Miller KC248746 Owner's manual

Brand: Miller

Model: KC248746

Category: Welding System

Type: Owner's manual

This manual is also suitable for

MODEL:

XR

ATM

And

XR

WTM

Wire

Feeder

And

~Gun

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

MILLER

ELECTRIC

Mfg.

Co.

material

throughout

the

manual,

before

installing,

operating,

or

maintaining

this

A

Mifler

Group

Ltd..

Company

equipment.

This

unitand

these

instructions

are

foruse

only

by

persons

trained

and

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.

/1

~MiHerﬁ

June

1992

FORM:

OM-1581B

Effective

With

Serial

No.

KC248746

4~.A

PRINTED

IN

LISA

La

MILLERS

TRUE

BLUE~

LIMiTED

WARRANTY

Effective

January

I,

1992

(Equipment

with

a

serial

number

preface

of

KC

or

newer)

This

limited

warranty

supersedes

alt

previous

MILLER

warranties

snd

is

exclusive

with

no

other

gusrsntees

or

warrenties

espressed

or

implied.

LIMITED

WARRANTY



Subject

to

the

terms

snd

conditions

below.

MILLER

Electric

Mtg.

Co..

Appleton.

Wisconsin.

warrsnts

to

its

originsl

retsil

purchaser

that

new

MILLER

equipment

sold

after

the

effective

date

of

this

limited

warrsnly

is

free

ot

de

tects

in

msterisl

end

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

wsrranty

periods

listed

below.

MILLER

wilt

repair

or

replace

sny

war

rsnted

parts

or

components

that

tell

due

to

such

detects

in

material

or

workmanship.

MILLER

must

be

notified

In

writing

within

thirty

(30)

days

ot

such

detect

or

failure,

at

which

time

MILLER

wilt

provide

instructions

on

the

warranty

claim

procedures

to

be

followed.

MILLER

shall

honor

warranty

claims

on

warranted

equipment

listed

below

in

the

event

ot

such

a

failure

within

the

warranty

time

periods.

Alt

warranty

time

periode

start

on

the

date

that

the

equipment

was

delivered

to

the

original

retail

purchaser.

and

are

aa

follows:

1.

5

Years

Parts



3

Years

Labor

Original

main

power

rectifiers

2.

3

Years



Parts

and

Labor



Transformer/Rectifier

Power

Sources



Plasma

Arc

Cutting

Power

Sources

*

Semi-Automatic

and

Automatic

Wire

Feeders



Robots

3.

2

Years



Parts

and

Labor

*

Engine

Driven

Welding

Generators

(NOTE:

Engines

are

warranted

separately

by

the

engine

manufacturer.)

4.

1

Year



Parts

and

Labor



Motor

Driven

Guns



Process

Controllers



Water

Coolant

Systems



HF

Units

Grids

Spot

Welders

Load

Banks

SDX

Transtormers

Running

Gear/Trailers

Field

Options

(NOTE:

Field

options

are

covered

under

True Blue

TM

tor

the

remaining

warranty

period

ot

the

product

they

are

installed

in.

or

for

a

minimum

ot

one

year



whichever

is

grester.l

5.

6

Months



Batteries

6.

90

Days



Parts

and

Labor



MIG

Guns/TIG

Torches



Plasma

Cutting

Torches



Remote

Controls



Accessory

Kits



Replacement

Parts

MILLERS

True

Blue

r

Umited

Warranty

shall

not

epply

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.

it

any.

2.

Consumable

components:

such

as

contact

tips,

cutting

nozzles,

contactora

and

relays.

3.

Equipment

that

hsa

been

moditled

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

CDMMER

CIAL/INDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

IN

THE

USE

AND

MAINTENANCE

OF

WELDING

EOUIPMENt

In

the

event

of

a

warranty

claim

covered

by

this

warranty,

the

eacluaive

remedlea

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

ot

or

credit

for

the

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

relum

of

the

goods

at

customers

risk

and

espense.

MILLERS

option

of

repair

or

replacement

will

be

FOB..

Factory

at

Appleton.

Wisconsin.

or

FOB,

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

CONSEOUENTIAL

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

EOUIPMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

AND

DISCLAIMED

DY

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

esclusion

may

not

apply

to

you.

This

warrsnty

provides

ape

citic

legal

rights,

and

other

rights

may

be

available,

but

may

very

from

state

to

state.

