2. Industrial & lab equipment
  3. Welding System
  4. Miller
  5. KG057558

Miller KG057558, PD22 CE POWCON Owner's manual

  • Hello! I am an AI chatbot trained to assist you with the Miller KG057558 Owner's manual. I’ve already reviewed the document and can help you find the information you need or explain it in simple terms. Just ask your questions, and providing more details will help me assist you more effectively!
January
1996
Form:
OM-180
058
~i
Pow
Con
Effective
With
Serial
No.
KG057558
OPERATION
MANUAL
~
1I~
PD22
For
GMAW
And
FCAW
Welding
CE
rype
of
Input
Power
Welding
Power
Source
Type
Wire
Feed
Speed
Range
Wire
Diameter
Range
Welding
Circuit
Rating
IP
Rating
Overall
Dimensions
Weight
24
Volts
AC
Single
Phase
3.5
Amperes
50/60
Hz
Constant
Voltage
(CV)
or
Constant
Power,
DC
With
14-Pin
And
Contactor
Control
75
to
630
ipm
(1.9
To 16
mpm)
.023
To
5/64
in
(0.6
To
2
mm)
Max
Spool
Weight:
60
lb
(27
kg)
100
Volts,
500
Amperes,
100%
Duty
Cycle
P
23
Length:
22-1/2
in
(572
mm)
Width:
10-1/2
in
(267
mm)
Height:
12
in
(305
mm)
32
lb
(14.5
kg)
PowCon
incorporated
8123
Miralani
Drive,
San
Diego,
CA
92126
(619)
621-6300
FAX
(619)
621-6301
Declaration
of
Conformity
for
European
Community
(CE)
Products
N
OTE
~
This
information
is
provided
for
units
with
CE
certification
(see
rating
label
on
unit).
Manufacturers
Name:
PowCon
Incorporated
Manufacturers
Address:
8123
Miralani
Drive
San
Diego,
CA
92126
USA
Declares
that
the
product:
P
D22
con
forms
to
the
following
Directives
and
Standards:
Directives
Low
Voltage
Directive:
73/23/EEC
Electromagnetic
Compatability
(EMC)
Directive:
89/336/EEC
Machinery
Directives:
89/392/EEC,
91/368/EEC,
93/C
133/04,
93/68/EEC
Standards
Arc
Welding
Equipment
Part
I:
Welding
Power
Sources:
IEC
974-1
(April
1995
Draft
Revision)
Arc
Welding
Equipment:
Wirefeed
Systems:
IEC
974-4
(May
1995
Draft
Revision)
Degrees
of
Protection
Provided
By
Enclosures
(IP
Code):
lEG
529:1989
Insulation
Coordination
For
Equipment
With
Low-Voltage
Systems:
Part
I:
Principles,
Requirments
and
Tests:
IEC
664-1:1992
Electromagnetic
Capatibility,
(EMC):
EN
50199
European
Contact:
Mr.
Stewart
Brown,
European
Sales
Manager
PowCon
(Europe)
Springfield
House,
Water
Lane
Wilmslow,
Cheshire
8K9
5AL
United
Kingdom
Telephone:
44
(0)
1625525556
Fax:
44
(0)
1625537553
dec_coni
7/95
SECTION
1
-
SAFETY
PRECAUTIONS
FOR
ARC
WELDING
OM-1
80058
1/96
sat
ety_somi
4/95
1-1.
Symbol
Usage
4A
Means
Warning!
Watch
Out!
There
are
possible
hazards
with
this
A
Marks
a
special
safety
message.
I
procedure!
The
possible
hazards
are
shown
in
the
adjoining
symbols.
~
Means
NOTE;
not
safety
related.
I
~
This
group
of
symbols
means
Warning!
Watch
Out!
possible
ELECTRIC
SHOCK,
MOVING
PARTS,
and
HOT
PARTS
hazards.
Consult
symbols
and
related
instructions
below
for
necessary
I
actions
to
avoid
the
hazards.
1-2.
Arc
Welding
Hazards
a
WARNING
The
symbols
shown
below
are
used
throughout
this
manual
to
call
attention
to
and
identify
possible
hazards.
When
you
see
the
symbol,
watch
out,
and
follow
the
related
instructions
to
avoid
the
hazard.
