Miller D-62 WIRE FEEDER Owner's manual

Category
Welding System
Type
Owner's manual

This manual is also suitable for

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
previous
MILLER
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.
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096-A
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
next
page.
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
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
WARNING
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
serious
personal
injury
or
loss
of
life.
a
CAUTION
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
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
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 Owner's manual

Category
Welding System
Type
Owner's manual
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