Miller KB123143 Owner's manual

Miller
Brand
Miller
Model
KB123143
Category
Welding System
Type
Owner's manual

This manual is also suitable for

iii
Millerfi
September
1991
FORM:
OM-1584A
Effective
With
Serial
No.
KB1
231
43
I
MODEL:
DS-12
DS-16
OWNERS
MANUAL
IMPORTANT:
Read
and
understand
the
entire
contents
of
both
this
manual
and
the
power
source
manual
used
with
this
unIt,
with
speclai
emphasis
on
the
safety
material
throughout
both
manuals,
before
InstallIng,
operating,
or
maintaining
this
equipment.
This
unit
and
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
safe
operation
of
welding
equip
ment.
Do
not
allow
untrained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
MILLER
ELECTRIC
Mfg.
Co.
A
Miller
Group
Ltd.,
Company
P.O.
Box
1079
Appleton,
WI
54912
USA
Tel.
414-734-9821
SC-142
595-A
PRINTED
IN
U.S.A.
j
I
r
LIMITED
WARRANTY
EFFECTIVE:
AUGUST
6,
1990
L
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY
Subject
to
the
terms
and
conditions
hereot.
MILLER
Electric
Mfg.
Co.,
Appleton,
Wisconsin
war
rants
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
furnished
by
MILLER
is
tree
trom
defect
in
workmanship
and
material
as
of
the
time
and
place
of
delivery
by
MILLER.
No
warranty
is
made
by
MILLER
with
respect
to
engines,
trade
accessories
or
other
items
manufactured
by
others.
Such
engines,
trade
accessories
and
other
items
are
sold
sublect
to
the
warranties
of
their
respective
manufacturers,
if
any.
All
engines
are
warrantied
by
their
manufacturer
for
two
years
from
date
of
original
purchase,
except
Deutz
engines
which
have
a
one
year.
2000
hour
warranty.
Except
as
specified
below,
MILLERs
warranty
does
not
apply
to
components
having
normal
useful
life
of
less
than
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
MILLERMATIC
parts
that
come
in
contact
with
the
welding
wire
including
nozzles
and
nozzle
insulators
where
failure
does
not
result
from
defect
in
workmanship
or
material.
MILLER
shall
be
required
to
honor
warranty
claims
on
war
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
within
the
following
periods
from
the
date
of
delivery
of
Equipment
to
the
original
user:
1,
Arc
welders,
power
sources,
robots,
and
1
year
components
2.
Load
banks
1
year
3.
Original
main
power
rectifiers
3
years
(labor
1
year
only)
4.
All
welding
guns,
feeder/guns
and
torches
.
.
.
90
days
5.
All
other
MILLERMATIC
Feeders
1
year
6.
Replacement
or
repair
parts,
exclusive
of
labor
60
days
7.
Batteries
6
months
provided
that
MILLER
is
notified
in
writing
within
thirty
(30)
days
of
the
date
of
such
failure.
As
a
matter
of
general
policy
only,
MILLER
may
honor
claims
submitted
by
the
original
user
within
the
foregoing
periods.
In
the
case
of
MILLERs
breach
of
warranty
or
any
other
duty
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
therefore
shall
be.
at
MILLERs
option
(1)
repair
or
(2)
replace
ment
or,
where
authorized
in
writing
by
MILLER
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
MILLER
service
station
or
(4)
payment
of
or
credit
for
the
purchase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
Customers
risk
and
expense.
MILLERs
option
of
repair
or
replacement
will
be
F.O.B.,
Factory
at
Appleton.
Wisconsin.
or
FOB.
at
a
MILLER
authorized
service
facility,
therefore,
no
compensation
for
transportation
costs
of
any
kind
will
be
allowed.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
MILLER
shall
instruct
the
claimant
on
the
warranty
claim
procedures
to
be
followed.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRE-.
SENTATION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION.
OPERATIQN
OF
LAW,
CUSTOM
OF
TRADE
OR COURSE
OF
DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHAN
TABiLITY
OR
OF
FtTNESS
FOR
PARTICULAR
PURPOSE.
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLERS
WARRANTIES
DO
NOT
EXTEND
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
U
UI
OM-1584A
-
9/91
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
dam-
Use
the
following
spaces
to
record
the
Model
Designa
age
that
may
have
occurred
during
shipment.
File
any
tion
and
Serial
or
Style
Number
of
your
unit.
The
infor
claims
for
loss
or
damage
with
the
delivering
carrier.
mation
is
located
on
the
data
card
or
the
nameplate.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
the
distributor
and/or
the
equipment
manufactur-
Model
_________________________________________
ers
Transportation
Department.
Serial
or
Style
No.
_____________________________
When
requesting
information
about
this
equipment,
al
ways
provide
the
Model
Description
and
Serial
or
Style
Date
of
Purchase
_____________________________
Number.
TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1
SAFETY
RULES
FOR
OPERATION
OF
ARC
WELDING
POWER
SOURCE
1-1.
Introduction
1
1-2.
General
Precautions
1
1-3.
Arc
Welding
4
1-4.
Standards
Booklet
Index
5
SECTION
2
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
2-1.
General
Information
And
Safety
6
2-2.
Safety
Alert
Symbol
And
Signal
Words
6
SECTION
3
SPECIFICATIONS
3-1.
DESCRIPTION
7
SECTION
4-
INSTALLATION
OR
RELOCATION
4-1.
Location
8
4-2.
Base
And
Boom
Assembly
8
4-3.
Installation
Of
Control
Box
To
Base
10
4-4.
Installation
Of
Wire
Support
10
4-5.
Installation
Of
Wire
Guide
Extension
10
4-6.
Wire
Guide
And
Drive
Roll
Installation
10
4-7.
Welding
Gun
Connections
11
4-8.
Connections
From
Boom
To
Control
Box
12
4-9.
Shielding
Gas
Connection
13
4-10.
Welding
Power
Source
Connections
To
Control
Box
And
Boom
13
4-11.
Motor
Start
Control
14
4-12.
DIP
Switches
15
4-13.
Voltage
Sensing
Connection
(Optional)
18
4-14.
Run-In
Control
Connections
(Optional)
18
4-15.
Synergic
Connections
(Optional)
18
4-16.
Welding
Wire
Installation
18
4-17.
Safety
Collar
Removal
18
4-18.
Boom
Adjustments
19
4-19.
Welding
Wire
Threading
19
4-20.
Changing
From
Standard
Digital
Voltage
Control
To
MILLER
Inverter
Digital
Voltage
Control
20
Section
No.
Page
No.
SECTION
5OPERATOR
CONTROLS
5-1.
Power
Switch
21
5-2.
Wire
Speed
Controls
21
5-3.
Jog/Purge
Switches
21
5-4.
Voltage
Control(s)
(Optional)
22
5-5.
Digital
Voltage
Control(s)
(Optional)
22
5-6.
Burnback
Control(s)
(Optional)
22
5-7.
Preflow
Control(s)
(Optional)
22
5-8.
Postflow
Control(s)
(Optional)
22
5-9.
Trigger
Hold
Switch(es)
(Optional)
22
5-10.
Spot/Continuous
Switch(es)
And
Spot
Time
Control(s)
(Optional)
23
5-11.
Digital
Meter
(Optional)
23
5-12.
Run-In
Control(s)
(Optional)
23
5-13.
Dual
Schedule
Control(s)
(Optional)
23
5-14.
Digital
Dual
Schedule
Control(s)
(Optional)
24
SECTION
6
SEQUENCE
OF
OPERATION
6-1.
Gas
Metal
Arc
Welding
(GMAW)
And
Flux
Cored
Arc
Welding
(FCAW)
24
6-2.
Shutting
Down
25
SECTION
7
MAINTENANCE
&
TROUBLESHOOTING
7-1.
Routine
Maintenance
25
7-2.
Reinstallation
Of
Hub
Assembly
26
7-3.
Brush
Inspection
And
Replacement
27
7-4.
Overload
Protection
27
7-5.
Circuit
Board
Handling
Precautions
28
7-6.
Troubleshooting
28
SECTION
8
ELECTRICAL
DIAGRAMS
Diagram
8-1.
Circuit
Diagram
For
Wire
Feeder
31
Diagram
8-2.
Circuit
Diagram
For
Wire
Feeder
With
Optional
Equipment
32
Diagram
8-3.
