Miller KF923720 Owner's manual

cover 5/94 − ST-143 327-A PRINTED IN USA

Read and follow these instructions and all

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.

Give this manual to the operator.

For help, call your distributor

or: MILLER Electric Mfg. Co., P.O. Box 1079,

Appleton, WI 54912 414-734-9821

OWNER’S

MANUAL

November 1995 Form: OM-1582J

Effective With Serial No. KF923720

24 Volts AC, 10 Amperes, 50/60 Hertz Wire Feeder

For Use With CV/DC Welding Power Source With Contactor

For GMAW And FCAW Welding

Rated At 100 Volts, 750 Amperes, 100% Duty Cycle

Circuit Breaker CB1 Protects Unit From Overload

Wire Feed Speed Range: 50 To 780 ipm (1.3 To 20 mpm)

Wire Diameter Range: .023 To 1/8 in (0.6 To 3.2 mm)

For Options And Accessories, See Rear Cover

D-64 Wire Feeder

miller_war1 6/95

MILLER’S TRUE BLUE® LIMITED WARRANTY

Effective January 1, 1995

(Equipment with a serial number preface of “KD” or newer)

This limited 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 below, MILLER Electric

Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new

MILLER equipment sold after the effective date of this limited warranty is free of de-

fects in material and workmanship at the time it is shipped by MILLER. THIS WAR-

RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR

IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT-

NESS.

Within the warranty periods listed below, MILLER will repair or replace any war-

ranted parts or components that fail due to such defects in material or workmanship.

MILLER must be notified in writing within thirty (30) days of such defect or failure, at

which time MILLER will provide instructions on the warranty claim procedures to be

followed.

MILLER shall honor warranty claims on warranted equipment listed below in the

event of such a failure within the warranty time periods. All warranty time periods

start on the date that the equipment was delivered to the original retail purchaser, or

one year after the equipment is sent to a North American distributor or eighteen

months after the equipment is sent to an International distributor.

1. 5 Years Parts − 3 Years Labor

* Original main power rectifiers

* Inverters (input and output rectifiers only)

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources

* Plasma Arc Cutting Power Sources

* Semi-Automatic and Automatic Wire Feeders

* Inverter Power Supplies

* Intellitig

* Robots

3. 2 Years — Parts and Labor

* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the engine manufacturer.)

* Air Compressors

4. 1 Year — Parts and Labor

* Motor Driven Guns

* Process Controllers

* IHPS Power Sources

* Water Coolant Systems

* HF Units

* Grids

* Spot Welders

* Load Banks

* SDX Transformers

* Running Gear/Trailers

* Plasma Cutting Torches (except APT, ZIPCUT & PLAZCUT Models)

* Tecumseh Engines

* Deutz Engines (outside North America)

* Field Options

(NOTE: Field options are covered under True Blue® for the remaining

warranty period of the product they are installed in, or for a minimum of

one year — whichever is greater.)

5. 6 Months — Batteries

6. 90 Days — Parts and Labor

* MIG Guns/TIG Torches

* APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches

* Remote Controls

* Accessory Kits

* Replacement Parts

MILLER’S True Blue® 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, cutting nozzles, contactors

and relays or parts that fail due to normal wear.

3. Equipment that has been modified 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 for operation

outside of the specifications for the equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER-

CIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN

THE USE AND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the exclusive 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 cost of repair or replace-

ment at an 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 expense. MILLER’S option of repair or replacement

will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a MILLER authorized ser-

vice facility 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 of how long an implied warranty

lasts, or the exclusion of incidental, indirect, special or consequential damages, so

the above limitation or exclusion may not apply to you. This warranty provides spe-

cific legal rights, and other rights may be available, but may vary from state to state.

In Canada, legislation in some provinces provides for certain additional warranties

or remedies other than as stated herein, and to the extent that they may not be

waived, the limitations and exclusions set out above may not apply. This Limited

Warranty provides specific legal rights, and other rights may be available, but may

vary from province to province.

WHO DO I CONTACT?

For help,

H contact your distributor

For additional information, such as

Technical Manuals (Service And Parts)

Engine Manuals

Circuit And Wiring Diagrams

Process Handbooks

User’s Guides

Distributor Directories

H contact your distributor

To file a claim for loss or damage during

shipment,

H contact the delivering carrier

For assistance in filing or settling claims,

H contact your distributor and/or equipment

manufacturer’s Transportation

Department

Miller Electric Mfg. Co.

H CALL:

414-735-4505

H FAX:

800-637-2348 (in USA), or

414-735-4136 (outside USA)

H WRITE:

Miller Electric Mfg. Co.

