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OM-1315 January 1997 Eff. w/Serial Number KH303568 Processes Gas Metal Arc (MIG) Welding Flux Cored Arc (FCAW) Welding Description Arc Welding Power Source and Wire Feeder R Millermatic 250MP Visit our website at www.MillerWelds.com From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929. This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you Miller is the first welding figure out what the problem is. The parts list equipment manufacturer in will then help you to decide which exact part the U.S.A. to be registered to the ISO 9001 Quality System you may need to fix the problem. Warranty and Standard. service information for your particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web. Working as hard as you do – every power source from Miller is backed by the most hassle-free warranty in the business. Miller offers a Technical Manual which provides more detailed service and parts information for your unit. To obtain a Technical Manual, contact your local distributor. Your distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMAW-P. TABLE OF CONTENTS The following terms are used interchangeably throughout this manual: MIG = GMAW SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Additional Symbols for Installation, Operation, and Maintenance . . . . . . . . . . . . . . . . . . . . . . 1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4. Installing Work Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5. Installing Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6. Setting Gun Polarity For Wire Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7. Installing Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8. Installing Drive Roll And Wire Inlet Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9. Installing Wire Spool And Adjusting Hub Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10. Positioning Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12. Selecting A Location And Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13. Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Installing Receptacle Module For Use With A Spool Gun (Optional) . . . . . . . . . . . . . . . . . . . . SECTION 4 – PROGRAMMING THE MICROPROCESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Mode Selection Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Parameter Select Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Parameter Increase And Decrease Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Weld Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. Timer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. Dual Schedule Mode And Gun Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7. Material Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8. Setting Language, Wire Speed Units, And Burnback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9. Using One Switch To Control Voltage And Wire Speed (Synergic Welding) . . . . . . . . . . . . . 4-10. Resetting Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Circuit Breaker CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Unit Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Replacing Gun Contact Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5. Aligning Drive Rolls And Wire Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6. Unicable Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7. Cleaning Or Replacing Gun Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8. Replacing Switch And/Or Head Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10. Selftest Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11. Troubleshooting Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 – ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONS AND ACCESSORIES WARRANTY 1 1 1 3 3 4 5 5 5 6 6 7 7 7 8 8 8 9 9 10 11 11 11 12 12 13 13 14 14 15 15 16 17 17 18 18 18 18 19 19 19 20 21 22 23 24 25 26 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. 1-2. Arc Welding Hazards Y The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-4. Read and follow all Safety Standards. D If earth grounding of the workpiece is required, ground it directly with a separate cable – do not use work clamp or work cable. Y Only qualified persons should install, operate, maintain, and repair this unit. D Wear a safety harness if working above floor level. D Keep all panels and covers securely in place. Y During operation, keep everybody, especially children, away. D Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. 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. D Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. D Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. D Insulate work clamp when not connected to workpiece to prevent contact with any metal object. D Do not connect more than one electrode or work cable to any single weld output terminal. SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters. D Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts. D Do not touch live electrical parts. D Wear dry, hole-free insulating gloves and body protection. D Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. D Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling. D Use AC output ONLY if required for the welding process. D If AC output is required, use remote output control if present on unit. D Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards). D Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. D Keep your head out of the fumes. Do not breathe the fumes. D Always verify the supply ground – check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet. D When making input connections, attach proper grounding conductor first – double-check connections. D Frequently inspect input power cord for damage or bare wiring – replace cord immediately if damaged – bare wiring can kill. D Turn off all equipment when not in use. D Do not use worn, damaged, undersized, or poorly spliced cables. D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. D Do not drape cables over your body. FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. D If ventilation is poor, use an approved air-supplied respirator. D Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers. D Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. D Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. OM-1315 Page 1 ARC RAYS can burn eyes and skin. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). D Wear approved safety glasses with side shields under your helmet. D Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc. D Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. D Always ventilate confined spaces or use approved air-supplied respirator. HOT PARTS can cause severe burns. D Do not touch hot parts bare handed. D Allow cooling period before working on gun or torch. MAGNETIC FIELDS can affect pacemakers. WELDING can cause fire or explosion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. D Protect yourself and others from flying sparks and hot metal. D Do not weld where flying sparks can strike flammable material. D Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. D Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. D Watch for fire, and keep a fire extinguisher nearby. D Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. D Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWS F4.1 (see Safety Standards). D 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. D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use. D Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. D Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. FLYING METAL can injure eyes. D Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. D Wear approved safety glasses with side shields even under your welding helmet. OM-1315 Page 2 D Pacemaker wearers keep away. D Wearers should consult their doctor before going near arc welding, gouging, or spot welding operations. NOISE can damage hearing. Noise from some processes or equipment can damage hearing. D Wear approved ear protection if noise level is high. 