Miller D-62 WIRE FEEDER Owner's manual

February

1992

FORM:

OM-1582A

Millerﬁ

Effective

With

Serial

No.

KC1

74786

MODEL:

D-62

D-64

OWNERS

MANUAL

IMPORTANT:

Read

and

understand

the

entire

contents

of

both

this

manual

and

the

power

source

manual

used

with

this

unit,

with

special

emphasis

on

the

safety

material

throughout

the

manual,

before

installing,

operating,

or

maintaining

this

MILLER

ELECTRIC

Mfg.

Co.

A

Miller

Group

Ltd..

Company

equipment.

This

unitand

these

instructions

are

foruse

only

by

persons

trainedand

P.O.

Box

1079

experienced

in

the

safe

operation

of

welding

equipment.

Do

not

allow

untrained

persons

to

install,

operate,

or

maintain

this

unit.

Contact

your

distributor

if

you

do

Appleton,

WI

54912

USA

Tel.

414-734-9821

not

fully

understand

these

instructions.

cover2

1/92



ST-143

327-A

PRINTED

IN

USA

LIMITED

WARRANTY

EFFECTIVE:

AUGUST

6,

1990

This

warranty

supersedes

all

warranties

and

is

exclusive

with

no

other

guarantees

or

warranties

expressed

or

implied.

LIMITED

WARRANTY



Subject

to

the

terms

and

conditions

hereof,

MILLER

Electric

Mfg.

Co.,

Appleton,

Wisconsin

war

rants

to

its

Distributor/Dealer

that

all

new

and

unused

Equipment

furnished

by

MILLER

is

free

from

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

subject

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

I_I

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

Customers

risk

and

expense.

MILLERs

option

of

repair

or

replacement

will

be

FOB.,

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,

OPERATION

OF

LAW,

CUSTOM

OF

TRADE

OR

COURSE

OF

DEALING,

INCLUDING

ANY

IMPLIED

WARRANTY

OF

MERCHAN

TABILITY

OR

OF

FITNESS

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.

RECEIVING-HANDLING

Before

unpacking

equipment,

check

carton

for

any

damage

that

may

have

occurred

during

shipment.

File

any

claims

for

loss

or

damage

with

the

delivering

carrier.

Assistance

for

filing

or

settling

claims

may

be

obtained

from

distributor

and/or

equipment

manufacturers

Transportation

Department.

When

requesting

information

about

this

equipment,

always

provide

Model

Designation

and

Serial

or

Style

Number.

Use

the

following

spaces

to

record

Model

Designation

and

Serial

or

Style

Number

of

your

unit.

The

information

is

located

on

the

rating

label

or

nameplate.

Model

__________

Serial

or

Style

No.

Date

of

Purchase

-

miller

8/91

ERRATA

SHEET

April

10,

1992

FORM:

OM-1582A

Use

above

FORM

number

when

ordering

extra

manuals.

After

this

manual

was

printed,

refinements

in

equipment

design

occurred.

This

sheet

lists

exceptions

to

data

appearing

later

in

this

manual.

CHANGES

TO

SECTION

6

ELECTRICAL

DIAGRAMS

Replace

Diagram

6-2.

Circuit

Diagram

For

Wire

Feeder

With

Optional

Equipment

(see

Pages

2

and

3

on

this

Errata

Sheet).

CHANGES

TO

SECTION

7

PARTS

LIST

Change

Parts

List

as

follows:

Dia.

Part

Replaced

Mkgs.

No

With

Description

Quantity

41-8

150980

153195..

NUT,face

1

43-

Added

154

031

..

SPACER,

locating

(Effw/KC211335)

2

40-

.

PC51,52

.

133515

153631

..

CIRCUIT

CARD,

digital

torch

2

~First

digit

represents

page

no



digits

following

dash

represent

item

no.

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

MIEN

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OM-1582A

Page

3

ARC

WELDING

SAFETY

PRECAUTIONS

ELECTRIC

SHOCK

can

kill.

Touching

live

electrical

parts

can

cause

fatal

shocks

or

severe

burns.

The

electrode

and

work

circuit

is

electrically

live

whenever

the

output

is

on.

The

input

power

circuit

and

machine

internal

circuits

are

also

live

when

power

is

on.

In

semiautomatic

or

automatic

wire

welding,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live.

Incorrectly

installed

or

improperly

grounded

equipment

is

a

hazard.

