

Pacemakers:

allow

us

to

draw

definite

conclusions

about

questions

of

possible

The

above

procedures

are

among

those

also

normally

risk

or

to

offer

clear

science-based

advice

on

strategies

to

minimize

recommended

for

pacemaker

wearers.

Consult

your

doctor

for

or

avoid

potential

risks.

complete

information.

modlo.l

4/93

TABLE

OF

CONTENTS

.

SECTION

1



SAFETY

INFORMATION

1

SECTION

2

SPECIFICATIONS

1

SECTION

3-INSTALLATION

3-1.

Typical

Equipment

Location

3

3-2.

Installing

Pivot

Mounting

Bracket

3

3-3.

Removing

Vent

Screw

And

Mounting

Wire

Drive

Assembly

4

3-4.

Installing

Wire

Guide

And

Drive

Rolls

4

3-5.

Plug

Connections

5

3-6.

Gun,

Weld

Cable

And

Gas

Connections

6

3-7.

Threading

And

Feeding

Welding

Wire

7

SECTION

4OPERATION

7

SECTION

5-

MAINTENANCE

AND

TROUBLESHOOTING

5-1.

Routine

Maintenance

8

5-2.

Aligning

Drive

Rolls

And

Wire

Guides

9

5-3.

Brush

Inspection

And

Replacement

10

5-4.

Troubleshooting

11

SECTION

6

PARTS

LIST

Figure

6-1.

Motor

&

Drive

Assembly

(Al

-2

Model

Illustrated)

12

Figure

6-2.

Motor

&

Drive

Assembly

(Al

-D4

Model

Illustrated)

15

Table

6-1.

Drive

Roll

&

Wire

Guide

Kits

(2

Drive

Roll)

17

Table

6-2.

Drive

Roll

&

Wire

Guide

Kits

(4

Drive

Roll)

18

OM-1538C

-4/94

SECTION

1

-

SAFETY

INFORMATION





modl.12/93

RNING

WARNING

a

CAUTION



Read

all

safety

messages

throughout

this

manual.



Obey

all

safety

messages

to

avoid

injury.



Learn

the

meaning

of

WARNING

and

CAUTION.

6~

1

Safety

Alert

Symbol

1

2

Signal

Word

\~

WARNING

means

possible

death

or

serious

injury

can

happen.

3

CAUTION

means

possible

minor

ELECTRIC

SHOCK

can

kill

MOVING

PARTS

can

Injure,

injury

or

equipment

damage

can



Do

not

touch

live

electflcal

parts.

I~P~~P.



Keep

away

fi~m

moving

parts.

happen.



Disconnect

input

power

beforejj_

~

I



Keep

all

panels

and

covers

closed

I

3

Statement

Of

Hazard

And

Installing

or

servicing.

when

operating.

I

Result

4

Safety

instructions

To

Avoid

5

Hazard

5

Hazard

Symbol

(If

Available)

6

Safety

Banner

READ

SAFETY

BLOCKS

at

start

of

Section

3-1

before

proceeding.

Read

safety

blocks

for

each

sym

bol

shown.

7

NOTE

7f~~TE

~

Turn

Off

switch

when

using

high

frequency.

Special

instructions

for

best

oper

ation



not

safety.



Figure

1-1.

Safety

information

SECTION

2-

SPECIFICATIONS



Table

2-1.

Wire

Drive

Assemblies

Specification

Description

Type

Of

Input

Power

115

Volts

DC

Mounting

Bracket

Adjustment

Up

To

200

In

Any

Direction

Input

Power

Cord

2

ft

(0.6

m)

Overall

Dimensions

See

Figure

2-1

Options

See

Rear

Cover

Weight



Two-Drive

Roll

Assemblies

18

lb

(7.9

kg)

Weight

Four-Drive

Roll

Assemblies

22

lb

(10kg)

Digital

With

Standard

Digital

Low-Speed

Motor

Wire

Feed

Speed

Range

70

To

750

ipm

50

To

780

ipm

15

To

200

ipm

(1.8To19.1

mpm)