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. D Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs. D Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. D Keep cylinders away from any welding or other electrical circuits. D Never drape a welding torch over a gas cylinder. D Never allow a welding electrode to touch any cylinder. D Never weld on a pressurized cylinder – explosion will result. D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition. D Turn face away from valve outlet when opening cylinder valve. D Keep protective cap in place over valve except when cylinder is in use or connected for use. D Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards. 1-3. Additional Symbols for Installation, Operation, and Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit. D Keep away from moving parts such as fans. D Keep all doors, panels, covers, and guards closed and securely in place. FALLING UNIT can cause injury. H.F. RADIATION can cause interference. D Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. D Use equipment of adequate capacity to lift and support unit. D If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit. D OVERUSE can cause OVERHEATING D D Allow cooling period; follow rated duty cycle. D Reduce current or reduce duty cycle before starting to weld again. D Do not block or filter airflow to unit. D D D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. If notified by the FCC about interference, stop using the equipment 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 to minimize the possibility of interference. STATIC (ESD) can damage PC boards. D Put on grounded wrist strap BEFORE handling boards or parts. D Use proper static-proof bags and boxes to store, move, or ship PC boards. ARC WELDING can cause interference. MOVING PARTS can cause injury. D Keep away from moving parts. D Keep away from pinch points such as drive rolls. D D WELDING WIRE can cause injury. D Do not press gun trigger until instructed to do so. D Do not point gun toward any part of the body, other people, or any metal when threading welding wire. D D D Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots. D Be sure all equipment in the welding area is electromagnetically compatible. To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area. 1-4. Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent 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, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 National Electrical Code, NFPA Standard 70, from National Fire Protection 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, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3. Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018. Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. OM-1315 Page 3 1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields 1. Keep cables close together by twisting or taping them. Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.” However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting. 2. Arrange cables to one side and away from the operator. To reduce magnetic fields in the workplace, use the following procedures: Pacemaker wearers consult your doctor first. If cleared by your doctor, then following the above procedures is recommended. OM-1315 Page 4 3. Do not coil or drape cables around your body. 4. Keep welding power source and cables as far away from operator as practical. 5. Connect work clamp to workpiece as close to the weld as possible. About Pacemakers: SECTION 2 – INSTALLATION 2-1. Specifications Max. OpenCircuit Voltage Rated Output 250 A at 28 VDC, 40% Duty Cycle 200 A at 28 VDC, 60% Duty Cycle Amps Input at Rated Output, 50 or 60 Hz, Single-Phase 200 V 220 V 230 V 380 V 415 V 460 V 575 V KVA KW 50 2.3* 45 2.2* 44 2* 26 1.3* 24 1.2* 22 1* 18 0.8* 10 0.46* 7.7 0.13* 32 Wire Type and Diameter Solid Steel Stainless Steel Flux Cored .023 – .045 in (0.6 – 1.2 mm) .023 – .035 in (0.6 – 0.9 mm) .030 – .045 in (0.8 – 1.2 mm) Wire Feed Speed Dimensions Net Weight 50–670 IPM (1.2–1.7 m/min) H: 37 in (940 mm) W: 19 in (483 mm) D: 30-1/4 in (768 mm) 225 lb (102 kg) * While idling 2-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or voltage, or duty cycle before welding. Y Exceeding duty cycle can damage unit and void warranty. 60% Duty Cycle At 200 Amperes 6 Minutes Welding 40% Duty Cycle At 250 Amperes 4 Minutes Resting 4 Minutes Welding 6 Minutes Resting Overheating A or V 0 15 Minutes OR Reduce Duty Cycle duty1 4/95 – SB-150 215 OM-1315 Page 5 2-3. Volt-Ampere Curves 1 Normal Volt-Ampere Curves The volt-ampere curves show the normal minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. 1 2 Overload Volt-Ampere Curves When unit is used beyond capacity, circuitry senses the overload and shuts down unit output. Release trigger and lower weld voltage setting before trying to weld. This shut down circuitry protects internal circuits and parts from overload damage. 60 50 2 DC VOLTS 40 30 * * 20 *Approximate shutdown voltage/amperage points shown for reference only. 10 0 0 50 100 150 200 250 300 350 400 DC AMPERES ssb1.1 10/91 – SB-144 925 / S-0700 2-4. Installing Work Clamp 1 2 Work Cable Boot Slide boot onto work cable. Route cable out front panel opening from inside. 3 Negative (–) Output Terminal Connect cable to terminal and cover connection with boot. 4 4 5 Hardware Work Clamp Route cable through clamp handle and secure as shown. 5 Close door. 1 2 3 Tools Needed: 1/2, 3/4 in ST-150 228-E OM-1315 Page 6 2-5. Installing Welding Gun 1 2 3 1 Drive Assembly Gun Securing Knob Gun End Loosen securing knob. Insert gun end through opening until it bottoms against drive assembly. Tighten knob. 2 4 4 Gun Trigger Plug Insert plug into receptacle, and tighten threaded collar. Close door. 3 Ref. ST-150 256-D 2-6. Setting Gun Polarity For Wire Type . Always read and follow wire manufacturer’s recommended polarity, and see label inside unit by wire drive assembly. Tools Needed: 3/4 in 2-7. Installing Gas Supply Chain gas cylinder to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. 1 Regulator/Flow Gauge Install so face is vertical. 2 Gas Hose Connection Fitting has threads. 3 5/8-18 right-hand Flow Adjust Typical flow rate is 20 cfh (cubic feet per hour). Check wire manufacturer’s recommended flow rate. This flow gauge can be adjusted between 5 and 25 cfh. 1 Argon Gas 4 CO2 Adapter Customer Supplied OR 2 5 O-Ring Install adapter with O-ring between regulator/flow gauge and CO2 cylinder. 3 4 5 CO2 Gas Tools Needed: 1-1/8, 5/8 in Ref. ST-148 265-B / Ref. ST-149 827-B / Ref. ST-158 697-A OM-1315 Page 7 2-8. Installing Drive Roll And Wire Inlet Guide 1 2 5 3 2 Securing Screw Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. 