The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
found
in
the
Safety
Standards
listed
in
Section
1-4.
Read
and
follow
all
Safety
Standards.
Only
qualified
persons
should
install,
operate,
maintain,
and
repair
this
unit.
During
operation,
keep
everybody,
especially.children,
away.
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.
1.
Do
not
touch
live
electrical
parts.
2.
Wear
dry,
hole-free
insulating
gloves
and
body
protection.
3.
Insulate
yourself
from
work
and
ground
using
dry
insulating
mats
or
covers
big
enough
to
prevent
any
physical
contact
with
the
work
or
ground.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
Lockout/tagout
input
power
according
to
OSHA
29
CFR
1910.147
(see
Safety
Standards).
5.
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual and
national,
state,
and
local
codes.
6.
Always
verify
the
supply
ground
check
and
be
sure
that
input
now~r
nord
orotind
wira
is
~~
~
to
rirotinri
terminal
in
disconnect
box
or
that
cord
plug
is
connected
to
a
properly
grounded
receptacle
outlet.
7.
When
making
input
connections,
attach
proper
grounding
conductor
first
double-check
connections.
8.
Frequently
inspect
input
power
cord
for
damage
or
bare
wiring
replace
cord
immediately
if
damaged
bare
wiring
can
kill.
9.
Turn
oft
all
equipment
when
not
in
use.
10.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
11.
Do
not
drape
cables
over
your
body.
12.
If
earth
grounding
of
the
workpiece
is
required,
ground
it
directly
with
a
separate
cable
do
not
use
work
clamp
or
work
cable.
13.
Do
not
touch
electrode
if
you
are
in
contact
with
the
work,
ground,
or
another
electrode
from
a
different
machine.
14.
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
Maintain
unit
according
to
manual.
15.
Wear
a
safety
harness
if
working
above
floor
level.
16.
Keep
all
panels
and
covers
securely
in
place.
17.
Clamp
work
cable
with
good
metal-to-metal
contact
to
or
~
as
n~ar
th~
wAld
as
....
.
WI
,JIJCI
IV
uu,
,,
,cutcu
.
WUI
fl4J101,O
.
YVU,
flIQIj~C

__.
IJIfl(.#II%,QI.
ARC
RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing;
FLYING
~
SLAG
OR
SPARKS
can
injure
eyes.
Arc
rays
from
the
welding
process
produce
intense
visible
and
invisible
(ultraviolet
and
infrared)
rays
that
can
burn
eyes
and
skin.
Noise
from
some
processes
can
damage
hearing.
Chipping,
grinding,
and
welds
cooling
throw
off
pieces
of
metal
or
slag.
NOISE
1.
Use
approved
ear
plugs
or
ear
muffs
if
noise
level
is
high.
AR
2.
3.
4.
5.
C
RAYS
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
to
protect
your
face
and
eyes
when
welding
or
watching
(see
ANSI
Z49.1
and
Z87.
1
listed
in
Safety
Standards).
Wear
approved
safety
glasses
with
side
shields.
Use
protective
screens
or
barriers
to
protect
others
from
flash
and
glare;
warn
others
not
to
watch
the
arc.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(wool
and
leather)
and
foot
protection.
FUMES
AND
GASES
can
be
5.
Work
in
a
confined
space
only
if
it
is
well
ventilated,
or
while
hazardous
to
your
health.
Welding
produces
fumes
and
gases.
Breathing
these
fumes
and
gases
can
be
hazardous
to
your
health.
wearing
an
air-supplied
respirator.
Always
have
a
trained
watchperson
nearby.
Welding
fumes
and
gases
can
displace
air
and
lower
the
oxygen
level
causing
injury
or
death.
Be
sure
the
breathing
air
is
safe.
1.
2.
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
fumes.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
6.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
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
the
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
cleaners,
and
degreasers.
containing
these
elements
can
give
off
toxic
fumes
if
welded.
OM.180058
Page
1
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.
1.
Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
slag,
open
flames,
sparks,
and
arcs.
2.
Install
cylinders
in
an
upright
position
by
securing
to
a
stationary
support
or
cylinder
rack
to
prevent
falling
or
tipping.
3.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
4.