In

Canada.

legislation

in

some

provinces

provides

for

certain

additional

warrantIes

or

remedies

other

than

as

stated

herein.

snd

to

the

extent

that

they

may

not

be

waived,

the

limitations

and

esciusiona

set

out

above

may

not

apply.

This

Limited

Warranty

providea

specific

legal

rights,

and

other

rights

may

be

available,

but

may

vary

from

province

to

province.

ii

a

J

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

5/92

ERRATA

SHEET

September

18,

1992

FORM:

OM-1581B

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

3-

INSTALLATION

Replace

Section

3-7.

115

VAC/Contactor

Control

Plug

Information

I

Interconnecting

Cord

2

115

VAC/Contactor

Control

Plug

PLG5

If

welding

power

source

is

eauipped

with

matching

14-socket

receptacle,

insert

plug,

and

tighten

threaded

collar.

Proceed

to

Section

3-9

in

manual.

If

plug

PLG5

will

not

connect

to

welding

power

source

receptacle.

use

the

following

pin

information

and

following

Section

3-8

to

re

place

PLG5

with

a

suitable

plug.

Pin

Information

to

connect

the

following

equipment:

Remote

Contactor

A,B

Contact

closure

completes

the

contactor

control

circuit

Remote

Voltage

Control

(Optional)

C

Command

reference;

+10

volts

dc.

D

Remote

control

circuit

common.

E

Input

command

signal

from

potentiometer

wiper;

0

to

+10

volts

dc.

Remote

Contactor

G

Circuit

common

for

115

volts

ac

circuit.

l,J

Contact

closure

completes

the

115

volts

ac

contactor

control

circuit.

1<

Circuit

common.

Remaining

pins

are

not

used.

Ref.

S-0004.A

/

Ref.

ST.tSl

772

2

Figure

3-12.

115

VAC/Contactor

Control

Plug

Information

Replace

Section

3-8.

Replacing

115

VAC/Contactor

Control.Plug

With

Supplied

5-Pin

Or

Twistlock

Plug

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.



Have

only

aualified

persons

make

wiring

connections.

wiwarni

i

gigi

1

115

VAC/Contactor

Control

Plug

PLG5

2

Contactor

Control

Cord

3

I15VACCord

Find

and

label

cords

by

following

leads

back

to

PLG5:

Contactor

control

cord

connects

to

pins

A

&

B

of

PLG5

115

VAC

cord

connects

to

pin

J

of

PLG5.

Cut

off

plug

PLG5.

4

5-Pin

Plug

5

Twistlock

Plug

For

connections

shown

in

Figure

3-3

or

Figure

3-4

in

manual,

install

5-pin

or

twistlock

plug

onto

contac

tor

control

cord.

For

Figure

3-2

connection

in

manu

al,

obtain

plug

to

match

contactor

control

receptacle

on

welding

pow

er

source,

and

install

plug

onto

contactor

control

cord.

Obtain

115

VAC

plug

and

connect

to

115

VAC

cord

as

follows:

green

lead

to

ground

white

lead

to

11

5VAC

common

black

lead

to

11

5VAC

hot.

6

Plug

PLG5O

7

Plug

PLG51

8

Plug

PLG52

Unit

shipped

with

PLG5O

con

nected

to

PLG5I

to

provide

115

VAC

for

contactor.

If

contact

closure

needed

for

con

tactor.

connect

PLG5O

to

PLG52.

ST-151

773-B

Figure

3-13.

Replacing

115

VAC/Contactor

Control

Plug

With

Supplied

5-Pin

Or

Twistlock

Plug

OM-1581B

Page

2

CHANGES

TO

SECTION

7

PARTS

LIST

Change

Parts

List

as

follows:

Quantity

-

.

22ft

.2

PULL

MOTOR

B2

GUN

ASSEMBLY

B

C

A

0

V

0

CORD

#1

CHANGES

TO

SECTION6



ELECTRICAL

DIAGRAMS

Replace

Figure

6-1.

Circuit

Diagram

For

Wire

Feeder

(see

Page

4

on

this

Errata

Sheet)

IReplace

Figure

6-2.

Wiring

Diagram

For

Wire

Feeder

(see

Page

5

on

this

Errata

Sheet)

IReplace

Figure

6-3.