3 Anti-Wear Guide Install guide as shown. 1 4 Drive Roll Install correct drive roll for wire size and type. Tools Needed: 5 5/64 in Drive Roll Securing Nut Turn nut one click to secure drive roll. 7/16 in 4 ST-150 227-C 2-9. Installing Wire Spool And Adjusting Hub Tension Use compression spring with 8 in (200 mm) spools. When a slight force is needed to turn spool, tension is set. Tools Needed: 15/16 in ST-072573-B 2-10. Positioning Jumper Links Check input voltage available at site. 1 200 VOLTS 230 VOLTS 220 VOLTS Jumper Links Access Door Open door. 3 2 Jumper Link Label Check label – only one is on unit. 230 VOLTS 460 VOLTS 460 VOLTS 575 VOLTS 3 380 VOLTS Input Voltage Jumper Links Move jumper links to match input voltage. Close and secure access door. S-144 918-C S-144 916-A 415 VOLTS S-144 915-A 2 Tools Needed: 1 3/8 in Ref. ST-148 263-C OM-1315 Page 8 2-11. Electrical Service Guide Input Voltage 200 220 230 380 415 460 575 Input Amperes At Rated Output 50 45 44 26 24 22 17 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 80 70 70 40 35 35 25 Min Input Conductor Size In AWG/Kcmil 8 10 8 12 12 10 12 Max Recommended Input Conductor Length In Feet (Meters) 93 (28) 75 (23) 124 (38) 137 (42) 163 (50) 329 (100) 313 (95) Min Grounding Conductor Size In AWG/Kcmil 8 10 8 12 12 10 12 Reference: 1996 National Electrical Code (NEC) S-0092-J 2-12. Selecting A Location And Connecting Input Power Have only qualified persons make this installation. 1 Rating Label Supply correct input power. Y Special installation may be required where gasoline or volatile liquids are present – see NEC Article 511 or CEC Section 20. 18 in (457 mm) for airflow GND/PE GND/PE Connect First 1 L1 L2 Size and ratings must comply with applicable codes. Install conductors in conduit or equivalent into a deenergized line disconnect device. ST-149 406-D OM-1315 Page 9 2-13. Threading Welding Wire 1 2 3 4 5 6 7 4 7 Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Outlet Wire Guide Gun Conduit Cable Lay gun cable out straight. Tools Needed: 1 2 3 5 6 . Hold wire tightly to keep it from unraveling. 4 in (102 mm) 6 in (150 mm) Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun; continue to hold wire. Tighten Close and tighten pressure assembly, and let go of wire. Remove gun nozzle and contact tip. Turn On. WOOD Press gun trigger until wire comes out of gun. Reinstall contact tip and nozzle Feed wire to check drive roll pressure. Tighten knob enough to prevent slipping. Cut off wire. Close and latch door. Ref. ST-148 261-C / ST-159 218-B / ST-801 083 / S-0627-A OM-1315 Page 10 SECTION 3 – OPERATION 3-1. Controls 1 2 3 4 5 6 7 8 1 Parameter Increase Button Parameter Decrease Button Parameter Display Parameter Select Button Mode Select Button Mode Display Pilot Light Power Switch 7 2 8 6 5 4 3 Ref. ST-147 589-A / Ref. ST-174 835-A 3-2. Installing Receptacle Module For Use With A Spool Gun (Optional) Remove existing options panel. 1 Module 2 Plug PLG9 3 Plug PLG7 Connect PLG9 to PLG7. 2 1 3 Slide module into upper front panel where options panel was removed. Secure with screws. See Options And Accessories page at end of manual, or contact your Factory Authorized Service Agent for details. Tools Needed: ST-152 594 OM-1315 Page 11 SECTION 4 – PROGRAMMING THE MICROPROCESSOR NOTE Experiment with the microprocessor. If you have difficulties, reset the unit according to Section 4-10, and unit returns to original factory settings. 4-1. Mode Selection Button 1 1 Mode Display 2 Mode Select Button Press Mode button to move indicator >. Ma t e r i a l >We l d T i me r Dua l Sc hd 2 Ma t e r i a l We l d >T i m e r Dua l Sc hd Ma t e r i a l We l d T i me r >D u a l S c h d >M a t e r i a l We l d T i me r Dua l Sc hd Ref. ST-147 589-A OM-1315 Page 12 4-2. Parameter Select Button 1 1 2 2 Parameter Display Moving Line Moving line is under value that can be changed. 3 Parameter Select Button Press Parameter button to move indicator >. Ma t e r i a l >We l d T i me r Dua l Sc hd >M e m o r y O f f 122 I PM 17 . 5 Vo l t Memo r y O f f I PM >1 2 2 17 . 5 Vo l t Memo r y O f f 122 I PM >1 7 . 5 V o l t 3 Ref. ST-147 589-A 4-3. Parameter Increase And Decrease Buttons 1 Increase Button Press buttons to change value on moving line. Decrease button is used to decrease value on moving line. Ma t e r i a l >We l d T i me r Dua l Sc hd >M e m o r y 1 122 I PM 17 . 5 Vo l t >M e m o r y O f f 122 I PM 17 . 5 Vo l t 1 >M e m o r y 2 122 I PM 17 . 5 Vo l t Ref. ST-147 589-A OM-1315 Page 13 4-4. Weld Mode 1 Weld Mode Select Weld to set wire speed and volts. Unit must be in Weld mode to select program Memory number. 2 1 Ma t e r i a l >We l d T i me r Dua l Sc hd Memory Memory can store up to 9 weld programs. On power up, “Memory Off” is displayed. Values are a copy of last weld program used. >M e m o r y O f f 122 I PM 17 . 5 Vo l t 2 Value changes in “Memory Off” do not affect other programs. 3 3 4 Value can be set between 50 and 670 ipm (1.3 to 17.0 mpm). Wire Speed Use the Increase/Decrease buttons or gun switch to change values. 4 Volts Value can be set between 10.0 and 32.0 volts. Use the Increase/Decrease buttons or gun switch to change values. 4-5. Timer Mode 1 Timer Mode Select Timer to set spot, skip, or burnback time. 1 2 Memory Memory displays number set in Weld mode. Ma t e r i a l We l d >T i m e r Dua l Sc hd Mem o > 0 . 0 . 0 . r 0 0 0 y Of f s On sO f f 9 s BB 2 3 3 Value can be set between 0.1 and 30.0 seconds. 4 4 5 On Time (Spot Time) Off Time Value can be set between 0.5 and 30.0 seconds. Skip welds use both on and off time. 5 Burnback Value can be set between 0.00 and 0.25 seconds when unit is configured for burnback (see Section 4-8). OM-1315 Page 14 4-6. Dual Schedule Mode And Gun Switches 1 Ma t e r i a l We l d T i me r >D u a l S c h d Sw i >M e m o Sw i Memo t r t r ch y ch y A 1 B 2 2 2 Switch A Or B Memory number is preset weld program. 3 Increase/Decrease Switch Increases or decreases wire feed speed set by welding power source/ wire feeder. Activates weld program A or B. 1 Wire Speed (B) – Dual Schedule Mode Select Dual Schedule to set any combination of the 9 available memories for dual scheduling. 4 + (A) Trigger Switch When pressed, energized wire feeds and shielding gas flows. 3 4 Ref. ST-801 031 4-7. Material Mode 1 1 2 >M a t e r i a l We l d T i me r Dua l Sc hd Material Mode Select Material to set wire type, gas type, and metal thickness. A voltage and wire speed are displayed when gun trigger is pressed. Mem o r y O f f >W i r e T y p e Ga s Th i c knes s Memory 2 Memory displays number set in Weld mode. 3 3 4 Value can be set for wire type and size. 5 4 Wire Type Gas Gas type can be set to match wire type. 5 Thickness Value can be set to match thickness of metal. OM-1315 Page 15 4-8. Setting Language, Wire Speed Units, And Burnback 1 1 Mode And Parameter Select Buttons 2 Power Switch 2 Mode Parameter Select Select Press and hold down both buttons while turning On unit. 3 Language Select any one of six languages by pressing Increase or Decrease button. The Language choices are: English (default setting), French, German, Italian, Spanish, and Japanese. 