S-22A

Processes

Description

MIG (GMAW) WeldingFlux Cored (FCAW) Welding

Wire Feeder

OM-1570 123 528MOctober 2000

Visit our website atwww.MillerWelds.com

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributorto receive the latest full line catalog orindividual catalog sheets. To locate your nearestdistributor or service agency call 1-800-4-A-Miller,or visit us at www.MillerWelds.com on the web.

Thank you and congratulations on choosing Miller. Nowyou can get the job done and get it done right. We knowyou dont have time to do it any other way.

Thats why when Niels Miller first started building arcwelders in 1929, he made sure his products offeredlong-lasting value and superior quality. Like you, hiscustomers couldnt afford anything less. Miller productshad to be more than the best they could be. They had tobe the best you could buy.

Today, the people that build and sell Miller products continue thetradition. Theyre just as committed to providing equipment and servicethat meets the high standards of quality and value established in 1929.

This Owners Manual is designed to help you get the most out of yourMiller products. Please take time to read the Safety precautions. They willhelp you protect yourself against potential hazards on the worksite. Weve

made installation and operation quick and easy.With Miller you can count on years of reliableservice with proper maintenance. And if forsome reason the unit needs repair, theres aTroubleshooting section that will help youfigure out what the problem is. The parts listwill then help you to decide which exact partyou may need to fix the problem. Warranty andservice information for your particular modelare also provided.

Miller is the first weldingequipment manufacturer inthe U.S.A. to be registered tothe ISO 9001 Quality SystemStandard.

Working as hard as you do every power source fromMiller is backed by the mosthassle-free warranty in thebusiness.

From Miller to You

Miller offers a TechnicalManual which providesmore detailed service andparts information for yourunit. To obtain a TechnicalManual, contact your localdistributor. Your distributorcan also supply you withWelding Process Manualssuch as SMAW, GTAW,GMAW, and GMAW-P.

TABLE OF CONTENTSSECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Additional Symbols for Installation, Operation, and Maintenance 3. . . . . . . . . . . . . . . . . . . . . . 1-4. Principal Safety Standards 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . . 1-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Dangers relatifs au soudage larc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement

et la maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. Principales normes de scurit 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Information sur les champs lectromagntiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 DEFINITIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Warning Label Definitions 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Rating Label For CE Products 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Symbols And Definitions 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 INSTALLATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Specifications 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Site Selection 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Gun Recommendation Table 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. Equipment Connection Diagrams 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5. Connecting 14-Pin Plug, Shielding Gas And Optional Volt Sense Lead 12. . . . . . . . . . . . . . . . . 3-6. 14-Pin Plug Information 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7. Connecting Welding Gun And Weld Cable 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8. Setting Time Range For Optional Spot Time Control 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9. Installing And Aligning Wire Guide And Drive Roll 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10. Installing And Threading Welding Wire 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 OPERATION 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Front Panel Controls 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Optional Side Panel Controls 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 MAINTENANCE & TROUBLESHOOTING 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Routine Maintenance 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Overload Protection 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Troubleshooting 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 ELECTRICAL DIAGRAM 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 PARTS LIST 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONS AND ACCESSORIESWARRANTY

OM-1570M

dec_con1 1/96

Declaration of Conformity forEuropean Community (CE) Products

This information is provided for units with CE certification (see rating label on unit).NOTE

Manufacturers Name: Miller Electric Mfg. Co.Manufacturers Address: 1635 W. Spencer Street

Appleton, WI 54914 USA

Declares that the product: S-22Aconforms to the following Directives and Standards:

Directives

Low Voltage Directive: 73/23/EEC

Electromagnetic Compatibility (EMC) Directive: 89/336/EECMachinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC

Standards

Arc Welding Equipment Part I: Welding Power Sources: IEC 974-1(April 1995 Draft Revision)

Arc Welding Equipment: Wirefeed Systems: IEC 974-4(May 1995 Draft Revision)

Degrees of Protection Provided By Enclosures (IP Code): IEC 529:1989Insulation Coordination For Equipment With Low-Voltage Systems:

Part I: Principles, Requirements and Tests: IEC 664-1: 1992

Electromagnetic Compatibility, (EMC): EN 50199

European Contact: Mr. Luigi Vacchini, Managing DirectorMILLER Europe S.P.A.Via Privata Iseo20098 San GiulianoMilanese, Italy

Telephone: 39(02)98290-1Fax: 39(02)98281-552

OM-1570 Page 1

SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USINGsom _nd_4/98

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols.

Marks a special safety message.

Means Note; not safety related.

This group of symbols means Warning! Watch Out! possibleELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.Consult symbols and related instructions below for necessary actionsto avoid the hazards.

1-2. Arc Welding Hazards The symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you seethe symbol, watch out, and follow the related instructions toavoid the hazard. The safety information given below is onlya summary of the more complete safety information found inthe Safety Standards listed in Section 1-4. Read and follow allSafety Standards.

Only qualified persons should install, operate, maintain, andrepair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocksor severe burns. The electrode and work circuit iselectrically live whenever the output is on. The inputpower circuit and machine internal circuits are also

live when power is on. In semiautomatic or automatic wire welding, thewire, wire reel, drive roll housing, and all metal parts touching thewelding wire are electrically live. Incorrectly installed or improperlygrounded equipment is a hazard. Do not touch live electrical parts. Wear dry, hole-free insulating gloves and body protection. Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the workor ground.

Do not use AC output in damp areas, if movement is confined, or ifthere is a danger of falling.

Use AC output ONLY if required for the welding process. If AC output is required, use remote output control if present on

unit. Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according toOSHA 29 CFR 1910.147 (see Safety Standards).

Properly install and ground this equipment according to itsOwners Manual and national, state, and local codes.

Always verify the supply ground check and be sure that inputpower cord ground wire is properly connected to ground terminal indisconnect box or that cord plug is connected to a properlygrounded receptacle outlet.

When making input connections, attach proper grounding conduc-tor first double-check connections.

Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill.

Turn off all equipment when not in use. Do not use worn, damaged, undersized, or poorly spliced cables. Do not drape cables over your body.

If earth grounding of the workpiece is required, ground it directlywith a separate cable.

Do not touch electrode if you are in contact with the work, ground,or another electrode from a different machine.

Use only well-maintained equipment. Repair or replace damagedparts at once. Maintain unit according to manual.

Wear a safety harness if working above floor level. Keep all panels and covers securely in place. Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical. Insulate work clamp when not connected to workpiece to prevent

contact with any metal object. Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists after removal ofinput power on inverters. Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Sectionbefore touching any parts.

Welding produces fumes and gases. Breathingthese fumes and gases can be hazardous to yourhealth.

FUMES AND GASES can be hazardous.

Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or use exhaust at the arc to remove

welding fumes and gases. If ventilation is poor, use an approved air-supplied respirator. Read the Material Safety Data Sheets (MSDSs) and the

manufacturers instructions for metals, consumables, coatings,cleaners, and degreasers.

Work in a confined space only if it is well ventilated, or whilewearing an air-supplied respirator. Always have a trained watch-person nearby. Welding fumes and gases can displace air andlower the oxygen level causing injury or death. Be sure the breath-ing air is safe.

Do not weld in locations near degreasing, cleaning, or spraying op-erations. The heat and rays of the arc can react with vapors to formhighly toxic and irritating gases.

Do not weld on coated metals, such as galvanized, lead, orcadmium plated steel, unless the coating is removed from the weldarea, the area is well ventilated, and if necessary, while wearing anair-supplied respirator. The coatings and any metals containingthese elements can give off toxic fumes if welded.

