Miller A1-2 Owner's manual

Miller
Brand
Miller
Model
A1-2
Category
Welding System
Type
Owner's manual

This manual is also suitable for

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
previous
MILLER
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
pin
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
pin
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
next
page.
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
2
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
related
to
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
4-1/4
108
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
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
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
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
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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Miller A1-2 Owner's manual

Miller
Brand
Miller
Model
A1-2
Category
Welding System
Type
Owner's manual
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