Never
drape
a
welding
torch
over
a
gas
cylinder.
5.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
6.
Never
weld
on a
pressurized
cylinder
explosion
will
result.
7.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
8.
Turn
face
away
from
valve
outlet
when
opening
cylinder
valve.
9.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
in
use
or
connected
for
use.
10.
Read
and
follow
instructions
on
compressed
gas
cylinders,
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
1-3.
Additional
Installation,
Operation,
And
Maintenance
Hazards
FIRE
OR
EXPLOSION
can
result
from
placing
unit
on,
over,
or
near
combustible
surfaces.
1.
Do
not
locate
unit
on,
over,
or
near
combustible
surfaces.
2.
Do
not
install
unit
near
flammables.
FALLING
EQUIPMENT
can
cause
serious
personal
injury
and
equipment
damage.
1.
Use
lifting
eye
to
lift
unit
only,
NOT
running
gear~
gas
cylinders,
or
any
other
accessories.
Use
equipment
of
adequate
capacity
to
lift
unit.
If
using
lift
forks
to
move
unit,
be
sure
forks
are
long
enough
to
extend
beyond
opposite
side
of
unit.
HOT
PARTS
can cause
severe
burns.
1.
Do
not
touch
hot
parts
bare
handed.
2.
Allow
cooling
period
before
working
on
gun
or
torch.
MOVING
PARTS
can
cause
injury.
1.
Keep
away
from
moving
parts
such
as
fans.
2.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
can
affect
pacemaker
operation.
1.
Pacemaker
wearers
keep
away.
2.
Wearers
should
consult
their
doctor before
going
near
arc
welding,
gouging,
or
spot
welding
operations.
MOVING
PARTS
can
cause
injury.
1.
Keep
away
trom
moving
parts.
2.
Keep
away
from
pinch
points
such
as
drive
rolls.
FLYING
PIECES
OF
METAL
or
DIRT
can
injure
eyes.
1.
Wear
safety
glasses
with
side
shields
or
face
shield.
WELDING
WIRE
can
cause
puncture
wounds.
1.
Do
not
press
gun
trigger
until
instructed
to
do
so.
2.
Do
not
point
gun
toward
any
part
of
the
body,
other
people,
or
any
metal
when
threading
welding
wire.
WELDING
can
cause
fire
or
explosion.
Welding
on
closed
containers,
such
as
tanks,
drums,
or
pipes,
can
cause
them
to
blow
up.
Sparks
can
fly
off
from
the
welding
arc.
The
flying
sparks,
hot
workpiece,
and
hot
equipment
can
cause
fires
and
burns.
Accidental
contact
of
electrode
to
metal
objects
can
cause
sparks,
explosion,
overheating,
or
fire.
Check
and
be
sure
the
area
is
safe
before
doing
any
welding.
1.
Protect
yourself
and
others
from
flying
sparks
and
hot
metal.
2.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
3.
Remove
all
flammables
within
35
ft
(10.7
m)
of
the
welding
arc.
If
this
is
not
possible,
tightly
cover
them
with
approved
covers.
4.
Be
alert
that
welding
sparks
and
hot
materials
from
welding
can
easily
go
through
small
cracks
and
openings
to
adjacent
areas.
5.
Watch
for
tire,
and
keep
a
tire
extinguisher
nearby.
6.
Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side.
7.
Do
not
weld
on
closed
containers
such
as
tanks,
drums,
or
pipes,
unless
they
are
properly
prepared
according
to
AWS
F4.
1
(see
Safety
Standards).
8.
Connect
work
cable
to
the
work
as
close
to
the
welding
area
as
practical
to
prevent
welding
current
from
traveling
long,
possibly
unknown
paths
and
causing
electric
shock
and
fire
hazards.
9.
Do
not
use
welder
to
thaw
frozen
pipes.
10.
Remove
stick
electrode
from
holder
or
cut
off
welding
wire
at
contact
tip
when
not
in
use.
11.
Wear
oil-free
protective
garments
such
as
leather
gloves,
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
12.
Remove
any
combustibles,
such
as
a
butane
lighter
or
matches,
from
your
person
before
doing
any
welding.
4
~QHF)JJ,
HIGH-FREQUENCY
RADIATION
can
interfere
with
radio
navigation,
safety
services,
computers,
and
communications
equipment.