OM-1570 Page 2

Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sparks fly off from theweld.

ARC RAYS can burn eyes and skin.

Wear a welding helmet fitted with a proper shade of filter to protectyour face and eyes when welding or watching (see ANSI Z49.1and Z87.1 listed in Safety Standards).

Wear approved safety glasses with side shields under yourhelmet.

Use protective screens or barriers to protect others from flash andglare; warn others not to watch the arc.

Wear protective clothing made from durable, flame-resistant mate-rial (leather and wool) and foot protection.

Welding on closed containers, such as tanks,drums, or pipes, can cause them to blow up. Sparkscan fly off from the welding arc. The flying sparks, hotworkpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode to metal objects can causesparks, explosion, overheating, or fire. Check and be sure the area issafe before doing any welding.

WELDING can cause fire or explosion.

Protect yourself and others from flying sparks and hot metal. Do not weld where flying sparks can strike flammable material. Remove all flammables 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

easily go through small cracks and openings to adjacent areas. 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, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (seeSafety Standards).

Connect work cable to the work as close to the welding area aspractical to prevent welding current from traveling long, possiblyunknown 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. Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap. Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

FLYING METAL can injure eyes. Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,they can throw off slag.

Wear approved safety glasses with sideshields even under your welding helmet.

BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Always ventilate confined spaces or use

approved air-supplied respirator.

HOT PARTS can cause severe burns. Do not touch hot parts bare handed. Allow cooling period before working on gun or

torch.

MAGNETIC FIELDS can affect pacemakers.

Pacemaker wearers keep away. Wearers should consult their doctor before

going near arc welding, gouging, or spotwelding operations.

NOISE can damage hearing.

Noise from some processes or equipment candamage hearing. Wear approved ear protection if noise level is

high.

Shielding gas cylinders contain gas under highpressure. If damaged, a cylinder can explode. Sincegas cylinders are normally part of the weldingprocess, be sure to treat them carefully.

CYLINDERS can explode if damaged.

Protect compressed gas cylinders from excessive heat, mechani-cal shocks, slag, open flames, sparks, and arcs.

Install cylinders in an upright position by securing to a stationarysupport or cylinder rack to prevent falling or tipping.

Keep cylinders away from any welding or other electrical circuits. Never drape a welding torch over a gas cylinder. Never allow a welding electrode to touch any cylinder. Never weld on a pressurized cylinder explosion will result. Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them andassociated parts in good condition.

Turn face away from valve outlet when opening cylinder valve. Keep protective cap in place over valve except when cylinder is in

use or connected for use. Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in SafetyStandards.

OM-1570 Page 3

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard. Do not install or place unit on, over, or near

combustible surfaces. Do not install unit near flammables.

Do not overload building wiring be sure power supply system isproperly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury. Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories. Use equipment of adequate capacity to lift and

support unit. If using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side ofunit.

OVERUSE can cause OVERHEATING Allow cooling period; follow rated duty cycle. Reduce current or reduce duty cycle before

starting to weld again. Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards. Put on grounded wrist strap BEFORE handling

boards or parts. Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can cause injury. Keep away from moving parts. Keep away from pinch points such as drive

rolls.

WELDING WIRE can cause injury. Do not press gun trigger until instructed to do

so.

Do not point gun toward any part of the body,other people, or any metal when threadingwelding wire.

MOVING PARTS can cause injury. Keep away from moving parts such as fans. Keep all doors, panels, covers, and guards

closed and securely in place.

H.F. RADIATION can cause interference.

High-frequency (H.F.) can interfere with radionavigation, safety services, computers, andcommunications equipment.

Have only qualified persons familiar withelectronic equipment perform this installation.

The user is responsible for having a qualified electrician prompt-ly correct any interference problem resulting from the installa-tion.

If notified by the FCC about interference, stop using theequipment at once.

Have the installation regularly checked and maintained. Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding tominimize the possibility of interference.

ARC WELDING can cause interference.

Electromagnetic energy can interfere withsensitive electronic equipment such ascomputers and computer-driven equipmentsuch as robots.

Be sure all equipment in the welding area iselectromagnetically compatible.

To reduce possible interference, keep weld cables as short aspossible, close together, and down low, such as on the floor.

Locate welding operation 100 meters from any sensitive elec-tronic equipment.

Be sure this welding machine is installed and groundedaccording to this manual.

If interference still occurs, the user must take extra measuressuch as moving the welding machine, using shielded cables,using line filters, or shielding the work area.

1-4. Principal Safety StandardsSafety in Welding and Cutting, ANSI Standard Z49.1, from AmericanWelding Society, 550 N.W. LeJeune Rd, Miami FL 33126Safety 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 Cut-ting of Containers That Have Held Hazardous Substances, AmericanWelding Society Standard AWS F4.1, from American Welding Society,550 N.W. LeJeune Rd, Miami, FL 33126National Electrical Code, NFPA Standard 70, from National Fire Protec-tion Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,from Compressed Gas Association, 1235 Jefferson Davis Highway,Suite 501, Arlington, VA 22202.Code for Safety in Welding and Cutting, CSA Standard W117.2, fromCanadian Standards Association, Standards Sales, 178 RexdaleBoulevard, Rexdale, Ontario, Canada M9W 1R3.Safe Practices For Occupation And Educational Eye And FaceProtection, ANSI Standard Z87.1, from American National StandardsInstitute, 1430 Broadway, New York, NY 10018.Cutting And Welding Processes, NFPA Standard 51B, from NationalFire Protection Association, Batterymarch Park, Quincy, MA 02269.

OM-1570 Page 4

1-5. EMF InformationConsiderations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flows through welding cables, will cause electro-magnetic fields. There has been and still is some concern about suchfields. However, after examining more than 500 studies spanning 17years of research, a special blue ribbon committee of the NationalResearch Council concluded that: The body of evidence, in thecommittees judgment, has not demonstrated that exposure to power-frequency electric and magnetic fields is a human-health hazard.However, studies are still going forth and evidence continues to beexamined. Until the final conclusions of the research are reached, youmay wish to minimize your exposure to electromagnetic fields whenwelding or cutting.To reduce magnetic fields in the workplace, use the followingprocedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from opera-tor as practical.

5. Connect work clamp to workpiece as close to the weld as possi-ble.

About Pacemakers:Pacemaker wearers consult your doctor first. If cleared by your doctor,then following the above procedures is recommended.

OM-1570 Page 5

SECTION 1 CONSIGNES DE SECURITE LIRE AVANTUTILISATION

som _nd_fre 4/98

1-1. Signification des symbolesSignifie Mise en garde ! Soyez vigilant ! Cette procdureprsente des risques de danger ! Ceux-ci sont identifispar des symboles adjacents aux directives.

Identifie un message de scurit particulier.

Signifie NOTA ; nest pas relatif la scurit.

Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a desrisques de danger relis aux CHOCS LECTRIQUES, aux PICES ENMOUVEMENT et aux PICES CHAUDES. Reportez-vous aux symboleset aux directives ci-dessous afin de connatre les mesures prendre pourviter tout danger.

1-2. Dangers relatifs au soudage larc Les symboles prsents ci-aprs sont utiliss tout au long du

prsent manuel pour attirer votre attention et identifier les risquesde danger. Lorsque vous voyez un symbole, soyez vigilant etsuivez les directives mentionnes afin dviter tout danger. Lesconsignes de scurit prsentes ci-aprs ne font que rsumerlinformation contenue dans les normes de scurit numres la section 1-4. Veuillez lire et respecter toutes ces normes descurit.