Circuit

Diagram

For

Gun

~1

I

TRIGGER

.~

L

flPBI~~I

CORD

#2

SA.138

956-B

Figure

6-3.

Circuit

Diagram

For

Gun

Dia.

Part

Replaced

-~

Mkgs.

No.

With

Description

33-

007 826

...

007826

..

CABLE,

(qty

chg)

(order

by

ft)

-.

34-

601

219

601

219

..

LINK,

(qty

chg)

-.

34-

...

PLG51,52

..

Added

131

204

-.

HOUSING

PLUG

&

SOCKET,

(consisting

of)

-.

113

746

.

. .

.

TERMINAL,

female

lskt

24-18

wire

34-

PLG5O

...

Added

131

203

..

HOUSING

PLUG

&

PINS,

(consisting

of)

114

656

-

. . .

TERMINAL,

male

1

pin

24-18

wire

~First

digit

represents

page

no



digits

following

dash

represent

item

no.

l3E

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

\V

G

E

F

PLG2

OM-1581B

Page

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Figure

6-1.

Circuit

Diagram

For

Wire

Feeder

Effective

With

Serial

No.

KC288497

And

Following

60)21-K)

446(68LICEI)

88(R44-CW)

38)

SPL

ICE-3)

FI~Jjj~g

67A

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31A(PLCI-2)

IC(SL-80)

TI

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326(PLGI

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MOTOR

GRN/YEL-CIIASSIS

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will

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3A

(Pl~Gl

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88(P1616-21

8A(PtG3-S)

IOA(PIGJ

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64A(PLG4-2

31

Æ2A)2T-A)

~

~

I3AIPt614-1)

65A(PLGA-))

/

80

I~j

S2

~o(r)-PRI)

(

________________

1II33c~35T0~

~

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~

A

C

62A(41-A)

si

I4A(FI-r~I

OA(SPLICE-2)

PCI

PLG2

67A1C8)-4)

~

~j~1.ii!j1

PLG3

6

59(0

PLGI

0

z

(0 C

BRAKE

PLG4

(31-A)

(31-B)

LAAPLGIlJl~

4AB(2T-Lj

SPLICE-

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REED

RELAY

II

~

i!i

-~

~9-~

,~I

iii

~1J1J1J~

J

JL

-

~

~

SPLICE2

6

I

6

CHASSIS

F

E

0

8

A

2T

~

~I~T)PLG5~}T0

PLC

~

SC-156

400

Figure

6-2.

Wiring

Diagram

For

Wire

Feeder

Effective

With

Serial

No.

KC288497

And

Following

ARC

WELDING

SAFETY

PRECAUTIONS

a

WARNING

ARC

WELDING

can

be

hazardous.

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.

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.

WELDING

can

cause

fire

or

explosion.

Sparks

and

spatter

fly

off

from

the

welding

arc.

The

flying

sparks

and

hot

metal,

weld

spatter.

hot

workpiece.

and

hot

equipment

can

cause

fires

and

burns.

Accidental

contact

of

electrode

or

welding

wire

to

metal

oblects

can

cause

sparks.

overheating,

or

fire.

Protect

yourself

and

others

from

flying

sparks

and

hot

metal

Do

not

weld

where

flying

sparks

can

strike

flammable

material.

Remove

allflammables

within

35

ft(10.7

m)

of

the

welding

arc.

If

this

is

not

possible,

tightly

cover

them

with

approved

covers.

Be

alert

that

welding

sparks

and

hot

materials

from

welding

can

i

through

small

cracks

and

openings

to

adjacent

areas.

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

if

working

above

floor

level.

Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.

Be

aware

that

welding

on

a

ceiling,

floor,

bulkhead,

or

partition

can

cause

fire

on

the

hidden

side,

Do

not

weld

on

closed

containers

such

as

tanks

or

drums.

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.

Do

not

use

welder

to

thaw

frozen

pipes.

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.

Wear

approved

face

shield

or

safety

goggles.

Side

shields

recommended,

2.

Wear

proper

body

protection

to

protect

skin.

6.

7

8.

9.

10.

13.

Keep

all

panels

and

covers

securely

in

place.

/~

...Li

ARC

RAYS

can

burn

eyes

and

skin;

1.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

(see

NOISE

can

damage

hearing.

ANSI

Z49.

I

listed

in

Safety

Standards)

to

protect

your

face

and

eyes

when

welding

or

watching.