(1.3To19.Bmpm)

(0.4To5.1

mpm)

Wire Diameter

Range

.030

Thru

1/8

in

(0.8

Thru

3.2

mm)

.030

Thru

1/8

in

(0.8

Thru

3.2

mm)

5/64

Thru

5/32

in

(2

Thru

4

mm)

OM-1538

Page

1

Inches

Millimeters

A

9-1/4

235

B

10-1/4

260

C*

11-1/2

292

Inches

Millimeters

A

B

C

10-1/4

13-1/4

12

260

337

305

Inches

Millimeters

A

B

4-1/4

108

C

13/32

Dia.

4

Holes

lODia.

4

Holes

Figure

2-1.

Overall

Dimensions

And

Mounting

Hole

Layout

SECTION

3-

INSTALLATION.

~A

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

weld

control

and

welding

power

source,

and

disconnect

input

power

before

inspecting

or

installing.

The

welding

wire,

drive

rolls,

drive

assembly,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live

when

welding

or

feeding

wire.



Have

only

qualified

persons

install

this

unit

WELDING

WIRE

can

cause

puncture

wounds.



Do

not

try

to

feed

wire

until

instructed

to

do

so.



Do

not

point

gun

toward

any

part

of

the

body

when

threading

welding

wire.

HOT

SURFACES

can

burn

skin.



Allow

drive

assembly

and

gun

to

cool

before

touching.

Two-DrIve

Roll

Models

*Add

7/8

in

(22

mm)

for

D

models.

Four-Drive

Roll

Models

Add

7/8

in

(22

mm)

for

D

models.

Mounting

Holes*

C

________

___________

Holes

shown

used

for

mounting

to

optional

cross

slide.

Additional

holes

provided

for

mounting

to

weld

oscillator.

ST-O8O

487-C

/

ST-070

885-B

I

Ref.

ST-O7O

885-B

MOVING

PARTS

can

cause

injury.



Keep

away

from

moving

parts.



Keep

away

from

pinch

points

such

as

drive

rolls

OM-1538

Page

2

3-1.

Typical

Equipment

Location

Figure

3-1.

Typical

Equipment

Location

3-2.

Installing

Pivot

Mounting

Bracket

i

welding

Power

Source

2

Gas

Cylinder

3

Side

Beam

4

Gas/Current

Sensing

Control

5

Weld

Control

6

SpoolSupport

7

Wire

Drive

Assembly

8

Automatic

Welding

Gun

6

4

3

7

8

ST-131

138-A

1

2

4

2

.3

1

Motor

Mounting

Bracket

2

Mounting

Holes

3

Pivot

Bracket

Mount

motor

bracket

onto

pivot

bracket

using

hardware

from

pivot

bracket

as

shown.

To

adjust

position

of

pivot

bracket,

proceed

as

follows:

4

Secunng

Screw

5

Clamp

Loosen

screws

on

clamp.

Adjust

pivot

bracket

position

as

neces

sary.

lighten

securing

screws.

ST.156

543

3

Tools

Needed:

~

9/161n

Figure

3-2.

Installing

Pivot

Mounting

Bracket

OM-1538

Page

3

3-3.

Removing

Vent

Screw

And

Mounting

Wire

Drive

Assembly

AA

CAUTION

LOSS

OF

GEAR

OIL

OR

DIRT

ENTERING

GEAR

CASE

DAMAGES

MOTOR.



Do

not

remove

either

vent

screw

if

both

are

at

the

bottom

or

positioned

so

that

gear

oil

runs

out.



Do

not

remove

either

vent

screw

if

dirt

can

easily

enter

gear

case.

-~

Figure

3-3.

Removing

Vent

Screw

And

Mounting

Assembly

3-4.

Installing

Wire

Guide

And

Drive

Rolls

READ

SAFETY

BLOCKS

at

start

of

Section

3

before

proceeding.

When

changing

wire

size

or

type,

check

drive

roll

and

guide

size

(see

Table

6-1

and

Table

6-2).