P.O. Box 1079

Appleton, WI 54912 USA

Always provide Model Name and Serial or Style Number

OM-1582J − 11/95

EMF INFORMATION

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.”

To reduce magnetic fields in the workplace, use the following

procedures:

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 among those also normally

recommended for pacemaker wearers. Consult your doctor for

complete information.

Considerations About Welding And The Effects Of Low Frequency Electric And

Magnetic Fields

NOTE

mod10.1 4/93

TABLE OF CONTENTS

SECTION 1 − SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − INSTALLATION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Site Selection 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Equipment Connection Diagrams 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Wire Guide And Drive Roll Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Welding Gun Connections 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Motor Start Control 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Dip Switches Options 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Changing Optional Digital Voltage Control For Use With A

MILLER Inverter-Type Power Source 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. 14-Pin Plug Connection 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Shielding Gas And Weld Cable Connections 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10. Voltage Sensing Lead (Optional) 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11. Welding Wire Installation 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-12. Threading Welding Wire With Drive Assembly Horizontal 17. . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-13. Rotating The Drive Assembly And Threading Welding Wire 19. . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − OPERATION 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − MAINTENANCE & TROUBLESHOOTING 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Routine Maintenance 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Replacing The Hub Assembly 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Overload Protection 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Troubleshooting 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − ELECTRICAL DIAGRAMS 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − PARTS LIST 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7-1. Main Assembly 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7-2. Control Box 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7-3. Control Panel 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7-4. Panel, Front w/Components 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 7-1. Wire Drive Assembly Kits 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7-5. Drive Assembly, Wire (4 Drive Roll Assembly Illustrated) 44. . . . . . . . . . . . . . . . . . . . . . . . .

Table 7-2. Drive Roll And Wire Guide Kits 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-1582 Page 1

SECTION 1 − SAFETY INFORMATION

mod1.1 2/93

Read all safety messages throughout this manual.

Obey all safety messages to avoid injury.

Learn the meaning of WARNING and CAUTION.

1 Safety Alert Symbol

2 Signal Word

WARNING means possible death

or serious injury can happen.

CAUTION means possible minor

injury or equipment damage can

happen.

3 Statement Of Hazard And

Result

4 Safety Instructions To Avoid

Hazard

5 Hazard Symbol (If Available)

6 Safety Banner

Read safety blocks for each sym-

bol shown.

7 NOTE

Special instructions for best oper-

ation − not related to safety.

2

NOTE

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Disconnect input power before

installing or servicing.

WARNING

READ SAFETY BLOCKS at start of

Section 3-1 before proceeding.

WARNING

5

4

6

7

1 2

CAUTION

MOVING PARTS can injure.

• Keep away from moving parts.

• Keep all panels and covers closed

when operating.

3

Turn Off switch when using high frequency.

Figure 1-1. Safety Information

SECTION 2 − SPECIFICATIONS

Table 2-1. Wire Feeder

Specification Description

Type Of Input Power From Welding

Power Source

Single-Phase 24 Volts AC, 10 Amperes, 50/60 Hertz (If 115 Volts AC Is The Only Power Available,

Use Optional Power Supply Adapter Model PSA-2.)

Maximum Weld Circuit Rating 100 Volts, 750 Amperes, 100% Duty Cycle

Welding Power Source Type Constant Voltage (CV) DC, With Contactor

Wire Feed Speed Range Standard Motor: 50 To 780 ipm (1.3 To 20 mpm)

High Speed Motor: 90 To 1400 ipm (2.3 To 35.6 mpm)

Welding Processes Gas Metal Arc (GMAW), Flux Cored Arc Welding (FCAW)

Input Power Cord 10 ft (3.1 m)

Overall Dimensions Length: 32 in (812 mm); Width: 18 in (457 mm); Height: 14 in (356 mm)

Weight Shipping: 82 lb (37.2 kg); Net: 74 lb (33.6 kg) Add 4 lb (1.8 kg) For 4-Drive Roll Models

OM-1582 Page 2

SECTION 3 − INSTALLATION

3-1. Site Selection

WARNING: FALLING WIRE FEEDER can

cause serious personal injury and

equipment damage.

• Do not put wire feeder where it will tip or fall.

• Put all four rubber feet solidly on a flat surface.

CYLINDERS can explode if damaged.

• Keep cylinders away from welding and other

electrical circuits.

• Never touch cylinder with welding electrode.

• Always secure cylinder to running gear, wall, or

other stationary support.

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

The welding wire, drive rolls, drive assembly, and all

metal parts touching the welding wire are electrically

live when welding or feeding wire using gun trigger.