1.
Have
only
qualified
persons
familiar
with
electronic
equipment
perform
this
installation.
2.
The
user
is
responsible
for
having
a
qualified
electrician
promptly
correct
any
interference
problem
resulting
from
the
installation.
3.
If
notified
by
the
FCC
about
interference,
stop
using
the
equipment
at
once.
4.
Have
the
installation
regularly
checked
and
maintained.
5.
Keep
high-frequency
source
doors
and
panels
tightly
shut,
keep
spark
gaps
at
correct
setting,
and
use
grounding
and
shielding
to
minimize
the
possibility
of
interference.
OM-180058
Page
2
OVERUSE
can
cause
OVERHEATED
EQUIPMENT.
1.
Allow
cooling
period.
2.
Reduce
current
or
reduce
duty
cycle
before
starting
to
weld
again.
3.
Follow
rated
duty
cycle.
STATIC
ELECTRICITY
can
damage
par
on
circuit
boards.
1.
Put
on
grounded
wrist
strap
BEFORE
handling
boards
or
parts.
2.
Use
proper
static-proof
bags
and
boxes
to
move,
or
ship
PC
boards.
SIGNIFICANT
DC
VOLTAGE
exists
after
removal
of
input
power
on
inverters.
1.
Turn
Off
inverter,
disconnect
input
power,
and
discharge
input
capacitors
according
to
instructions
in
Maintenance
Section
before
~g
any
parts.
SHIELDING
GAS
can
harm
ng
gas
supply
when
not
in
use.
1-4.
Principal
Safety
Standards
1-5.
EMF
Information
Safety
in
Welding
and
Cutting,
ANSI
Standard
Z49.1,
from
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami
FL
33126
Safety
and
Health
Standards,
OSHA
29
CFR
1910,
from
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
Recommended
Safe
Practices
for
the
Preparation
for
Welding
and
Cutting
of
Containers
That
Have
Held
Hazardous
Substances,
American
Welding
Society
Standard
AWS
F4.1,
from
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126
National
Electrical
Code,
NFPA
Standard
70,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
Highway,
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
Boulevard,
Rexdale,
Ontario,
Canada
M9W
I
R3.
Safe
Practices
For
Occupation
And
Educational
Eye
And
Face
Protection,
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,
Batterymarch
Park,
Quincy,
MA
02269.
To
reduce
magnetic
fields
in
the
workplace,
use
the
following
procedures:
Considerations
About
Welding
And
The
Effects
Of
Low
Frequency
Electric
And
Magnetic
Fields
The
following
is
a
quotation
from
the
General
Conclusions
Section
of
the
U.S.
Congress,
Office
of
Technology
Assessment,
Biological
Effects
of
Power
Frequency
Electric
&
Magnetic
Fields
Background
Paper,
OTA-BP-E-53
(Washington,
DC:
U.S.
Government
Printing
Office,
May
1989):.
. .
there
is
now
a
very
large
volume
of
scientific
findings
based
on
experiments
at
the
cellular
level
and
from
studies
with
animals
and
people
which
clearly
establish
that
low
frequency
magnetic
fields
can
interact
with,
and
produce
changes
in,
biological
systems.
While
most
of
this
work
is
of
very
high
quality,
the
results
are
complex.
Current
scientific
understanding
does
not
yet
allow
us
to
interpret
the
evidence
in
a
single
coherent
framework.
Even
more
frustrating,
it
does
not
yet
allow
us
to
draw
definite
conclusions
about
questions
of
possible
risk
or
to
offer
clear
science-based
advice
on
strategies
to
minimize
or
avoid
potential
risks.
1.
Keep
cables
close
together
by
twisting
or
taping
them.
2.
Arrange
cables
to
one
side
and
away
from
the
operator.
3.
Do
not
coil
or
drape
cables
around
the
body.
4.
Keep
welding
power
source
and
cables
as
far
away
as
practical.
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
possible.
About
Pacemakers:
The
above
procedures
are
also
recommended
for
pacemaker
wearers.
Consult
your
doctor
for
complete
information.
OM-1
80058
Page
3
2-2.