4 3 >L a n g Wi r e Memo Se l f u f r t age eed y es t Wire Feed Select units for wire feed speed display from either IPM (inches per minute – default setting) or MPM (meters per minute) by pressing Increase or Decrease button. >E n g l i s h 5 Memory See Section 4-10. Mode Select 6 Selftest See Section 5-10. 4 Lang >W i r e Memo Se l f u f r t age eed y es t 7 >I PM 8 Lang Wi r e >M e m o Se l f u f r t Burnback Select a preset burnback time (default setting) or an adjustable burnback time. Mode Select 5 PC Link (Optional) For instructions see PC Data Storage Owner’s Manual. age eed y es t >N o Re s e t Mode Select Wi r e Memo >S e l f PC L f r t i eed y es t nk > Sw i t c h A Of f 6 Mode Select 7 Memo Se l f >P C L Bu r n r t i b y es t nk ack Mode Select 8 OM-1315 Page 16 Memo Se l f PC L >B u r n r t i b y es t nk ack No Ad j us t 4-9. Using One Switch To Control Voltage And Wire Speed (Synergic Welding) Ma t e r i a l >We l d T i me r Dua l Sc hd Set up weld program. See Section 4-4. >M e m o r y 3 125 I PM 18 . 6 Vo l t Press Parameter Select 3 Times Memo r y 3 I PM >1 2 5 >1 8 . 6 V o l t Ma t e r i a l >We l d T i me r Dua l Sc hd Memo r y 3 >1 2 5 I PM >1 8 . 6 V o l t Gun Trigger . One switch operation will not work unless the Material mode Use Gun Switch To Change Values (see Section 4-7) was used for set up, or it will not work if the IPM and/or Volt values were changed before both were selected by pressing the Parameter Select button three times. 4-10. Resetting Memory 1 2 1 Mode And Parameter Select Buttons Press and hold down both buttons while turning On unit. Mode Parameter Select Select 2 Power Switch 3 No Reset Memory cannot be reset. 4 Press Mode Select Twice Lang Wi r e >M e m o Se l f u f r t age eed y es t >N o Reset Press Parameter Select button to reset (clear) memory. Unit defaults to original factory settings. 3 5 Reset (Default) Displays Re s e t 4 Increase/ Decrease >R e s e t 5 P r ess Parameter Select Ma t e r i a l >We l d T i me r Dua l Sc hd >M e m o r y O f f 122 I PM 17 . 5 Vo l t OM-1315 Page 17 SECTION 5 – MAINTENANCE AND TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. Repair or replace cracked weld cable. Clean and tighten weld terminals. 6 Months Blow out or vacuum inside. During heavy service clean monthly. OR 5-2. Circuit Breaker CB1 1 Circuit Breaker CB1 If CB1 opens, wire feeding stops. 2 Welding Gun Check gun liner for blockage or kinks. 1 3 Wire Drive Assembly Check for jammed wire, binding drive gear or misaligned drive rolls. 2 Allow cooling period and reset breaker. Close door. 3 Ref. ST-148 261-C 5-3. Unit Overload If unit is used beyond capacity (excessive wire feed, shorted output, etc.), wire feeds but is not energized. Release gun trigger to reset this condition. OM-1315 Page 18 5-4. Replacing Gun Contact Tip Y Turn Off power. 1 2 Nozzle Contact Tip Cut off welding wire at contact tip. Remove nozzle. Remove contact tip and install new contact tip. Reinstall nozzle. 2 1 Tools Needed: ST-149 326-B 5-5. Aligning Drive Rolls And Wire Guide Y Turn Off power. Horizontal Alignment Correct 4 Incorrect 5 3 2 1 6 View is from top of drive rolls looking down with pressure assembly open. 1 2 3 4 5 6 Allen Wrench (Supplied) Drive Roll Securing Nut Drive Roll Wire Guide Welding Wire Drive Gear Insert wrench, and turn screw in or out until drive roll groove lines up with wire guide. Tools Needed: 5/16, 9/16 in 3/16 in Ref. ST-800 412-A 5-6. Unicable Repair To repair or replace unicable, order Unicable Clamp Kit, part number 172 018. OM-1315 Page 19 5-7. Cleaning Or Replacing Gun Liner Y Disconnect gun first. Tools Needed: 3/8 in Head tube Remove nozzle, contact tip, adapter, and wire outlet guide. Wire Outlet Guide 3/8 in Remove liner. Lay gun cable out straight before installing new liner. To Reassemble Gun: Blow out gun casing. Insert new liner. Install and tighten wire outlet guide. Cut liner off 3/4 in (20 mm) (3/8 in [9.5 mm] for aluminum) from head tube. Install adapter, contact tip, and nozzle. Ref. ST-800 797-A OM-1315 Page 20 5-8. Replacing Switch And/Or Head Tube Y Disconnect gun first. 3 1 4 2 Remove handle locking nut. Secure head tube in vice. 5 Remove shock washers from front and rear of head tube. 6 Slide handle. Remove switch housing. Note: If installing new switch, push switch lead connectors onto terminal of new switch (polarity is not important). Install switch back into handle, and secure with handle locking nut. If replacing head tube, continue to end of figure. Loosen jam nut. Remove from vice and turn head tube out by hand. Do not disturb cable connection between cable connector and connector nut. 7 Install both existing shock washers to new head tube and hand-tighten head tube into connector cable. 9 8 Place head tube in vice and tighten to within 1/8 in (3.2 mm) spacing between connector cable and body. Remove from vice. Reposition handle and install switch housing. Secure with handle locking nut. Tools Needed: 3/4 in Ref. ST-800 795-A OM-1315 Page 21 5-9. Troubleshooting Trouble No weld output; wire does not feed. Remedy Be sure line disconnect switch is On (see Section 2-12). Replace building line fuse or reset circuit breaker if open (see Section 2-12). Reset circuit breaker CB1 (see Section 5-2). Secure gun trigger connections (see Section 2-5). Check and replace Power switch if necessary. Have Factory Authorized Service Agent check all board connections and main control board. No weld output; wire feeds. Thermostat TP1 open (overheating). Allow fan to run; the thermostat will close when the unit has cooled (see Section 2-2). Connect work clamp to get good metal to metal contact. Replace contact tip (see Section 5-4). An overload condition occurred. Release gun trigger (see Section 5-3). Have Factory Authorized Service Agent check main control board and main rectifier. Low weld output. Connect unit to proper input voltage or check for low line voltage (see Section 2-12). Check input voltage jumper links and correct position if necessary (see Section 2-10). Have Factory Authorized Service Agent check main control board. Fan motor does not run. NOTE: Fan only Have Factory Authorized Service Agent check fan-on-demand circuit. runs when cooling is necessary. Low, high, or erratic wire speed. Reprogram microprocessor (see Section 3-1). Change to correct size drive rolls (see Section 2-8). Readjust drive roll pressure (see Section 2-13). Replace inlet guide, contact tip, and/or liner if necessary (see Sections 5-4, and 5-7). Check position of input jumper links (see Section 2-10). Have Factory Authorized Service Agent check main control board. No wire feed. Reset circuit breaker CB1 (see Section 5-2). Reprogram microprocessor (see Section 3-1). Clear obstruction in gun contact tip or liner (see Sections 5-4 and 5-7). Readjust drive roll pressure (see Section 2-13). Change to correct size drive rolls (see Section 2-8). Rethread welding wire (see Section 2-13). Check gun trigger and leads. Repair or replace gun if necessary. Have Factory Authorized Service Agent check main control board. Poor weld bead, or welding wire is noodle welding. OM-1315 Page 22 Check polarity setting for type of welding wire being used (see Section 2-6). 5-10. Selftest Procedure 1 2 Press and hold down both buttons while turning On unit. 2 1 Mode And Parameter Select Buttons Power Switch Mode Parameter Select Select 3 Switch A This checks the increase position. 