WARNING

wfwarn7.1* 9/91

ST−152 586 / ST-152 566

1 Wire Feeder

2 Lifting Eye

3 Rubber Feet

4 Installation Slots

When installing wire feeder over a

lifting eye on a welding power

source, select the slot that will al-

low all four rubber feet on base of

feeder to sit securely on top of

welding power source.

5 Wire Spool/Reel

6 Gas Cylinder (Customer

Supplied)

7 Welding Power Source

Position wire feeder on welding

power source so that welding wire,

or wire spool/reel, does not touch

gas cylinder.

1

Do not put feeder where

welding wire hits cylinder.

5

2

4

7

6

3

Figure 3-1. Installing Wire Feeder Over A Lifting Eye

OM-1582 Page 3

3-2. Equipment Connection Diagrams

WARNING

CYLINDERS can explode if damaged.

• Keep cylinders away from welding and other

electrical circuits.

• Never touch cylinder with welding electrode.

• Always secure cylinder to running gear, wall, or

other stationary support.

HOT SURFACES can burn skin.

• Allow gun to cool before touching.

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Turn Off wire feeder and welding power source, and

disconnect input power before making

connections. Stop engine on welding generator.

The welding wire, drive rolls, drive assembly, and all

metal parts touching the welding wire are electrically

live when welding or feeding wire using gun trigger.

Have only qualified persons install this unit.

wfwarn9.1 2/93

If using wire feeder with an engine-driven power source, place engine control

switch in Run (high speed) position. Some wire feeders may work with switch in

Run/Idle position.

NOTE

ST-152 616

1 CV Or CC/CV Welding Power

Source Supplying 24 VAC To

Feeder

2 14-Pin Plug PLG10 And In-

terconnecting Cord

3 Positive (+) Weld Cable

4 Negative (−) Weld Cable

5 Workpiece

6 Voltage Sensing Lead

7 Gun

8 Wire Feeder

9 “Y” Adapter Gas Hose

10 Gas Cylinder

1

2

3

4

5

6

7

8

9

10

Figure 3-2. Connections With A Constant Voltage (CV) Or Constant Voltage/Constant Current (CV/CC)

Welding Power Source Having A 14-Socket Receptacle And 24 VAC Supply

OM-1582 Page 4

ST-152 320

1 CV Welding Power Source

2 PSA-2 Interconnecting Cord

(Supplied With PSA-2 Con-

trol)

3 Positive (+) Weld Cable

4 Negative (−) Weld Cable

5 Workpiece

6 Voltage Sensing Lead

7 Gun

8 Wire Feeder

9 14-Pin Plug PLG10 And In-

terconnecting Cord.

10 PSA-2 Control (Optional)

11 “Y” Adapter Gas Hose

12 Gas Cylinder

1

2

3

4

5

6

7

8

9

10

11

12

Figure 3-3. Connections With A Constant Voltage (CV) Welding Power Source

Having Only 115 VAC Available

OM-1582 Page 5

3-3. Wire Guide And Drive Roll Installation

WARNING

CYLINDERS can explode if damaged.

• Keep cylinders away from welding and other

electrical circuits.

• Never touch cylinder with welding electrode.

• Always secure cylinder to running gear, wall, or

other stationary support.

HOT SURFACES can burn skin.

• Allow gun to cool before touching.

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Turn Off wire feeder and welding power source, and

disconnect input power before making

connections. Stop engine on welding generator.

The welding wire, drive rolls, drive assembly, and all

metal parts touching the welding wire are electrically

live when welding or feeding wire using gun trigger.

Have only qualified persons install this unit.

wfwarn9.1 2/93

A. Wire Guide Installation

ST-153 125-B / ST-137 377-D

When changing wire size or type,

check guide size (see Table 7-2).

1 Drive Rolls

Remove drive rolls before install-

ing wire guides (see Figure 3-5).

2 Wire Guide Securing Screws

Loosen wire guide screws.

3 Antiwear Guide

4 Inlet Wire Guide

Install inlet wire guide into antiwear

guide.

Install inlet guide so wire guide

screw is centered in groove in

guide.

5 Intermediate Wire Guide

Insert intermediate guide until

flange on guide rests against cast-

ing, and secure with guide screw.

Install drive rolls (see Figure 3-5).

Repeat procedure for opposite

side of wire feeder.

1

Tools Needed:

2

5

4

3

5/64 in

Figure 3-4. Wire Guide Installation

OM-1582 Page 6

B. Drive Roll Installation

When changing wire size or type,

check drive roll size (see

Table 7-2).

1 Spring Shaft Carrier

Close spring shaft carrier.