1

Wire

Guide

Securing

Screw

2

InletWireGuide

3

Intermediate

Wire

Guide

(Four-Drive

Roll

Models

Only)

Loosen

wire

guide

screws.

Slide

tip

as

close

to

drive

rolls

as

possible

without

touching.

lighten

screw.

4

Drive

Gear

5

Pressure

Gear

Drive

and

pressure

gears

(1

of

each

in

two

drive

roll

model)

installed

be

fore

unit

is

shipped

from

factory.

6

Pressure

Gear

Assembly

Open

pressure

gear

assembly.

7

Drive

Roll

8

Gear

Securing

Bolt

9

Drive

Roll

Securing

Screw

Install

correct

drive

roll

for

wire

size

and

type

using

supplied

hardware.

Close

pressure

gear

assembly.

ST-Ole

887-E

Do

not

tilt

assembly.

Position

assembly

level.

1

Motor

Mounting

Bracket

2

Wire

Drive

Gears

3

Upper

Vent

Screw

Remove

and

discard

upper

vent

screw

before

operation.

4

Motor

Mount

motor

level

with

wire

drive

gear

end

so

that

gear

oil

does

not

enter

motor

seal.

Tools

Needed:

5T-156

578

Tools

Needed:

~~~~7/16in

5

4

Figure

3-4.

Installing

Wire

Guide

And

Drive

Roll

(Four-Drive

Roll

Model

Shown)

OM-1

538

Page

4

3-5.

Plug

Connections

Figure

3-5.

Plug

Connections

1

Plug

2

Keyway

-

3

Typical

Weld

Control

Connect

plug

to

matching

plug

from

weld

control.

To

connect

plugs,

align

keyways,

insert

plug,

and

tighten

connection.

ST-158

933/

S-0749-A

3

Non-Digital

Model

1

OM-1

538

Page

5

3-6.

Gun,

Weld

Cable

And

Gas

Connections

READ

SAFETY

BLOCKS

at

start

of

Section

3

before

proceeding.

Four-Drive

Roll

Model

1

Gun/Feeder

Securing

Knob

2

Gun/Feeder

Opening

3

Gun

End

Loosen

knob.

Insert

gun

end

into

opening.

Position

as

close

as

pos

sible

to

drive

rolls

without

touching.

Tighten

knob.

4

Weld

Cable

Terminal

5

Weld

Gable

Select

and

prepare

weld

cable

ac

cording

to

welding

power

source

Owners

Manual.

6

Gun

Weld

Cable

Terminal

(Four-Drive

Roll

Models

Only)

For

guns

with

external

weld

cable,

connect

weld

cable

from

gun

to

terminal.

7

Shielding

Gas

Fitting

8

Gas

Hose

Gas

fitting

is

located

behind

gun/

feeder

opening.

For

guns

requiring

external

gas

connection,

remove

hose

from

f

it

ting

and

connect

to

gun.

Tools

Needed:

-:~

9/l6in

Figure

3-6.

Gun,

Weld

Cable

And

Gas

Connections

7

ST-156

544

Connect

To

Positive

(+)

Weld

Output

Terminal

On

Welding

Power

Source

For

Reverse

Polarity

Weld

Process

Or

Connect

To

Negative

()

Weld

Output

Terminal

On

Welding

Power

Source

For

Straight

Polarity

Weld

Process.

2

6

Two-Drive

Roll

Model

OM-1

538

Page

6

3-7.

Threading

And

Feeding

Welding

Wire

Figure

3-7.

Threading

And

Feeding

Welding

Wire

SECTION

4-OPERATION

FUMES

AND

GASES

can

be

hazardous

to

your

health.



Keep

your

head

out

of

the

fumes.



Ventilate

area,

or

use

breathing

device.



Read

Material

Safety

Data

Sheets

(MSDSs)

and

manufacturers

instructions

for

material

used.

WELDING

can

cause

fire

or

explosion.



Do

not

weld

near

flammable

material.



Watch

for

fire;

keep

extinguisher

nearby.



Do

not

locate

unit

over

combustible

surfaces.



Do

not

weld

on

closed

containers.