Symbols
And
Definitions
NOTE
~
Some
symbols
are
found
only
on
CE
products.
SIN:
KG111111
115
396
Model
P022
U1=24
V\.~
1\.
50/60
Hz
11=
3.5
A
IP
23
U2=
100
V
12=
500
A
X
100
%
MILLER
ELECTRIC
MEG.
CO.,
APPLETON,
WI
USA
ST-us
794-A
OM-180058
Page
5
3-1.
Site
Selection
SECTION
3-INSTALLATION
Process
Gun
GMAW
Hard
or
Corded
Wires
M25
Or
M40
FCAW
Self-Shielding
Wires
GA-4OGL
3-2.
Gun
Recommendation
Table
OM-180058
Page
6
3-3.
Equipment
Connection
Diagrams
REMOTE
14
~j~*
Pin
Information
A
24
volts
ac
with
respect
to
socket
G.
B
Contact
closure
to
A
completes
24
volts
ac
contactor
control
circuit.
G
Circuit
common.
C
+10
volts
dc
output
to
remote
control
with
respect
to
socket
D.
D
Remote
control
circuit
common.
E
0
to
+10
volts
dc
input
command
signal
from
remote
control
with
respect
to
socket
D.
*The
remaining
pins
are
not
used.
3-4.
Connecting
14-Pin
Plug,
Shielding
Gas
And
Optional
Volt
Sense
Lead
Tools
Needed:
z~
5/8,11/l6in
1
Gas
Hose
With
5/8-18
Right-
hand
Thread
Fittings
(Cus
tomer
Supplied)
2
14
Pin
Plug
PLG2
Use
plug
to
make
connection
to
welding
power
source.
3
Optional
Volt
Sense
Lead
(Part
Of
Meter
Option)
Connect
to
work.
ST-156
272-B
3-5.
14-Pin
Plug
Information
OM-180058
Page
7
3-6.
Connecting
Welding
Gun
And
Weld
Cable
1
Gun
Securing
Knob
2
Gun
Block
3
Gun
Outlet
Wire
Guide
Loosen
knob,
insert
gun
into
block.
Position
outlet
wire
guide
as
dose
as
possible
to
drive
rolls
without
touching.
Tighten
knob.
4
Gun
Trigger
Plug
5
Gun
Trigger
Receptacle
6
Weld
Cable
Terminal
7
Weld
Cable
From
Welding
Power
Source
Tools
Needed:
~
5/8,9/l6in
3-7.
Setting
Time
Range
For
Optional
Spot
Time
Control
ST-155
246-B
OM-180058
Page
8
3-8.
Installing
And
Aligning
Wire
Guide
And
Drive
Roll
Tools
Needed:
3/16
in
r
3/8in
Install
and
secure
wire
guide.
Install
drive
rolls
and
turn
drive
roll
nut
one
click.
Only
drive
gear
is
adjustable.
Turn
adjustment
screw
in
or
out
until
groove
in
drive
roll
lines
up
with
wire
guide
as
shown.
Remove
drive
rolls,
and
clean
grooves
using
a
wire
brush.
OM-180058
Page
9
If
necessary,
move
hub
on
support
for
use
of
different
size
wire
spool.
Install
wire
spool.
Adjust
tension
nut
so
wire
is
taut
when
wire
feed
stops.
Lay
gun
cable
out
straight.
Open
pressure
assembly,
hold
wire
tightly,
and
cut
off
end.
Push
wire
through
guides
into
gun.
Close
and
tighten
pressure
assem
bly.
Press
Jog
button
until
wire
comes
out
gun.
To
adjust
drive
roll
pressure,
press
gun
trigger
to
feed
wire
against
wood
surface.
Tighten
knob
so
wire
does
not
slip.
Cut
off
wire.
Close
door.
3-9.
Installing
And
Threading
Welding
Wire
3
Tighten
DI
Ill
Tools
Needed:
r
15/l6in
Ref.
ST-155
244-C
/
S-0627-A
OM-180058
Page
10
4-1.
Front
Panel
Controls
SECTION
4
OPERATION
4-2.
Optional
Side
Panel
Controls
1
Optional
Voltage/Wire
Speed
Meter
II
2
0
3
Li
I
/
/
6
5
4
2
Optional
Voltage/Wire
Speed
Switch
Use
to
choose
volts
or
wire
feed
speed
display.