2 Drive Roll Nut

3 Drive Roll Carrier

Turn nut one click until lobes of nut

line up with lobes of drive roll carri-

er.

Open spring shaft carrier.

4 Drive Roll

Slide drive roll onto drive roll carri-

er. Turn nut one click.

Repeat procedure for top drive roll.

5 Drive Assembly Cover

Close cover.

Repeat procedure for opposite

side of wire feeder.

ST-137 377-D

1

5

4

23

Figure 3-5. Drive Roll Installation

3-4. Welding Gun Connections

WARNING

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Turn Off wire feeder and welding power source, and disconnect input power before inspecting or installing. Stop engine on

welding generator.

wfwarn1.1* 2/93

Ref. ST-148 702 / Ref. ST-152 466

1 Gun Securing Knob

2 Gun Block

3 Gun End

Loosen gun securing knob. Insert

end into block. Position as close as

possible to drive rolls without touch-

ing. Tighten knob.

4 Gun Trigger Plug

Insert plug into receptacle, and tight-

en threaded collar.

5 Gun Trigger Receptacle

6 Drive Assembly Cover

Close cover.

Repeat procedure for welding gun

on opposite side of wire feeder.

5

1

2

3

4

6

Figure 3-6. Gun And Trigger Lead Connections

OM-1582 Page 7

3-5. Motor Start Control

WARNING

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Turn Off wire feeder and welding power source, and

disconnect input power before inspecting or

installing. Stop engine on welding generator.

STATIC ELECTRICITY can damage parts

on circuit boards.

• Put on grounded wrist strap BEFORE handling

boards or parts.

wfwarn1.1* 2/93

Ref. ST-143 259-E / Ref. SB-146 862-D

To change wire feed starting

speed, proceed as follows:

Turn Off wire feeder and welding

power source.

Remove wrapper.

1 Front Panel

Front panel shown open for illus-

tration purposes.

2 Left Side Inner Control Panel

It may be necessary to remove

panel to access Motor Start Con-

trol. Remove panel only as far as

required if options are attached to

panel.

3 Motor Board PC1

4 Motor Start Control Poten-

tiometer R70

Turn potentiometer clockwise to in-

crease time it takes the motor to

ramp up to speed. Remove protec-

tive white rubber cap before mak-

ing adjustment. Adjust potentiome-

ter R70 using a small nonconduc-

tive screwdriver.

Reinstall left side inner control pan-

el if it was removed.

Reinstall wrapper.

1

Tools Needed:

1/4 in

2

4

3

Figure 3-7. Motor Start Control On Motor Control Board PC1

OM-1582 Page 8

3-6. Dip Switches Options

WARNING

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Turn Off wire feeder and welding power source, and

disconnect input power before inspecting or

installing. Stop engine on welding generator.

STATIC ELECTRICITY can damage parts

on circuit boards.

• Put on grounded wrist strap BEFORE handling

boards or parts.

wfwarn1.1* 2/93

A. Spot/Time DIP Switch S1

Ref. ST-143 259-E / SA-146 866-B

Change DIP switch position if a dif-

ferent range of Spot/Time is de-

sired.

Turn Off wire feeder and welding

power source.

Remove wrapper.

1 Front Panel

Remove screw from upper left cor-

ner, and open hinged front panel if

necessary.

2 4-In-1 Board PC30

3 Spot/Time DIP Switch S1

Place switch (on either or both

PC30 boards) in desired position:

Long Time for 0-5 seconds, and

Short Time for 0-2.5 seconds (see

Figure 4-11 for control operation).

Close and secure front panel, and

reinstall wrapper.

1

Tools Needed:

1/4 in

3 2

Figure 3-8. Spot/Time DIP Switch S1

OM-1582 Page 9

B. Digital Meter Functions And Positions

Ref. ST-143 259-E / Ref. S-0389 / SA-148 666-E

The Digital Meter Board PC60 for

the Two Meter Option is equipped

with DIP switch S3. This switch is

shipped from the factory in the Off

position, and should not be

changed.

Change DIP switch positions if a

different mode of operation is de-

sired.

Turn Off wire feeder and welding

power source.

Remove the six (6) screws from

front edge of wrapper.

1 Front Panel

Front panel shown open for illus-

tration purposes.

2 Digital Meter Board PC60

3 Meter Functions DIP Switch

S2

Place switch in appropriate posi-

tion for desired mode (see

Figure 4-7 for meter operation).

Reinstall wrapper screws.

Tools Needed:

1/4 in

1

2

3

123 45

12

Or

Or Or

Standard

Motor

Inches/Minute

Standard

Motor

Meters/Minute

High Speed

Motor

Inches/Minute

High Speed

Motor

Meters/Minute

Voltage Hold Voltage Monitor

X Means switch can be in either position.