4 switch gun switch Switch B This checks the decrease position. 5 gun Trigger This checks the gun trigger. 6 Press Mode Select 3 Times 7 8 u f r t age eed y es t > S wi t c h Gun Increase Switch A Overload This checks for an overload condition. 3 Lang Wi r e Memo >S e l f Remote This checks the Spoolmatic gun or other remote device. > S wi t c h A 9 Of f On On This means an overload is present. Off means no overload. Wire feed This checks the wire feed motor. 10 Gas This checks the gas valve. 11 Contactor Increase 5 Increase >T r i g g e r This checks the welding power source contactor. 4 > S wi t c h Of f B Gun Decrease Switch > S wi t c h On Gun Trigger B Of f 6 Increase >T r i g g e r >R e m o t e On 7 Increase >R e m o t e Of f >O v e r l o a d On 8 On Increase 10 Parameter Select >G a s On P r es s >G a s Increase Of f P r ess 9 >W i r e f e e d Parameter Select On >W i r e f e e d Of f P r ess P r ess 11 Increase >C o n t a c t o r Y The welding wire and all metal parts in contact with it carry weld output when the welding power source contactor is energized. Of f P r ess Parameter Select >C o n t a c t o r On P r ess OM-1315 Page 23 5-11. Troubleshooting Displays Trouble Release Trigger displayed. Remedy Release gun trigger. Check gun trigger and leads. There is high frequency in the area of the welder. Turn it off or move welder. Release Remote displayed. Release spool gun or remote control trigger. Check spool gun trigger and leads according to spool gun Owner’s Manual. Check remote control switch and switch leads according to unit Owner’s Manual. There is high frequency in the area of the welder. Turn it off or move welder. Overload displayed. Adjust weld parameters to reduce output. Keep contact tip from shorting to the workpiece. Thermal shutdown has occurred. Allow a cooling period (see Section 2-2). Have nearest Factory Authorized Service Agent check the microprocessor panel, capacitor bank, main rectifier, and main transformer. OM-1315 Page 24 SECTION 6 – ELECTRICAL DIAGRAM SC-168 541-A Figure 6-1. Circuit Diagram OM-1315 Page 25 . Hardware is common and 16 15 14 SECTION 7 – PARTS LIST 19 20 Fig 7-3 Fig 7-6 25 1 2 24 3 23 22 4 Fig 7-2 21 6 7 5 8 9 10 Fig 7-5 8 11 7 12 17 13 18 not available unless listed. ST-148 324-E Figure 7-1. Main Assembly OM-1315 Page 26 Item No. Dia. Mkgs. Part No. Description Quantity Figure 7-1. Main Assembly . . . 1 . . . . . . . . . . . 148 597 . . . 2 . . . . . . . . . . . 146 168 . . . 3 . . PLG7 . . 083 526 . . . 4 . . . . . . . . . . . . Fig 7-2 . . . 5 . . . . T1 . . . 144 043 . . . 5 . . . . T1 . . . 150 381 . . . 5 . . . . T1 . . . 150 382 . . . . . . . . . . . . . . . . . 143 853 . . . . . . . . . . . . . . . . . 150 326 . . . . . . . . . . . . . . . . . 150 314 . . . . . . . . . TP3 . . . 121 497 . . . 6 . . . . . . . . . . . 150 387 . . . 7 . . . . . . . . . . . 602 250 . . . 8 . . . . . . . . . . . 070 799 . . . 9 . . . . Z1 . . . 143 892 . . . 9 . . . . Z1 . . . 150 385 . . . 10 . . . . . . . . . . . . Fig 7-5 . . . 11 . . . . . . . . . . . 146 165 . . . 12 . . . . . . . . . . . 089 899 . . . 13 . . . . . . . . . . +146 167 . . . . . . . . . . . . . . . . . 146 991 . . . 14 . . . . . . . . . . . 134 464 . . . 15 . . . . . . . . . . +170 513 . . . . . . . . . . . . . . . . . 117 860 . . . 16 . . PLG20 . 144 086 . . . . . . . . . . . . . . . . . 039 778 . . . 16 . . . . . . . . . . . 144 085 . . . 17 . . . . . . . . . . . 146 161 . . . 18 . . . . . . . . . . . 052 692 . . . 19 . . . . . . . . . . . 121 614 . . . 20 . . . SR1 . . . 173 713 . . . . . . . . . . . . . . . . . 166 667 . . . . . . . . . . . . . . . . . 173 784 . . . . . . . . . C3,4 . . 031 689 . . . . . . . . . . . . . . . . . 143 818 . . . . . . . . . TP1 . . . 154 243 . . . . . . . . . . . . . . . . . 171 405 . . . . . . . . . . . . . . . . . 143 852 . . . . . . . . . TP2 . . . 154 244 . . . . . . . . . . . . . . . . . 173 714 . . . 21 . . . . . . . . . . . 602 213 . . . 22 . . . . . . . . . . . 008 999 . . . 23 . . . . . . . . . . . 601 871 . . . 24 . . . . . . . . . . . . Fig 7-3 . . . 25 . . . . . . . . . . . 169 600 . . . . . . . . . . . . . . . . . 182 137 . . . . . . . . . . . . . . . . . 144 108 . . . . . . . . . . . . . . . . . 130 750 . . . . . . . . . . . . . . . . . 600 318 . . COUPLER, rod threaded .312-18 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . PANEL, center enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . HOUSING RECEPTACLE & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . BAFFLE, center w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . TRANSFORMER, pwr main (200/230/460) (consisting of) . . . . . . . . . . . . . . . 1 . . TRANSFORMER, pwr main (230/460/575) (consisting of) . . . . . . . . . . . . . . . 1 . . TRANSFORMER, pwr main (220/380/415) (consisting of) . . . . . . . . . . . . . . . 1 . . . . COIL, pri/sec (200/230/460) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . COIL, pri/sec (230/460/575) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . COIL, pri/sec (220/380/415) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . THERMOSTAT, NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . BAFFLE, air transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . WASHER, flat stl SAE .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . WHEEL, rubolene 10 in dia x 2.250 wide x .750 bore . . . . . . . . . . . . . . . . . . . 2 . . STABILIZER, (60Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . STABILIZER, (50Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . PANEL, rear w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . PANEL, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . LATCH, slide flush mtg hole 1.000 wide x 1.500 lg . . . . . . . . . . . . . . . . . . . . . 2 . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . LABEL, weld parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . BLANK, snap-in nyl .187mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . CORD SET, pwr 250V 8-10ga 3/c 600V 12ft (200/230V) . . . . . . . . . . . . . . . . 1 . . RECEPTACLE, str 2P3W 50A 250V (200/230V only) . . . . . . . . . . . . . . . . . . . 1 . . CORD SET, pwr 8-10ga 3/c 600V 12ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . AXLE, running gear (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . RING, retaining ext .750 shaft x .085grv depth . . . . . . . . . . . . . . . . . . . . . . . 2 . . RECTIFIER, SCR main (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . CLAMP, spring thyristor rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . HEAT SINK, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . CAPACITOR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . THYRISTOR, SCR 325A 300V hockey puck . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . THERMOSTAT, NC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . HEAT SINK, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . FOOT, mtg rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . THERMOSTAT, NO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . CLAMP, thyristor rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . WASHER, lock stl split .