Arc

rays

from

the

welding

process

produce

intense

2.

Wear

approved

safety

glasses.

Side

shields

recommended.

heat

and

strong

ultraviolet

rays

that

can

burn

eyes

3,

Use

protective

screens

or

barriers

to

protect

others

from

flash

and

skirt.

Noise

from

some

processes

can

damage

and

glare:

warn

others

not

to

watch

the

arc.

hearing.

4.

Wear

protective

clothing

made

from

durable.

flame-resistant

material

(wool

and

leather)

and

foot

protection.

5.

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

Q

Welding

produces

fumes

and

gases.

Breathing

these

welding

can

displace

air

causing

n~ury

or

death.

Be

sure

the

fumes

and

gases

can

be

hazardous

to

your

health.

breathing

air

is

sate.

6.

Do

not

weld

in

locations

near

degreasing.

cleaning,

or

spraying

operations.

The

heat

and

rays

of

the

arc

can

react

with

vapors

to

1.

Keep

your

head

out

of

the

fumes.

Do

not

breath

the

fumes.

form

highly

toxic

and

irritating

gases.

2.

If

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

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

(MSDS5)

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

and

cleaners.

containing

these

elements

can

give

off

toxic

fumes

if

welded.

1.

2.

3.

4.

5

6.

7.

8.

9,

10

FLYING

SPARKS

AND

HOT

METAL

can

cause

injury.

Chipping

and

grinding

cause

flying

metal.

As

welds

cool,

they

can

throw

off

slag.

S.

9~

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

tailing

or

tipping.

~

MOVING

PARTS

can

cause

injury.

Moving

parts,

such

as

fans,

rotors,

and

belts

can

cut

fingers

and

hands

and

catch loose

clothing.

1.

Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

STEAM

AND

PRESSURIZED

HOT

COOLANT

can

burn

face,

eyes,

and

skin.

The

coolant

in

the

radiator

can

be

very

hot

and

under

pressure.

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.

associatedequipment.

and

CGA

publication

P-i

listed

in

Safety

Standards.

ENGINES

can

be

hazardous.

3.

Have

only

qualified

people

remove

guards

or

covers

for

maintenance

and

troubleshooting

as

necessary.

4.

To

prevent

accidental

starting

during

servicing,

disconnect

negative

()

battery

cable

from

battery.

5.

Keep

hands,

hair,

loose

clothing,

and

tools

away

from

moving

parts.

6.

Reinstall

panels

or

guards

and

close

doors

when

servicing

is

finished

and

before

starting

engine.

1.

Do

not

remove

radiator

cap

when

engine

is

hot.

Allow

engine

to

cool.

Wear

gloves

and

put

a

rag

over

cap

area

when

removing

cap.

Allow

pressure

to

escape

before

completely

removing

cap.

PRINCIPAL

SAFETY

STANDARDS

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.1,

from

American

Welding

Society,

550

N.W.

LeJeurie

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

Cutting

of

Containers

That

Have

Held

Hazardous

Substances.

Amen.

can

Welding

Society

Standard

AWS

F4.

1,

from

American

Welding

So

ciety.

550

N.W.

LeJeune

Pd,

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,

GSA

Standard

Wi

17.2.

from

Canadian

Standards

Association,

Standards

Sales,

178

Pexdale

Bou

levard,

Rexdale,

Ontario,

Canada

M9W

1

P3.

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

518.

from

National

Fire

Protection

Association,

Batterymarch

Park.

Quincy,

MA

02269.

a

WARNING

~.

~

ENGINE

EXHAUST

GASES

can

kill.

1.

Use

equipment

outside

in

open,

well-ventilated

areas.

2.

II

used

in

a

closed

area,

vent

engine

exhaust

outside

and

Engines

produce

harmful

exhaust

gases.

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.

3.

Allow

engine

to

cool

before

fueling.

If

possible,

check

and

add

Engine

fuel

is

highly

flammable.

fuel

to

cold

engine

before

beginning

job.

4.

Do

not

overfill

tank



allow

room

for

fuel

to

expand.

5.

Do

not

spill

fuel.

If

fuel

is

spilled,

clean

up

before

starting

engine.

2.

Stop

engine

before

installing

or

connecting

unit.

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.

3.

Do

not

allow

tools

to

cause

sparks

when

working

on

a

battery.

Batteries

contain

acid

and

generate

explosive

4.