Wiring
Diagram
For
Wire
Feeder 34
SECTION
9
PARTS
LIST
Figure
9-1.
Main
Assembly
36
Figure
9-2.
Support,
Hub
&
Reel
39
Figure
9-3.
Control
Box
40
Figure
9-4.
Boom
Assembly
44
Figure
9-5.
Wire
Drive
Assembly
46
Figure
9-6.
Panel,
Front
w/Components
48
Figure
9-7.
Control
Panel
50
Optional
Equipment
52
LIST
OF
CHARTS
AND
TABLES
Table
3-1.
Specifications
7
Table
3-2.
Options
Compatibility
8
Table
7-1.
Maintenance
Schedule
25
Table
7-2.
Troubleshooting
29
Table
9-1.
Drive
Roll
And
Wire
Guide
Kits
43
SECTION
1
SAFETY
RULES
FOR
PLASMA
ARC
CUTTING
(PAC)
1-1.
INTRODUCTION
We
learn
by
experience.
Learning
safety
through
per
sonal
experience,
like
a
child
touching
a
hot
stove,
is
harmful,
wasteful,
and
unwise.
Let
the
experience
of
oth
ers
teach
you.
Safe
practices
developed
from
experience
in
the
use
of
welding
and
cutting
are
described
in
this
manual.
From
research,
development,
and
field
experience
have
evolved
reliable
equipment
and
safe
installation,
opera
tion,
and
servicing
practices.
Accidents
occur
when
equipment
is
improperly
used
or
maintained.
The
rea
son
for
the
safe
practices
may
not
always
be
given.
Some
are
based
on
common
sense;
others
may
require
technical
volumes
to
explain.
It
is
wiser
to
follow
the
rules.
Read
and
understand
these
safe
practices
before
at
tempting
to
install,
operate,
or
service
the
equipment.
Comply
with
these
procedures
as
applicable
to
the
par
ticular
equipment
used
and
their
instruction
manuals
for
personal
safety
and
for
the
safety
of
others.
Failure
to
observe
these
safe
practices
may
cause
seri
ous
injury
or
death.
When
safety
becomes
a
habit,
the
equipment
can
be
used
with
confidence.
These
safe
practices
are
divided
into
two
Sections:
1-General
Precautions,
common
to
arc
welding
and
cut
ting;
and
2-Plasma
Arc
Cutting
(PAC).
Reference
standards.
Published
Standards
on
safety
are
also
available
for
additional
and
more
complete
pro
cedures
than
those
given
in
this
manual.
They
are
listed
in
the
Standards
Index
in
this
manual.
ANSI
Z49.
1
is
the
most
complete.
The
National
Electrical
Code,
Occupational
Safety
and
Health
Administration,
local industrial
codes,
and
local
inspection
requirements
also
provide
a
basis
for
equip
ment
installation,
use,
and
service.
1-2.
GENERAL
PRECAUTIONS
Different
metals
and
metal
coatings
can
produce
different
fumes,
gases,
and
radiation
levels.
In
addi
tion
to
the
information
in
this
manual,
be
sure
to
consult
the
manufacturers
Material
Safety
Data
Sheets
(MSDS5)
for
specific
technical
data
and
pre
cautionary
measures
concerning
any
materials
or
coatings
on
materials
cut
with
this
equipment.
A.
Burn
Prevention
Wear
protective
clothinggauntlet
gloves
designed
for
use
in
welding
or
cutting,
hat,
and
high
safety-toe
shoes.
Button
shirt
collar
and
pocket
flaps,
and
wear
cuffless
trousers
to
avoid
entry
of
sparks
and
slag.
Wear
helmet
with
safety
goggles
or
glasses
with
side
shields
underneath
and
appropriate
filter
lenses
or
plates
(protected
by
clear
cover
glass).
This
is
a
MUST
for
welding
or
cutting
(and
chipping
or
grinding)
to
pro
tect
the
eyes
from
radiant
energy
or
flying
metal.
Re
place
cover
glass
when
broken,
pitted,
or
spattered.
See
1
-3A.2.
Avoid
oily
or
greasy
clothing.
A
spark
may
ignite
them.
Hot
metal,
such
as
the
workpiece,
should
never
be
han
dled
without
gloves.
Medical
first
aid
and
eye
treatment.
First
aid
facilities
and
a
qualified
first
aid
person
should
be
available
for
each
shift
unless
medical
facilities
are
close
by
for
immediate
treatment
of
flash
burns
of
the
eyes
and
skin
burns.
Ear
plugs
should
be
worn
when
working
overhead
or
in
a
confined
space.
A
hard
hat
should
be
worn
when
others
work
overhead.
Flammable
hair
preparations
should
not
be
used
by
per
sons
intending
to
weld
or
cut.
B.
Toxic
Fume
Prevention
Severe
discomfort,
illness,
or
death
can
result
from
fumes,
vapors,
heat,
or
oxygen
enrichment
or
depletion
that
welding
or
cutting
may
produce.
Prevent
this
with
adequate
ventilation
as
described
in
ANSI
Standard
Z49.1
listed
in
Standards
Index.
NEVER
ventilate
with
oxygen.
Lead-,
cadmium
-,zinc-,
mercury-,
and
beryllium-bear
ing
and
similar
materials,
when
welded
or
cut,
may
pro
duce
harmful
concentrations
of
toxic
fumes.
Adequate
local
exhaust
ventilation
must
be
used,
or
each
person
in
the
area as
well
as
the
operator
must
wear
an
air-sup
plied
respirator.
For
beryllium,
both
methods
must
be
used.
Metals
coated
with
or
containing
materials
that
emit
toxic
fumes
should
not
be
heated
or
cut
unless
coating
is
re
moved
from
the
work
surface,
the
area
is
well
ventilated
or,
if
necessary,
while
wearing
an
air-supplied
respirator.
Work
in
a
confined
space
only
while
it
is
being
ventilated
and,
if
necessary,
while
wearing
an
air-supplied
respira
tor.
Gas
leaks
in
a
confined
space
should
be
avoided.
Leaked
gas
in
large
quantities
can
change
oxygen
con
centration
dangerously.
Do
not
bring
gas
cylinders
into
a
confined
space.
When
leaving
a
confined
space,
shut
OFF
gas
supply
at
source
to
prevent
possible
accumulation
of
gases
in
the
space
if
downstream
valves
have
been
accidentally
opened
or
left
open.
Check
to
be
sure
that
the
space
is
safe
before
reentering
it.
Vapors
from
chlorinated
solvents
can
be
decomposed
by
the
heat
of
the
arc
to
form
PHOSGENE,
a
highly
toxic
gas,
and
other
lung
and
eye
irritating
products.
The
ultra-
OM.1584
Page
1
violet
(radiant)
energy
of
the
arc
can
also
decompose
trichloroethylene
and
perchioroethylene
vapors
to
form
phosgene.
DO
NOT
WELD
OR
CUT
where
solvent
va
pars
can
be
drawn
into
the
welding
or
cutting
atmos
phere,
or
where
the
radiant
energy
can
penetrate
to
at
mospheres
containing
even
minute
amounts
of
trichioroethylene
or
perchioroethylene.
C.
Fire
and
Explosion
Prevention
Causes
of
fire
and
explosion
are
as
follows:
combus
tibles
reached
by
the
arc,
flame,
flying
sparks,
hot
slag,
or
heated
material;
misuse
of
compressed
gases
and
cylinders;
and
short
circuits.
BE
AWARE
THAT
flying
sparks
or
falling
slag
can
pass
through
cracks,
along
pipes,
through
windows
or
doors,
and
through
wall
or
floor
openings,
out
of
sight
of
the
goggled
operator.
Sparks
and
slag
can
travel
great
dis
tances.
To
prevent
fires
and
explosion:
Keep
equipment
clean
and
operable,
free
of
oil,
grease,
and
(in
electrical
parts)
of
metallic
particles
that
can
cause
short
circuits.
If
combustibles
are
in
the
area,
do
NOT
weld
or
cut.
Move
the
work,
if
practicable,
to
an
area
free
of
comb
ustibles.
Avoid
paint
spray
rooms,
dip
tanks,
storage
ar
eas,
and
ventilators.