Linstallation, lutilisation, lentretien et les rparations ne doi-vent tre confis qu des personnes qualifies.

Au cours de lutilisation, tenir toute personne lcart et plus par-ticulirement les enfants.

UN CHOC LECTRIQUE peut tuer.Un simple contact avec des pices lectriques peutprovoquer une lectrocution ou des blessures graves.Llectrode et le circuit de soudage sont sous tensionds que lappareil est sur ON. Le circuit dentre et lescircuits internes de lappareil sont galement sous

tension ce moment-l. En soudage semi-automatique ou automatique,le fil, le dvidoir, le logement des galets dentranement et les picesmtalliques en contact avec le fil de soudage sont sous tension. Desmatriels mal installs ou mal mis la terre prsentent un danger. Ne jamais toucher les pices lectriques sous tension. Porter des gants et des vtements de protection secs ne comportant

pas de trous. Sisoler de la pice et de la terre au moyen de tapis ou dautres

moyens isolants suffisamment grands pour empcher le contact phy-sique ventuel avec la pice ou la terre.

Ne pas se servir de source lectrique courant lectrique dans les zoneshumides, dans les endroits confins ou l o on risque de tomber.

Se servir dune source lectrique courant lectrique UNIQUEMENT si leprocd de soudage le demande.

Si lutilisation dune source lectrique courant lectrique savre nces-saire, se servir de la fonction de tlcommande si lappareil en est quip.

Couper lalimentation ou arrter le moteur avant de procder linstal-lation, la rparation ou lentretien de lappareil. Dverrouillerlalimentation selon la norme OSHA 29 CFR 1910.147 (voir normes descurit).

Installer et mettre la terre correctement cet appareil conformment son manuel dutilisation et aux codes nationaux, provinciaux etmunicipaux.

Toujours vrifier la terre du cordon dalimentation Vrifier et sassu-rer que le fil de terre du cordon dalimentation est bien raccord laborne de terre du sectionneur ou que la fiche du cordon est raccorde une prise correctement mise la terre.

En effectuant les raccordements dentre fixer dabord le conducteurde mise la terre appropri et contre-vrifier les connexions.

Vrifier frquemment le cordon dalimentation pour voir sil nest pasendommag ou dnud remplacer le cordon immdiatement sil estendommag un cble dnud peut provoquer une lectrocution.

Mettre lappareil hors tension quand on ne lutilise pas. Ne pas utiliser des cbles uss, endommags, de grosseur insuffi-

sante ou mal pisss. Ne pas enrouler les cbles autour du corps. Si la pice soude doit tre mise la terre, le faire directement avec un

cble distinct. Ne pas toucher llectrode quand on est en contact avec la pice, la

terre ou une lectrode provenant dune autre machine.

Nutiliser quun matriel en bon tat. Rparer ou remplacer sur-le-champ les pices endommages. Entretenir lappareil conformment ce manuel.

Porter un harnais de scurit quand on travaille en hauteur. Maintenir solidement en place tous les panneaux et capots. Fixer le cble de retour de faon obtenir un bon contact mtal-mtal

avec la pice souder ou la table de travail, le plus prs possible de lasoudure.

Isoler la pince de masse quand pas mis la pice pour viter le contactavec tout objet mtallique.

Il y a DU COURANT CONTINU IMPORTANT dans lesconvertisseurs aprs la suppression de lalimenta-tion lectrique. Arrter les convertisseurs, dbrancher le courant lectrique, et d-

charger les condensateurs dalimentation selon les instructionsindiques dans la partie entretien avant de toucher les pices.

Le soudage gnre des fumes et des gaz. Leurinhalation peut tre dangereux pour votre sant.

Eloigner votre tte des fumes. Ne pas respirerles fumes.

A lintrieur, ventiler la zone et/ou utiliser un chappement au niveaude larc pour lvacuation des fumes et des gaz de soudage.

Si la ventilation est insuffisante, utiliser un respirateur alimenta-tion dair homologu.

Lire les spcifications de scurit des matriaux (MSDSs) et lesinstructions du fabricant concernant les mtaux, les consomma-bles, les revtements, les nettoyants et les dgraisseurs.

Travailler dans un espace ferm seulement sil est bien ventil ou enportant un respirateur alimentation dair. Demander toujours unsurveillant dment form de se tenir proximit. Des fumes et desgaz de soudage peuvent dplacer lair et abaisser le niveau doxy-gne provoquant des blessures ou des accidents mortels. Sassu-rer que lair de respiration ne prsente aucun danger.

Ne pas souder dans des endroits situs proximit doprations dedgraissage, de nettoyage ou de pulvrisation. La chaleur et lesrayons de larc peuvent ragir en prsence de vapeurs et former desgaz hautement toxiques et irritants.

Ne pas souder des mtaux munis dun revtement, tels que laciergalvanis, plaqu en plomb ou au cadmium moins que le revte-ment nait t enlev dans la zone de soudure, que lendroit soit bienventil, et si ncessaire, en portant un respirateur alimentationdair. Les revtements et tous les mtaux renfermant ces lmentspeuvent dgager des fumes toxiques en cas de soudage.

LES FUMES ET LES GAZ peuventtre dangereux.

OM-1570 Page 6

Le rayonnement de larc du procd de soudagegnre des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles de provoquer

des brlures dans les yeux et sur la peau. Des tincelles sont projetespendant le soudage.

LES RAYONS DE LARC peuvent pro-voquer des brlures dans les yeux etsur la peau.

Porter un casque de soudage muni dun cran de filtre appropri pourprotger votre visage et vos yeux pendant le soudage ou pour regar-der (voir ANSI Z49.1 et Z87.1 numr dans les normes de scurit).

Porter des protections approuvs pour les oreilles si le niveau sondre esttrop lev.

Utiliser des crans ou des barrires pour protger des tiers de lclairet de lblouissement; demander aux autres personnes de ne pas re-garder larc.

Porter des vtements de protection constitu dans une matire dura-ble, rsistant au feu (cuir ou laine) et une protection des pieds.

Le soudage effectu sur des conteneurs ferms telsque des rservoirs, tambours ou des conduites peutprovoquer leur clatement. Des tincelles peuvent treprojetes de larc de soudure. La projection dtincel-

les, des pices chaudes et des quipements chauds peut provoquer desincendies et des brlures. Le contact accidentel de llectrode avec desobjets mtalliques peut provoquer des tincelles, une explosion, unsurchauffement ou un incendie. Avant de commencer le soudage, vrifieret sassurer que lendroit ne prsente pas de danger.

LE SOUDAGE peut provoquer unincendie ou une explosion.

Se protger et dautres personnes de la projection dtincelles et demtal chaud.

Ne pas souder dans un endroit l o des tincelles peuvent tomber surdes substances inflammables.

Dplacer toutes les substances inflammables une distance de 10,7m de larc de soudage. En cas dimpossibilit les recouvrir soigneuse-ment avec des protections homologus.

Des tincelles et des matriaux chauds du soudage peuvent facile-ment passer dans dautres zones en traversant de petites fissures etdes ouvertures.

Surveiller tout dclenchement dincendie et tenir un extincteur proxi-mit.

Le soudage effectu sur un plafond, plancher, paroi ou sparationpeut dclencher un incendie de lautre ct.

Ne pas effectuer le soudage sur des conteneurs ferms tels que desrservoirs, tambours, ou conduites, moins quils naient t prpa-rs correctement conformment AWS F4.1 (voir les normes descurit).

Brancher le cble sur la pice le plus prs possible de la zone de sou-dage pour viter le transport du courant sur une longue distance pardes chemins inconnus ventuels en provoquant des risques dlec-trocution et dincendie.