3
Optional
Remote
Voltage
Control
Use
to
set
welding
power
source
voltage
at
the
wire
feeder.
Num
bers
are
for
reference
only.
4
Wire
Speed
Control
5
Purge
Switch
Use
to
momentarily
energize
gas
valve
to
purge
air
from
gun
or
ad
just
gas
regulator.
6
Power
Switch
7
Jog
Switch
Use
to
momentarily
feed
welding
wire
at
speed
set
on
Wire
Speed
control
without
energizing
welding
circuit
or
shielding
gas
valve.
Li
ST-155
245
2
1
Pref
low
Control
Control
sets
time
gas
flows
before
welding
wire
is
energized.
2
Postf
low
Control
Control
sets
time
gas
flows
after
completion
of
bumback.
3
Bumback
Control
Control
adjusts
time
welding
wire
is
energized
after
wire
feed
stops.
4
Spot
Continuous
Switch
Switch
selects
an
untimed
continu
ous
weld
or
a
timed
spot
weld.
5
Spot
Time
Control
Factory
set
for
0.25
to
5
seconds
of
spot
time.
If
0.12
to
2.5
seconds
is
desired,
see
Section
3-7.
Close
side
door.
ST-155
243-C
OM-180058
Page
11
SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
5-1.
Routine
Maintenance
5-2.
Overload
Protection
2
A
Turn
Off
wire
feeder
and
welding
power
source.
Stop
engine
on
welding
generator.
1
Fuse
Fl
Fl
protects
wire
feeder
from
over
load.
Replace
Fl
if
open.
2
Circuit
Breaker
CB1
CB1
protects
motor
from
overload.
Correct
problem
and
manually
re
set
breaker.
Close
and
latch
door.
ST-155
243-B
I
Ref.
ST-800
185-A
OM-1
80058
Page
12
5-3.
Troubleshooting
~*HdH
Trouble
Remedy
Wire
does
not
feed,
unit
completely
in-
operative.
Turn
Power
switch
On.
~
Check
fuse
Fl
and
replace
if
necessary
(see
Section
5-2).
Check
14pin
plug
PLG2
connections.
Check
input
power.
Wire
does
not
feed.
~
Check
circuit
breaker
CB1
and
fuse
Fl.
(see
Section
5-2)
Check
gun
trigger
connection
at
wire
feeder.
Check
gun
trigger
leads
and
trigger
switch.
See
gun
Own
ers
Manual.
Have
Factory
Authorized
Service
Agent
check
drive
motor
and
control
board
PCi.
Wire
feeds
erratically.
Readjust
hub
tension
and
drive
roll
pressure
(see
Section
3-9).
Use
correct
size
drive
roll
(see
Parts
Listing)
Clean
or
replace
dirty
or
worn
drive
roll
(see
Section
3-8).
Remove
weld
spatter
around
nozzle
opening.
Replace
contact
tube
or
liner.
See
gun
Owners
Manual.
Have
Factory
Authorized
Service
Agent
check
drive
motor
and
control
board
PCi.
Wire
feeds
when
Jog
switch
is
pressed
but
not
when
gun
trigger
is
pressed.
Check
gun
trigger
connection
at
wire
feeder.
Check
gun
trigger
leads
and
trigger
switch.
See
gun
Own-
ers
Manual.
Wire
feeds
as
soon
as
power
is
applied.
Check
gun
trigger.
See
gun
Owners
Manual.
Wire
does
not
feed
until
trigger
is
pressed
but
continues
to
feed
after
trig
ger
is
released.
Check
for
short
between
gun
trigger
leads
and
weld
cable.
Repair
or
replace
gun
trigger
leads.
Gas
valve
rattles
loudly
and
wire
feeds
slowly
or
erratically.
Check
for
short
between
gun
trigger
leads
and
weld
cable.
Repair
or
replace
gun
trigger
leads.
Gas
does
not
flow;
wire
feeds.
Check
gas
valve
and
flowmeter.