If
the
work
cannot
be
moved,
move
combustibles
at
least
35
feet
away
out
of
reach
of
sparks
and
heat;
or
protect
against
ignition
with
suitable
and
snug-fitting,
fire-resistant
covers
or
shields.
Walls
touching
combustibles
on
opposite
sides
should
not
be
welded
on
or
cut.
Walls,
ceilings,
and
floor
near
work
should
be
protected
by
heat-resistant
covers
or
shields.
Fire
watcher
must
be
standing
by
with
suitable
fire
extin
guishing
equipment
during
and
for
some
time
after
weld
ing
or
cutting
if:
a.
appreciable
combustibles
(including
building
construction)
are
within
35
feet
b.
appreciable
combustibles
are
further
than
35
feet
but
can
be
ignited
by
sparks
c.
openings
(concealed
or
visible)
in
floors
or
walls
within
35
feet
may
expose
combustibles
to
sparks
d.
combustibles
adjacent
to
walls,
ceilings,
roofs,
or
metal
partitions
can
be
ignited
by
radiant
or
conducted
heat.
Hot
work
permit
should
be
obtained
before
operation
to
ensure
supervisors
approval
that
adequate
precautions
have
been
taken.
After
work
is
done,
check
that
area
is
free
of
sparks,
glowing
embers,
and
flames.
An
empty
container
that
held
combustibles,
or
that
can
produce
flammable
or
toxic
vapors
when
heated,
must
never
be
welded
on
or
cut,
unless
container
has
first
been
cleaned
as
described
in
AWS
Standard
F4.l
,
listed
7
in
Standards
Index.
This
includes
a
thorough
steam
or
caustic
cleaning
(or
a
solvent
or
water
washing,
depend
ing
on
the
combustibles
solubility)
followed
by
purging
with
nitrogen
or
carbon
dioxide,
and
using
protective
equipment
as
recommended
in
F4.l.
A
container
with
unknown
contents
should
be
cleaned
(see
preceding
paragraph).
Do
NOT
depend
on
sense
of
smell
or
sight
to
determine
if
it
is
safe
to
weld
or
cut.
Hollow
castings
or
containers
must
be
vented
before
welding
or
cutting.
They
can
explode.
Explosive
atmospheres.
Never
weld
or
cut
where
the
air
may
contain
flammable
dust,
gas,
or
liquid
vapors
(such
as
gasoline).
0.
Compressed
Gas
Equipment
Standard
precautions.
Comply
with
precautions
in
this
manual,
and
those
detailed
in
CGA
Standard
P-i,
SAFE
HANDLING
OF
COMPRESSED
GASES
IN
CYLIN
DERS,
listed
11
in
Standards
Index.
1.
Pressure
Regulators
Regulator
relief
valve
is
designed
to
protect
only
the
regulator
from
overpressure;
it
is
not
intended
to
protect
any
downstream
equipment.
Provide
such
protection
with
one
or
more
relief
devices.
Never
connect
a
regulator
to
a
cylinder
containing
gas
other
than
that
for
which
the
regulator
was
designed.
Remove
faulty
regulator
from
service
immediately
for
re
pair
(first
close
cylinder
valve).
The
following
symptoms
indicate
a
faulty
regulator:
External
gas
leaks.
Excessive
Creep.
If
delivery
pressure
continues
to
rise
with
downstream
valve
closed.
Faulty
Gauge.
If
gauge
pointer
does
not
move
off
stop
pin
when
pres
surized,
nor
returns
to
stop
pin
after
pressure
release.
Repair.
Do
NOT
attempt
to
repair.
Send
faulty
regulators
for
re
pair
to
manufacturers
designated
repair
center,
where
special
techniques
and
tools
are
used
by
trained
person-
nel.
2.
Cylinders
Cylinders
must
be
handled
carefully
to
prevent
leaks
and
damage
to
their
walls,
valves,
or
safety
devices.
Avoid
electrical
circuit
contact
with
cylinders
including
third
rails,
electrical
wires,
and
welding
or
cutting
cir
cuits.
They
can
produce
short
circuit
arcs
that
may
lead
to
a
serious
accident.
(See
1
-3C.)
ICC
or
DOT
marking
must
be
on
each
cylinder.
It
is
an
assurance
of
safety
when
the
cylinder
is
properly
han
dled.
Identifying
gas
content.
Use
only
cylinders
with
name
of
gas
marked
on
them;
do
not
rely
on
color
to
identify
gas
content.
Notify
supplier
if
unmarked.
NEVER
DEFACE
or
alter
name,
number,
or
other
markings
on
a
cylinder.
It
is
illegal
and
hazardous.
OM-1584
Page
2
Empties:
Keep
valves
closed,
replace
caps
securely,
mark
MT,
keep
them
separate
from
FULLS,
and
return
promptly.
Prohibited
use.
Never
use a
cylinder
or
its
contents
for
other
than
its
intended
use,
NEVER
as
a
support
or
roller.
Never
cut
on
a
cylinder.
Locate
or
secure
cylinders
so
they
cannot
be
knocked
over.
Passageways
and
work
areas.
Keep
cylinders
clear
of
areas
where
they
may
be
struck.
Transporting
cylinders.
With
a
crane,
use
a
secure
sup
port
such
as
a
platform
or
cradle.
Do
NOT
lift
cylinders
off
the
ground
by
their
valves
or
caps,
or
by
chains,
slings,
or
magnets.
Do
NOT
expose
cylinders
to
arcs,
excessive
heat,
sparks,
slag,
flame,
etc.,
that
may
cause
rupture.
Do
not
allow
contents
to
exceed
130F.
Cool
with
water
spray
where
such
exposure
exists.
Protect
cylinders,
particularly
valves,
from
bumps,
falls,
falling
objects,
and
weather.
Replace
caps
securely
when
moving
cylinders.
Stuck
valve.
Do
NOT
use
a
hammer
or
wrench
to
open
a
cylinder
valve
that
cannot
be
opened
by
hand.
Notify
your
supplier.
Mixing
gases.
Never
try
to
mix
any
gases
in
a
cylinder.
Never
refill
any
cylinder.
Cylinder
fittings
should
never
be
modified
or
exchanged.
3.
Hose
Prohibited
use.
Never
use
hose
other
than
that
designed
for
the
specified
gas.
A
general
hose
identification
rule
is
as
follows:
red
for
fuel
gas,
green
for
oxygen,
and
black
for
inert
gases.
Use
ferrules
or
clamps
designed
for
the
hose
(not
ordi
nary
wire
or
other
substitute)
as
a
binding
to
connect
hoses
to
fittings.
No
copper
tubing
splices.
Use
only
standard
brass
fit
tings
to
splice
hose.
Avoid
long
runs
to
prevent
kinks
and
abuse.
Suspend
hose
off
ground
to
keep
it
from
being
run
over,
stepped
on,
or
otherwise
damaged.
Coil
excess
hose
to
prevent
kinks
and
tangles.
Protect
hose
from
damage
by
sharp
edges,
and
by
sparks,
slag,
and
open
flame.
Examine
hose
regularly
for
leaks,
wear,
and
loose
con
nections.
Immerse
pressurized
hose
in
water;
bubbles
indicate
leaks.
Repair
leaky
or
worn
hose
by
cutting
area
out
and
splic
ing
(1-2D3).
Do
NOT
tape.
4.
Proper
Connections
Clean
cylinder
valve
outlet
of
impurities
that
may
clog
orifices
and
damage
seats
before
connecting
regulator.
Except
for
hydrogen,
crack
valve
momentarily,
pointing
outlet
away
from
people
and
sources
of
ignition.
Wipe
with
a
clean
lintless
cloth.
Match
regulator
to
cylinder.
Before
connecting,
check
that
the
regulator
label
and
cylinder
marking
area,
and
thatthe
regulator
inlet
and
cylinder
outlet
match.
NEVER
CONNECT
a
regulator
designed
for
a
particular
gas
or
gases
to
a
cylinder
containing
any
other
gas.
Tighten
connections.
When
assembling
threaded
con
nections,
clean
and
smooth
seats
where
necessary.
Tighten.
If
connection
leaks,
disassemble,
clean,
and
retighten
using
properly
fitting
wrench.
Adapters.
Use
a
CGA
adapter
(available
from
your
sup
plier)
between
cylinder
and
regulator,
if
one
is
required.
use
two
wrenches
to
tighten
adapter
marked
RIGHT-
and
LEFT-HAND
threads.