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.

4.

Disconnect

input

power

or

stop

engine

before

installing

or

servicing

this

equipment.

FLYING

SPARKS

AND

HOT

METAL

can

cause

injury.

Chipping

and

grinding

cause

flying

metal.

As

welds

cool,

they

can

throw

off

slag.

ARC

WELDING

can

be

hazardous.

5.

Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual

and

national,

state,

and

local

codes.

Turn

off

all

equipment

when

not

in

use.

Do

not

use

worn,

damaged,

undersized,

or

poorly

spliced

cables.

Do

not

wrap

cables

around

your

body.

Ground

the

workpiece

to

a

good

electrical

(earth)

ground.

Do

not

touch

electrode

while

in

contact

with

the

work

(ground)

circuit.

11.

Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

12.

Wear

a

safety

harness

to

prevent

falling

f

working

above

floor

level.

1.

Wear

approved

face

shield

or

safety

goggles.

Side

shields

recommended.

2.

Wear

proper

body

protection

to

protect

skin.

a

WARNING

PROTECT

YOURSELF

AND

OTHERS

FROM

POSSIBLE

SERIOUS

INJURY

OR

DEATH.

KEEP

CHILDREN

AWAY.

PACEMAKER

WEARERS

KEEP

AWAY

UNTIL

CONSULTING

YOUR

DOCTOR.

In

welding,

as

in

most

jobs,

exposure

to

certain

hazards

occurs.

Welding

is

safe

when

precautions

are

taken.

The

safety

information

given

below

is

only

a

summary

of

the

more

complete

safety

information

that

will

be

found

in

the

Safety

Standards

listed

on

the

Read

and

follow

all

Safety

Standards.

HAVE

ALL

INSTALLATION,

OPERATION,

MAINTENANCE,

AND

REPAIR

WORK

PERFORMED

ONLY

BY

QUALIFIED

PEOPLE.

6.

7.

8.

9.

10.

13.

Keep

all

panels

and

covers

securely

in

place.

,/~

.~

ARC

RAYS

can

burn

eyes

and

skin;

NOIS,E

can

damage

hearing.

Arc

rays

from

the

welding

process

produce

intense

heat

and

strong

ultraviolet

rays

that

can

burn

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

1.

2.

3.

4.

5.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

(see

ANSI

Z49.

1

listed

in

Safety

Standards)

to

protect

your

face

and

eyes

when

welding

or

watching.

Wear

approved

safety

glasses.

Side

shields

recommended.

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.

Use

approved

ear

plugs

or

ear

muffs

if

noise

level

is

high.

FUMES

AND

GASES

can

be

hazardous

5.

Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

to

your

health.

wearing

an

air-supplied

respirator.

Shielding

gases

used

for

Welding

producesfumes

and

gases.

Breathing

these

fumes

and

gases

can

be

hazardous

to

your

health.

welding

can

displace

air

causing

injury

or

death.

Be

sure

the

breathing

air

is

safe.

6.

Do

not

weld

in

locations

near

degreasing,

cleaning,

or

spraying

1.

2.

3.

Keep

your

head

out

of

the

fumes.

Do

not

breath

the

fumes.

If

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

remove

welding

fumes

and

gases.

If

ventilation

is

poor,

use

an

approved

air-supplied

respirator.

7.

operations.

The

heat

and

rays

of

the

arc

can

react

with

vapors

to

form

highly

toxic

and

irritating

gases.

Do

not

weld

on

coated

metals,

such

as

galvanized,

lead,

or

cadmium

plated

steel,

unless

the

coating

is

removed

from

the

4.

Read

the

Material

Safety

Data

Sheets

(MSDSs)

and

the

manufacturers

instruction

for

metals,

consumables,

coatings,

and

cleaners,

weld

area,

the

area

is

well

ventilated,

and

if

necessary,

while

wearing

ar-i

air-supplied

respirator.

The

coatings

and

any

metals

containing

these

elements

can

give

off

toxic

fumes

if

welded.

WELDING

can

cause

fire

or

explosion.

5.

Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.

Sparks

and

spatter

fly

off

from

the

welding

arc.

The

flying

sparks

and

hot

metal,

weld

spatter,

hot

6.

Be

aware

that

welding

on

a

ceiling,

floor,

bulkhead,

or

partition

can

cause

fire

on

the

hidden

side.

workpiece,

and

hot

equipment

can

cause

fires

and

burns.