Allow

work

and

equipment

to

cool

before

handling.

Figure

4-1.

Safety

Equipment

READ

SAFETY

BLOCKS

at

start

of

Section

3

before

proceeding.

1

Wire

Spool

3

Loosen

wire

from

wire

spool,

cutoff

bent

wire,

and

pull

6

in

(150mm)

of

wire

off

spool.

2

Wire

InletGuide

3

Drive

Roll

4

Intermediate

Wire

Guide

(Four-Dnve

Roll

Models

Only)

5

Gun

Thread

wire

through

inlet

guide,

along

drive

rolls,

through

interme

diate

guide

and

drive

rolls

(if

appli

cable),

and

into

gun.

Be

sure

wire

is

in

correct

groove.

6

Pressure

Adjustment

Knob

And

Arm

Close

pressure

roll

assembly.

Check

drive

roll

pressure

by

feed

ing

wire

against

a

wood

board

or

concrete

surface;

wire

should

feed

steadily

without

slipping.

If

pressure

adjustment

is

neces

sary,

tighten

pressure

knob(s).

ST-156

798

Tools

Needed:

A~

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Always

wear

dry

insulating

gloves.



Insulate

yourself

from

work

and

ground.

I

ARC

RAYS

can

burn

eyes

and

skin;

NOISE

can

damage

hearing.



Wear

welding

helmet

with

correct

shade

of

filter.



Wear

correct

eye,

ear,

and

body

protection.

MOVING

PARTS

can

cause

injury.



Keep

away

from

moving

parts.



Keep

away

from

pinch

points

such

as

drive

rolls.

MAGNETIC

FIELDS

FROM

HIGH

CUR-

RENTS

can

affect

pacemaker

operation.



Pacemaker

wearers

keep

away.



Wearers

should

consult

their

doctor before

going

near

any

welding

operations.

See

Safety

Precautions

at

beginning

of

manual

for

ba

sic

welding

safety

information.

~~rfl~1

~

3

Wear

the

following

while

welding:

1

Dry.

Insulating

Gloves

2

Safety

Glasses

With

Side

Shields

r1~2

g

3

Welding

Helmet

With

Correct

Shade

Of

Filter

(See

ANSI

Z49.1)

sb3.1

1/94

OM-1

538

Pago

7

Figure

4-2.

Sequence

Of

Operation

SECTION

5-

MAINTENANCE

AND

TROUBLESHOOTING

__

a

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

weld

control

and

welding

power

source,

and

disconnect

input

power

before

inspecting,

maintaining,

or

servicing.

MOVING

PARTS

can

cause

injury.



Keep

away

from

moving

parts.



Keep

away

from

pinch

points

such

as

drive

rolls.

HOT

PARTS

can

cause

severe

burns.



Allow

cooling

period

before

servicing

unit.

ance

to

be

performed

only

by

qualified

wfwarn4.r

8/92

5-1.

Routine

Maintenance

Thread

&

F~ed~\~

Put

On

~

Weld

Con

Shielding

Gas

And

Welding

I

Connect

Install

&

~

Welding

WireJ)

Equipment

______________

______________)~~Sourc~~~

Set

Turn

On

Turn

On

Control

Personal

Safety

J

Equipment~,1}

________________ ________________

_________________

)

Begin

Weldin~

Turn

Off

all

power

before

maintaining.

Figure

5-1.

Maintenance

OM-1

538

Page

8

5-2.

Aligning

Drive

Rolls

And

Wire

Guides

READ

SAFETY

BLOCKS

at

start

of

Section

5

before

proceeding.

Correct

Alignment

Incorrect

Alignment

Horizontal

Alignment

View

is

from

top

of

drive

rolls

look

ing

down

with

pressure

assembly

open.

1

Drive

Roll

Securing

Bolt

2

Drive

Roll

3

Wire

Guide

4

Welding

Wire

5

Drive

Gear

Turn

bolt

in

or

out

until

drive

roll