Regulator
outlet
(or
hose)
connections
may
be
identified
by
right-hand
threads
for
oxygen
and
left-hand
threads
(with
grooved
hex
on
nut
or
shank)
for
fuel
gas.
5.
Pressurizing
Steps
Drain
regulator
of
residual
gas
through
suitable
vent
be
fore
opening
cylinder
(or
manifold
valve)
by
turning
ad-
lusting
screw
in
(clockwise).
Draining
prevents
exces
sive
compression
heat
at
high
pressure
seat
by
allowing
seat
to
open
on
pressurization.
Leave
adjusting
screw
engaged
slightly
on
single-stage
regulators.
Stand
to
side
of
regulator
while
opening
cylinder
valve.
Open
cylinder
valve
slowly
so
that
regulator
pressure
in
creases
slowly.
When
gauge
is
pressurized
(gauge
reaches
regulator
maximum),
leave
cylinder
valve
in
fol
lowing
position:
For
oxygen
and
inert
gases,
open
fully
to
seal
stem
against
possible
leak.
For
fuel
gas,
open
to
less
than
one
turn
to
permit
quick
emergency
shutoff.
Use
pressure
charts
(available
from
your
supplier)
for
safe
and
efficient
recommended
pressure
settings
on
regulators.
Check
for
leaks
on
first
pressurization
and
regularly
thereafter.
Brush
with
soap
solution
(capfull
of
Ivory
Liq
uid*
or
equivalent
per
gallon
of
water).
Bubbles
indicate
leak.
Clean
off
soapy
water
after
test;
dried
soap
is
corn-
bustible.
E.
User
ResponsibilitIes
Remove
leaky
or
defective
equipment
from
service
im
mediately
for
repair.
See
User
Responsibility
statement
in
equipment
manual.
F.
Leaving
Equipment
Unattended
Close
gas
supply
at
source
and
drain
gas.
G.
Rope
Staging-Support
Rope
staging-support
should
not
be
used
for
welding
or
cutting
operation;
rope
may
burn.
*Tradernark
of
Proctor
&
Gamble.
OM-1584
Page
3
When
installing,
connect
the
frames
of
each
unit,
such
as
power
source,
control,
worktable,
and
water
circula
tor
to
the
building
ground.
Conductors
must
be
adequate
to
carry
ground
currents
safely.
Equipment
made
electri
cally
HOT
by
stray
current-may
shock,
possibly
fatally.
Do
NOT
GROUND
to
electrical
conduit,
or
to
a
pipe
car
rying
ANY
gas
or
flammable
liquid
such
as
oil
or
fuel.
Three-phase
connection.
Check
phase
requirements
of
equipment
before
installing.
If
only
3-phase
power
is
available,
connect
single-phase
equipment
to
only
two
wires
of
the
3-phase
line.
Do
NOT
connect
the
equip
ment
ground
to
the
third
(live)
wire,
or
the
equipment
will
become
electrically
HOTa
dangerous
condition
that
can
shock,
possibly
fatally.
Before
cutting,
check
ground
for
continuity.
Be
sure
con
ductors
are
touching
bare
metal
of
equipment
frames
at
connections.
If
a
line
cord
with
a
ground
lead
is
provided
with
the
equipment
for
connection
to
a
switchbox,
connect
the
ground
lead
to
the
grounded
switchbox.
If
a
three-prong
plug
is
added
for
connection
to
a
grounded
mating
re
ceptacle,
the
ground
lead
must
be
connected
to
the
ground
prong
only.
If
the
line
cord
comes
with
a
three-
prong
plug,
connect
to
a
grounded
mating
receptacle.
Never
remove
the
ground
prong
from
a
plug,
or
use
a
plug
with
a
broken
off
ground
prong.
2.
Plasma
Cutting
Torches
Fully
insulated
torches
should
be
used.
Do
NOT
use
torches
with
protruding
screws.Do
NOT
use
torches
with
cracks
on
pieces
missing
or
with
loose
or
missing
screws.
3.
Cables
Frequently
inspect
cables
for
wear,
cracks,
and
dam
age.
IMMEDIATELY
REPLACE
those
with
excessively
worn
or
damaged
insulation
to
avoid
possibly
lethal
shock
from
bared
cable.
Cables
with
damaged
areas
may
be
taped
to
give
resistance
equivalent
to
original
ca
ble.
Keep
cable
dry,
free
of
oil
and
grease,
and
protected
from
hot
metal
and
sparks.
4.
Terminals
And
Other
Exposed
Parts
Terminals
and
other
exposed
parts
of
electrical
units
should
have
insulating
covers
secured
before
operation.
5.
Cutting
Torch
Disassembly
Even
though
there
are
several
safety
shutdown
devices
provided
as
standard
equipment
on
the
cutting
torch,
it
is
still
a
recommended
safe
practice
to
turn
off
the
power
source
before
touching
any
torch
parts.
Power
sources
used
for
the
Plasma
Arc
Cutting
(PAC)
process
normally
are
equipped
with
devices
that
permit
on-off
control
of
the
cutting
power
output.
As
a
result,
the
cutting
torch
electrode
and
tip
become
electrically
HOT
whenever
the
power
source
is
ON
and
the
cutting
torch
switch
is
closed
(pressed).
Never
touch
the
torch
tip
or
electrode
and
any
conduct
ing
object
in
contact
with
the
cutting
circuit
unless
the
power
source
is
OFF.
6.
Safety
Devices
Safety
devices,
such
as
interlocks
and
circuit
breakers,
should
not
be
disconnected
or
shunted
out.
Before
installation,
inspection,
or
service
of
equipment,
shut
OFF
all
power,
and
remove
line
fuses
(or
lock
or
red-tag
switches)
to
prevent
accidental
turning
ON
of
power.
Disconnect
all
cables
from
power
source,
and
re
move
all
115
volts
line-cord
plugs
from
receptacles.
Do
not
open
power
circuit
while
cutting.
If,
in
an
emer
gency,
it
must
be
disconnected,
guard
against
shock,
burns,
or
flash
from
switch
arcing.
Never
leave
equipment
unattended.
Always
shut
OFF
and
disconnect
all
power
to
equipment
before
leaving.
Power
disconnect
switch
must
be
available
near
the
plasma
cutting
power
source.
1-4.
STANDARDS
BOOKLET
INDEX
For
more
information,
refer
to
the
following
standards
or
their
latest
revisions,
and
comply
as
applicable:
1.
ANSI
Standard
Z49.1,
SAFETY
IN
WELDING
AND
CUTTING,
obtainable
from
the
American
Welding
Society,
550
N.W.
LeJeune
Rd. Miami,
FL
33126.
2.
NIOSH,
SAFETY
AND
HEALTH
IN
ARC
WELD
ING
AND
GAS
WELDING
AND
CUTTING,
ob
tainable
from
the
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
3.
OSHA,
SAFETY
AND
HEALTH
STANDARDS,
29
CFR
1910,
obtainable
from
the
Superinten
dent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
4.
ANSI
Standard
Z87.1,
PRACTICE
FOR
OCCU
PATIONAL
AND
EDUCATIONAL
EYE
AND
FACE
PROTECTION,
obtainable
from
the
Ameri
can
National
Standards
Institute,
1430
Broad
way,
New
York,
NY
10018.
5.
ANSI
Standard
Z41
.1,
STANDARD
FOR
MENS
SAFETY-TOE
FOOTWEAR,
obtainable
from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
6.
ANSI
Standard
Z49.2,
FIRE
PREVENTION
IN
THE
USE
OF
CUTTING
AND
WELDING
PROC
ESSES,
obtainable
from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
OM-1584
Page
5
7.
American
Welding
Society
Standard
AWS
F4.1,
RECOMMENDED
SAFE
PRACTICES
FOR
THE
PREPARATION
FOR
WELDING
AND
CUTTING
OF
CONTAINERS
THAT
HAVE
HELD
HAZARD
OUS
SUBSTANCES,
obtainable
from
the
Ameri
can
Welding
Society,
550
N.W.
LeJeune
Rd,
Mi
ami,
FL
33126.
8.
NFPA
Standard
51,
OXYGEN-FUEL
GAS
SYS
TEMS
FOR
WELDING,
CUTTING,
AND
ALLIED
PROCESSES,
obtainable
from
the
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
9.