Ne pas utiliser le poste de soudage pour dgeler des conduites ge-les.

En cas de non utilisation, enlever la baguette dlectrode du porte-lectrode ou couper le fil la pointe de contact.

Porter des vtements de protection dpourvus dhuile tels que desgants en cuir, une chemise en matriau lourd, des pantalons sans re-vers, des chaussures hautes et un couvre chef.

Avant de souder, retirer toute substance combustible de vos pochestelles quun allumeur au butane ou des allumettes.

DES PARTICULES VOLANTESpeuvent blesser les yeux. Le soudage, lcaillement, le passage de la pice

la brosse en fil de fer, et le meulage gnrentdes tincelles et des particules mtalliques vo-

lantes. Pendant la priode de refroidissement des soudures, elles ris-quent de projeter du laitier. Porter des lunettes de scurit avec crans latraux ou un cran facial.

LES ACCUMULATIONS DE GAZ ris-quent de provoquer des blessures oumme la mort. Fermer lalimentation du gaz protecteur en cas de

non utilisation. Veiller toujours bien arer les espaces confins ou se servir dun respi-

rateur dadduction dair homologu.

DES PICES CHAUDES peuvent pro-voquer des brlures graves. Ne pas toucher des parties chaudes mains nues Prvoir une priode de refroidissement avant

dutiliser le pistolet ou la torche.

LES CHAMPS MAGNTIQUES peuventaffecter les stimulateurs cardiaques.

Porteurs de stimulateur cardiaque, restez distance. Les porteurs dun stimulateur cardiaque doivent

dabord consulter leur mdecin avant de sapprocherdes oprations de soudage larc, de gougeage oude soudage par points.

LE BRUIT peut affecter loue.

Le bruit des processus et des quipements peut affecterloue.

Porter des protections approuvs pour les oreilles sile niveau sondre est trop lev.

Des bouteilles de gaz protecteur contiennent du gazsous haute pression. Si une bouteille est endomma-ge, elle peut exploser. Du fait que les bouteilles de gazfont normalement partie du procd de soudage, les

manipuler avec prcaution.

Protger les bouteilles de gaz comprim dune chaleur excessive,des chocs mcaniques, du laitier, des flammes ouvertes, des tin-celles et des arcs.

Placer les bouteilles debout en les fixant dans un support stationnai-re ou dans un porte-bouteilles pour les empcher de tomber ou dese renverser.

Tenir les bouteilles loignes des circuits de soudage ou autres cir-cuits lectriques.

Ne jamais placer une torche de soudage sur une bouteille gaz. Une lectrode de soudage ne doit jamais entrer en contact avec une

bouteille. Ne jamais souder une bouteille pressurise risque dexplosion. Utiliser seulement des bouteilles de gaz protecteur, rgulateurs,

tuyaux et raccords convenables pour cette application spcifique;les maintenir ainsi que les lments associs en bon tat.

Ne pas tenir la tte en face de la sortie en ouvrant la soupape de labouteille.

Maintenir le chapeau de protection sur la soupape, sauf en cas duti-lisation ou de branchement de la bouteille.

Lire et suivre les instructions concernant les bouteilles de gaz com-prim, les quipements associs et les publications P-1 CGA nu-mres dans les normes de scurit.

Si des BOUTEILLES sont endomma-ges, elles pourront exploser.

OM-1570 Page 7

1-3. Dangers supplmentaires en relation avec linstallation, le fonctionnementet la maintenance

Risque DINCENDIE OUDEXPLOSION. Ne pas placer lappareil sur, au-dessus ou proxi-

mit de surfaces infllammables. Ne pas installer lappareil proximit de produits inflammables Ne pas surcharger linstallation lectrique sassurer que lalimen-

tation est correctement dimensionn et protg avant de mettrelappareil en service.

LA CHUTE DE LAPPAREIL peutblesser.

Utiliser lanneau de levage uniquement pour sou-lever lappareil, NON PAS les chariot, les bouteil-les de gaz ou tout autre accessoire.

Utiliser un engin dune capacit approprie poursoulever lappareil.

En utilisant des fourches de levage pour dplacer lunit, sassurerque les fourches sont suffisamment longues pour dpasser du ctoppos de lappareil.

LEMPLOI EXCESSIF peutSURCHAUFFER LQUIPEMENT. Prvoir une priode de refroidissement, respec-

ter le cycle opratoire nominal. Rduire le courant ou le cycle opratoire avant de

recommancer le soudage. Ne pas obstruer les passages dair du poste.

LES CHARGES LECTROSTATI-QUES peuvent endommager lescircuits imprims. tablir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pices. Utiliser des pochettes et des botes antistatiques

pour stocker, dplacer ou expdier des cartes decircuits imprimes.

DES ORGANES MOBILES peuventprovoquer des blessures. Ne pas sapprocher des organes mobiles. Ne pas sapprocher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuventprovoquer des blessures. Ne pas appuyer sur la gachette avant den avoir

reu linstruction. Ne pas diriger le pistolet vers soi, dautres person-

nes ou toute pice mcanique en engageant le filde soudage.

DES ORGANES MOBILES peuventprovoquer des blessures. Rester lcart des organes mobiles comme le

ventilateur. Maintenir ferms et fixement en place les portes,

panneaux, recouvrements et dispositifs deprotection.

LE RAYONNEMENT HAUTE FR-QUENCE (H.F.) risque de provoquerdes interfrences. Le rayonnement haute frequence peut provoquer

des interfrences avec les quipements de ra-dionavigation et de communication, les servicesde scurit et les ordinateurs.

Demander seulement des personnes qualifies familiarisesavec des quipements lectroniques de faire fonctionner linstalla-tion.

Lutilisateur est tenu de faire corriger rapidement par un lectricienqualifi les interfrences rsultant de linstallation.

Si le FCC signale des interfrences, arrter immdiatement lappa-reil.

Effectuer rgulirement le contrle et lentretien de linstallation. Maintenir soigneusement ferms les portes et les panneaux des

sources de haute frquence, maintenir les clateurs une distancecorrecte et utiliser une terre et et un blindage pour rduire les interf-rences ventuelles.

LE SOUDAGE LARC risque deprovoquer des interfrences. Lnergie lectromagntique risque de provoquer

des interfrences pour lquipement lectroniquesensible tel que les ordinateurs et lquipementcommand par ordinateur tel que les robots.

Veiller ce que tout lquipement de la zone de soudage soit com-patible lectromagntiquement.

Pour rduire la possibilit dinterfrence, maintenir les cbles desoudage aussi courts que possible, les grouper, et les poser aussibas que possible (ex. par terre).

Veiller souder une distance de 100 mtres de tout quipementlectronique sensible.

Veiller ce que ce poste de soudage soit pos et mis la terreconformment ce mode demploi.

En cas dinterfrences aprs avoir pris les mesures prcdentes, ilincombe lutilisateur de prendre des mesures supplmentaires tel-les que le dplacement du poste, lutilisation de cbles blinds, luti-lisation de filtres de ligne ou la pose de protecteurs dans la zone detravail.

LES CHAMPS MAGNTIQUES peuventaffecter les stimulateurs cardiaques.

Porteurs de stimulateur cardiaque, restez dis-tance.

Les porteurs dun stimulateur cardiaque doiventdabord consulter leur mdecin avant de sappro-cher des oprations de soudage larc, de gou-geage ou de soudage par points.