Do

not

use

welder

to

charge

batteries

or

jump

start

vehicles.

gases.

5.

Observe

correct

polarity

(+

and

)

on

batteries.

2.

3.

Sri

9/Si

TABLE

OF

CONTENTS

SECTION

1



SAFETY

SIGNAL

WORDS

.

1

SECTION

2

SPECIFICATIONS

2-1.

Duty

Cyc!e

1

SECTION

3INSTALLATION

3-1.

Equipment

Connection

Diagrams

2

3-2.

Removing

Top

Cover

Of

Gun

5

3-3.

Gun

To

Feeder

Connections

5

3-4.

Internal

Connections

To

Feeder

6

3-5.

Adjusting

Contact

Tube

Position

9

3-6.

Voltage

Sensing

Lead

Connections

9

3-7.

115

VAC/Contactor

Control

Plug

Information

10

3-8.

Replacing

115

VAC/Contactor

Control

Plug

With

Supplied

5-Pin

Or

Twistlock

Plug

10

3-9.

Installing

Wire

Spool

ti

3-10.

Threading

Welding

Wire

12

3-11.

Coolant

Guidelines

To

Prevent

Corrosion

13

SECTION

4

OPERATION

14

SECTION

5-

MAINTENANCE

&

TROUBLESHOOTING

5-1.

Routine

Maintenance

19

5-2.

Changing

Or

Cleaning

Gun

Drive

Roll

20

5-3.

Changing

Feeder

Drive

Roll

And

Wire

Inlet

Guide

21

5-4.

Replacing

Or

Cleaning

Gun

Drive

Roll

Bearing

22

5-5.

Replacing

Or

Cleaning

Feeder

Drive

Roll

Bearing

22

5-6.

Changing

Gun

Contact

Tube

And

Liner

23

5-7.

Replacing

Contact

Tube

Adapter

23

5-8.

Replacing

Hub

Assembly

24

5-9.

Adjusting

Hub

Tension

25

5-10.

Overload

Protection

25

5-11.

Water

Flow

Switch

(Optional

For

Water-Cooled

Models)

26

5-12.

Troubleshooting

26

SECTION

6

ELECTRICAL

DIAGRAMS

28

SECTION

7

PARTS

LIST

Figure

7-1.

Main

Assembly

32

Figure

7-2.

Motor

&

Wire

Drive

35

Figure

7-3.

Panel,

Front

w/Components

(XR-W

Model

Illustrated)

36

Figure

7-4.

Exploded

View

Of

Gun

38

OM.1

581

B

692

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.

4~

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.

~l

M

PORTANT:

statements

identify

special

instructions

necessary

for

the

most

efficient

operation

of

this

equipment.

SECTION

2SPECIFICATIONS

Table

2-1.

~1ire

Feeder

Specification

Description

Type

Of

Input

Power

115

Volts

AC,

3

Amperes

At

50/GO

Or

100

Hz

Power

Control

Circuit

Voltage

Provided

At

Gun

30

Volts

DC

Wire

Feed

Speed

Range

70.875

ipm

(1.9-22.2

mpm)

Overall

Dimenstons

Length:

19

in.

(483

mm);

Width:

9-1/4

in,

(235

mm);

Height:

15-1/4

in.

(387

mm)

Maximum

Spool

Capacity

12

in.

(305

mm)

Cooling

Method

Air-Cooled

(A

Models)

Or

Water-Cooled

(W

Models)

Weight

(Feeder

With

Gun)

Models

With

15

ft.

(4.6

m)

Cable

Assembly

Net:

56

lbs.

(25

kg):

Ship:

58

lbs.

(26

kg)

Models

With

30

ft.

(9.1

m)

Cable

Assembly

Net:

63

lbs.

(29

kg);

Ship:

65

lbs.

(30

kg)

Table

2-2.

Gun

Specification

Description

Input

Voltage

30

Volts

DC

Duty

Cycle

(Air-Cooled

Models)

At

200

Amperes.

100%

Using

Argon

Or

Argon

Mixture

Shielding

Gas

At

250

Amperes,

60%

Using

Argon

Or

Argon

Mixture

Shielding

Gas

(See

Sec

tion

2.1)

Duty

Cycle

(Water-Cooled

Models)

At

400

Amperes,

100%

Using

Argon

Or

Argon

Mixture

Shielding

Gas

(See

Section

2-1)

Wire

Size

Range

.030

Thru

1/16

in.