NFPA
Standard
70,
NATIONAL
ELECTRICAL
CODE,
obtainable
from
the
National
Fire
Protec
tion
Association,
Batterymarch
Park,
Quincy,
MA
02269.
10.
NFPA
Standard
518,
CUTTING
AND
WELDING
PROCESSES,
obtainable
from
the
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
11.
CGA
Pamphlet
P-i,SAFE
HANDLING
OF
COM
PRESSED
GASES
IN
CYLINDERS,
obtainable
from
the
Compressed
Gas
Association,
1235
Jef
ferson
Davis
Highway,
Suite
501,
Arlington,
VA
22202.
12.
GSA
Standard
W117.2,
CODE
FOR
SAFETY
IN
WELDING
AND
CUTTING,
obtainable
from
the
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
13.
NWSA
booklet,
WELDING
SAFETY
BIBLIOG
RAPHY,
obtainable
from
the
National
Welding
Supply
Association,
1900
Arch
Street,
Philadel
phia,
PA
19103.
14.
American
Welding
Society
Standard
AWS
C5.2,
RECOMMENDED
PRACTICES
FOR
PLASMA
ARC
CUTTING,
obtainable
from
the
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126.
15.
ANSI
Standard
Z88.2,
PRACTICE
FOR
RESPI
RATORY
PROTECTION,
obtainable
from
the
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
OM-1584
Page
6
SECTION
3
SPECIFICATIONS
Table
3-1.
Specifications
Model
Dual
12
Dual
16
Electrode
Wire
Diameter
Capacity
0.023
thru
118
in.
(0.6
thru
3.2
mm)
Speed
Range
50
780
ipm
(1.3
19.8
mpm)
Control
Circuit
Voltage
At
Gun
24
Volts
AC
Boom
Length
12
ft.
(3.7
m)
16
ft.
(4.9
m)
Swing
360
Vertical
Lift
Horizontal
To
60
Above
21
ft.
(6.4
m)
17ft.
(5.2m)
Compression
Spring
Is
Designed
To
Balance
Boom
At
Any
Angle.
Pressure
Adjustment
Is
Provided
To
Hold
The
Boom
At
Any
Desired
Angle
Or
To
Limit
The
Vertical
Lift
At
40,
50,
or
60.
Maximum
Heiaht
(With
4
ft.
or
1.2
m
Post)
At
pull
Lift
Of
Boom
Counterbalance
(Patented)
Weight
Net
I
Ship
Net
Ship
280
lbs.
I
411
lbs.
(127
kg)
(186
kg)
207
lbs.
I
318
lbs.
(94
kg)
(144
kg)
*Optional
high
speed
motor
range:
90
to
1400
ipm
(2.3
to
35.6
mpm)
3-1.
DESCRIPTION
This
unit
is
a
boom
mounted
semiautomatic
constant
speed
wire
feeder
which
operates
on
24
volts
ac.
This
unit
has
the
capability
of
feeding
wire
alternately
from
two
welding
guns.
The
feeder
is
designed
for
connection
to
a
constant
voltage
type
welding
power
source
through
a
1
4-pin
connector.
If
115
volts
ac
is
the
only
power
avail
able
for
use
with
the
feeder,
the
optional
power
supply
adapter
Model
PSA-2
115/24
is
required
to
convert
the
power
to
24
volts
ac.
The
case
is
tightly
secured
to
help
keep
out
dust
and
dirt,
while
still
allowing
easy
access
to
optional
controls.
The
boom
is
a
patented
design
allowing
both
vertical
and
horizontal
lift
and
swing.
Cables
are
routed
through
the
boom
from
the
control
to
the
wire
drive
assembly.
The
following
optional
equipment
can
be
provided
on
the
wire
feeder
and
is
covered
within
this
Owners
Manual:
*
Digital
Meter/Tachometer
Feedback
*
Voltage
Control
*
Digital
Voltage
Control
*
Burnback
Control
*
Four
In
One
-
Which
includes
the
following:
Spot/Burnback
Control
Preflow
Control
Postf
low
Control
Trigger
Hold
*
Option
Interface
(required
to
install
the
following
options)
*
Run-In
Control
*
Dual
Schedule
*
Digital
Dual
Schedule
*
Synergic
Connections
IMPORTANT:
For
a
complete
listing
of
Options
and
Ac
cessories,
see
back
cover
of
this
wire
feeder
Owners
Manual.
OM-1584
Page
7
Table
3-2.
Options
Compatibility
-
-
The
table
below
should
be
used
to
determIne
the
options
that
can
be
used
together
on
a
wire
feeder.
Use
the
column
on
the
left
side
of
the
table
to
choose
the
desired
option
and
follow
the
line
across
to
see
which
options
are
compatible.
DESIRED
OPTION
-
Burn-
back
Control
4-~-1
OptIon
DIgItal
Meter/
Tech
Feedback
Olaltal
~
Control
Voltage
Control
Run-In
Control
DIgItal
Dual
Scheduli
Dual
Schedule
Control
Remote
Pendant
Control
Cord
#137
552
(For
RCSP-45)
Burnback
Control
No
Yes
Yes
Yes
Yes Yes
Yes
Yes
Yes
4-IN-i
Option
(Includes
preflowlpostflow,
spotlburnback,
and
trigger
hold
Control)
No
Yes
Yes
Yes
Yes Yes
Yes
Yes
Yes
Digital
Meter/Tach
Feedback
Yes
Yes
Yes Yes
Yes
Yes
No
Yes Yes
Digital
Voltage
Control
(DVC)
Yes Yes
Reqd
No
Yes
Yes
No
Yes
No
Voltage
Control
Yes
Yes
Yes
No
Yes
No
No
No
No
Run-In
Control
(Option
Interface
Required)
Yes
Yes
Yes
Yes Yes
Yes
Yes
Yes Yes
Digital
Dual
Schedule
(Option
Interface
Required)
Yes
Yes
Reqd
Reqd
No
Yes
No
No No
Dual
Schedule
Control
(Option
Interface
Required)
Yes
Yes
No
No
No
Yes
No
No
No
Remote
Pendant
Control
(Option
Interface
Required)
Yes
Yes
Yes
Yes
No
Yes
No
No
No
Cord
#137
552
(For
RCSP-45)
(Option
Interface
Required)
Yes Yes
Yes
No
No
Yes
No
No
No
SECTION
4
INSTALLATION
OR
RELOCATION
4-1.
LOCATION
The
service
life
and
efficiency
of
this
unit
and
associated
components
are
reduced
when
they
are
subjected
to
high
levels
of
dust,
dirt,
moisture,
corrosive
vapors,
and
extreme
heat.
A
suitable
location
for
this
unit
will
allow
room
for
the
boom
to
swing
horizontally
in
the
desired
arc
and
to
pivot
upward
to
the
desired
angle.
Proper
placement
will
also
provide
sufficient
clearance
from
obstruction
at
the
wire
support
end
of
the
unit
when
the
boom
swings.
The
structure
to
which
the
unit
is
being
installed
should
be
of
sufficient
construction
to
support
the
weight
of
the
unit
when
the
boom
is
in
the
horizontal
position.
4-2.
BASE
AND
BOOM
ASSEMBLY
(Figure
4-1)
1.
Existing
Support
(Customer
Supplied)
a
WARNING:
FALLING
BOOM
can
cause
serI
ous
personal
injury
and
equipment
damage.
Use
5
in.
(127
mm)
diameter,
Schedule
40
pipe
(wall
thickness
of
0.258
in.
or
6.6mm)
as
support
pipe
for
16
foot
(4.9
m)
booms.
a.
Uncrate
and
remove
all
packing
material
from
the
unit.
b.
Mount
post
support
to
the
desired
structure.
OM-i
584
Page
8
Wire
Guide
Fitting
a
WARNING:
FALLING
BOOM
can
cause
seri
ous
personal
injury
and
equipment
damage.
Securely
mount
unit
to
a
structure
that
can
support
the
weight
of
the
unit
when
the
boom
is
in
the
horizontal
position.
c.
Complete
Steps
c
thru
g
in
Subsection
2.
Post
Support.
2.
Post
Support
(Optional)
a.
Uncrate
and
remove
all
packing
material
from
the
unit.
b.