OM-1570 Page 8

1-4. Principales normes de scuritSafety in Welding and Cutting, norme ANSI Z49.1, de lAmerican Wel-ding Society, 550 N.W. Lejeune Rd, Miami FL 33126Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendentof Documents, U.S. Government Printing Office, Washington, D.C.20402.Recommended Safe Practice for the Preparation for Welding and Cut-ting of Containers That Have Held Hazardous Substances, norme AWSF4.1, de lAmerican Welding Society, 550 N.W. Lejeune Rd, Miami FL33126National Electrical Code, NFPA Standard 70, de la National Fire Protec-tion Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,de la Compressed Gas Association, 1235 Jefferson Davis Highway,Suite 501, Arlington, VA 22202.Rgles de scurit en soudage, coupage et procds connexes, normeCSA W117.2, de lAssociation canadienne de normalisation, vente denormes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.Safe Practices For Occupation And Educational Eye And Face Protec-tion, norme ANSI Z87.1, de lAmerican National Standards Institute,1430 Broadway, New York, NY 10018.Cutting and Welding Processes, norme NFPA 51B, de la National FireProtection Association, Batterymarch Park, Quincy, MA 02269.

1-5. Information sur les champs lectromagntiquesDonnes sur le soudage lectrique et sur les effets, pour lorganisme,des champs magntiques basse frquence

Le courant de soudage, pendant son passage dans les cbles de sou-dage, causera des champs lectromagntiques. Il y a eu et il y a encoreun certain souci propos de tels champs. Cependant, aprs avoir ex-amin plus de 500 tudes qui ont t faites pendant une priode derecherche de 17 ans, un comit spcial ruban bleu du National Re-search Council a conclu: Laccumulation de preuves, suivant lejugement du comit, na pas dmontr que lexposition aux champsmagntiques et champs lectriques haute frquence reprsente unrisque la sant humaine. Toutefois, des tudes sont toujours en courset les preuves continuent tre examines. En attendant que les con-clusions finales de la recherche soient tablies, il vous seraitsouhaitable de rduire votre exposition aux champs lectromagnti-ques pendant le soudage ou le coupage.

Afin de rduire les champs lectromagntiques dans lenvironnementde travail, respecter les consignes suivantes :1 Garder les cbles ensembles en les torsadant ou en les

attachant avec du ruban adhsif.2 Mettre tous les cbles du ct oppos de loprateur.3 Ne pas courber pas et ne pas entourer pas les cbles autour de

votre corps.4 Garder le poste de soudage et les cbles le plus loin possible de

vous.

5 Relier la pince de masse le plus prs possible de la zone desoudure.

Consignes relatives aux stimulateurs cardiaques :Les personnes qui portent un stimulateur cardiaque doivent avant toutconsulter leur docteur. Si vous tes dclar apte par votre docteur, il estalors recommand de respecter les consignes cidessus.

OM-1570 Page 9

SECTION 2 DEFINITIONS

2-1. Warning Label Definitions

1 1.1 1.2 1.3

3 3.1 3.2 3.3

4 4.1

+

2 2.1 2.2

+

+

5 6

+

2.3

S-178 936

Warning! Watch Out! There arepossible hazards as shown by thesymbols.

Drive rolls can injure fingersWelding wire and drive parts are atwelding voltage during operation keep hands and metal objectsaway.1 Electric shock can kill.1.1 Wear dry insulating gloves.

Do not touch electrode withbare hand. Do not wear wet ordamaged gloves.

1.2 Protect yourself from electricshock by insulating yourselffrom work and ground.

1.3 Disconnect input plug orpower before working onmachine.

2 Breathing welding fumes canbe hazardous to your health.

2.1 Keep your head out of thefumes.

2.2 Use forced ventilation or localexhaust to remove the fumes.

2.3 Use ventilating fan to removefumes.

3 Welding sparks can causeexplosion or fire.

3.1 Keep flammables away fromwelding. Do not weld nearflammables.

3.2 Welding sparks can causefires. Have a fire extinguishernearby, and have awatchperson ready to use it.

3.3 Do not weld on drums or anyclosed containers.

4 Arc rays can burn eyes andinjure skin.

4.1 Wear hat and safety glasses.Use ear protection and buttonshirt collar. Use weldinghelmet with correct shade offilter. Wear complete bodyprotection.

5 Become trained and read theinstructions before working onthe machine or welding.

6 Do not remove or paint over(cover) the label.

OM-1570 Page 10

2-2. Rating Label For CE Products

ST-178 794-A

S/N:

247.0

Hz50/60IP 21

V100 A500 X 100 %

VU1= A I1=

1

U2=

I2=

2-3. Symbols And Definitions

Some symbols are found only on CE products.NOTE

On Off Input Output

A Amperes V Volts Alternating Current X Duty CycleIP Degree OfProtection Hz Hertz Circuit Breaker Wire Feed

Jog U1 Primary Voltage Gas Metal ArcWelding (GMAW)Gun Line ConnectionPurge Spot Weld Time Spot Weld Continuous Weld

Burnback Time Preflow Time Postflow Time Read Instructions

U2 Load Voltage I1 Primary Current I2 Rated Current U1 Primary Voltage

OM-1570 Page 11

SECTION 3 INSTALLATION3-1. Specifications

Type of InputPower

WeldingPower

Source TypeWire Feed

Speed RangeWire

DiameterRange

WeldingCircuitRating

IPRating

OverallDimensions Weight

24 Volts ACSingle Phase

7 Amperes 50/60Hz

Constant Voltage(CV) DC With

14-Pin AndContactor

Control

75 to 630 ipm(1.9 To 16 mpm)

.023 To 5/64 in(0.6 To 2 mm)

Max SpoolWeight:

60 lb (27 kg)

100 Volts,500 Amperes,

100%Duty Cycle

IP 21

Length: 22-1/2 in(572 mm)

Width: 10-1/2 in(267 mm)

Height: 12 in(305 mm)

32 lb (14.5 kg)

3-2. Site Selection

ST-801 687 / Ref. ST-152 468-A / ST-155 242

1 Wire Feeder2 Lifting Eye3 Rubber Feet4 SlotChoose slot that allows all rubberfeet to sit securely on top of weldingpower source.5 Wire Spool/Reel6 Gas Cylinder (Customer

Supplied)7 Welding Power Source Do not put feeder where

welding wire hits cylinder. Do not move or operate

equipment when it could tip.1

24

56

7

3

3-3. Gun Recommendation TableProcess Gun

GMAW Hard or Corded Wires M25 Or M40

FCAW Self-Shielding Wires GA-40GL

OM-1570 Page 12

1 CV Welding Power SourceWith 24 VAC Power

2 CV Welding Power SourceWithout 24 VAC Power

3 115 Volts AC /24 Volts ACPower Adapter

4 14-Pin Control Cord5 Weld Cable6 Work

3-4. Equipment Connection Diagrams

3

2115VAC

Contactor

6

6

5

5

4

1

4

1 Gas Hose With 5/8-18 Right-hand Thread Fittings (Cus-tomer Supplied)

2 14 Pin Plug PLG2Use plug to make connection towelding power source.3 Optional Volt Sense Lead

(Part Of Meter Option)Connect to work.4 Power Switch

3-5. Connecting 14-Pin Plug, Shielding Gas And Optional Volt Sense Lead

ST-801 688

Tools Needed:1

2

3

5/8, 11/16 in

4

3-6. 14-Pin Plug InformationPin* Pin Information

A 24 volts ac with respect to socket G.

AJ B Contact closure to A completes 24 volts ac contactor control circuit.AJBKI G Circuit common for 24 volts AC circuit.CLNH C +10 volts dc output to remote control with respect to socket D.