Accidental

contact

of

electrode

or

welding

wire

7.

Do

not

weld

on

closed

containers

such

as

tanks

or

drums.

to

metal

objects

can

cause

sparks,

overheating,

or

fire.

8.

Connect

work

cable

to

the

work

as

close

to

the

welding

area as

practical

to

prevent

welding

current

from

traveling

long,

possibly

1.

2.

Protect

yourself

and

others

from

flying

sparks

and

hot

metal.

Do

not

weld

where

flying

sparks

can

strike

flammable

material.

9.

unknown

paths

and

causing

electric

shock

and

fire

hazards.

Do

not

use

welder

to

thaw

frozen

pipes.

3.

Removeallflammableswithin35ft(10.7m)oftheweldingarc.lf

10.

Remove

stick

electrode

from

holder

or

cutoff

welding

wire

at

this

is

not

possible,

tightly

cover

them

with

approved

covers,

contact

tip

when

not

in

use.

4.

Be

alert

that

welding

sparks

and

hot

materials

from

welding

can

11.

Wear

oil-free

protective

garments

such

as

leather

gloves,

heavy

easily

go

through

small

cracks

and

openings

to

adjacent

areas.

shirt,

cuffless

trousers,

high

shoes,

and

a

cap.

Sri

9/91

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,

and

arcs.

2.

Install

and

secure

cylinders

in

an

upright

position

by

chaining

them

to

a

stationary

support

or

equipment

cylinder

rack

to

prevent

falling

or

tipping.

3.

Keep

cylinders

away

from

any

welding

or

other

electrical

circuits.

4.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

5.

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

in

good

condition.

6.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

7.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

in

use

or

connected

for

use.

8.

Read

and

follow

instructions

on

compressed

gas

cylinders,

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

Standards.

a

WARNiNG

.A

ENGINES

can

be

hazardous.

PRINCIPAL

SAFETY

STANDARDS

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.1,

from

American

Welding

Society,

550

NW.

LeJeune

Rd.

Miami

FL

33126

Safety

and

Health

Standards,

OSHA

29

CFR

1910,

from

Superinten

dent

of

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

Recommended

Safe

Practices

for

the

Preparation

for

Welding

and

Culling

of

Containers

That

Have

Held

Hazardous

Substances,

Ameri

can

Welding

Society

Standard

AWS

F4.1

,from

American

Welding

So

ciety,

550

NW.

LeJeune

Rd. Miami,

FL

33126

National

Electrical

Code,

NFPA

Standard

70,

from

National

Fire

Pro.

tection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

P-i,

from

Compressed

Gas

Association,

1235

Jefferson

Davis

High

way,

Suite

501,

Arlington,

VA

22202.

Code

for

Safety

in

Welding

and

Cutting,

CSA

Standard

Wi

17.2,

from

Canadian

Standards

Association,

Standards

Sales,

178

Rexdale

Bou

levard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

Protec

tion,

ANSI

Standard

Z87.1,

from

American

National

Standards

Insti

tue.

1430

Broadway,

New

York,

NY

10018.

Cutting

And

Welding

Processes,

NFPA

Standard

51

B,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

~-~-



ENGINE

Engines

pr

EXHAUST

GASES

can

kill.

oduce

harmful

exhaust

gases.

1.

2.

Use

equipment

outside

in

open,

well-ventilated

areas.

If

used

in

a

closed

area,

vent

engine

exhaust

outside

and

away

from

any

building

air

intakes.

ENGINE

FUEL

can

cause

fire

or

1.

Stop

engine

before

checking

or

adding

fuel.

explosion.

2.

Do

not

add

fuel

while

smoking

or

if

unit

is

near

any

sparks

or

open

flames.

Engine

fuel

is

highly

flammable.

3.

4.

5.

Allow

engine

to

cool

before

fueling.

If

possible,

check

and add

fuel

to

cold

engine

before

beginning

job.

Do

not

overfill

tank



allow

room

for

fuel

to

expand.

Do

not

Spill

fuel.

If

fuel

is

spilled,

clean

up

before

starting

enaine.

1.

T

MOVING

PARTS

can

cause

injury.

Moving

parts,

such

as

fans,

rotors,

and

belts

can

cut

fingers

and

hands

and

catch

loose

clothing,

Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

3.

4.

5.

6.