Means place switch in this position.

Figure 3-9. Digital Meter Functions DIP Switch S2

OM-1582 Page 10

C. Remote Input DIP Switch S1

Ref. S-0380 / SA-150 588-D / Ref. ST-143 259-E

Change DIP switch position if a dif-

ferent mode of operation is de-

sired.

Turn Off wire feeder and welding

power source.

Remove wrapper.

1 Front Panel

Front panel shown open for illus-

tration purposes.

2 Option Interface Board PC70

3 Remote Input DIP Switch S1

Place DIP switch S1 (on either or

both PC70 boards) in appropriate

position for desired mode.

Reinstall wrapper.

1

Tools Needed:

1/4 in

2

3

OFF

12

OFF

12

Or

Remote

Input

Standard

Dual Schedule Or

Remote Pendant

Means place switch

in this position.

Figure 3-10. Remote Input DIP Switch S1

OM-1582 Page 11

3-7. Changing Optional Digital Voltage Control For Use With A MILLER Inverter-Type

Power Source

WARNING

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Turn Off wire feeder and welding power source, and

disconnect input power before inspecting or

installing. Stop engine on welding generator.

STATIC ELECTRICITY can damage parts

on circuit boards.

• Put on grounded wrist strap BEFORE handling

boards or parts.

wfwarn1.1* 2/93

A. Electrical Connections

Ref. ST-143 259-E / SA-171 708

Turn Off wire feeder and welding

power source.

Remove the six (6) screws from

front edge of wrapper.

If optional Digital Voltage Control is

used with a MILLER inverter-type

welding power source, make the

following changes:

1 Front Panel

Remove screw from upper left cor-

ner, and open hinged front panel.

2 Digital Voltage Control Board

PC40

3 Receptacle RC42

Disconnect plug PLG42 from

RC42.

4 Receptacle RC44

Reconnect PLG42 to RC44.

5 Receptacle RC45

Disconnect jumper plug PLG61

from RC45.

6 Receptacle RC41

Disconnect plug PLG41 from

RC41.

Reconnect PLG41 to RC45.

Reconnect jumper plug PLG61 to

RC41.

7 Potentiometer R31

See Section 3-7B.

Close and secure front panel, and

reinstall wrapper screws.

1

2

3

4

6

5

Tools Needed:

1/4 in

7

Figure 3-11. Digital Voltage Control Connections

OM-1582 Page 12

B. Calibrating The Digital Voltage Meter For Use With A MILLER Inverter-Type Power Source

If wire feeder is being used with a MILLER inverter-type power source that has a

voltage range of 10 to 35 volts in the CV mode, no calibration is required.

NOTE

1. If wire feeder is equipped with Two Meter option, read voltage from the Volts meter. If wire feeder is equipped

with One Meter option (see Figure 4-7 for meter operation), place Wire Speed/Volts switch in the Volts position.

2. Rotate Schedule A or Schedule B Voltage Control, whichever is active, to the maximum position (see Figure 4-8

for control operation).

3. Turn On wire feeder and welding power source (see Figure 4-15).

4. Adjust potentiometer R31 (see Figure 3-11 for location) until wire feeder Volts meter displays a voltage equal to

the maximum voltage listed on the Voltage/Amperage control of the welding power source nameplate. Make a

sample weld (at desired preset voltage) to see if actual arc voltage displayed by the wire feeder Volts meter is

different than preset arc voltage due to cable resistance, poor connections, etc. If there is a difference, R31 can

be adjusted until preset voltage is closer to actual arc voltage.

5. Close front panel, and install wrapper.

3-8. 14-Pin Plug Connection

Ref. ST-143 260-A / Ref. S-0512

1 Plug PLG10

2 Keyway

3 Threaded Collar

Connect 14-pin plug PLG10 to

matching receptacle on welding

power source as follows: align key-

ways, insert plug, and tighten

threaded collar.

AJ

B

K

I

C

L

NH

D

M

G

E

F

1

3

21

A, B Contact closure completes 24 volts ac contactor control circuit.

G Circuit common for 24/115 volts ac circuit.

C Command signal; +10 volts dc.

D Control circuit common.

E Remote power source voltage command signal from feeder (potentiometer

wiper or 0-10 volts dc source); 0 to +10 volts dc.

F Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes.

H Voltage feedback; 0 to +10 volts dc, 1 volt per 10 arc volts.

Pin Information

*The remaining pins are not used.

Pin*

Figure 3-12. 14-Pin Plug With Pin Information

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