DMGF D Remote control circuit common.EF

E 0 to +10 volts dc input command signal from remote control with respect to socket D.

*The remaining pins are not used.

OM-1570 Page 13

1 Gun Securing Knob2 Gun Block3 Gun Outlet Wire GuideLoosen knob, insert gun into block.Position outlet wire guide as closeas possible to drive rolls withouttouching. Tighten knob.4 Gun Trigger Plug5 Gun Trigger Receptacle6 Weld Cable Terminal7 Weld Cable From Welding

Power Source

3-7. Connecting Welding Gun And Weld Cable

ST-801 689

1

2 3

45

7

6Tools Needed:

9/16, 5/8 in

3-8. Setting Time Range For Optional Spot Time Control

ST-801 694 / Ref. SA-125 969-C

Tools Needed:

1/4 in

Long SpotTime

0.25-5 Seconds

Short SpotTime

0.12-2.5 Seconds

OM-1570 Page 14

3-9. Installing And Aligning Wire Guide And Drive Roll

3/16 in

ST-801 690 / S-0856

Install and secure wire guide. Installdrive rolls and turn drive roll nut oneclick.Only drive gear is adjustable. Turnadjustment screw in or out untilgroove in drive roll lines up with wireguide as shown.Remove drive rolls, and cleangrooves using a wire brush.

Tools Needed:

3/8 in

Installation

Alignment

OM-1570 Page 15

3-10. Installing And Threading Welding Wire

Tools Needed:

1 Retaining Ring2 Hub Tension Adjustment NutIf necessary, move hub on supportfor use of different size wire spool.Remove retaining ring, and installspool so hub pin fits spool hole.Reinstall retaining ring.Adjust tension nut so wire is tautwhen wire feed stops.3 Pressure Assembly

Adjustment KnobLay gun cable out straight.Open pressure assembly, hold wiretightly, and cut off end. Push wirethrough guides into gun.Close and tighten pressure assem-bly. Press JOG button until wirecomes out gun.To adjust drive roll pressure, pressgun trigger to feed wire againstwood surface. Tighten knob so wiredoes not slip.Cut off wire. Close door.

Ref. ST-801 691 / S-0627-A

WOOD

Tighten

1 2 3

15/16 in

OM-1570 Page 16

SECTION 4 OPERATION

4-1. Front Panel Controls

1 Optional Voltage/Wire SpeedMeter

2 Optional Voltage/Wire SpeedSwitch

Use to choose volts or wire feedspeed display.3 Optional Remote Voltage

ControlUse to set welding power sourcevoltage at the wire feeder. Numbersare for reference only.4 Wire Speed Control5 Jog/Purge SwitchUse Jog position to momentarilyfeed welding wire at speed set onWire Speed control without ener-gizing welding circuit or shieldinggas valve.Use Purge position to momentarilyenergize gas valve to purge air fromgun or adjust gas regulator.Power switch is on rear panel (seeSection 3-5)

ST-801 692

2

3

45

1

4-2. Optional Side Panel Controls

Ref. ST-801 690

1 Preflow ControlControl sets time gas flows beforewelding wire is energized.2 Postflow ControlControl sets time gas flows aftercompletion of burnback.3 Burnback ControlControl adjusts time welding wire isenergized after wire feed stops.4 Spot Continuous SwitchSwitch selects an untimed continu-ous weld or a timed spot weld.5 Spot Time ControlFactory set for 0.25 to 5 seconds ofspot time. If 0.12 to 2.5 seconds isdesired, see Section 3-8.Close side door.

5

3

41

2

OM-1570 Page 17

SECTION 5 MAINTENANCE & TROUBLESHOOTING

5-1. Routine Maintenance

Disconnect power before maintaining.

3 Months

ReplaceUnreadable

Labels

Clean AndTightenWeld

Terminals

Repair OrReplaceCracked

Weld Cable

14-Pin Cord Gas HoseGun Cable

ReplaceCracked

Parts

6 Months

Blow Out Or VacuumInside,

During Heavy Service,Clean Monthly

ORCleanDriveRolls

5-2. Overload Protection Turn Off wire feeder and

welding power source. Stopengine on weldinggenerator.

1 Fuse F1F1 protects wire feeder from over-load. Replace F1 if open.2 Circuit Breaker CB1CB1 protects motor from overload.Correct problem and manually re-set breaker.Close and latch door.

ST-801 690 / Ref. ST-800 185-A

2

1

OM-1570 Page 18

5-3. Troubleshooting

Trouble RemedyWire does not feed, unit completely inop-erative.

Turn Power switch On.

Check fuse F1 and replace if necessary (see Section 5-2).Check 14pin plug PLG2 connections.

Check input power.

Wire does not feed. Check circuit breaker CB1 and fuse F1. (see Section 5-2)Check gun trigger connection at wire feeder. Check gun trigger leads and trigger switch. See gun OwnersManual.

Have Factory Authorized Service Agent check drive motor and control board PC1.

Wire feeds erratically. Readjust hub tension and drive roll pressure (see Section 3-10).Use correct size drive roll (see Parts List).Clean or replace dirty or worn drive roll (see Section 3-9).Remove weld spatter around nozzle opening.

Replace contact tube or liner. See gun Owners Manual.

Have Factory Authorized Service Agent check drive motor and control board PC1.

Wire feeds when Jog switch is pressedbut not when gun trigger is pressed.

Check gun trigger connection at wire feeder. Check gun trigger leads and trigger switch. See gun OwnersManual.

Wire feeds as soon as power is applied. Check gun trigger. See gun Owners Manual.

Wire does not feed until trigger ispressed but continues to feed after trig-ger is released.

Check for short between gun trigger leads and weld cable. Repair or replace gun trigger leads.

Gas valve rattles loudly and wire feedsslowly or erratically.

Check for short between gun trigger leads and weld cable. Repair or replace gun trigger leads.

Gas does not flow; wire feeds. Check gas valve and flowmeter.

OM-1570 Page 19

SECTION 6 ELECTRICAL DIAGRAM

SC-182 776

Figure 6-1. Circuit Diagram For Wire Feeder With Optional Equipment

OM-1570 Page 20

Notes

OM-1570 Page 21

SECTION 7 PARTS LIST

DescriptionPartNo.

ItemNo.

Figure 7-1. Main Assembly

Quantity

1 153 779 CONTROL BOX, (Fig 7-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 072 094 HUB & SPINDLE ASSEMBLY, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 058 427 RING, retaining spool 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 180 572 SHAFT, spool support 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 010 233 SPRING, cprsn .970 OD x .120 wire x 1.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 057 971 WASHER, flat stl keyed 1.500dia x .125thk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 010 191 WASHER, fbr .656 ID x 1.500 OD x .125thk 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 058 628 WASHER, brake stl 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 058 428 HUB, spool 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 135 205 NUT, stl slflkg hex reg .625-11 w/nylon insert 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 134 306 FOOT, rbr 1.250dia x 1.375 high 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 137 461 BASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

108 008 REEL, wire (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 103 NUT, spanner retaining 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+168 104 RETAINER, spool support (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 594 LABEL, caution falling wire reel can cause damage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 900 SUPPORT, reel support 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

2

3

4

56

78

9

10

11

12

78

Fig 7-2

ST-801 693

Hardware is common andnot available unless listed.

Figure 7-1. Main AssemblyOPTIONAL+When ordering a component originally displaying a precautionary label, the label should also be ordered.To maintain the factory original performance of your equipment, use only Manufacturers SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.