Mount
post
support
to
desired
structure.
a
WARNING:
FALLING
BOOM
can
cause
seri
ous
personal
injury
and
equipment
damage.
Securely
mount
unit
to
a
structure
that
can
support
the
weight
of
the
unit
when
the
boom
is
in
the
horizontal
position.
c.
Remove
yoke
pin,
nut,
washers,
and
bolt
from
yoke
and
swivel
plates.
Hole
in
Yoke
Yoke
Cotter
Pin
Screw
Lock
Washer
a
WARNING:
RELEASE
OF
SPRING
PRES
SURE
WITHOUT
BOOM
ATTACHED
can
cause
serious
personal
Injury
and
equip
ment
damage.
Perform
installation
exactly
as
outlined
in
fo!
lowing
step-by-step
instructions.
Do
not
remove
safety
collar
until
instructed
to
do
so.
d.
Insert
swivel
into
post.
e.
Place
the
boom
base
plate
between
the
two
swivel
plates.
f.
Slide
washer
onto
bolt
and
insert
through
appro
priate
hole
in
swivel
plates
(see
inset
portion
of
Figure
4-1).
Slide
washer
onto
bolt
and
install
nut
onto
bolt.
Tighten
nut;
then
back
off
nut
1/2
turn.
g.
Insert
pin
through
yoke,
hole,
and
install
cotter
pin
through
pin.
CAUTION:
EXCESSIVE
FRICTION
can
dam
age
equipment.
Every
six
months
lubricate
swivel
to
prevent
wear
Excessive
lubrication
is
not
required
or
recom
mended.
Wire
Support
Swivel
Base
Nut
Washer
Post
Support
Figure
4-1.
Base
And
Boom
Assembly
SB-142
598.A
OM-1
584
Page
9
3.
Base
Support
(Optional)
remaining
end
of
monocoil
liner
is
flush
with
end
IMPORTANT:
If
an
optional
base
support
was
pur-
of
tube.
chased
with
the
unit,
mounting
holes
are
provided
for
3.
Tighten
bolt
to
secure
monocoil
liner.
Be
sure
not
fastening
the
base
support
to
the
floor,
to
crush
the
liner.
~
WARNING:
FALLING
BOOM
can
cause
seri
ous
personal
injury
and
equipment
damage.
4-6.
WIRE
GUIDE
AND
DRIVE
ROLL
INSTALLA
For
mounting
base
support
use,
as
a
mini-
lION
(Figure
4-2)
mum,
1/2
in.
(12.7
mm)
diameter,
S.A.E.
Upon
initial
installation,
or
as
a
result
of
changes
in
wire
grade
5
bolts.
size
and
type,
it
is
necessary
to
install
the
required
drive
Use
equivalent
strength,
non-corrosive
bolts
rolls
and
wire
guides.
Select
drive
rolls
according
to
if
unit
is
mounted
in
an
extremely
damp
envi-
Table
9-1.
ronment.
IMPORTANT:
All
directions
for
wire
guide
and
drive
roll
a.
Uncrate
and
remove
all
packing
material
from
installation
such
as
left
and
right,
are
with
respect
to
the
the
unit.
operator
facing
the
front
of
the
drive
assembly.
b.
Fasten
base
support
to
the
floor.
c.
Complete
Steps
c
thru
g
in
Subsection
2.
Post
IMPORTANT:
All
adjustments
are
made
usinga3/l6in.
Support.
Follow
all
precautionary
data.
alien
wrench,
which
is
included
with
this
unit.
4.
Swingpak
Base
(Optional)
After
obtaining
the
appropriate
drive
rolls
and
wire
a.
Uncrate
and
remove
all
packing
material
from
guides,
proceed
as
follows:
the
Swingpak
base.
A.
Wire
Guide
Installation
A~
WARNING:
FALLING
BOOM
can
cause
seri
ous
personal
injury
and
equipment
damage.
3.
Open
drive
assembly
cover.
Mount
welding
power
source
on
Swingpak
4.
Remove
drive
rolls
if
applicable.
base
before
mounting
Swingarc.
5.
Loosen
the
wire
guide
screw
and
wire
guide
re
b.
Uncrate
and
remove
all
packing
material
from
tamer.
the
Swingpak
unit.
6.
Place
wire
guide
with
arrow
pointing
down,
into
c.
Complete
Steps
c
thru
g
in
Subsection
2.
Post
Support.
Follow
all
precautionary
data.
guide
holder
seat.
7.
Secure
wire
guide
by
tightening
wire
guide
screw,
4-3.
INSTALLATION
OF
CONTROL
BOX
TO
BASE
making
certain
that
wire
guide
retainer
is
posi
(Figures
4-1
And
43)
tioned
in
groove
on
guide
holder
seat.
Do
not
The
control
box
is
shipped
with
four
(4)
screws
partially
overtighten.
installed
into
bottom
side
of
control
box.
To
secure
con
trol
box
to
base
proceed
as
follows:
8.
Install
remaining
wire
guide
by
repeating
Steps
2
through
5.
1.
Set
control
box
onto
base
with
the
four
screws
protruding
through
the
four
keyhole
shaped
holes
B.
Drive
Roll
Installation
in
base
plate.
1.
Close
spring
shaft
carrier.
2.
Slide
control
box
forward,
so
that
screws
are
in
slotted
portion
of
keyholes,
and
tighten
the
four
2.
Turn
drive
roll
nut
on
each
drive
roll
carrier
coun
terclockwise
until
the
three
lobes
of
each
nut
line
screws.
up
with
the
three
lobes
of
each
drive
roll
carrier.
4-4.
INSTALLATION
OF
WIRE
SUPPORT
3.
Open
spring
shaft
carrier.
(FIgure
4-1)
1.
Remove
the
securing
screws
and
lock
washers
4.
Slide
a
drive
roll
over
drive
roll
nut
onto
drive
roll
from
the
swivel
base.
carrier.
2.
Place
the
wire
support
over
the
holes
in
the
swivel
5.
Repeat
Step
4
for
all
drive
rolls.
base.
6.
Close
spring
shaft
carrier,
and
turn
each
drive
roll
3.
Insert
securing
screws
with
lock
washers
and
nut
clockwise
until
tight.
Do
not
overtighten.
tighten.
C.
Drive
Roll
Pressure
Adjustment
4-5.
INSTALLATION
OF
WIRE
GUIDE
EXTENSION
(Figure
43)
The
drive
roIl
pressure
indicator
is
located
on
the
top
front
side
of
the
spring
shaft
carrier.
The
scale
on
the
in-
1.
Locate
supplied
wire
guide
extension.
dicator
is
a
relative
scale
only,
and
does
not
indicate
ac
2.
Loosen
bolt
on
wire
guide
fitting,
and
insert
end
of
tual
drive
roll
pressure.
Increase
drive
roll
pressure
by
monocoil
liner
near
cable
tie
into
fitting.
Be
sure
rotating
the
pressure
adjustment
knob
clockwise.
OM-1584
Page
10
FIgure
4-2.
Wire
Guide
And
Drive
Roll
Installation
4-7.
WELDING
GUN
CONNECTIONS
A.
Gun
Connector
To
Drive
Assembly
(Provides
Weld
Power
And
Shielding
Gas)
(Figure
4-2)
IMPORTANT:
The
outlet
guide
is
provided
as
part
of
the
gun
or
gun
adapter
assembly.
1.
Loosen
the
gun/feeder
connector
securing
knob.
IMPORTANT:
The
outlet
guide
should
be
installed
so
that
tip
of
guide
is
as
close
to
the
drive
rolls
as
possible
without
touching.
2.
Insert
the
gun/feeder
connector,
or
gun/feeder
adapter
if
required,
which
includes
installed
outlet
guide,
into
drive
assembly
opposite
inlet
guide.
3.
Tighten
gun/feeder
connector
securing
knob.
B.
Gun
Trigger
(Figure
4-3)
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Do
not
touch
electrode
wire
when
gun
trigger
is
pressed.
The
welding
wire
and
all
metal
parts
in
contact
with
it
carry
weld
output
when
the
welding
power
source
contactor
is
energized.
Two
4
socket
free-hanging
receptacles
extend
Out
of
the
motor
end
of
the
boom
for
connecting
the
gun
trigger
plugs
to
the
wire
feeder.