OM-180058
Page
13
0
01
-.1
0
(U
ID
JJ~R
F~R
p~F1~0wmE1FWw
~PTQ~
A
~1___~~
~
~
010
~3
b
000
7
35
38
4
38
5
PC3-0
I
0
1071
1EJ~24AL
I
PC3-A
>
I
I
851
1C5583ft01
PC1-~
>>
~-
A
87
I
PC1-E
>>
~
>-.---
~
0
I
i
~0~r
I
PC1-9
>>
-
~-
F
~
I
PCi-A
>)
82
<~
I
I
PC2-A>
I
I
PC2-D>
P~EFLOW/PO5TFLOW
I
I
PC2~
>
F
A
I
_
L
I
I
I
PC3-B>
I
I
~OT/3J~8AD<
PC1-f
>
I
R.G1
I
~<0
I
I
_____
L
I
<PCi-A
(rpiot~t)
I
wvt
Jj~s
NO
0~4CT
<PCi-C
sP0T4~A0(
PCi-B
~ft0W
<PCi-C
<PCi-f~
0c2
I
I
>
-~-<
PC3-A
{
>
1C3-c
PC3-H
PC4-B
PC4-A
PC3-C
PC
~0T/~RaA~
~AJ~
(~TQ~AL)
PCI
ICTIP
cO~TWI.
B385
R2~C1
11
(0
C
-
CD
P
-I
C)
-
C)
C
C
(0
-I
3
1
0
m
a.
CD
I
C)
9
(11
F)
-J
PCI-C
PC1-O
PCI-A
PC2-A
PC2-B
PC2-D
PC2-C
>~
7,
-
>>~-
-~
-
>>-
~
C
A
>>
~
<a
>>
~75
~TND.8
6
>>-_~---O~5i
PC4-E
PC4-O
PC4-G
w~
II
I
I
~
~thc~6~~i
I
V
V
V
V
V~VVV~V__
________
-
-
~
I
_______________________________________________
L
_____
I__~!~~~<
I
85
AAAEA,sAAAAA
I
I
~
901I~RaAzx
~
~
~thC~r11416
PC3fp~013
prFLGW/POSTFUIW
&
9OT/~J~AcI<
IPTD4S
-(
~
TO
~CTC~
82
84
<~
83
Ii
B
~PflJ1AL
I
I
<<
I
I
~
I
I
s&
LE1%~
~
>
~
I
L:
-(C
I
Fig
7-2
SECTION
7-
PARTS
LIST
Figure
7-1.
Main
Assembly
13
OPTIONAL
+When
ordering
a
component
originally
displaying
a
precautionary
label,
the
label
should
also
be
ordered.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
ST-124
942-C
Item
Part
No.
No.
Description
Quantity
Figure
7-1.
Main
Assembly
1
Fig7-2
2
....
072094
3
....
058427
4....
141700
5
....
605941
6
....
154098
7
....
010233
8....
057971
9....
010191
10....
058628
...11....
058428
12....
135205
13....
134306
14....
137461
108008
168103
+168
104
166594
124900
CONTROL
BOX
1
HUB
&
SPINDLE
ASSEMBLY,
(consisting
of)
1
RING,
retaining
spool
1
RING,
retaining
.625
shaft
x
.O5Othk
1
WASHER,
flat
stl
.640
ID
x
1.000
OD
x
l4ga
thk
1
SHAFT,
spool
support
1
SPRING,
cprsn
.970
OD
x
.120
wire
x
1.250
1
WASHER,
flat
stl
keyed
1.SOOdia
x
.l25thk
1
WASHER,
fbr
.656
ID
x
1.500
00
x
.l25thk
2
WASHER,
brake
stl
2
HUB,
spool
1
NUT,
stl
slflkg
hex
reg
.625-11
w/nylon
insert
1
FOOT,
rbr
1
.25Odia
x
1.375
high
4
BASE
1
REEL,
wire
(consisting
of)
1
NUT,
spanner
retaining
1
RETAINER,
spool
support
(consisting
of)
1
LABEL,
caution
falling
wire
reel
can
cause
damage
1
SUPPORT,
reel
support
1
2
A
14
OM-180058
Page
15
Figure
7-2.
Control
Box
ST-134
909
Co
CO
/
CO
0
0)
to
-
01
(\1
to
Cv,
to
Co
01
CO
to
to
U,
OM-180058
Page
16
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
/