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . CASTER, plstc swvl 4 in dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . NUT, stl hex jam .375-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . PANEL, front w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . GUN, 12ft .030-.035 wire (Fig 7-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . REGULATOR/FLOWMETER, 10-50 CFH Argon/CO2 . . . . . . . . . . . . . . . . . . 1 . . HOSE, gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . CLAMP, ground 350A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . CABLE, weld cop strd No. 3 (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10ft +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 Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-1315 Page 27 . Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 9 7 6 34 10 11 33 Fig 7-4 35 32 12 13 14 31 15 30 16 26 18 19 20 25 24 17 29 27 28 21 23 22 ST-148 325-C Figure 7-2. Baffle, Center w/Components OM-1315 Page 28 Item No. Dia. Mkgs. Part No. Description Quantity Figure 7-2. Baffle, Center w/Components (Fig 7-1 Item 4) . . . 1 . . . . . . . . . . . 058 427 . . . 2 . . . . . . . . . . . 085 980 . . . 3 . . . . . . . . . . . 605 941 . . . 4 . . . . . . . . . . . 057 543 . . . 5 . . . . . . . . . . . 057 971 . . . 6 . . . . . . . . . . . 010 191 . . . 7 . . . . . . . . . . . 058 628 . . . 8 . . . . . . . . . . . 057 745 . . . 9 . . . . . . . . . . . 058 428 . . . 10 . . . . . . . . . . . 177 307 . . . 11 . . . . . . . . . . . 174 813 . . . . . . . . . . . . . . . . . 186 998 . . . 12 . . . . . . . . . . . 082 902 . . . 13 . . . . . . . . . . . 185 643 . . . 14 . . . . C5 . . . 184 584 . . . . . . . . . . . . . . . . . 083 147 . . . . . . . . . . . . . . . . . 187 752 . . . 15 . . . CR1 . . . 006 393 . . . 16 . . . VR1 . . . 149 542 . . . 17 . . . TE1 . . . 143 911 . . . 18 . . . . . . . . . . . 010 913 . . . 19 . . . . . . . . . . . 038 887 . . . 20 . . . . . . . . . . . 083 426 . . . 21 . . . . . . . . . . . 601 835 . . . 22 . . . . . . . . . . . 038 618 . . . 23 . . . . . . . . . . . 010 199 . . . 24 . . . PC1 . . . 184 316 . . . . . . . . PLG3 . . 115 094 . . . . . . . . PLG4 . . 131 052 . . . . . . . . PLG5 . . 131 056 . . . . . . . . PLG6 . . 115 092 . . . 25 . . . . R1 . . . 119 998 . . . 26 . . . . 1T . . . 129 524 . . . 27 . . . C7,8 . . 128 750 . . . 28 . . . POS . . 039 047 . . . 29 . . . NEG . . 039 046 . . . 30 . . . . . . . . . . . 071 971 . . . 31 . . . CB1 . . . 123 745 . . . 32 . . . . . . . . . . . 134 201 . . . 33 . . . . . . . . . +144 933 . . . 34 . . . . . . . . . . . 021 469 . . . 35 . . . . . . . . . . . . Fig 7-4 . . . RING, retaining spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUT, stl hex full .625-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WASHER, flat stl .640 ID x 1.000 OD x 14ga thk . . . . . . . . . . . . . . . . . . . . . . . . . . SPRING, cprsn .845 OD x .091 wire x 1.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WASHER, flat stl keyed 1.500dia x .125thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WASHER, fbr .656 ID x 1.500 OD x .125thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WASHER, brake stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPRING, cprsn 2.430 OD x .090 wire x 2.500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HUB, spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REEL, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BAFFLE, center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR KIT,(consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STRIP, mtg center capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STRIP, mtg capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR, elctlt 15000uf 45VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GROMMET, scr No. 8/10 panel hole .312sq .500 high . . . . . . . . . . . . . . . . . . . . . INSULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RELAY, encl 24VAC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VARISTOR, 75 joule 350VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TERMINAL ASSEMBLY, pri 1ph triple voltage (consisting of) . . . . . . . . . . . . . . . . . WASHER, flat brs .218 ID x .460 OD x .031thk . . . . . . . . . . . . . . . . . . . . . . . . . . . STUD, pri bd brs 10-32 x 1.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TERMINAL BOARD, pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUT, brs hex 10-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LINK, jumper term bd pri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TUBING, stl .275 ID x .048 wall x 1.000 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD, control main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOUSING PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOUSING RECEPTACLE & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOUSING RECEPTACLE & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOUSING PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RESISTOR, WW fxd 300W 5 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TERMINAL, frict male .250 x .032 3 pair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COVER, cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT BREAKER, man reset 1P 4A 250VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . STAND-OFF SUPPORT, PC card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DOOR, access chgov . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LABEL, danger high voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIRE DRIVE & GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 1 1 2 2 1 1 1 1 1 1 2 8 6 1 1 1 1 6 6 1 12 2 2 1 1 1 1 1 1 1 2 1 1 1 1 4 1 1 1 +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 Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-1315 Page 29 Item No. Dia. Mkgs. Part No. Description Quantity Figure 7-3. Panel, Front w/Components (Fig 7-1 Item 24) . . . 1 . . . . . . . . . . . . . 147 582 . . . . . 2 . . . . . . . . . . . . . 147 791 . . . . . 3 . . . . PC5 . . . . 182 021 . . . . . 4 . . . . PC1 . . . . 147 472 . . . . . . . . . . . PLG8 . . . 143 322 . . . . . . . . . . . . . . . . . . . . . . 113 746 . . . . . 5 . . . . . . . . . . . . . 143 974 . . . . . 6 . . . . C9 . . . . . 146 158 . . . . . 6 . . . . C10 . . . . 175 719 . . . . . 6 . . . . C11 . . . . 146 159 . . . . . 6 . . . . C12 . . . . 146 157 . . . . . 7 . . . . RC1 . . . . 048 282 . . . . . 8 . . . C1,2 . . . . 148 240 . . . . . 9 . . . . S1 . . . . . 128 755 . . . . . 10 . . . . . . . . . . . . . 174 814 . . . . . 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 . . . . PL1 . . . . 157 958 . . . . . 13 . . . . . . . . . . . . . 057 357 . . . . . 14 . . . . . . . . . . . . . 144 844 . . . . . 15 . . . . . . . . . . . . . 147 584 . . . . . 16 . . . . . . . . . . . . . 144 127 . . . . . 17 . . . . . . . . . . . . . 153 169 . . . . . 18 . . . . . . . . . . . . . . . . . . . . . . . . LENS, clear anti-glare .030 x 2.125 x 3.225 . . . . . . . . . . . . . . . . . . . . . . . . . BEZEL, LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LCD, w/ribbon cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT CARD, microprocessor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOUSING, term hdr 24skt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TERMINAL, female 1skt 24-18 wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HANDLE, running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEAD ASSEMBLY, elect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECEPTACLE w/SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAPACITOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH, tgl DPST 40A 600VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLATE, indicator lower (order by model and serial number) . . . . . . . . . . . LIGHT, ind white lens 28V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUSHING, snap-in nyl .937 ID x 1.125mtg hole . . . . . . . . . . . . . . . . . . . . . STAND-OFF, No. 6-32 x .875 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, front control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COVER, opening module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACTUATOR, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . 1 1 1 1 1 24 1 1 1 1 1 1 2 1 1 1 1 2 5 1 1 4 1 3 . Hardware is common and 2 not available unless listed. 4 1 5 6 18 17 7 16 15 8 14 9 13 12 11 10 ST-148 326-C Figure 7-3. Panel, Front w/Components To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-1315 Page 30 Item No. Dia. Mkgs. Part No. Description Quantity Figure 7-4. Wire Drive And Gears (Fig 7-2 Item 35) . . . 1 . . . . . . . . . . . 602 009 . . . 2 . . . . . . . . . . . 172 075 . . . 3 . . . . . . . . . . . 166 072 . . . 4 . . . . . . . . . . . 010 224 . . . 5 . . . . . . . . . . . 182 788 . . . 6 . . . . . . . . . . . 085 242 . . . 7 . . . . . . . . . . . 085 244 . . . 8 . . . . . . . . . . . 010 231 . . . 9 . . . . . . . . . . . 085 243 . . . 10 . . . . . . . . . . . 166 071 . . . 11 . . . . . . . . . . . 079 634 . . . 12 . . . . . . . . . . . 151 828 . . . 13 . . . . . . . . . . . 173 616 . . . 14 . . . PM . . . 173 435 . . . 15 . . . . . . . . . . . 079 633 . . . 16 . . . . . . . . . . . 601 966 . . . 17 . . . . . . . . . . . 145 237 . . . 18 . . . . . . . . . . . 604 538 . . . 19 . . . . . . . . . . . 124 778 . . . 20 . . . . . . . . . . . 173 619 . . . 21 . . . . . . . . . . . 174 609 . . . 22 . . . . . . . . . . . 174 610 . . . 23 . . . . . . . . . . . 173 620 . . . . . . . . . . . . . . . . . 045 233 . . . . . . . . . . . . . . . . . 010 287 . . . SCREW, .250-20 x 1.25 soc hd gr 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARRIER, drive roll w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPACER, gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PIN, spring CS .187 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOUSING, adapter gun/feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FASTENER, pinned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WASHER, cupped stl .328 ID x .812 OD x .125 lip . . . . . . . . . . . . . . . . . . . . . . . . . SPRING, cprsn .770 OD x .105 wire x 1.225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KNOB, adj tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEVER, mtg pressure gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PIN, hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PIN, cotter hair .054 x .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COVER, right angle motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOTOR, gear 24VDC 122RPM 20:1 ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FITTING, hose brs barbed M 3/16tbg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCREW, .375–16 x 1.25hexhd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STOP, cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WASHER, flat stl SAE .312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KNOB, plstc T 1.000 lg x .312-18 x 2.000 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARRIER, drive roll w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCREW, M 4–.7 x 12 soc hd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCREW, M 6–1.0 x 20 soc hd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUSHING, motor mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GUIDE, anti-wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WRENCH, hex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hardware is common and not available unless listed. 13 9 See Table 7-1 For Drive Roll & Wire Guide Kits. 8 10 7 11 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 3 1 1 1 1 1 3 3 1 1 14 12 6 5 4 3 2 1 23 15 22 16 21 17 20 19 18 ST-148 529-C Figure 7-4. Wire Drive And Gears *Recommended Spare Parts. To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-1315 Page 31 Table 7-1.Drive Roll And Wire Guide Kits Note Base selection of drive rolls upon the following recommended usages: 1 2 3 4 5 V-Grooved rolls for hard wire. U-Grooved rolls for soft and soft shelled cored wires. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types). V-Knurled rolls for hard shelled cored wires. Drive roll types may be mixed to suit particular requirements (example: V-Knurled roll in combination with U-Grooved). Wire Diameter Drive Roll Part No. Type Inlet Wire Guide 087 131 087 130 V-Grooved 056 192 079 594 053 695 V-Grooved 056 192 0.9 mm 079 595 053 700 V-Grooved 056 192 1.2 mm 079 596 053 697 V-Grooved 056 193 Fraction Decimal Metric .023/.025 in. .023/.025 in. 0.6 mm .030 in. .030 in. 0.8 mm .035 in. .035 in. .045 in. .045 in. Kit No. Ref. S-0026-B/7-91 Item No. Dia. Mkgs. Part No. Description Quantity Figure 7-5. Panel, Rear w/Components (Fig 7-1 Item 10) ... ... ... ... ... ... ... ... ... ... ... ... ... 1 2 3 4 5 6 7 8 9 10 11 12 13 . . . . . . . . . . . 134 834 . . . . . . . . . . . 149 332 . . . GS1 . . . 125 785 . . . . . . . . . . . 143 810 . . . . . . . . . . . 169 654 . . . . . . . . . . . 602 387 . . . . . . . . . . . 605 227 . . . . . . . . . . . 044 426 . . . . . . . . . . . 010 493 . . . . . . . . . . . 148 242 . . . FM1 . . . 148 808 . . . . . . . . . . . 148 809 . . . . . . . . . . . 049 399 . . . HOSE, SAE .187 ID x .410 OD (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLAMP, hose .405-.485clp dia slfttng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VALVE, 24VAC 2 way custom port 1/8 orf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRACKET, support tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHAIN, weldless 2/0 x 27.000 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUT, nyl hex jam .750NPST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR, clamp cable .690/1.070 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BUSHING, snap-in nyl .625 ID x .875mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDTUNNEL, 9 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOTOR, fan 230V 1550RPM .312dia shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BLADE, fan 9 in 5wg 34deg .309 bore CCW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUT, speed push-on-type .312 stud .625 OD x .456 ID . . . . . . . . . . . . . . . . . . 3ft 2 1 1 1 1 1 1 1 1 1 1 1 5 . Hardware is common and 4 not available unless listed. 6 3 2 1 7 8 9 10 13 11 12 ST-148 327-C Figure 7-5. Panel, Rear w/Components To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-1315 Page 32 Item No. Part No. Description Quantity Figure 7-6. M-25M Gun (Fig 7-1 Item 25) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 1 1 1 1 1 1 2 2 2 2 3 4 5 6 7 8 9 10 11 12 1 . . . ♦169 724 . . . ♦169 725 . . . ♦169 726 . . . ♦169 727 . . . ♦176 238 . . . ♦176 240 . . . ♦176 242 . . . ♦087 299 . . . ♦000 067 . . . ♦000 068 . . . ♦000 069 . . . . . 169 728 . . . . . 169 729 . . . . . 170 467 . . . . . 170 468 . . . . . 169 730 . . . . . 169 731 . . . . . 