Connect
the
left
gun
to
the
free-
hanging
receptacle
labeled
LEFT,
and
the
right
gun
to
the
remaining
free-hanging
receptacle.
To
make
con
nections,
align
keyways,
insert
plug,
and
rotate
threaded
collar
fully
clockwise.
Set
Screw
Liner
Wire
Guide
Weld
Cable
Terminal
Drive
Roil
Carrier
Drive
Roll
Pressure
indicator
pring
Shaft
Carrier
(Shown
Open)
Drive
Roll
Nut
~
One
Piece
Drive
Roll
Pressure
Adjustment
Knob
Gun/Feeder
Connector
Opening
Gun/Feeder
Connector
Securing
Knobs
Guide
Holder
Seat.
Wire
Guide
Wire
Guide
Retainer
Wire
Screw
Guide
Holder
Seat
Groove
SA-142
597
SA137
391-A
OM-1584
Page
11
C.
Shielding
Gas
(If
Applicable)
ARCING
can
damage
weld
cable
terminal.
An
integral
gas
input
fitting
is
provided
on
the
wire
drive
assembly
for
guns
utilizing
this
type
of
connection.
If
the
gun
requires
a
separate
shielding
gas
connection,
dis
connect
the
hose
from
the
gas
fitting
on
drive
assembly,
install
proper
fittings
or
connectors,
and
connect
to
gas
hose
from
gun.
--
0.
Weld
Cable
(If
Applicable)
WARNING:
ELECTRIC
SHOCK
can
kill.
_____
Do
not
touch
live
electrical
parts.
Shut
down
wire
feeder
and
welding
power
source
and
disconnect
input
poweremploying
lockout/tagging
procedures
before
making
weld
cable
connections.
Lockout/tagging
procedures
for
the
wire
feeder
consist
of
disconnecting
interconnecting
cord,
and
for
welding
power
source
consist
of
pad
locking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
Stop
engine,
and
disconnect
nega
tive
()
battery
cable
from
battery
on
welding
generators.
Clean
weld
cable
terminal
before
connecting
weld
cable
if
necessary.
Tighten
terminal
nut
securely.
Loose
or
dirty
connections
can
cause
erratic
weld
output.
Connect
the
weld
cable
from
the
gun,
if
applicable,
to
the
weld
cable
terminal
on
the
drive
assembly.
4-8.
CONNECTIONS
FROM
BOOM
TO
CONTROL
BOX
(Figure
4-3)
A.
Gun
Trigger
Two
receptacles,
labeled
TRIGGER
RECEPTACLE,
are
provided
on
the
front
of
the
control
box.
Connect
the
left
gun
trigger
control
plug
from
the
boom,
labeled
LEFT,
to
control
box
left
TRIGGER
RECEPTACLE.
Con
nect
remaining
gun
trigger
control
plug
to
matching
re
ceptacle.
To
make
connections,
align
keyways,
insert
plug,
and
rotate
threaded
collar
fully
clockwise.
Ref.
SD-I
42
598-A
Control
Motor
Control
Box
Plugs
Trigger
Control
Plugs
Gas
Hoses
Weld
Cables
Wire
Guide
FitlIng
Weld
Cable
Liner
Gun
Trigger
Plugs
Figure
4-3.
Control
Box
And
Boom
ConnectIons
OM-1584
Page
12
10
ft.
(3
m)
Gas
Hose
with
Extension
Adapter
(supplied
with
feeder)
10
ft.
(3
rn)
24
VAC
and
Contactor
Cord
(supplied
with
feeder)
10
ft.
(3
m)
Weld Power
Cable
(supplied
with
feeder)
Standard
or
Deluxe
Model
10
ft.
(3
m)
Gas
Hose
with
Extension
Miller
electrically
Adapter
(supplied
with
feeder)
controlled
CV
and
CCICV
power
source
with
a
14-pin
lOft.
(3
m)
24
VAC
and
Contactor
I
I
Standard
Deluxe
or
receptacle
and
24
VAC
Cord
(supplied
with
feeder)
~
k
Super
Deluxe
Model
Supply
_______________________________________________________________
lOft.
(3
m)
Weld
Power
Cable
(supplied
with
feeder)
Optional
PSA-2
Control
(allows
60
Series
Feeders
to
be
used
with
power
sources
having
only
115
VAC
available
can
be
mounted
at
power
source
or
feeder.
Refer
to
OPTIONAL
CONTROLS
AND
ACCESSORIES
section
for
detailed
information.)
lOft.
(3
m)
Gas
Hose
with
Extension
Adapter
(supplied
with
feeder)
\
1/
10
ft.
(3
m)
Weld
Power
Cable
(supplied
with
feeder)
IMPORTANT:
If
using
the
SS
or
DS
feeder
with
a
power
source
having
only
115
VAC
supply,
the
PSA-2
(Power
Source
Adapter)
is
required.
Refer
to
OPTIONAL
CONTROLS
AND
ACCESSORIES
section.
Figure
4-4.
Typical
Connections
To
Welding
Power
Source
S-0534
B.
Motor
Control
Two
motor
control
receptacles
are
provided
on
the
rear
of
the
control
box
for
making
motor
control
connections.
Connect
the
left
motor
control
plug
from
boom,
labeled
LEFT,
to
control
box
left
motor
control
receptacle.
Con
nect
remaining
motor
control
plug
to
matching
recep
tacle.
To
make
connections,
align
keyways,
insert
plug,
and
rotate
threaded
collar
fully
clockwise.
4-9.
SHIELDING
GAS
CONNECTION
(Figure
4-3)
The
shielding
gas
hoses
extend
lOft.
(3
m)
from
the
rear
of
the
boom.
If
necessary,
obtain
extension
for
hoses.
Route
and
connect
end
of
gas
hose
to
regulator/flowme
ter
at
gas
supply.
4-10.
WELDING
POWER
SOURCE
CONNECTIONS
TO
CONTROL
BOX
AND
BOOM
(Figures
4-3
thru
4-5)
A.
14-Pin
Plug
Connection
The
14-pin
plug
PLG
lOon
the
end
of
the
interconnecting
cord
provides
a
means
for
connecting
the
wire
feeder
to
a
welding
power
source
(see
Figure
4-6).
This
connec
tion
provides
24
volt
ac
power,
contactor
control,
and
op
tional
voltage
control
when
used
with
a
constant
voltage
(CV)
welding
power
source
with
a
14-socket
receptacle.
To
make
connections,
align
keyway,
insert
plug,
and
ro
tate
threaded
collar
fully
clockwise.
The
pins
on
plug
PLG1O
are
defined
in
relation
to
both
the
power
source
and
wire
feeder.
The
welding
power
source
provides
six
functions
to
the
wire
feeder.
The
pins
are
designated
as
follows:
FIgure
4-5.
Front
View
Of
14-Pin
Plug
With
PIn
Locations
Ret.
S-0512
Miller
CV
power
source
equipped
with
a
14-pin
receptacle
and
24
VAC
supply
Optional
115
VAC
and
Contactor
Cord
or
Control
Cord
from
existing
50
Series
feeder
installation
(cord
connects
to
4-pin
connector
on
cord
from
PSA-2
Control)
EXTENSION
CORDS
loft.
3m)
#122
972
25
ft.
7.6
m)
#122
973
SOft.
15m
(#122974
75ft.
23m
(#122975
Can
be
added
to
the
standard
lOft.
(3
m)
cord
to
extend
feeder
farther
from
power
source.
Miller
CV
or
competitive
CV
power
source
with
115
VAC
power
or
competitive
power
source
requiring
contact
closure
for
coritactor
control
4-Pin
Plug
Standard
or
J L
Deluxe
Model
OM-1
584
Page
13
Pin
A:
Up
to
10
amperes
of
24
volts
ac,
60
Hz,
with
re
spect
to
socket
G
(circuit
common);
protected
by
fuse
in
welding
power
source.
Pin
B:
24
volts
ac
input
power
to
energize
the
weld
contactor.
The
feeder
sends
back
24
volts
ac
by
means
of
a
contact
closure
from
Pin
A
to
Pin
B.
Pin
C:
+10
volts
dc
with-respect
to
Pin
D.
Pin
D:
Control
circuit
common
from
power
source.