groove

lines

up

with

wire

guide.

Vertical

Alignment

~:-

-~

9/l6ln

AA

CAUTION

Horizontal

Alignment

IMPROPER

CLEARANCE

between

motor

gear

and

drive

gears

on

four-drive

roll

models

can

damage

equipment.



Maintain

0.003

in

(0.076

mm)

clearance

between

motor

gear

and

drive

gears.

Gears

may

wear

severely,

bind,

break,

or

cause

erratic

wire

feed

if

proper

clearance

is

not

maintained.

3.

2.

4

I

Vertical

Alignment

6

Housing

Bolts

7

Weld

Cable

Terminal

Loosen

bolts

and

terminal

nut(s).

8

Wire

Guide

9

Drive

Roll

10

Pressure

Roll

Slide

housing

up

or

down

until

groove

in

drive

roll

and

pressure

roll

line

up

with

wire

guide.

Tighten

hardware.

Close

pressure

roll

assembly.

Two-Drive

Roll

Model

Tools

Needed:

7/l6iri

Four-Drive

Roll

Model

7

6

Figure

5-2.

AlIgning

Drive

Rolls

And

Wire

Guides

7

5-0629-A

/

Ref.

ST-080

487-C

/

Ref.

ST.070

885-B

/

S-0087

OM-1538

Page

9

5-3.

Brush

Inspection

And

Replacement

1

Motor

Tools

Needed:

2

Brush

Cap

Remove

cap.

3

Removing

Brush

4

Brush

Box

5

Spring

Assembly

Bracket

Remove

bracket

from

box.

6

Spring

Assembly

2

7

Brush

Pigtail

~,/

Pull

pigtail

to

remove

brush.

8

Brush

0

9

Checking

Brush

Replace

if

near

minimum

length.

10

Installing

Brush

To

reinstall

spring

assembly,

slide

into

box

as

shown

to

hook

bracket

into

box.

Install

brush

cap.

Check

brush

on

other

side

of

motor.

~5t%

Push

Back

And

Up

1/4

in

(6.3

mm)

Minimum

Length

Side

View

Of

Box

Install

Push

Up

And

Down

I

10

ST-156

693

FIgure

5-3.

Brush

Inspection

And

Replacement

6

Pull

3

Remove

Check

T

9

OM-1538

Page

10

5-4.

Troubleshooting

a

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Turn

Off

weld

control

and

welding

power

source,

and

disconnect

input

power

before

inspecting,

maintaining,

or

servicing.

MOVING

PARTS

can

cause

injury.



Keep

away

from

moving

parts.



Keep

away

from

pinch

points

such

as

drive

rolls

HOT

PARTS

can

cause

severe

burns.



Allow

cooling

period

before

servicing

unit.

~hooting

to

be

performed

only

by

qualified

wfwarn4.1

8/92

Table

5-1.

Troubleshooting

Trouble

~e

feeds

erratically.

Remedy

Section

Adjust

drive

roll

pressure

by

turning

pressure

adjustment

knob(s)

1/4

turn

clockwise

until

wire

stops

slipping.

Check

gun

contact

tip

for

obstructions.

Check

size

of

drive

roll.

Replace

drive

roll

if

worn.

Clean

drive

roll,

and

check

wire

spool

hub

tension.

Align

drive

rolls.

Motor

runs

slowly.

---

3-4

---

Reduce

load.

5.2

Check

for

correct

input

voltage.

-0~

--

-a.

--

Motor

runs

at

full

speed

regardless

of

i.



-a.

Have

Factory

Authorized

Service

Station/Service

Distributor

~



-a.

 

wire

speed

setting

on

weld

control.

check

digital

wire

drive

motor

Tachometer

board

and

encoder

disc.

OM-1538

Page

11

SECTION

6-

PARTS

LIST

Figure

6-1.

Motor

&

Drive

Assembly

(Al

-2

Model

Illustrated)

ST-080

366-K

1

32

47.

35

~1

C

38

15

39

11

43

31

47

44

30

41

42

45

J

OM-1

538

Page

12

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