169 738 . . . . . 169 732 . . . . . 169 733 . . . . . 169 734 2 3 4 .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. NOZZLE, slip type .500 orf .125 recess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NOZZLE, slip type .625 orf .125 recess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NOZZLE, slip type .625 orf flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NOZZLE, slip type .625 orf .125 stickout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NOZZLE, spot flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NOZZLE, spot inside corner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NOZZLE, spot outside corner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIP, contact scr .023 wire x 1.125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIP, contact scr .030 wire x 1.125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIP, contact scr .035 wire x 1.125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TIP, contact scr .045 wire x 1.125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADAPTER, contact tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADAPTER, nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RING, retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WASHER, shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TUBE, head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUT, locking handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUT, jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR, cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUT, connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 6 7 1 1 1 1 1 1 1 2 2 2 2 1 1 1 1 1 1 2 2 2 2 . Hardware is common and 8 not available unless listed. 9 10 11 12 14 25 15 16 13* 27 26 17 23 24 22 19 29 20 18 21 10 9 11 12 17 28 *Includes Item 18 21 ST-801 730 Figure 7-6. M-25M Gun OM-1315 Page 33 Item No. Part No. Description Quantity Figure 7-6. M-25M Gun (Fig 7-1 Item 25) (Continued) . . . 13 . . . . . 172 018 . . . 14 . . . . . 169 735 . . . 15 . . . . . 169 742 . . . 16 . . . . . 169 743 . . . 17 . . . . . 170 469 . . . 18 . . . . . 169 746 . . . 19 . . . . . 172 690 . . . 20 . . . . . 172 691 . . . . . . . . . . . 602 063 . . . 21 . . . . . 169 741 . . . 22 . . . . . 180 431 . . . 23 . . . . . 173 521 . . . 24 . . . . . 079 974 . . . 25 . . . ♦172 257 . . . 25 . . . ♦172 258 . . . 26 . . . . . 079 975 . . . 27 . . . . . 169 723 . . . 28 . . . . . 169 737 . . . 29 . . . . . 169 739 . . M25 UNICABLE CLAMP KIT, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLIP, compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TUBE, support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLAMP, inner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLAMP, jacket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR, switch lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH ASSEMBLY, inc/dec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HANDLE, (gun end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SCREW, 4-40 x .250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STRAIN RELIEF, cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CABLE, trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTOR, feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-RING, .500 ID x .103CS rbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KIT, liner monocoil .023/.025 wire x 15ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KIT, liner monocoil .030/.035 wire x 15ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-RING, .187 ID x .103CS rbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GUIDE, outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SWITCH, trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 1 1 1 2 1 1 1 2 1 1 2 1 1 1 1 1 1 ♦OPTIONAL To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. OM-1315 Page 34 Notes Notes Notes OPTIONS AND ACCESSORIES M40AL GUN (#169 608) For welding with aluminum wire. Rated 525 amps at 60% duty cycle or 275 amps at 100% duty cycle using argon gas. Gun designed to run 3/64 in (1.2 mm) wire. 10 ft (3.0 m). SPOOLMATICE 30A SPOOL GUN (#130 831) Ideal for aluminum welding jobs. 200 amp, 100% duty cycle, air-cooled, 1 lb spool gun with 30 ft (9.1 m) cable assembly. Plugs into Receptacle Module 2. For detailed information, see Spoolmatic literature, Index No. M/1.2. RECEPTACLE MODULE Required if welding with spool gun. Provides a convenient way for you to plug in Spoolmatic gun. Installs in less than 15 minutes. GUN HOLDER (#042 710) Installs onto side of power source. Provides convenient way to store gun when not in use. MODULE #2 (#042 607) Use with Spoolmatic 30A and Spoolmatic 3. POWER CORD EXTENSION (#041 688) 25 ft (7.6 m) power cord extension with plug. Note: Only one spool gun can be used at a time. REPLACEMENT GUNS DUAL CYLINDER RACK (#042 758) Converts single cylinder rack to a dual rack. GUN CABLE HOLDER (#042 701) A convenient way to store gun and cable. M25M FOR MILLERMATICE 250MP (#169 600) 12 ft (3.7 m) (#169 601) 15 ft (4.6 m) Rated 300 amps at 60% duty cycle or 200 amps at 100% duty cycle using CO2. Gun is designed to run .030 – .035 in (0.8 – 0.9 mm) wire. The gun features an Increase/ Decrease switch to easily fine tune weld parameters while welding. 1/95 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. Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way. * LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS. Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed. Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor. 1. 5 Years Parts – 3 Years Labor * * 2. 3 Years — Parts and Labor * * * * * * 3. Original main power rectifiers Inverters (input and output rectifiers only) 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 by the engine manufacturer.) 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 True Blue for the remaining warranty period of the product they are installed in, or for a minimum of one 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 Cutting Torches Remote Controls Accessory Kits Replacement Parts (No labor) Spoolmate 185 & Spoolmate 250 Canvas Covers Miller’s 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 are covered by the manufacturer’s warranty, if any. 3. Equipment that has been modified by any party other than Miller, or equipment 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 COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT. In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed. TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, 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, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER. Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state. In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province. miller_warr 7/00 Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA Replacement Parts Training (Schools, Videos, Books) International Headquarters–USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 Technical Manuals (Servicing Information and Parts) Circuit Diagrams European Headquarters – United Kingdom Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066 Welding Process Handbooks www.MillerWelds.com Contact the Delivering Carrier for: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. PRINTED IN USA 2000 Miller Electric Mfg. Co. 6/00