Pin
E:
Input
command
signal
from
wiper
of
remote
control
potentiometer,
0
volts
equals
machine
minimum;
+10
volts
equals
machine
maximum.
Pin
G:
24
volts
ac
circuit
common;
also
connected
to
welding
power
source
chassis.
Pin
H:
Reserved
for
future
use.
IMPORTANT:
The
remaining
pins
in
the
plug
are
not
used
by
the
feeder.
B.
Weld
Cable
4~
ELECTRIC
SHOCK
can
kill.
_____
Do
not
touch
live
electrical
parts.
Shut
down
wire
feeder
and
welding
power
source
and
dis
conr7ect
input
poweremploying
lockout/tagging
procedures
before
making
weld
cable
connections.
Lockoutltagging
procedures
for
the
wire
feeder
consist
of
disconnecting
interconnecting
cord,
and
for
welding
power
source
Consist
of
pad
locking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
Stop
engine,
and
disconnect
nega
tive
()
battery
cable
from
battery
on
welding
generators.
ARCING
can
damage
weld
cable
terminal.
Clean
weld
cable
terminal
before
connecting
weld
cable
if
necessary
Tighten
terminal
nut
securely.
Loose
or
dirty
connections
can
cause
erratic
weld
output.
Two
10
ft.
(3
m)
weld
cables
extend
Out
of
the
boom
for
making
weld
output
connection
to
the
welding
power
source.
For
Electrode
Positive/Reverse
Polarity
connections
proceed
as
follows:
1.
Route
and
connect
both
weld
cables
extending
out
of
the
control
box
end
of
the
boom
to
the
Posi
tive
(+)
weld
output
terminal
on
welding
power
source
(see
power
source
Owners
Manual).
If
necessary,
use
a
weld
cable
extension
of
ade
quate
size
and
capacity
to
reach
power
source.
If
cable
extension
is
used,
securely
bolt
and
insu
late
connection
point.
2.
Route
and
connect
another
weld
cable
of
ade
quate
size
and
capacity
from
the
Negative
()
weld
output
terminal
(see
power
source
Owners
Manual)
to
workpiece.
IMPORTANT:
For
Electrode
Negative/Straight
Polarity
connections,
reverse
cable
connections
to
weld
output
terminals;
electrode
becomes
negative.
4-11.
MOTOR
START
CONTROL
(Figure
4-6)
a
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
wire
feeder
and
welding
power
source
and
disconnect
input
poweremploying
lockout/tagging
procedures
before
opening
control
box
wrapper.
Lockout/tagging
procedures
for
the
wire
feeder
consist
of
disconnecting
interconnecting
cord,
and
for
welding
power
source
consist
of
pad
locking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
Stop
engine,
and
disconnect
nega
tive
()
battery
cable
from
battery
on
welding
generators.
ELECTROSTATIC
DISCHARGE
(ESD)
can
damage
circuit
board
components.
Put
on
properly
grounded
wrist
strap
BEFORE
handling
circuit
boards.
Perform
work
only
at
a
static-safe
work
area.
The
Motor
Start
Control
potentiometer
R70,
located
on
the
motor
control
board
PCi,
provides
the
ability
to
se
lect
wire
feed
speed
acceleration
at
the
be~inning
of
wire
feed
up
to
the
rate
set
on
the
Wire
Speed
control.
The
Motor
Start
Control
is
factory
set
to
provide
required
arc
starting
characteristics
with
a
wide
range
of
welding
power
sources.
To
adjust
the
Motor
Start
Control,
proceed
as
follows:
1.
Remove
wrapper.
2.
Remove
screws
from
nameplate
and
side
panels,
and
lower
hinged
front
panel.
3.
Adjust
R70
using
a
non-conductive
screwdriver.
Rotating
the
potentiometer
clockwise
increases
the
amount
of
time
it
takes
the
motor
to
ramp
up
to
speed.
4.
Secure
hinged
front
panel
lowered
in
Step
2.
5.
Reinstall
and
secure
wrapper
removed
in
Step
1.
OM-1584
Page
14
4-12.
DIP
SWITCHES
(Figure
4-7)
It
may
be
necessary
to
change
DIP
switch
positions
if
dif
ferent
options
are
added,
or
if
different
functions
are
de
Rear
Panel
Wire
Clamp
sired.
Follow
the
procedure
in
Subsection
A
when
changing
DIP
switches.
A.
Procedure
For
Changing
DIP
Switches
To
change
switch
positions,
proceed
as
follows:
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
wire
feeder
and
welding
power
source,
and
disconnect
interconnecting
cord
from
the
welding
power
source
before
reset
ting
DIP
switches.
1.
Remove
wrapper.
2.
Locate
DIP
switches
and
remove
protective
coat
ing
if
necessary.
3.
Reposition
appropriate
DIP
switch
using
a
non-
conductive
pointed
tool,
such
as
the
edge
of
a
small
screwdriver.
4.
Reinstall
wrapper.
DIgital
Meter
Circuit
Board
PC6O
And
Digital
Meter
Functions
DIP
Switch
Ret.
SB.131
819.8
Figure
4-6.
Motor
Start
Control
On
Motor
Control
Board
PCi
Left
Side
View
Optional
Interface
Circuit
Board
PC7O
And
Remote
input/Run-in
Voltage
Sense
DIP
Switch
Tachometer
Conversion
Circuit
Board
PC5O
Motor
Board
PCi
And
Motor
Start
Control
Potentiometer
R70
4-in-i
Circuit
Board
PC3O
or
Burnback
Circuit
Board
PC1O
Digital
Voltage
Control
Circuit
Board
PC4O
Relay
Circuit
Board
PC3
Hinged
Front
Panel
Figure
4-7.
Circuit
Board
And
DIP
Switch
Locations
SC.142
110
OM-1584
Page
15
B.
DIP
Switch
Description
1.
Digital
Meter
Functions
DIP
Switch
(Optional)
(Figures
4-7
And
4-8)
The
digital
meter
function
DIP
switches
are
located
on
digital
meter
circuit
board
PC6O
(see
Figure
4-7
for
cir
cuit
board
location).
Figure
4-8
shows
correct
switch
po
sitioning
for
the
different
modes
available.
See
Section
5-11
for
description
of
a
desired
mode.
2.
Spot
Time
DIP
Switch
(Optional)
(Figure
4-7)
The
spot
time
DIP
switch
is
located
on
4-In-I
board
PC3O.
The
DIP
switch
comes
factory
set
to
operate
in
the
0
to
5
second
(LONG)
range.
If
it
is
desired
to
oper
ate
wire
feeder
in
the
0
to
2.5
second
range,
change
DIP
switch
to
the
(SHORT)
position.
See
Section
5-10
for
a
description
of
the
control
functions.
Inches/Minute
3.
Remote
Input/Run-In
DIP
Switch
(Optional)
(Fig
ures
4-7
And
4-9)
The
remote
input/run-in
DIP
switch
is
located
on
option
interface
board
P070.
The
DIP
switch
consists
of
two
switches,
1
and
2.
Both
switches
come
factory
set
in
the
ON
position.
Switch
1:
To
interface
wire
feeder
with
a
synergic
control,
place
switch
I
in
the
OFF
position.
For
standard
use
or
for
use
with
dual
schedule
or
remote
control,
place
switch
1
in
the
ON
position.
Switch
2:
For
RUN-IN
SPEED
control
with
voltage
sensing,
place
switch
2
in
the
ON
position.
For
RUN-IN
SPEED
control
without
voltage
sensing,
place
switch
2
in
the
OFF
position.
Figure
4-8.
Digital
Meter
Functions
DIP
Switch
U,
C,,
High
Speed
Motor
U
U
I
High
Speed
Motor
Meters/MInute
I~
Meters/Minute
U
I
I
I
e
Moni
br
U,
Voltat
be
in
either
position.
The
voltage
hold
function
can
be
used
in
conjunction
with
the
following
modes:
high
speed
motor,
meters/minute,
and
high
speed
motor-meters/minute.
Do
not
use
the
high
speed
motor,
or
high
speed
motor-
meters/minute
modes
unless
unit
is
equipped
with
a
high
speed
motor.
Ref.
S-0399
OM-1584
Pa9e
16
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Miller KB123143 Owner's manual

Miller
Brand
Miller
Model
KB123143
Category
Welding System
Type
Owner's manual
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