(0.8

Thru

1.6

mm)

Aluminum

Wire

.030

Thru

.045

in.

(0.8

Thru

1.1

mm)

Hard

Or

Cored

Wire

2-1.

Duty

Cycle

a

CAUTION

USING

GUN

BEYOND

DUTY

CYCLE

RATING

can

damage

gun.

S

Do

not

exceed

indicated

duty

cycles.

OM.1581

Page

1

Duty

cycle

is

how

long

the

gun

can

operate

within

a

ten

minute

period

without

causing

overheating

or

damage.

Both

models

are

rated

using

argon

or

argon

mixture

shielding

gas.

The

air-cooled

model

is

rated

at

100%

duty

cycle

when

operated

at

200

amperes,

allowing

continuous

welding.

When

operated

at

250

amperes,

the

air-cooled

model

is

rated

at

60%

duty

cycle,

allowing

welding

6

minutes

out

of

every

10

minutes.

The

water-cooled

model

~s

rated

at

100%

duty

cycle

when

operated

at

400

amperes,

allowing

continuous

welding.

SECTION

3INSTALLATION

Table

3-1.

Items

Included

With

Feeder

And

Gun

Item

Quantity

Feeder

Drive

Roll

(Small

Groove

For

.030

Thru

1/16

in.

Wire,

Large

Groove

For

.045

Thru

1/16

in.

Wire)

Shipped

With

Large

Groove

In

Feed

Position

I

Gun

Drive

Roll*

(Small

Groove

For

.025

Thru

.035

in.

Wire,

Large

Groove

For

.047

Thru

1/16

in.

Wire)

Shipped

With

Large

Groove

In

Feed

Position

I

Contact

Tubes

(1

For

Each

Wire

Size



.023/.025,

.030.

.035,

.047,

And

1/16

in.)

Shipped

With

.047

Installed

5

lOft.

(3

m)

Gas

Hose

I

lOft.

(3

m)

Water

Hose

With

Adapter

Fitting

(Water-Cooled

Models

Only)

I

10

ft.

(3

m)

Water

Hose

(Water-Cooled

Models

Only)

I

Contact

Tube

Wrench

i

5-Pin

Plug

1

Twistlock

Plug

1

*A

.023/025

contact

tube

is

supplied

with

gun,

but

feeder

is

not

designed

to

feed

these

wire

sizes.

~

IMPORTANT:

Be

sure

that

contact

tube,

line,;

and

drive

rolls

are

correct

for

wire

size

and

type,

see

Section

5

to

change

parts

as

needed.

See

Section

7

for

list

of

other

available

contact

tubes.

3-1.

Equipment

Connection

Diagrams

a

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.

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.

Review

Figure

3-1

through

Figure

3-4

to

determine

how

equipment

will

be

connected.

Air-cooled

models

are

shown

in

Figure

3-1

through

Figure

3-4.

For

water-cooled

models,

supplied

water

hoses

must

be

connected

from

wire

feeder

to

coolant

supply.

Read

entire

Section

3

before

installing

equipment.

OM-1581

Page

2

Have

only

qualified

persons

install

this

unit.

wtwarn71

9/91

Figure

3-1.

Connections

With

A

Constant

Voltage

(CV)

Or

Constant

Voltage/Constant

Current

(CV/CC)

Welding

Power

Source

Having

A

14-Socket

Receptacle

Figure

3-2.

Connections

With

A

Constant

Voltage

(CV)

Welding

Power

Source

Having

Separate

115

VAC

And

Contactor

Control

Receptacles

1

CV

Or

CC/CV

Welding

Power

Source

2

115

VAC/Contactor

Control

14-Pin

Plug

PLG5

3

Positive

(+)

Weld

Cable

4

Negative

()

Weld

Cable

5

Workpiece

6

Voltage

Sensing

Lead

Connect

lead

to

workpiece

for

CC

welding

only.

7

Gun

8

Wire

Feeder

9

lOft.(3m)Gas

Hose

10

115

VAC/Contactor

Controt

Cord

11

Gas

Cylinder

ST-t5t

774

1

CV

Welding

Power

Source

2

Plug

Obtain

matching

plugs

for

connect

ing

to

power

source

receptacles.

3

Positive

1+)

Weld

Cable

4

Negative

()

Weld

Cable

5

Workpiece

6

Voltage

Sensing

Lead

Do

not

connect

to

workpiece.

7

Gun

8

Wire

Feeder

9

lOft.(3m)GasHose

10

115

VAC/Contactor

Control

Cord

11

Gas

Cylinder

10

9

8

STt51

775A

OM-1581

Page

3

FIgure

3-3.

Connections

With

A

Constant

Current

(CC)

Welding

Power

Source

Having

Contactor

Control

Receptacle

Figure

3-4.

Connections

With

A

Constant

Current

(CC)

Welding

Power

Source

And

A

115VAC/12VDC

Secondary

Contactor

1

CC

Welding

Power

Source

2

5-Pin

Or

Twistlock

Plug

(Supplied)

3

Positive

(+)

Weld

Cable

4

Negative

()

Weld

Cable

5

Workpiece

6

Voltage

Sensing

Lead

7

Gun

8

Wire

Feeder

9

lOft.(3m)GasHose

10

2-Conductor

Contactor

Con

trol

Cord

11

3-Conductor

115

VAC

Cord

12

Gas

Cylinder

13

115

VACPIug

Obtain

plug

for

wire

feeder.

ST-151

176

I

CC

Welding

Power

Source

2

Positive

(+)

Weld

Cable

3

Negative

()

Weld

Cable

4

Workpiece

5

Voltage

Sensing

Lead

6

Gun

7

Wire

Feeder

8

lOft.(3m)GasHose

9

3-Conductor

115

VAC

Cord

10

2-Conductor

Contactor

Con

trol

Cord

11

5-Pin

Plug

12

Secondary

Contactor

13

Gas

Cylinder

14

115

VACPIug

Obtain

plug

for

wire

feeder.

ST.~5~

177

3-2.

Removing

Top

Cover

Of

Gun

1

Top

Cover

Push

back

and

lift

off

as

shown.

To

reinstall

cover,

set

rear

of

cover

in

gun,

and

push

cover

back

and

down

until

it

clicks

into

position.

Ret.

ST.150

862-A

Figure

3-5.

Removing

Top

Cover

Of

Gun

3-3.

Gun

To

Feeder

Connections

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.

wtwarnl

9J9~

A.

Air-Cooled

Gun

Connections

1

Gun

Control

Cable

Insert

plug

into

GUN

CONTROL

receptacle,

and

tighten

threaded

collar.

2

Gas

Hose

Connect

to

GAS

fitting

on

feeder.

3

Wetd

Cable

4

Weld

Cable

Terminal

In

Feeder

Connect

gun

weld

cable

to

weld

cable

terminal

in

feeder.

5

Wire

Conduit

6

Thumbscrew

7

Wire

Conduit

Block

Loosen

thumbscrew,

and

insert

conduit

through

WIRE

opening

un

til

it

bottoms

against

block.

Tighten

thumbscrew.

Close

and

latch

door.

Tools

Needed;

~Z~

5/6

in.,

3/4

~fl.

Ref.

ST.151

778-A

/

ST151

666

/

S1.145

432.A

3

Figure

3-6.

Air-Cooled

Gun

Connections

OM-1581

Page

5

B.

Water-Cooled

Gun

Connections

FIgure

3-7.

Water-Cooled

Gun

Connections

3-4.

Internal

Connections

To

Feeder

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.

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.

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.

HiGH

GAS

PRESSURE

can

cause

gun

gas

valve

to

leak.



Do

not

use

gas

pressure

above

50

psi

(345

kPa)

or

mechanical

gas

valve

in

gun

can

leak.

OVERHEATING

can

damage

gun

parts.



If

using

recirculating

coolant

system,

do

not

make

connections

from

coolant

system

to

water

valve;

instead

make

connections

directly

from

coolant

system

to

gun

hoses.

INCORRECT

COOLANT

FLOWRATE

can

damage

gun

parts.



Maintain

minimum

1

qt./min.

flowrate

at

all

times.

w~warn7

1.9191

2

I

I

Gas

Hose

Connect

to

GAS

fitting

on

feeder.

2

Water

Hose

Connect

to

WATER

TO

GUN

fitting

on

feeder

(left-hand

threads).

3

Wire

Conduit

4

Thumbscrew

5

Wire

Conduit

Block

Loosen

thumbscrew,

and

insert

conduit

through

WIRE

opening

un

til

it

bottoms

against

block.