OM

-1570 Page 22

Figure 7-2. Control Box

ST-801 685

1 2 3 4 5 6

7

8

910

1161

59

58 57 56 55

12 17

18 19

20

22

23

24

25

30

31

37

38

39

40

41

42

43

44

4748

4950

51

52

5354

64

13 14 15 16

21

26 27 28 29

323334

35

36

4546

60

6263

H

ardware is

comm

on andnot available unless listed.

OM-1570 Page 23

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 7-2. Control Box (Fig 7-1 Item 1)Quantity

1 602 009 SCREW, .250-20 x 1.250 soc hd hex gr 8 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 166 072 SPACER, gear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 151 828 PIN, cotter hair .054 x .750 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 166 071 LEVER, mtg pressure gear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 079 634 PIN, hinge 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 085 243 KNOB, adjustment tension 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 089 477 SPRING, cprsn .770 OD x .105 wire x 1.225 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 085 244 WASHER, cupped stl .328 ID x .812 OD x .125 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 085 242 FASTENER, pinned 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 048 449 WASHER, shldr nyl .363 OD x .194 ID x .703 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 010 224 PIN, spring CS .187 x 1.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 079 624 SCREW, cap stl hexhd slflkg .375-16 x 2.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 130 365 INSULATOR, housing drive 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 178 937 LABEL, warning electric shock 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 010 291 WASHER, flat nylafil .625 ID x 1.250 OD x 1.000 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

601 880 NUT, stl hex jam .500-13 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 F1 *011 116 FUSE, mintr gl slo-blo 7A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 046 432 HOLDER, fuse mintr .250 x 1.250 panel mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 010 494 BUSHING, snap-in nyl 1.375 ID x 1.750mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 131 181 WIRE GUIDE & NUT, inlet (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

039 796 NUT, term jack rcpt black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 182 GUIDE, wire inlet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 180 634 PLATE, ident control panel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 134 834 HOSE, SAE .187 ID x .410 OD (order by ft) 2ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 GS1 125 785 VALVE, 24VAC 2 way custom port 1/8 orf 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 089 572 CATCH, link-lock 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

089 573 PLATE, keeper link-lock 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 134 464 LABEL, warning general precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 178 936 LABEL, warning general precautionary CE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 +152 725 WRAPPER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

126 873 BUMPER, polyurethane polymer .500sq adh back 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 090 439 LABEL, warning electric shock can kill 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 CB1 123 745 CIRCUIT BREAKER, man reset 1P 4A 250VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 S1 111 997 SWITCH, rocker SPST 10A 250VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 605 227 NUT, nyl hex jam .750NPST 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 182 270 CABLE, power 10 ft 8 in (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

182 271 CABLE, port No. 18 3/c 11ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG2 141 162 HOUSING PLUG & PINS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 182 758 CABLE, power 10 ft 8 in (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 475 CABLE, port No. 18 6/c 11ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG2 141 162 HOUSING PLUG & PINS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 601 222 CLAMP, univ 50A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 601 225 INSULATOR, vinyl clamp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 600 399 LEAD, sensing (order by ft) 15ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 115 104 CONNECTOR, clamp cable .500 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 087 111 CLAMP, capacitor 1.375dia clip 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 C1 048 504 CAPACITOR, elctlt 5000uf 50V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 PC1 183 047 CIRCUIT CARD, motor speed control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG1 115 093 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG3 115 092 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG4 115 091 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 134 201 STAND-OFF SUPPORT, PC card 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 PC2 139 897 CIRCUIT CARD, meter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG15 115 092 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLG16 131 055 CONNECTOR & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

115 443 STAND-OFF, 6-32 x .750 lg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 339 COVER, opening meter (not used when unit has Meter Kit) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 134 201 STAND-OFF SUPPORT, PC card 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-1570 Page 24

DescriptionPartNo.

Dia.Mkgs.

ItemNo.

Figure 7-2. Control Box (Fig 7-1 Item 1) (Continued)Quantity

40 605 308 RING, retaining 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 092 865 KEY, stl .1215/.1230 x .750 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 M1 122 741 MOTOR, gear 24VDC 122RPM (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*136 745 BRUSH & SPRING ASSEMBLY 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 079 625 WASHER, spring stl .500 shakeproof 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 S2 134 846 SWITCH, tgl SPTT 6A 125VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 035 897 POTENTIOMETER, CP std slot 1T 2W 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 R1 073 562 POTENTIOMETER, C sltd sft1/T 2W 10K ohm 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 152 728 CASE ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 090 440 INSULATOR, cover housing 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 NAMEPLATE (order by model and serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 097 922 KNOB, pointer .875dia x .250 ID 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 097 922 KNOB, pointer .875dia x .250 ID 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 107 983 BLANK, snap-in nyl .500mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 RC2 048 282 CONNECTOR w/SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 057 084 BUSHING, snap-in nyl .250 ID x .375mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 172 391 HOUSING, adapter gun/feeder 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 144 172 FITTING, hose brs barbed 3/16tbg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 604 538 WASHER, flat stl SAE .312 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 124 778 KNOB, plstc T 1.000 lg x .312-18 x 2.000 bar 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 010 910 WASHER, flat stl SAE .375 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 602 213 WASHER, lock stl split .375 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 601 872 NUT, stl hex full .375-16 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 172 076 CARRIER, drive roll w/components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 121 271 SCREW, .250-20 x .500 soc hd hex gr 8 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 172 075 CARRIER, drive roll w/components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

189 285 ROLL, drive V groove .035/.045 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 994 GUIDE, wire inlet .045 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 304 BLANK, snap-in nyl .250mtg hole 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*Recommended Spare Parts.+When ordering a component originally displaying a precautionary label, the label should also be ordered.Part of 152 212 Optional Digital Meter V/WFSPart of 121 569 Optional Remote VoltageTo maintain the factory original performance of your equipment, use only Manufacturers SuggestedReplacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-1570 Page 25

Table 7-1. Drive Roll And Wire Guide Kits

Base selection of drive rolls upon the following recommended usages:1. V-Grooved rolls for hard wire.2. U-Grooved rolls for soft and soft shelled cored wires.3. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types).4. V-Knurled rolls for hard shelled cored wires.5. Drive roll types may be mixed to suit particular requirements (example: V-Knurled roll in combination with U-Grooved).

NOTE

Wire DiameterFraction Decimal Metric

.023/.025 in..030 in..035 in..045 in..052 in.1/16 in..035 in..045 in..052 in.1/16 in.5/64 in..035 in..045 in..052 in.1/16 in.

5/64 in..045 in..052 in.1/16 in.5/64 in.

.023/.025 in..030 in..035 in..045 in..052 in..062 in.

.035 in.

.045 in.

.052 in.

.062 in.

.079 in.

.035 in.

.045 in.

.052 in.

.062 in.

.079 in.

.045 in.

.052 in.

.062 in.

.079 in.

0.6 mm0.8 mm0.9 mm1.2 mm1.3 mm1.6 mm

0.9 mm1.2 mm1.3 mm1.6 mm2.0 mm

0.9 mm1.2 mm1.3 mm1.6 mm

2.0 mm

1.2 mm1.3 mm1.6 mm2.0 mm

Kit No.