Have

only

qualified

people

remove

guards

or

covers

for

maintenance

and

troubleshooting

as

necessary.

To

prevent

accidental

starting

during

servicing,

disconnect

negative

()

battery

cable

from

battery.

Keep

hands,

hair,

loose

clothing,

and

tools

away

from

moving

parts.

Reinstall

panels

or

guards

and

close

doors

when

servicing

is

2.

Stop

eng

ne

before_installing_or_connecting

unit,

finished

and

before_starting_engine.

SPARKS

can

cause

BATTERY

GASES

1.

Always

wear

a

face

shield

when

working

on

a

battery.

TO

EXPLODE;

BATTERY

ACID

can

2.

Stop

engine

before

disconnecting

or

connecting

battery

burn

eyes

and

skin,

cables.

Batteries

contain

acid

and

generate

explosive

3.

4.

Do

not

allow

tools

to

cause

sparks

when

working

on

a

battery.

Do

not

use

welder

to

charge

batteries

or

jump

start

vehicles.

gases.

5.

Observe

correct

polarity

(+

and

)

on

batteries.

-

~

--

STEAM

AND

COOLANT

can

skin.

The

coolant

in

the

r

under

pressure.

PRESSURIZED

burn

face,

eyes,

adiator

can

be

very

h

HOT

and

ot

and

1.

2.

3.

Donotremoveradiatorcapwhenengineishot.Allowengine

tocool.

Wear

gloves

and

put

a

rag

over

cap

area

when

removing

cap.

Allow

pressure

to

escape

before

completely

removing

cap.

Sri

9/91

TABLE

OF

CONTENTS

SECTION

1



SAFETY

SIGNAL

WORDS

1

SECTION

2

SPECIFICATIONS

1

SECTION

3

INSTALLATION

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

6

3-6.

Dip

Switches

Options

7

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

14

3-12.

Threading

Welding

Wire

With

Drive

Assembly

Horizontal

16

3-13.

Threading

Welding

Wire

And

Rotating

The

Drive

Assembly

17

SECTION

4

OPERATION

18

SECTION

5

MAINTENANCE

&

TROUBLESHOOTING

5-1.

Routine

Maintenance

25

5-2.

Replacing

The

Hub

Assembly

25

5-3.

Overload

Protection

26

5-4.

Troubleshooting

26

SECTION

6

ELECTRICAL

DIAGRAMS

29

SECTION7PARTSLIST

Figure

7-1.

Main

Assembly

34

Figure

7-2.

Control

Box

36

Figure

7-3.

Control

Panel

38

Figure

7-4.

Panel,

Front

w/Components

40

Figure

7-5.

Wire

Drive

Assembly

(4

Drive

Roll

Assembly

Illustrated)

42

Table

7-1.

Drive

Roll

And

Wire

Guide

Kits

44

OM-1582A

2192

SECTION

1



SAFETY

SIGNAL

WORDS

modl.1

9/91

The

following

safety

alert

symbol

and

signal

words

are

used

throughout

this

manual

to

call

attention

to

and

identify

different

levels

of

hazard

and

special

instructions.

a

WARNING

statements

identify

procedures

or

practices

which

must

be

followed

to

avoid

serious

personal

injury

or

loss

of

life.

a

CAUTION

statements

identify

procedures

or

practices

which

must

be

followed

to

avoid

minor

personal

injury

or

damage

to

this

equipment.

~

IMPORTANT:

statements

identn~j

special

instructions

necessary

for

the

most

efficient

operation

of

this

equipment.

SECTION

2

SPECIFICATIONS

Table

2-1.

Wire

Feeder

Specification

Description

Type

Of

Input

Power

From

Welding

Power

Source

Maximum

Weld

Circuit

Rating

Welding

Power

Source

Type

Wire

Feed

Speed

Range

Wire

Feed

Speed

Range

With

Option

al

High

Speed

Motor

Wire

Diameter

Range

Welding

Process

Input

Power

Cord

Overall

Dimensions

Weight

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.)

100

Volts,

750

Amperes,

100%

Duty

Cycte

Constant

Voltage

(CV)

DC,

With

Contactor

50

To

780

ipm

(1.3

To

20

mpm)

90

To

1400

ipm

(2.3

To

35.4

mpm)

Options

.023

To

1/8

in.

(0.6

To

3.2

mm)

Gas

Metal

Arc

Welding

(GMAW),

Flux

Cored

Arc

Welding

(FCAW)

lOft.

(3.1

m)

Length:

32

in.

(812

mm);

Width:

18

in.

(457

mm);

Height:

14

in.

(356

mm)

Shipping:

82

lbs.

(37.2

kg);

Net:

74

lbs.

(33.6

kg)

Add

4

lbs.

(1.8

kg)

For

4-Drive

Roll

Models

See

Rear

Cover

OM-1582

Page

1

Table

2-2.

Options

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-In-i

Control

Digital

Meter(s)

Tach

Feed-

back

Digital

Voltage

Control

Voltage

Control

Run-In

Control

Digital

Dual

Schedule

Dual

Schedule

Control

Remote

Pendant

Control

Cord

#137

552

(For

RCSP.45)

Burnback

Control



No

Yes

4-IN-I

Control

(in

cludes

pref

low/post-

flow,

spotlburnback,

and

trigger

hold

con

trol)

No



Yes

Yes Yes

Digital

Meter(s)/Tach

Feedback

(one

or

two

meter

option)

Yes



Yes Yes Yes

Yes

No

Yes

Digital

Voltage

Control

(DVC)

Yes

Reqd



No

Yes

No

Yes

Voltage

Control

Yes

No



Yes

No

Yes

Run-In

Control

(Option

Interface

Required)

Yes



Yes

Digital

Dual

Schedule

(Option

Interface

Re-

quired)

Yes

Reqd

iReqd

No

Yes



No

No No

Dual

Schedule

Control

(Option

Interface

Re-

quired)

Yes

No

Yes

No



No

Remote

Pendant

Con

trol

(Option

Interface

Required)

Yes

No

Yes

No



No

Cord

#137

552

(For

RCSP-45)

(Option

In-

terface

Required)

Yes

Yes Yes

Yes

No



SECTION

3INSTALLATION

3-1.

Site

Selection

A~

WARNING

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.

wfwam71*

9/91

,~,

III

OM-1582

Page

2

3-2.

Equipment

Connection

Diagrams

a

WARNING

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.

..4~iJ

-c-

C



YLINDERS

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,

other

stationary

support.

or

HOT

SURFACES

can

burn

skin.



Allow

gun

to

cool

before

touching.

wfwarng.1

9/91

Do

not

put

feeder

where

welding

wire

hits

cylinder.

5

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.

3

STI

52566

/

ST.1

52566

Figure

3-1.

Installing

Wire

Feeder

Over

A

Lifting

Eye

OM-1

582

Page

3

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

1

CV

Or

CC/CV

Welding

Power

Source

Supplying

24

VAC

To

Feeder

2

14-Pin

Plug

PLG1O

And

Inter

connecting

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

9

ST-i

52

616

5

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

PLG1O

And

Inter

connecting

Cord.

10

PSA-2

Control

(Optional)

11

Y

Adapter

Gas

Hose

12

Gas

Cylinder

ST-i52

320

7

11

Figure

3-3.

Connections

With

A

Constant

Voltage

(CV)

Welding

Power

Source

Having

Only

115

VAC

Available

OM-l5B2Page4

3-3.

Wire

Guide

And

Drive

Roll

Installation

a

WARNING

ELECTRIC

SHOCK,

CYLINDERS,

AND

HOT

PARTS

HAZARDS.

Read

safety

informa

tion

at

beginning

of

Section

3-2

before

proceeding.

A.

Wire

Guide

Installation

B.

Drive

Roll

Installation

When

changing

wire

size

or

type,

check

guide

size

(see

Table

7-1).

1

Drive

Rolls

Remove

drive

rolls

before

installing

wire

guides

(see

Figure

3-5).

2

Wire

Guide

Securing

Screws

Loosen

wire

guide

screws.

3

Inlet

Wire

Guide

Install

inlet

guide

so

wire

guide

screw

is

centered

in

groove

in

guide.

4

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.

ST-I

53

125/

ST.137

377.0

Figure

3-4.

Wire

Guide

Installation

(Four-Drive

Roll

Model

Shown)

1

When

changing

wire

size

or

type,

check

drive

roll

size

(see

Table

7-1).

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-I

37

377-D

4

Figure

3-5.

Drive

Roll

Installation

(Four-Drive

Roll

Model

Shown)

OM-1562

Page

5

3-4.

Welding

Gun

Connections

___

AA

WARNING

ELECTRIC

SHOCK

can

kill.



Do

not

touch

Jive

electrical

parts.



Turn

OFF

wire

feeder

and

weJding

power

source,

and

disconnect

input

power

before

inspecting

or

installing.

Stop

engine

on

welding

generator.

3-5.

Motor

Start

Control

Figure

3-6.

Gun

And

Trigger

Lead

Connections

wfwam1.1~

9/91

ELECTRIC

SHOCK

can

kill.



Do

not

touch

Jive

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.

wfwarnl.V

9/91

3

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

touching.

lighten

knob.

4

Gun

Trigger

Plug

Insert

plug

into

receptacle,

and

tighten

threaded

collar.

5

Gun

Trigger

Receptacle

6

Drive

Assembly

Cover

Close

cover.

Repeat

procedure

for

welding

gun

on

opposite

side

of

wire

feeder.

Ref.

ST.148

701

/

Ref.

ST.152

466

___

£~

WARNING

OM-1

582

Page

6

Figure

3-7.

Motor

Start

Control

On

Motor

Control

Board

PCi

3-6.

Dip

Switches

Options

To

change

wire

feed

starting

speed

proceed

as

follows:

Turn

OFF

wire

feeder

and

welding

power

source.

Front

panel

shown

open

for

illustra

tion

purposes.

3 Motor

Start

Control

Poten

tiometer

1R70

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.

Ref.

ST-I

43

259-0

/

Ref.

SB-I

46

862

____

a

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.

wtwarnl

.1

9/91

Remove

wrapper.

1

Front

Panel

2

Motor

Board

PCI

Reinstall

wrapper.

Tools

Needed:

1/4

in.

OM-1582

Page

7

A.

SpotTime

DIP

Switch

Si

a

WARNING

ELECTRIC

SHOCK

AND

STATIC

ELECTRICITY

HAZARDS.

Read

safety

information

at

beginning

of

Section

3-6

before

proceeding.

B.

Digital

Meter

Functions

And

Positions

4~

WARNING

ELECTRIC

SHOCK

AND

STATIC

ELECTRICITY

HAZARDS.

Read

safety

information

at

beginning

of

Section

3-6

before

proceeding.

IMPORTANT:

The

Digital

Meter

Board

PC6O

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.

Figure

3-8.

Spot/Time

DIP

Switch

Si

OM-1

582

Page

8

Standard

Motor

Inches/Minute



U,



U

High

Speed

High

Speed

Motor Motor

Inches/Minute

Meters/Minute



U

 U

U

I

U U

7

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

illustra

tion

purposes.

2

Digital

Meter

Board

PC6O

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.

Voltage

Hold

I-

X

Means

switch

can

be

in

either

position.

U

Means

place

switch

in

this

position.

Figure

3-9.

DIgital

Meter

Functions

DIP

Switch

S2

ST-143

259-0

/

SA-135

461.G

/

Ref.

S-0389

2

3

Tools

Needed:

1/4

in.

Standard

Motor

Meters/Minute

U

c1

OM-1

582

Page

9

C.

Remote

Input!

Run-In

DIP

Switch

Si

4~

WARNING

ELECTRIC

SHOCK

AND

STATIC

ELECTRICITY

HAZARDS.

Read

safety

information

at

beginning

of

Section

3-6

before

proceeding.

o

~

Tools

Needed:

Change

DIP

switch

position

if

a

dif

ferent

mode

ol

operation

is

de

sired.

Turn

OFF

wire

feeder

and

welding

power

source.

Remove

wrapper.

1

Front

Panel

Front

panel

shown

open

for

illustra

tion

purposes.

2

Option

Interface

Board

PC7O

3

Remote

Input/Run-In

DIP

Switch

Si

Place

DIP

switch

Si

(on

either

or

both

PC7O

boards)

in

appropriate

position

for

desired

mode.

Reinstall

wrapper.

c:::I:::z:I=::=~IJ

1/4

in.

Figure

3-10.

Remote

Input/Run-In

DIP

Switch

Si

Ref.

5~O3BQ

I

5A.~33

072.C

I

ST.143

259-0

X

Means

switch

can

in

either

position.

Run-In

Control

With

Voltage

Sensing

OFF

OM-1

582

Page

10

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Miller D-62 WIRE FEEDER, D-64 WIRE FEEDER, KC174786 Owner's manual

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