Tighten

thumbscrew.

6

Gun

Control

Cable

Insert

plug

into

GUN

CONTROL

receptacle,

and

tighten

threaded

collar.

7

Strain

Relief

Remove

strain

relief

as

shown.

8

PoweriWater

Cable

Route

cable

through

strain

relief

and

connect

to

WELD/WATER

FROM

GUN

outlet

on

feeder.

Rein

stall

strain

relief.

Close

and

latch

door.

Ref

ST-151

778-A/

ST-152

456

7

8

6

Tools

Needed:

:~

518in..

l-1/8in.

OM-1581

Page

6

A.

Air-Cooled

Feeder

Connections

Rear

Panel

Figure

3-8.

Air-Cooled

Feeder

Connections

1

Gas

Hose

Grommet

2

lOft.(3m)GasHose

3

Rear

Of

Gas

Fitting

Route

one

end

of

gas

hose

through

grommet,

and

connect

hose

to

rear

of

GAS

fitting

in

feeder.

Connect

re

maining

end

of

hose

to

regulator/

flowmeter.

4

Weld

Cable

To

Welding

Power

Source

Select

and

prepare

weld

cable

ac

cording

to

welding

power

source

manual.

5

Weld

Cable

Grommet

6

Reed

Switch

7

Weld

Cable

Terminal

In

Feeder

Route

one

end

of

weld

cable

through

grommet.

through

reed

switch,

and

connect

to

weld

cable

terminal

in

feeder.

Connect

remaining

end

of

cable

to

positive

(+)

weld

output

ter

minal

on

welding

power

source.

8

Gun

Weld

Cable

Be

sure

that

terminal

of

welding

pow

er

source

weld

cable

is

in

direct

con

tact

with

terminal

from

gun

weld

cable.

Close

and

latch

door.

Ref.

ST.151

771

2

4

6

7

3

Tools

Needed:

5/8

in..

1-1/8

in.

OM-1581

Page

7

B.

Water-Cooled

Feeder

Connections

Rear

Panel

Obtain

coolant

supply.

1

Gas

Hose

Grommet

2

lOft.(3m)GasHose

3

Rear

Of

Gas

Fining

Route

one

end

of

gas

hose

through

grommet.

and

connect

hose

to

rear

of

GAS

fitting

in

feeder.

Connect

re

maining

end

of

hose

to

regulator/

flowmeter.

4

Coolant

Supply

Hose

Grom

met

5

10

ft.

(3

m)

Water

Supply

Hose

With

5/8

in.

Adapter

Fit

ting

6

Rear

Of

Water

Fitting

Remove

5/8

in.

adapter

fining

from

hose.

Route

one

end

of

a

water

hose

through

grommet,

and

con

nect

to

rear

of

WATER

TO

GUN

fit

ting

in

feeder.

Connect

remaining

end

to

supply

fitting

on

coolant

sup

ply.

7

Coolant

Return

Hose

Grom

met

8

lOft.

(3

m)

Water

Return

Hose

Connect

To

Regulator/

9

Connection

Block

Flowmeter

Route

one

end

of

remaining

water

hose

through

grommet.

and

con

nect

to

rear

of

connection

block

(not

shown).

Connect

remaining

end

of

hose

to

return

fining

on

cool

ant

supply.

10

Weld

Cable

Grommet

11

Weld

Cable

To

Welding

Pow

er

Source

Select

and

prepare

weld

cable

ac

cording

to

welding

power

source

manual.

12

Reed

Switch

6

13

Weld

Cable

Screw

In

Feeder

Route

one

end

of

weld

cable

through

grommet.

through

reed

switch,

and

connect

to

block

in

feeder

using

hardware

shown.

Connect

remaining

end

of

cable

to

positive

(+)

weld

output

terminal

on

welding

power

source.

Close

and

latch

door.

Tools

Needed:

~

5/Bin.,

1-1/Bin.

Ref.

ST.152

43l.A

Connect

To

Positive

(+)

Weld

Output

Terminal

On

Welding

Power

Source

2

11

9

3

Figure

3-9.

Water-Cooled

Feeder

Connections

OM-1581

Page

8

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Miller KC248746 Owner's manual

Brand: Miller

Model: KC248746

Category: Welding System

Type: Owner's manual

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