087 131079 594079 595079 596079 597079 598

044 749079 599079 600079 601079 602

079 606079 607079 608079 609

079 610

083 318083 317079 614079 615

Drive RollPart No. Type087 130053 695053 700053 697053 698053 699

072 000053 701053 702053 706053 704

132 958132 957132 956132 955

132 960

083 489083 490053 708053 710

V-GroovedV-GroovedV-GroovedV-GroovedV-GroovedV-GroovedU-GroovedU-GroovedU-GroovedU-GroovedU-GroovedV-KnurledV-KnurledV-KnurledV-Knurled

V-KnurledU-CoggedU-CoggedU-CoggedU-Cogged

Inlet

056 192056 192056 192056 193056 193056 195

056 192056 193056 193056 195056 195

056 192056 193056 193056 195

056 195

056 193056 193056 195056 195

Wire Guide

S-0157-C

.068-.072 in. .068-.072 in. 1.8 mm 089 984 132 959 V-Knurled 056 195

OM-1570 Page 26

Notes

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.

miller_warr 7/00

Your distributor also givesyou ...ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours.SupportNeed fast answers to thetough welding questions?Contact your distributor.The expertise of thedistributor and Miller isthere to help you, everystep of the way.

Effective January 1, 2000(Equipment with a serial number preface of LA or newer)This limited warranty supersedes all previous Miller warranties and is exclusive with no other

guarantees or warranties expressed or implied.

LIMITED WARRANTY Subject to the terms and conditionsbelow, Miller Electric Mfg. Co., Appleton, Wisconsin, warrantsto its original retail purchaser that new Miller equipment soldafter the effective date of this limited warranty is free of defectsin material and workmanship at the time it is shipped by Miller.THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHERWARRANTIES, EXPRESS OR IMPLIED, INCLUDING THEWARRANTIES OF MERCHANTABILITY AND FITNESS.Within the warranty periods listed below, Miller will repair orreplace any warranted parts or components that fail due tosuch defects in material or workmanship. Miller must benotified in writing within thirty (30) days of such defect orfailure, at which time Miller will provide instructions on thewarranty claim procedures to be followed.Miller shall honor warranty claims on warranted equipmentlisted below in the event of such a failure within the warrantytime periods. All warranty time periods start on the date thatthe equipment was delivered to the original retail purchaser, orone year after the equipment is sent to a North Americandistributor or eighteen months after the equipment is sent to anInternational distributor.

1. 5 Years Parts 3 Years Labor* Original main power rectifiers* Inverters (input and output rectifiers only)

2. 3 Years Parts and Labor* Transformer/Rectifier Power Sources* Plasma Arc Cutting Power Sources* Semi-Automatic and Automatic Wire Feeders* Inverter Power Supplies* Intellitig* Engine Driven Welding Generators

(NOTE: Engines are warranted separately bythe engine manufacturer.)

3. 1 Year Parts and Labor* DS-2 Wire Feeder* Motor Driven Guns (w/exception of Spoolmate

185 & Spoolmate 250)* Process Controllers* Positioners and Controllers* Automatic Motion Devices* RFCS Foot Controls* Induction Heating Power Sources* Water Coolant Systems* HF Units* Grids* Maxstar 140* Spot Welders* Load Banks* Miller Cyclomatic Equipment* Running Gear/Trailers* Plasma Cutting Torches (except APT & SAF

Models)* Field Options

(NOTE: Field options are covered under TrueBlue for the remaining warranty period of theproduct they are installed in, or for a minimum ofone year whichever is greater.)

4. 6 Months Batteries

5. 90 Days Parts* MIG Guns/TIG Torches* Induction Heating Coils and Blankets

* APT, ZIPCUT & PLAZCUT Model Plasma CuttingTorches

* Remote Controls* Accessory Kits* Replacement Parts (No labor)* Spoolmate 185 & Spoolmate 250* Canvas Covers

Millers True Blue Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,cutting nozzles, contactors, brushes, slip rings,relays or parts that fail due to normal wear.

2. Items furnished by Miller, but manufactured by others,such as engines or trade accessories. These items arecovered by the manufacturers warranty, if any.

3. Equipment that has been modified by any party otherthan Miller, or equipment that has been improperlyinstalled, improperly operated or misused based uponindustry standards, or equipment which has not hadreasonable and necessary maintenance, or equipmentwhich has been used for operation outside of thespecifications for the equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASEAND USE BY COMMERCIAL/INDUSTRIAL USERS ANDPERSONS TRAINED AND EXPERIENCED IN THE USEAND MAINTENANCE OF WELDING EQUIPMENT.In the event of a warranty claim covered by this warranty, theexclusive remedies shall be, at Millers option: (1) repair; or (2)replacement; or, where authorized in writing by Miller inappropriate cases, (3) the reasonable cost of repair orreplacement at an authorized Miller service station; or (4)payment of or credit for the purchase price (less reasonabledepreciation based upon actual use) upon return of the goodsat customers risk and expense. Millers option of repair orreplacement will be F.O.B., Factory at Appleton, Wisconsin, orF.O.B. at a Miller authorized service facility as determined byMiller. Therefore no compensation or reimbursement fortransportation costs of any kind will be allowed.TO THE EXTENT PERMITTED BY LAW, THE REMEDIESPROVIDED HEREIN ARE THE SOLE AND EXCLUSIVEREMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FORDIRECT, INDIRECT, SPECIAL, INCIDENTAL ORCONSEQUENTIAL DAMAGES (INCLUDING LOSS OFPROFIT), WHETHER BASED ON CONTRACT, TORT ORANY OTHER LEGAL THEORY.ANY EXPRESS WARRANTY NOT PROVIDED HEREINAND ANY IMPLIED WARRANTY, GUARANTY ORREPRESENTATION AS TO PERFORMANCE, AND ANYREMEDY FOR BREACH OF CONTRACT TORT OR ANYOTHER LEGAL THEORY WHICH, BUT FOR THISPROVISION, MIGHT ARISE BY IMPLICATION,OPERATION OF LAW, CUSTOM OF TRADE OR COURSEOF DEALING, INCLUDING ANY IMPLIED WARRANTY OFMERCHANTABILITY OR FITNESS FOR PARTICULARPURPOSE, WITH RESPECT TO ANY AND ALLEQUIPMENT FURNISHED BY MILLER IS EXCLUDED ANDDISCLAIMED BY MILLER.Some states in the U.S.A. do not allow limitations of how longan implied warranty lasts, or the exclusion of incidental,indirect, special or consequential damages, so the abovelimitation or exclusion may not apply to you. This warrantyprovides specific legal rights, and other rights may beavailable, but may vary from state to state.In Canada, legislation in some provinces provides for certainadditional warranties or remedies other than as stated herein,and to the extent that they may not be waived, the limitationsand exclusions set out above may not apply. This LimitedWarranty provides specific legal rights, and other rights maybe available, but may vary from province to province.

PRINTED IN USA 2000 Miller Electric Mfg. Co. 6/00

Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA

International HeadquartersUSAUSA Phone: 920-735-4505 Auto-AttendedUSA & Canada FAX: 920-735-4134International FAX: 920-735-4125

European Headquarters United KingdomPhone: 44 (0) 1204-593493FAX: 44 (0) 1204-598066www.MillerWelds.com

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

Please complete and retain with your personal records.

Always provide Model Name and Serial/Style Number.

Call 1-800-4-A-Miller or see our website at www.MillerWelds.comto locate a DISTRIBUTOR or SERVICE AGENCY near you.

Welding Supplies and ConsumablesOptions and AccessoriesPersonal Safety EquipmentService and RepairReplacement PartsTraining (Schools, Videos, Books)Technical Manuals (Servicing Informationand Parts)Circuit DiagramsWelding Process Handbooks

Contact the Delivering Carrier for:

For assistance in filing or settling claims,contact your distributor and/or equipmentmanufacturers Transportation Department.

For Service

Owners Record

File a claim for loss or damage duringshipment.

Contact your Distributor for: