Miller Electric 22A Specification

Miller Electric 22A Specification
22A
24 Volt, Constant-Speed Wire Feeder
Index No. M/11.0
Issued Dec. 1999
Processes
Simple to use but with all the features needed for
the industrial manufacturing and fabricating
markets. Built with the strength and flexibility to
handle strenuous work loads, the 22A delivers
proven reliability and economy.
MIG (GMAW)
Welding
Flux Cored (FCAW) Welding
(Gas- and Self-shielded)
This wire feeder is ideal for most high-duty-cycle
applications requiring day-in day-out trouble-free
operation.
Applications
Light-duty fab shops
Trailer manufacturers
Furniture manufacturers
Automotive products
Educational institutions
Features
Benefits
Increased wire-feed-speed range
The 22A wire-feed-speed range is 75 – 750! This offers a wider operating range than the competition.
Trigger hold control
Allow operator to make long extended welds without having to hold gun trigger.
Gear-driven drive rolls
Offers smooth, positive and accurate wire feed with long, uninterrupted service life.
On-board burnback and motor
ramp control
Unmatched starting and stopping performance on a variety of power sources. This helps to ensure positive arc
starting performance.
16 gauge sheet metal housing
Robust in rough service applications. Less prone to damage.
Optional presettable voltage and
wire feed speed
Allows voltage and wire feed speed to be preset and monitored. Does not require a volt sense lead.
Miller’s True Blue® Warranty
Wire feeder is warranted for 3 years — parts and labor.
Typical Installation
See back cover for complete system checklist.
Miller CV or CV/CC power source
equipped with a 14-pin receptacle
and 24 VAC power.
10 ft (3 m) 24 VAC and contactor
cord supplied with feeder
Note: For power sources only supplying 115 VAC power the R-115 (#193 164) model is recommended.
Specifications (Subject to change without notice.)
Industrial
(Use with CV
Power Sources.)
Input Power
Electrode Wire Diameter Capacity
Wire Speed
Dimensions
Net Weight
24 VAC, 7 A, 50/60 Hz
.023 – 5/64 in (0.6 – 2.0 mm)
75 – 750 IPM (1.9 – 19 m/min)
H: 11 in (279 mm)
W: 10-3/4 in (273 mm)
D: 23-1/2 in (597 mm)
36 lb (15.4 kg)
®
Certified by Canadian Standards Association to both Canadian and U.S. Standards.
NRTL/C
Ordering Information
☞ See back page.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
Control Panel
1. Gun Connection
2. Trigger Receptacle
3. Voltage/Wire Speed Meter*
4. Meter Selection Switch*
5. Remote Voltage Control*
6. Wire Speed Control
7. Jog/Purge
8. Trigger hold (On/Off)
3
4
5
Power On/Off (on rear panel)
*Optional
6
1
2
7
8
Drive Roll Kits
(Order from Miller Service Parts.)
Select drive roll kits from chart below according to type and wire size being used. Drive roll kits include the necessary guides and feature an anti-wear sleeve for inlet guide.
Wire size
“V” groove
for hard wire
“U” groove for
soft wire or
soft-shelled
cored wires
“V” knurled
for hard-shelled
cored wires
“U” cogged for
extremely soft
wire or softshelled cored
wires (i.e., hard
facing types)
.023 / .025 in (0.6 mm)
#087 131
—
—
.030 in (0.8 mm)
#079 594
—
—
—
—
.035 in (0.9 mm)
#079 595
#044 749
#079 606
—
.040 in (1.0 mm)
#161 189
—
—
—
.045 in (1.1/1.2 mm)
#079 596
#079 599*
#079 607
#083 318
.052 in (1.3/1.4 mm)
#079 597
#079 600
#079 608
#083 317
1/16 in (1.6 mm)
#079 614
#079 598
#079 601
#079 609
.068/.072 in (1.8 mm)
—
—
#089 984
—
5/64 in (2.0 mm)
—
#079 602
#079 610
#079 615
*Accommodates .045 and .047 (3/64) wires.
Nylon Wire Guides for Feeding Aluminum Wire (Order from Miller Service Parts.)
Wire Size
.035 – .047 in (1.2 mm)
1/16 in (1.6 mm)
Inlet Guide
#151 203
#151 205
Note: “U” groove drive rolls
are recommended when
feeding aluminum wire.
Options
2
Skill Level Index
The bracketed entry to the right of the stock number of
field-installed options contains a letter and number. The
letter indicates the skill level required to install the option.
The number indicates the approximate time required for
installation (see legend).
A– Easy. No previous experience needed.
B– Average. Requires removal of service panels.
Mechanical ability is helpful.
C– Difficult. May require the use of an ohmmeter and/or
splicing of electrical wires. Repair or replacement of
component parts is more difficult.
D– Technical. May require the use of an ohmmeter and the
ability to read a circuit diagram. Repair or replacement
of component parts is complex.
Digital Display V/WFS #186 498 Field [ B: 30 ]
Dual-function, back-lit LCD digital meter with
selector switch. The digital meter allows the
wire feed speed to be preset in inches per
minute or meters per minute. The voltage
function, if used with a current manufactured
Miller electronically controlled constant
voltage power source, allows the arc voltage to
be preset and monitored on the digital display.
When used with voltage control #194 211.
Voltage Control #194 211 Field [ A: 15 ]
Installs in front panel of the feeder to allow
remote voltage control of most Miller electrically controlled CV or CC/CV power sources.
Preflow/Postflow and Spot Control
#186 496 Field [ A: 25 ]
Installs inside feeder under an easy access
hinged cover. Provides up to 5 seconds of spot
weld time and has adjustable timers (0.25 to 5
seconds) for controlling gas flow prior to arc
initiation and after completion of weld.
Note: The field kit voltage control includes a 10 ft (3 m) cord
that replaces the standard cord supplied with the feeder.
Run-In Control #193 391 Field [ A: 25 ]
A separate wire feed speed adjustment to
control wire speed prior to arc initiation. This
control may be beneficial to aid arc starting
with certain types of power sources.
Example:
[ B: 30 ] Skill Level: B, Time: 30 minutes
Accessories
Carrying Handle
Feeder Cart
Blue Runner #043 965
Simple, convenient, and easy-to-assemble
running gear for the XMT-304 and Invision
354MP. Designed for factory floor MIG applications using the 22A or S-60 Series wire feeders.
Carrying Handle #193 762
For lifting and moving feeder. (Cannot be used
with wire reel assembly #108 008.)
Hanging Bail
Reel or Spool Cover
Extension Cords
#122 973 25 ft (7.6 m)
#122 974 50 ft (15 m)
#122 975 75 ft (23 m)
These extension cords can be added to the
standard 10 ft cord to extend feeder farther
from the power source.
Hanging Bail #058 435 [ A: 05 ]
Suspends feeder over the work area.
Carrying Cart #056 301 [ A: 30 ]
A utility cart for the wire feeder and other
miscellaneous welding supplies. Height: 34 in
(863 mm) Lower tray height: 9 in (228 mm)
Shipped disassembled.
Reel Cover #058 256
For 60 lb (27.2 kg) coil.
PSA-2 Control #141 604 [ A: 10 ]
Required when using the 22A wire feeder with
power sources having only 115 VAC available.
The PSA-2 control can be conveniently
mounted on the wire feeder or positioned at the
power source. The control is equipped with a
14-pin receptacle for direct connection of the
wire feeder control cord. A short cord with a
4-pin Amp plug is hard wired to the control.
A 10 ft (3 m) interconnecting cord with a 4-pin
Amp for connection to the PSA-2 and Hubbell
connectors for older-style Miller CV power
sources is included. The PSA-2 control can
also be used with competitive power sources
requiring a contact closure for contactor control.
[ A: 05 ]
2/0 MIG Welding Accessory Kit #173 856
25 ft (7.6 m). Includes gas hose, weld cable and
ground cable with clamp.
Spool Cover #057 607 [ A: 05 ]
For 12 in (304 mm) spool.
M-25 and M-40 Guns
See Lit. Index No. M/10.0.
Wire Reel Assembly
GW-500 Gun
See Lit. Index No. M/13.4.
Turntable
Assembly
Feeder Cart #142 382 [ A: 20 ]
A low-profile, creeper cart which allows the
operator to easily move the feeder around the
work area. Shipped disassembled.
Wire Reel Assembly #108 008 [ A: 05 ]
For 60 lb (27.2 kg) coil of wire. (Cannot be used
with carrying handle #193 762.)
Turntable Assembly #146 236 [ B: 20 ]
Allows rotation of feeder as operator changes
work positions. This reduces strain and bending
on gun cable.
Spool Adapter #047 141 [ A: 05 ]
For use with 14 lb (6.4 kg) spool of Lincoln
self-shielding wire.
3
System Checklist and Quotation Sheet
Equipment and Options
Stock No.
Description
22A
#193 066
#193 066-01-1
#193 066-02-2
With run-in control
With digital display and voltage control
Digital Display Meter
#186 498
Field
Voltage Control
#194 211
Field
Run-In Control
#193 391
Field
Preflow/Postflow and Spot Control
#186 496
Field
Drive Roll Kit
Qty.
See table on page 2
Power Sources
Regency 250 Package
See Lit. Index No. DC/12.6
CP-302
See Lit. Index No. DC/13.0
CP-252TS
See Lit. Index No. DC/13.0
Deltaweld 302
See Lit. Index No. DC/16.2
Shopmaster
See Lit. Index No. AD/2.3
XMT-304 CC/CV
See Lit. Index No. DC/18.8
Invision 354 MP
See Lit. Index No. DC/23
Accessories
Blue Runner
#043 965
Carrying Cart
#056 301
Feeder Cart
#142 382
Carrying Handle
#193 762
Hanging Bail
#058 435
Reel Cover
#058 256
For 60 lb coil
Spool Cover
#057 607
For 12 in spool
Wire Reel Assembly
#108 008
Turntable Assembly
#146 236
Spool Adapter
#047 141
PSA-2 Control
#141 604
Extension Cords
#122 973
#122 974
#122 975
2/0 MIG Accessory Kit
#173 856
Interconnecting Cable
#043 695
#043 696
#043 697
For 14 lb spool of Lincoln self-shielding wire
25 ft
50 ft
75 ft
10 ft
25 ft
75 ft
M-25 and M-40 MIG Guns
See Lit. Index No. M/10.0
GW-500 MIG Gun
See Lit. Index No. M/13.4
Miscellaneous
Primary Power Cable
Secondary Weld Cable
Ground Cable with Work Clamp
Gas Cylinder
Gas Hose with Fittings
Regulator/Flowmeter
Welding Wire
Helmet
Welding Gloves
Date:
Distributed by:
Litho in USA
Total Quoted Price:
Price
60
Series
Single and Dual Semiautomatic, Constant-Speed Wire Feeders
Processes
Index No. M/2.0
Issued June 2001
Outstanding performance in the most demanding
MIG applications—that’s the 60 Series heavy-duty
wire feeder. Designed with flexibility in mind, the
60 Series offers multiple configurations. A customer
can start with a simple system, and add options as
welding needs change. Performance and flexibility
meet virtually every job requirement with the 60 Series.
MIG (GMAW)
Welding
Flux Cored (FCAW) Welding
(Gas- and Self-shielded)
Applications
Heavy equipment
manufacturing
Automotive products
Rail car
Heavy steel fabricators
Agricultural
S-60 Model
D-60 Model
Features
Benefits
New!
A separate wire feed adjustment to control wire speed prior to arc initiation.
Optional run-in control
Tank manufacturing
Industrial equipment
manufacturing
Commercial equipment manufacturing
Trailer manufacturing
Unique Posifeed™ wire drive system
Provides positive wire feeding performance.
Easy loading and threading of welding wire
Wire threads easily through drive system without having to release the drive roll pressure arm.
Rotatable drive assembly
Reduces sharp bends in the gun cable. Improves wire feeding performance and extends the service life of the gun liner.
Solid-state speed control and
brake circuit
Excellent speed control and regulation. Eliminates the need for electrical/mechanical relays. Increased service life.
Two sealed ball bearing all-gear-driven
drive-roll carriers
Offers a smooth, positive and accurate wire feed with long uninterrupted service life.
Quick-change drive rolls
No tools required to change or service drive rolls.
Gas purge control
Purges gas line without feeding wire.
Wire jog control
Feeds welding wire without energizing contactor.
Quick-release, calibrated drive-roll
pressure-adjustment arm
Allows drive roll change without losing spring preload setting. Reduced weld cycle time.
Two to four drive roll conversion
Allows two-drive-roll feeder to be quickly, easily and economically converted to a four-drive-roll feeder. (Requires optional
Drive Roll Conversion Kit.)
Accommodates a variety of internally
installed, plug-in options
Easy to upgrade feeder as the customers needs and requirements change.
Optional trigger hold
Reduces fatigue by allowing the operator to weld without holding the gun trigger.
Specifications (Subject to change without notice.)
*
Input Power
Electrode Wire
Diameter Capacity
Wire Speed
24 VAC, 10 A,
50/60 Hz
.023–1/8 in
(0.6 – 3.2 mm)
50–780 IPM
(1.3 –19.8 m/min)
®
Heavy Industrial
Dimensions
S-60
D-60
H: 13-1/4 in (337 mm)
W: 13 in (330 mm)
D: 26-1/2 in (673 mm)
H: 13-1/2 in (343 mm)
W: 17-1/2 in (445 mm)
D: 32-1/4 in (819 mm)
Net Weight
S-60
D-60
43 lb
(19.5 kg)
74 lb
(33.6 kg)
Certified by Canadian Standards Association to both Canadian and U.S. Standards.
NRTL/C
**
50/60 Hz models with CE Specifications are manufactured according to the Standards IEC-974-1 and EN-60974-1.
Ordering Information
(Use with CV
Power Sources.)
☞ See back page.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
Typical Installations
Miller electrically controlled CV
and CC/CV power source with a
14-pin receptacle and 24 VAC
supply
Basic or
D* Model
10 ft (3 m) 24 VAC, Contactor and
Voltage Control Cord (supplied with feeder)
10 ft (3 m) interconnecting cord included with PSA-2 control.
Includes a 4-pin Amp connector for connecting to PSA-2 control
and Hubbell connectors on older-style Miller CV power sources.
Optional PSA-2 Control
*When using the D model with Miller power sources that DO NOT
have remote voltage control capabilities, i.e., CP type, the voltage
control in the feeder IS NOT functional.
Basic or
D* Model
4-Pin Amp
Miller CV or competitive CV power
source with only 115 VAC power or
competitive power source requiring
contact closure for contactor control
1ft (305 mm)
Note: If using the S-60 or D-60 with a power source having only
115 VAC supply, the PSA-2 (Power Source Adapter) is required.
When using the PSA control, optional remote voltage is not functional.
Control Panels
Single 60 Series
Dual 60 Series
4
5
6
1
7
2
3
8
9
S-62 and S-64
1. Trigger Hold Control*†
2. Jog/Gas Purge Switch
3. Trigger Receptacle
4. Voltage and Wire Speed Meters*
5. Wire Speed Control
6. Voltage Control*
7. Wire Feed Speed
8. Voltage Control for Dual Schedule*
9. Press to Set Schedule B*
Note: Power on/off switch is on back panel
Dual model trigger hold located on side panel
†
*Optional
2
D-64
D-64 (dual) models have two
sets of the controls.
Posifeed Wire Drive Assembly Features
24 VDC high-torque, permanent-magnet
motor.
Quick-change drive rolls.
Quick-release, calibrated drive roll pressure
adjustment arm allows drive roll change
without losing spring preload setting.
Simple conversion from two-drive-roll to
four-drive-roll feeder
Rotatable drive assembly helps eliminate
sharp bend in gun cable.
Four-Drive-Roll Model
Easy loading and threading of welding wire.
Uses Miller standard 1-5/8 in (41 mm)
diameter drive rolls.
Quick-connect for all Miller guns
Drive assembly rotated.
Covered drive rolls — easy access, heavy-duty,
molded composite cover over drive assembly.
Floating positive drive systems provide
trouble-free feeding on a variety of wires.
Drive Roll Kits (Order from Miller Service Parts.)
Select drive roll kits from chart below according to type and wire size being used and the type of wire drive assembly (two-drive-roll or four-drive-roll system). Drive roll kits include the
necessary guides and feature an anti-wear sleeve for inlet guide.
Wire size
“U” groove for
soft wire or
soft-shelled
cored wires
“V” groove
for hard wire
“U” cogged for
extremely soft
wire or softshelled cored
wires (i.e., hard
facing types)
“V” knurled
for hard-shelled
cored wires
2 Rolls
4 Rolls
2 Rolls
4 Rolls
2 Rolls
4 Rolls
2 Rolls
4 Rolls
.023 / .025 in (0.6 mm)
#151 030
#151 024
—
—
—
—
—
—
.030 in (0.8 mm)
#151 031
#151 025
—
—
—
—
—
—
.035 in (0.9 mm)
#151 032
#151 026
#151 044
#151 036
#151 061
#151 052
—
—
.040 in (1.0 mm)
#161 189
#161 190
—
—
—
—
—
—
.045 in (1.1/1.2 mm)
#151 033
#151 027
#151 045*
#151 037*
#151 062
#151 053
#151 077
#151 070
.052 in (1.3/1.4 mm)
#151 034
#151 028
#151 046
#151 038
#151 063
#151 054
#151 078
#151 071
1/16 in (1.6 mm)
#151 035
#151 029
#151 047
#151 039
#151 064
#151 055
#151 079
#151 072
.068/.072 in (1.8 mm)
—
—
—
—
#151 065
#151 056
—
—
5/64 in (2.0 mm)
—
—
#151 048
#151 040
#151 066
#151 057
#151 080
#151 073
3/32 in (2.4 mm)
—
—
#151 049
#151 041
#151 067
#151 058
#151 081
#151 074
7/64 in (2.8 mm)
—
—
#151 050
#151 042
#151 068
#151 059
#151 082
#151 075
1/8 in (3.2 mm)
—
—
#151 051
#151 043
#151 069
#151 060
#151 083
#151 076
*Accommodates .045 and .047 (3/64 in) wire
Nylon Wire Guides for Feeding Aluminum Wire
Wire Guides
(Order from Miller Service Parts.)
Wire Size
.047 in (1.2 mm)
1/16 in (1.6 mm)
3/32 in (2.4 mm)
Inlet Guide
#151 203
#151 205
#151 207
Intermediate Guide
#151 204
#151 206
#151 208
Note: “U” groove drive rolls are recommended when feeding aluminum wire.
Wire Size
.023 – .040 in (0.6 – 1.0 mm)
.045 – .052 in (1.1 – 1.4 mm)
1/16 – 5/64 in (1.6 – 2 mm)
3/32 – 7/64 in (2.4 – 2.8 mm)
1/8 in (3.2 mm)
Inlet Guide
#150 993
#150 994
#150 995
#150 996
#150 997
Intermediate Guide
#149 518
#149 519
#149 520
#149 521
#149 522
3
Options
Skill Level Index
The box to the right of the stock number of field-installed
options contains a letter and number. The letter indicates
the skill level required to install the option. The number
indicates the approximate time required for installation
(see legend).
A– Easy. No previous experience needed.
B– Average. Requires removal of service panels.
Mechanical ability is helpful.
C– Difficult. May require the use of an ohmmeter and/or
splicing of electrical wires. Repair or replacement of
component parts is more difficult.
Digital Meters with Presettable WFS and
Voltage Control
For S-60 model
#180 313 Field [ B: 45 ]
For D-60 model
#180 315 Field [ B: 1:20 ]
Meters use a back-lit liquid crystal display
which are easy to read in virtually any lighting
condition. The display and the ten-turn
potentiometers allow the power source
voltage and wire feed speed to be accurately
preset on the digital meters. Once the arc is
established, actual arc voltage and wire feed
speed is displayed.
Digital Dual Schedule
Control
For S-60 model
#173 751 Field [ B: 40 ]
For right side of D-60 model
#172 826 Field [ B: 40 ]
For left side of D-60 model
#173 749 Field [ B: 20 ]
Allows two separate welding conditions
(voltage and wire feed speed) to be used with
one wire. The parameters can be accurately
preset on the digital meters.
Note: This option is compatible with the following Miller
electronically controlled CV or CC/CV power sources:
Power Source
Effective Serial No.
Invision
all
Phoenix
all
XMT 304
all
Deltaweld (any)
serial no. KG141349 and newer
Dimension
serial no. KG253517 and newer
Maxtron 450
serial no. KG111783
For power sources manufactured prior to these serial
numbers, and for any Dimension power sources, please
consult the factory. For mechanically controlled power
sources, such as the CPs, the voltage control is not
functional.
Digital Voltage Control
For S-60 model [ B: 20 ]
#134 382
For D-60 model [ B: 25 ]
#138 549
Digital Meters (With wire feed speed)
For S-60 model [ B: 45 ]
#172 734
For D-60 model [ B: 1: 20 ]
#172 735
New! Run-In Control
For S-60 model [ A: 25 ]
#194 682
For left or right side
For D-60 model [ A: 50 ]
#194 680
A separate wire feed adjustment to control wire
speed prior to arc initiation.
Ground Current Sensor #160 963
Required when connecting to Deltaweld prior
to KG141349 or Dimension prior to KG253517
or Maxtron KG111783.
4
Note: The Digital Meters option (listed above) is required
to install the Digital Dual Schedule Control. Select an
appropriate Dual Schedule Switch (see Accessories).
Voltage Control (Non-Digital)
For S-60 model
#133 425 Field [ A: 10 ]
For D-60 model
#138 527 Field [ A: 10 ]
Installs in front panel of feeder to allow remote
voltage control of Miller electrically controlled
CV or CC/CV power sources having a 14-pin
receptacle.
S-model trigger
hold control on
front panel
4-in-1 Control
For S-60 model
#132 138 Field [ A: 15 ]
For left or right side of D-60 model
#138 543 Field [ A: 15 ]
Includes: spot/burnback and preflow/
postflow.
This control is mounted on an inside panel
and includes 0 (zero) to 5 second gas preflow
and postflow control, up to 5 seconds of spot
weld time, and up to 0.25 seconds of burnback
control.
D– Technical. May require the use of an ohmmeter and the
ability to read a circuit diagram. Repair or replacement
of component parts is complex.
Example:
[ B: 30 ] Skill Level: B, Time: 30 minutes
Control Detachment Kit ( installed only)
For S-60 model
#134 936 Field 10 ft (3 m)
#134 937 Field 25 ft (7.6 m) [ B: 55 ]
For D-60 model
#134 935 Field 25 ft (7.6 m) [ B: 1:00 ]
Allows separation of the control module from
the wire drive assembly and base.
Drive Roll Conversion Kit
For feeder manufactured with serial number
KE-756284 or newer.
#172 104 [ A: 10 ]
For feeder manufactured prior to serial number
KE-756284.
#132 128 [ A: 10 ]
Allows an existing S-62 or D-62 to be easily
converted from a two-drive-roll to a four-driveroll feeder. (Must order one kit for each side of
dual models.)
Water Flow Shutdown Switch
#180 390
Coolant protects the water-cooled gun from
overheating if water is not present or stops
flowing to the gun.
Burnback Control
For S-60 model [ A: 20 ]
#132 140
For left or right side of D-60 model [ A: 20 ]
#138 541
Burnback control up to 0.25 seconds
Trigger Hold
For S-60 model
#189 893 Field [ A: 15 ]
For D-60 model
#189 894 Field [ A: 20 ]
Allows the operator to make long, extended
welds without having to hold the gun trigger.
Accessories
Process Selector Control #042 872
Allows you to easily change weld processes
without changing cables — from TIG to MIG or
TIG to Stick. Can also connect two wire feeders
with one power source.
Carrying Cart
#056 301 [ A: 30 ]
A utility cart for the wire feeder and other
miscellaneous welding supplies. Height: 34 in
(863 mm) Lower tray height: 9 in (228 mm)
Shipped disassembled.
Feeder Cart #142 382 [ A: 20 ]
A low-profile, creeper cart which allows the
operator to easily move the feeder around the
work area. Shipped disassembled.
Wire Straightener
For .035–.045 in (0.9–1.1 mm) dia. wire
#141 580 [ A: 05 ]
For 1/16–1/8 in (1.6–3.2 mm) dia. wire
#141 581 [ A: 05 ]
Helps reduce the cast in wire to improve wire
feeding performance and increase the service
life of the gun liner and contact tip.
Spool Covers
For S-60 and left side of D-60 model
#057 607
For right side of D-60 model
#090 389
For 12 in (305 mm) spool.
2/0 MIG Welding Accessory Kit
#194 779 10 ft (3.1 m)
#173 856 25 ft (7.6 m)
#173 851 50 ft (15.2 m)
Includes gas hose, weld cable and ground
cable with clamp.
Polarity Reversing Isolation Control
For D-60 model only. #042 871 [ A: 15 ]
A dual-function control designed for use with
the D-60 dual-wire feeder or any application
where electrical isolation and/or polarity
reversing capabilities are required. For example,
one wire of the D-60 feeder can be electrically
cold while welding with the other wire. The
wires can also be run on opposite or the same
polarity (straight or reverse). Both functions
can be performed at the same time.
Note: Includes bracket to mount control on top of dual feeder.
Extension Cords
#122 973 25 ft (7.6 m)
#122 974 50 ft (15.2 m)
#122 975 75 ft (23 m)
Provides 14-pin, 24 VAC, contactor and voltage
control. Add to the standard 10 ft (3 m) feeder
cord to extend feeder farther from power source.
Turntable Assembly #146 236 [ B: 20 ]
Allows rotation of the feeder as the operator
changes work positions. Reduces strain and
bending on the gun cable.
Wire Reel Assembly #108 008
For 60 lb (27 kg) coil of wire.
Reel Covers
For S-60 and left side of D-60 model
#058 256
For right side of D-60 model
#091 668
For 60 lb (27 kg) coil. Helps to protect the welding
wire from dust and other contaminants.
Note: Reel and Spool Covers cannot be installed if the wire
drive assembly is in a rotated position.
Compression Spring #057 745
Required when using 8 in (203 mm) diameter
10 lb (4.5 kg) and 15 lb (6.8 kg) spools of wire.
Hanging Bail (Electrically Isolated)
#058 435 [ A: 05 ]
Used for suspending feeder over work area.
Spool Adapter #047 141
For use with 14 lb (6.4 kg) spool of Lincoln
self-shielding wire.
PSA-2 Control
#141 604 [ A: 10 ]
Required when
using the S-60
and D-60 wire
feeders with
power sources
having only
115 VAC available. The PSA-2 control can be
conveniently mounted on the wire feeder or
positioned at the power source. The control
is equipped with a 14-pin receptacle for direct
connection of the wire feeder control cord.
A short cord with a 4-pin Amp plug is hard
wired to the control. A 10 ft (3 m) interconnecting cord with a 4-pin Amp for connection
to the PSA-2 and Hubbell connectors for olderstyle Miller CV power sources is included.
The PSA-2 control can also be used with
competitive power sources requiring a
contact closure for contactor control.
5
Accessories (Continued)
Extension Cord #047 813
25 ft (7.6 m). Can be used to extend the 10 ft
cord supplied with the PSA-2 control (4-pin
Amp to 4-pin Amp connection).
Dual Schedule Switches
For use with digital dual schedule control.
Guns
Coolmate V3 #043 009 115 VAC
For use with water-cooled torches rated up to
500 amps. Vertical design conveniently mounts
to Miller cylinder rack in place of one cylinder.
GW-500 Gun
See Lit. Index No. M/13.4
M-25, M-40 Guns
See Lit. Index No. M/10.0
International Gun Adapter #164 902
Water Coolant Systems
DSS-8 #079 693 [ A: 05 ]
A two-position trigger switch which attaches
to the gun handle and is used in place of the
standard trigger for dual scheduling.
For more information, see Miller Coolant
Systems Lit. Index No. AY/7.2.
Coolmate V3
Coolmate 3
DSS-9 #071 833 [ A: 05 ]
A two-position slide switch which attaches
to the gun handle and is used to select the
desired welding condition for dual schedule
purposes. The gun trigger operates as a
standard gun trigger.
Adapter Cord #157 364
A 1 ft, Y-trigger cable that connects DSS switch
and control box to the gun.
Coolmate 4 #042 288
For use with water-cooled torches rated up to
600 amps. Tough molded polyethylene case
with carrying handle.
Coolant #043 810
Sold in cases of four 1-gallon recyclable plastic
bottles. Miller coolants contain a base of
ethylene glycol and deionized water to protect
against freezing to -37˚F (-38˚C) or boiling to
227˚F (108˚C). Also contains a compound that
resists algae growth.
Coolmate 4
Coolmate 3
#043 007 115 VAC
#043 008 230 VAC
For use with water-cooled torches rated up
to 600 amps. Unique paddle-wheel indicator,
external filter and easy-fill spout.
Swingarc™ Boom-Mounted Wire Feeders
Swingarc boom-mounted semiautomatic wire
feeders bring an extra dimension of flexibility
and efficiency to high-production wire welding
stations. You get an effective solution that
maximizes output, especially when dealing
with large weldments and hard-to-reach areas.
See Lit. Index No. M/13.0.
6
Typical Systems for 60 Series
Deltaweld 452
Dimension 452
S-62
D-64
Deltaweld® 452 #903 394
S-62 #131 785-02-44
Dimension™ 452 #903 255
D-64 #131 788-03-35
Invision 456MP
XMT 304
S-64D
D-64
Optima 304
XMT® 304 #903 471
D-64 #131 788-01-29
Optima™ 304 #043 186
Invision™ 456MP #903 725
S-64D #131 786-02-46
7
Important note: Digital feeders require
solid-state machine for optimum performance.
Recommended Power
Sources
Deltaweld®
Dimension
XMT® 304
Invision™ 354 MP
Invision™ 456P
Invision™ 456MP
XMT 456
Lit. Index No. DC/16.2
Lit. Index No. DC/19.2
Lit. Index No. DC/18.8
Lit. Index No. DC/23
Lit. Index No. DC/20
Lit. Index No. DC/23
Lit. Index No. DC/18.8
Ordering Information and System Checklist
Equipment and Options
Stock No.
Description
S-62 Single-wire, Two-drive-roll Models
(Order drive rolls and wire guides
separately. See page 3.)
S-64 Single-wire, Four-drive-roll Models
(Order drive rolls and wire guides
separately. See page 3.)
#131 785
#131 785-01-39
#131 785-02-39
#131 786
#131 786-01-26
#131 786-01-32
#131 786-01-37
#131 786-02-46
#131 786-02-52
#131 786-03-43
#131 786-02-44
#131 786-03-45
#131 788
#131 788-01-29
#131 788-01-30
#131 788-01-36
#131 788-03-35
#131 788-03-42
#180 313
#180 315
#134 382
#138 549
#172 734
#172 735
#173 751
#172 826
#173 749
#133 425
#138 527
#132 138
#138 543
#194 682
#194 680
#160 963
#134 936
#134 937
#134 935
#132 128
#172 104
#180 390
#132 140
#138 541
#189 893
#189 894
Basic Model
New! w/Run-In Control
w/CE and Euro Adapter
Basic Model
w/High-Speed Motor
w/Digital Display and Voltage Control
New! w/Run-In Control
w/Digital Display and Digital Dual Schedule
w/High-Speed Motor and Digital Display
w/CE, High-Speed Motor and Euro Accessory Kit
w/CE, and Euro Adapter
w/CE, Digital Display and Euro Adapter
Basic Model
w/Digital Display and Voltage Control
w/High-Speed Motor (left side only)
New! w/Run-In Control
w/Digital Display and Digital Dual Schedule
w/CE, Digital Display and Euro Adapter
Field. For S-60 model
Field. For D-60 model
Field. For S-60 model
Field. For D-60 model
Field. For S-60 model
Field. For D-60 model
Field. For S-60 model
Field. For right side of D-60 model
Field. For left side of D-60 model
Field. For S-60 model
Field. For D-60 model
Field. For S-60 model
Field. For left or right side D-60 model
Field. For S-60 model
Field. For D-60 model
D-64 Dual-wire, Four-drive-roll Models
(Order drive rolls and wire guides
separately. See page 3.)
Water Coolant Systems
Coolmate 3
Coolmate V3
Coolmate 4
Coolant
#043 007
#043 008
#043 009
#042 288
#043 810
115 VAC
230 VAC
115 VAC
115 VAC
Swingarc™ Mounting
Equipment
See Lit. Index No. M/13.0
Digital Meters with Presettable WFS
and Voltage Control
Digital Voltage Control
Digital Meters
Digital Dual Schedule
Voltage Control (Non-Digital)
4-in-1 Control
New! Run-In Control
MIG Welding Guns
Ground Sensor Control
Control Detachment Kit
GW-500
See Lit. Index No. AY/18.0
M-25, M-40
See Lit. Index No. AY/15.0
Roughneck C-Series (300 – 600 A)
See Lit. Index No. AY/17.0
Drive Roll Conversion Kit
Waterflow Shutdown Switch
Burnback Control
Trigger Hold
Accessories
Carrying Cart
Feeder Cart
Turntable Assembly
Hanging Bail
Wire Straightener
Spool Covers
Wire Reel Assembly
Reel Covers
Compression Spring
Spool Adapter
Process Selector Control
2/0 MIG Welding Accessory Kit
Polarity Reversing Isolation Control
Extension Cords
PSA-2 Control
PSA-2 Extension Cord
Dual Schedule Switches
Cord, Y-Adapter
Adapter, International Gun
Date:
Distributed by:
Litho in USA
#056 301
#142 382
#146 236
#058 435
#141 580
#141 581
#057 607
#090 389
#108 008
#058 256
#091 668
#057 745
#047 141
#042 872
#194 779
#173 856
#173 851
#042 871
#122 973
#122 974
#122 975
#141 604
#047 813
#079 693
#071 833
#157 364
#164 902
Qty.
Field. 10 ft (3 m), for S-60 model
Field. 25 ft (7.6 m), for S-60 model
Field. 25 ft (7.6 m), for D-60 model
Field. For serial nos. before KE-756284
Field. For serial nos. after KE-756284
Field. For S-60 model
Field. For D-60 model, Left or right side
Field. For S-60 model
Field. For D-60 model
Electrically isolated
For .035 – .045 in (0.9 – 1.1 mm) diameter wire
For 1/16 – 1/8 in (1.6 – 3.2 mm) diameter wire
For S-60 and left side of D-60 model
For right side of D-60 model
For S-60 and left side of D-60 model
For right side of D-60 model
10 ft (3.1 m)
25 ft (7.6 m)
50 ft (15.2 m)
For D-60 model
25 ft (7.6 m)
50 ft (15.2 m)
75 ft (23 m)
25 ft (7.6 m). For use with PSA-2 control
DSS-8
DSS-9
Total Quoted Price:
Price
Index No. M/2.4
Issued Oct. 2000
60M Series
Single and Dual, Programmable, Constant-Speed Wire Feeders
The 60M Series of semiautomatic wire feeders
offers the ultimate in versatility and performance.
Designed for pulse MIG and semiautomatic
welding, all 60M models are equipped with eight
synergic pulse programs. The dual models can
perform the same process on both sides, or one can
be used for conventional MIG, and the other used
for pulsed MIG welding.
Processes
MIG (GMAW) and Pulsed MIG
(GMAW-P) Welding
Flux Cored (FCAW) Welding
(Gas and Self-shielded)
Applications
S-60M Model
Metal fabrication
Heavy manufacturing
Construction
Light manufacturing
D-60M Model
Features
New!
New!
Benefits
SharpArc™ Technology
An arc control that offers a simple way to tailor factory weld programs to accommodate a variety of welding applications.
Start/Crater Ramp
Allows the output power to be tapered from start to weld and from weld to crater.
Microprocessor-based design
Flexible system with many standard features that can be customized for a variety of applications.
Digital control
Offers precise control and regulation of the welding arc not found in conventional systems.
User-friendly front panel
One simple and easy control for setting weld parameters.
Two back-lit liquid crystal displays
Easy-to-set and view all welding parameters and selectable features.
16 built-in synergic pulse programs
Quick and easy selection of the right pulse program based on your wire and gas. Eight programs each for the
Invision 456P and XMT 304.
New!
Power source selectable
No setup card required for the Invision 456P or XMT 304. 16 programs are stored in the software. Just select either power
source and do a system reset.
Teach mode for pulse programs
Allows easy field modification of pulse programs to meet your specific application.
Full-featured, adjustable weld
sequence control
You can select and adjust any parameter within the weld sequence — preflow, run-in, weld time, crater, burnback and
postflow, as required.
☞ See page 2 for additional features and benefits.
Specifications (Subject to change without notice.)
Model
S-60M (Single)
Input
Power
Electrode Wire
Diameter Capacity
Wire Speed
24 VAC
50/60 Hz
.023–1/8 in
(0.6–3.2 mm)
50–780 IPM
(1.3–19.8 m/min.)
Heavy Industrial
Peak Voltage
Range*
Peak Current
Range*
Background
Pulses per
Current Range* Second*
0–99.9 V
100–600 A
0–200 A
20–400 PPS
D-60M (Dual)
Pulse Width*
Dimensions
Net Weight
1.0–5.0
Milliseconds
H: 14 in (356 mm)
W: 14 in (356 mm)
D: 26-1/2 in (673 mm)
58 lb (26 kg)
H: 14-3/4 in (375 mm)
W: 18 in (457 mm)
D: 32 in (813 mm)
82 lb (37 kg)
*Applies only when 60M feeders are used with the Invision® 456 and Phoenix ™ 456 power sources.
Ordering Information
(Use with CC/CV
Power Sources.)
☞ See back page.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
Additional Features
Benefits
Programmable security system
Consistent results are possible by programming limits to the range of parameter adjustments. Eliminates inadvertent
changes of preset parameters.
Dual schedule capabilities
Allows two separate welding conditions to be programmed for one wire.
Arc time totalizer and cycle counter
Handy feature for conducting job studies and maintenance schedules.
Electronic trigger hold control
Allows the operator to make long extended welds without holding gun trigger.
Gas purge and wire jog control
Purge gas line and feed wire without energizing system.
Quick-change drive rolls
Gear-driven drive rolls are easy to change. No tools required.
Rotatable wire drive assembly
Eliminates sharp bends in the gun cable, thus improving wire feed performance and extending the service life of the gun
liner. (Bench models only.)
Sealed ball bearing, all-gear driven system
Smooth, positive and accurate wire feed offers long, uninterrupted service life.
Posifeed™ wire drive system
Four drive roll provides excellent feeding of welding wire.
Control Panels
60M Series Side Panel
1. Mode Displays.
4
5
5
1
1
6
2
3
2
6
2. Mode Select Button. Provides choice of four modes:
• Process Mode. (Pulse, adaptive pulse, or MIG.)
Also used to teach customized pulse programs.
• Sequence Mode. Allows variety of sequences in
weld program. (Refer to Sequence Chart.)
• Dual Schedule Mode. Links two weld programs
when two different welding conditions are
required for one wire.
• Card Mode. Writes programs to optional Data
Card or reads programs from the Data Card.
3. Parameter Select Button. Selects parameter to
be changed.
4. Parameter Display
5. Parameter Increase Button
6. Parameter Decrease Button
7
3
4
60M Series Front Panel
1. Parameter Select. Controls the selection of voltage or
arc length, wire feed speed, program number, and
also SharpArc™.
2. Purge Button. Purges gas line and gun without
energizing feeder.
3. Gun Trigger Receptacle. Prewired for single- and
dual-schedule operation. Receptacle will
accommodate a variety of dual schedule switches.
4. Trigger Hold Button and Light. System remains
energized when operator releases gun trigger—ideal
when making extended welds.
5. Digital Display
6. Jog Button. Feeds wire without energizing the power
source contactor and gas valve. (Independent control)
7. Display Control. Single-knob control for setting all
adjustable, displayed parameters.
2
Sequence Chart
Sequence
Time
Wire Feed Speed
Voltage or Trim
Preflow
0 – 9.9 sec.
not active during preflow
not active during preflow
Run-in
not active during run-in
not active during run-in
adjustable
Start
0 – 2.5 sec.
adjustable
adjustable
Weld*
0 – 25 sec.
adjustable
adjustable
Crater
0 – 2.5 sec.
adjustable
adjustable
Burnback
0 – 0.25 sec.
not active during burnback
adjustable (voltage only)
Postflow
0 – 9.9 sec.
not active during postflow
not active during postflow
*Inductance is adjustable in the MIG process mode only when using the Invision or Phoenix 456 power source.
Description of Pulsed MIG Welding Process
When pulsed MIG welding, the power source
rapidly switches the output from high peak
current to low background current in precisely
regulated intervals. The peak current pinches
off a spray-transfer droplet while the low background current “cools” the arc with little or no
metal transfer. With proper adjustment of the
pulse parameters, the pulsed MIG welding
process can produce high-quality welds when
using a broad range of material types, thicknesses, and joint configurations. Requires use
of a Miller inverter power source.
Amperage
Pulses Per Second
Pulse Width
(milliseconds)
Advantages of Pulsed MIG Process over MIG
Spray Transfer and Short Arc Welding
• Can use larger, more economical wire
diameters
• Reduces or eliminates spatter
• Lower heat input; therefore, reduced distortion
• Better out-of-position puddle control
• Optimum bead shape and penetration
• Potential reduction in fume particulate
emission
Note: For additional pulsed MIG information, order Miller
Electric’s GMAW-P Pulsed Spray Transfer Process Guide
(#168 336).
A 4-volume video training package (#175 773) is also
available.
Peak
Amperage
(Current)
•
•
•
•
What is Pulsed MIG Welding?
Pulsed MIG Process Variables
Pulsed MIG Equipment and Set -Up
Pulsed MIG Operator Techniques
Includes Pulsed Spray Transfer Process Guide (#168 336)
Time
Background
Amperage
(Current)
Pulsed MIG Wave Form
60M Design Features
Can be used with a variety of Miller
power sources :
For pulsed MIG/conventional MIG welding
use the 60M with the Invision™ 456,
Phoenix™ 456 CC/CV, or the XMT ® 304
CC/CV inverter power source.
For conventional MIG welding only, the
60M can also be used with the Deltaweld®
or Dimension™ Series power source.
Programming Features
Eight Synergic Pulsed MIG Programs
factory-set for use with the XMT® 304
welding power source:
Mild steel wire with Argon/CO2 shielding gas
(1) .030 in (0.8 mm)
(2) .035 in (0.9 mm)
(3) .045 in (1.1 mm)
Stainless steel wire with Argon/Helium/CO2
shielding gas
(4) .030 in (0.8 mm)
(5) .035 in (0.9 mm)
(6) .045 in (1.2 mm)
Nickel alloy wire with Argon/Helium
shielding gas
(7) .035 in (0.9 mm)
Metal core wire with Argon/CO2 shielding gas
(8) .045 in (1.2 mm)
Eight Synergic Pulsed MIG Programs factoryset for use with the Invision™ 456 welding
power source:
Mild steel wire with Argon/CO2 shielding gas
(1) .035 in (0.9 mm)
(2) .045 in (1.2 mm)
(3) .052 in (1.3 mm)
(4) .062 in (1.6 mm)
Stainless steel wire with Argon/Helium/CO2
shielding gas
(5) .035 in (0.9 mm)
(6) .045 in (1.2 mm)
Metal core wire with Argon/CO2 shielding gas
(7) .045 in (1.2 mm)
(8) .052 in (1.3 mm)
On-Board Programming and Diagnostics:
• All factory-set synergic pulse programs can
be modified to meet specific welding
applications
• Feeder can be manually programmed for
the voltage and/or amperage range of the
power source being used
• Automatic shutdown if arc voltage is not
detected when gun trigger is depressed
• Automatic shutdown if no wire feed speed
is present when the gun trigger is pressed
• Drops out contactor and gas valve if arc is
not sensed after 3 seconds
Selectable Operating Features:
• Feeder will compensate for variations in
tip-to-work distance and provide a constant
arc length (in Adaptive Pulse mode)
• Arc voltage can be regulated at the power
source output studs or at the welding gun
• Gun trigger can be used to make program
selection
• Arc time counter accumulates and displays
actual arc time (up to 9,999.99 hours)
and weld cycles (up to 999,999 cycles).
Counter can be reset to 0 (zero) as required.
Ideal for job time studies, shift output,
maintenance, etc.
Security Capabilities:
• Feeder can be programmed to limit the
range of parameter control, the number of
programs available, and the selectable
parameters that are available to the operator
• A three-digit code can be programmed
to restrict unauthorized access to the
set-up screen
3
Typical Installations
Pulsed MIG or Conventional MIG Welding
Invision 456, Phoenix 456
or XMT 304 power
source (MIG or Pulse)
60M
Feeder
10 ft (3 m) 14-pin cord
(supplied with 60M feeder)
Note: To connect the 60M feeder to an existing Maxtron ™ 450 power source use adapter cord #043 661.
Conventional MIG Welding
Miller electronically
controlled CV or CC/CV
power source with a
14-pin receptacle (MIG only)
60M
Feeder
10 ft (3 m) 14-pin cord
(supplied with 60M feeder)
Four Roll Drive Roll Kits
(Order from Miller Service Parts.)
Select drive roll kits from chart below according to type and wire size being used. Drive roll kits include necessary guides and feature an anti-wear sleeve for the inlet guide.
“U” cogged for
extremely soft
wire or softshelled cored
wires (i.e., hard
facing types)
Wire size
“V” groove
for hard wire
“U” groove for
soft wire or
soft-shelled
cored wires
“V” knurled
for hard-shelled
cored wires
.035 in (0.9 mm)
#151 026
#151 036
#151 052
—
.040 in (1.0 mm)
#161 190
—
—
—
.045 in (1.1/1.2 mm)
#151 027
#151 037
#151 053
#151 070
.052 in (1.3/1.4 mm)
#151 028
#151 038
#151 054
#151 071
1/16 in (1.6 mm)
#151 029
#151 039
#151 055
#151 072
.068/.072 in (1.8 mm)
—
—
#151 056
—
5/64 in (2.0 mm)
—
#151 040
#151 057
#151 073
3/32 in (2.4 mm)
—
#151 041
#151 058
#151 074
7/64 in (2.8 mm)
—
#151 042
#151 059
#151 075
1/8 in (3.2 mm)
—
#151 043
#151 060
#151 076
Nylon Wire Guides for Feeding Aluminum Wire
Wire Guides
(Order from Miller Service Parts.)
Wire Size
.047 in (1.2 mm)
1/16 in (1.6 mm)
3/32 in (2.4 mm)
Inlet Guide
#151 203
#151 205
#151 207
Intermediate Guide
#151 204
#151 206
#151 208
Note: “U” groove drive rolls are recommended when feeding aluminum wire.
4
Wire Size
.023 – .040 in (0.6 – 1.0 mm)
.045 – .052 in (1.1 – 1.4 mm)
1/16 – 5/64 in (1.6 – 2 mm)
3/32 – 7/64 in (2.4 – 2.8 mm)
1/8 in (3.2 mm)
Inlet Guide
#150 993
#150 994
#150 995
#150 996
#150 997
Intermediate Guide
#149 518
#149 519
#149 520
#149 521
#149 522
Options
Skill Level Index
The bracketed entry to the right of the stock number of
field-installed options contains a letter and number. The
letter indicates the skill level required to install the option.
The number indicates the approximate time required for
installation (see legend).
A– Easy. No previous experience needed.
B– Average. Requires removal of service panels.
Mechanical ability is helpful.
C– Difficult. May require the use of an ohmmeter and/or
splicing of electrical wires. Repair or replacement of
component parts is more difficult.
D– Technical. May require the use of an ohmmeter and the
ability to read a circuit diagram. Repair or replacement
of component parts is complex.
Cord, Y-Adapter 24V #043 387
Connects an old feeder to a new power source.
Digital Gas Flow Meter #186 313 [ B: 15 ]
Allows gas flow rate (CFH) to be accurately
set on the 60M front panel digital display. A
programming feature in the 60M control allows
a selectable gas range to be set and if for any
reason the gas flow deviates from the set range
the system will shut down and display a “GAS
FLOW ERROR” on the 60M front panel display.
This can be an excellent gas saver and will also
alert to a low gas supply.
Automation Upgrade Module
#172 886 [ B: 15 ]
This module consists of an I/O board and
software upgrade that enables the 60M control
to better communicate with other peripheral
equipment and improves performance in an
automatic welding cell.
Weld Current Sensor #160 963 [ A: 05 ]
This option is required when using M feeders
with older style Miller CV power sources:
Deltaweld® prior to serial no. KG141349 and
Dimension™ prior to serial no. KC 253517.
New! SharpArc™ Upgrade Kit #191 996 [ A: 15 ]
This kit allows 60M feeders manufactured prior
to serial no. KJ218744 to be upgraded to
include the SharpArc feature.
Blank Data Card #155 910
Stores up to 32 complete weld programs. Ideal
for saving custom programs and transferring
programs to other 60M feeders.
Example:
[ B: 30 ] Skill Level: B, Time: 30 minutes
Features: two programmable outputs, remote
start/stop, remote program select, arc voltage
monitor, arc error monitor and wire stick check.
Water Flow Shutdown Switch
#180 390 [ A: 15 ]
For use with the water hose kits. Protects
water-cooled gun from overheating by shutting
down system if water does not flow.
If required on both sides of a dual model, two
water flow shutdown switches must be ordered.
Swingarc™ Boom-Mounted Wire Feeders
Swingarc boom-mounted semiautomatic wire
feeders bring an extra dimension of flexibility
and efficiency to high-production wire welding
stations. You get an effective solution that
maximizes output, especially when dealing
with large weldments and hard-to-reach areas.
See Lit. Index No. M/13.0.
5
Accessories
Dual Schedule Switches
For use with dual schedule control. Dual
schedule switches require adapter cord
#157 364.
Control Detachment Kit
For S-60M model
#134 936 Field 10 ft (3 m) [ B: 55 ]
#134 937 Field 25 ft (7.6 m) [ B: 55 ]
For D-60M model
#134 935 Field 25 ft (7.6 m) [ B: 55 ]
For 60M bench models only. Separates the
feeder control module from the wire drive
assembly and base. Ideal when using
Automation Upgrade Module.
DSS-8 #079 693 [ A: 05 ]
A 15 ft two-position trigger switch that easily
attaches to the welding gun. Use in place of
the standard trigger for dual scheduling.
DSS-9M #041 793 [ A: 05 ]
A 15 ft, two-position slide switch that attaches
to the welding gun. Selects welding condition
when utilizing the dual schedule feature. Gun
trigger operates as standard trigger.
Wire Straightener
For .035–.045 in (0.9–1.1 mm) wire
#141 580 [ A: 05 ]
For 1/16–1/8 in (1.6–3.2 mm) wire
#141 581 [ A: 05 ]
Reduces cast in wire. Improves wire feeding
performance and increases life of gun liner and
contact tip.
DSS-10 Remote Increase/Decrease Switch
#042 749 [ A: 05 ]
A 15 ft, two-position, momentary contact
switch that attaches to the welding gun. Use
with the Remote Parameter Increase/Decrease
feature to fine tune parameters at the welding
gun while welding. Gun trigger operates as
standard trigger.
Adapter Cord #157 364
A 1 ft, Y trigger cable that connects DSS switch
and control box to the gun. Required for use
with dual schedule switches.
6
Wire Reel Assembly #108 008
Accommodates 60 lb (27 kg) coil of wire.
Reel Covers
For S-60M and left side of D-60M model
#058 256
For right side of D-60M model
#091 668
Accommodates 60 lb (27 kg) coil of wire.
Protects wire from contaminants.
Spool Covers
For S-60M and left side of D-60M model
#057 607 [ A: 05 ]
For right side of D-60M model
#090 389 [ A: 05 ]
Fits a 12 in (304 mm) spool of wire.
Guns
M-40 Guns
See Lit. Index No. M/10.0.
Accessories
Water Coolant Systems
For more information, see Miller Coolant
Systems Lit. Index No. AY/7.2.
Coolmate V3
Coolmate 3
Carrying Cart #056 301 [ A: 30 ]
Carries wire feeder and miscellaneous welding
supplies. Height: 34 in (863 mm). Lower tray
height: 9 in (228 mm). Shipped disassembled.
Hanging Bail #058 435 [ A: 15 ]
Electrically isolated. Suspends feeder over
work area.
Coolmate 4
Coolmate 3
#043 007 115 VAC
#043 008 230 VAC
For use with water-cooled torches rated up
to 600 amps. Unique paddle-wheel indicator,
external filter and easy-fill spout.
Coolmate V3 #043 009 115 VAC
For use with water-cooled torches rated up to
500 amps. Vertical design conveniently mounts
to Miller cylinder rack in place of one cylinder.
Coolmate 4 #042 288
For use with water-cooled torches rated up to
600 amps. Tough molded polyethylene case
with carrying handle.
Feeder Cart #142 382 [ A: 20 ]
Low-profile, creeper cart. Shipped disassembled.
Turntable Assembly #146 236 [ B: 20 ]
Allows feeder to rotate as operator changes
work position. Reduces strain and bending of
gun cable.
14-Pin Extension Cords
#043 690 25 ft (7.6 m)
#043 691 50 ft (15 m)
For optimum performance, do not extend 60M
feeder more than 60 ft (18 m) from power source.
Coolant #043 810
Sold in cases of four 1-gallon recyclable plastic
bottles. Miller coolants contain a base of
ethylene glycol and deionized water to protect
against freezing to -37˚F (-38˚C) or boiling to
227˚F (108˚C). Also contains a compound that
resists algae growth.
Water Hose Kit
#096 746 10 ft (3 m) [ A: 10 ]
For 60M bench models only. Use with Miller
coolant systems and water-cooled welding
guns. Can be used with or without optional
water flow safety switch.
If water kit is to be used on both sides of a dual
wire feeder, a kit must be ordered for each side
of the feeder.
7
Recommended Power
Sources
MIG or Pulsed MIG
Invision® 456P
Lit. Index. No. DC/20
XMT® 304 CC/CV Lit. Index No. DC/18.8
Lit. Index. No. DC/21
Phoenix™ 456
MIG only
Deltaweld®
Dimension™
Lit. Index No. DC/16.2
Lit. Index No. DC/19.2
Ordering Information and System Checklist
Equipment and Options
Stock No.
Description
60M Wire Feeder
Note: Drive rolls must be
ordered separately.
#131 794*
#131 794-01-3
#131 796*
#131 796-02-1
#131 794-02-2
#131 794-03-2
S-64M, single
S-64M, single, with high speed motor
D-64M, dual
D-64M, dual, with high speed motor (both sides)
S-64M, with CE, Europe
S-64M, with CE, Euro-French
Drive Roll Kit
Qty.
See table on page 4
Wire Guides
See table on page 4
Weld Current Sensor
#160 963
For use with older-style Miller power sources
Blank Data Card
#155 910
Store up to 32 programs
E-Prom /French Field Option
#198 564
Digital Gas Flow Meter
#186 313
SharpArc Upgrade Kit
#191 996
Automation Upgrade Module
#172 886
Water Flow Shutdown Switch
#180 390
Swingarc Boom-Mounted Feeders
For 60M feeders prior to serial No. KJ218744
Use with water hose kit #096 746
See Lit. Index No. M/13.0
Accessories
Control Detachment Kit
#134 936
#134 937
#134 935
Field. For S-60M, 10 ft
Field. For S-60M, 25 ft
Field. For D-60M, 25 ft
Wire Straightener
#141 580
#141 581
.035– .045 in wire
1/16– 1/8 in wire
DSS-8
#079 693
Dual schedule switch
DSS-9M
#041 793
Dual schedule switch
DSS-10
#042 749
Remote increase/decrease switch
Adapter Cord
#157 364
1 ft (0.3 m). For use with Dual Schedule Switches
PSA-2 Control
#141 604
Wire Reel Assembly
#108 008
Reel Covers
#058 256
#091 668
For S-60M and left side of D-60M
For right side of D-60M
Spool Covers
#057 607
#090 389
For S-60M and left side of D-60M
For right side of D-60M
M-40 Welding Guns
See Lit. Index No. M/10.0
Carrying Cart
#056 301
Feeder Cart
#142 382
Hanging Bail
#058 435
Turntable Assembly
#146 236
Adjustable Spool Carrier
#096 075
14-Pin Extension Cords
#043 690
#043 691
25 ft (7.6 m)
50 ft (15.2 m)
Coolmate™ 3
#043 007
#043 008
115 VAC
230 VAC
Coolmate™ V3
#043 009
Coolmate™ 4
#042 288
Coolant
#043 810
Water Hose Kit
#096 746
Swingarc™ Mounting Equipment
115 VAC
See Lit. Index No. M/13.0
Miscellaneous
Primary Power Cable
International-Style Connector
#138 181
For 4/0 weld cable. Two required when pulsing using
Miller inverter power sources
Ground Cable with Work Clamp
Gas Supply
Regulator/Flowmeter
Welding Wire
Spare Consumables
Helmet/Welding Gloves
Date:
*
® Certified by Canadian Standards Association to both Canadian and U.S. Standards.
NRTL/C
Distributed by:
Litho in USA
Total Quoted Price:
Price
Index No. M/8.0
Issued February 1999
R-115
115 Volt, Replacement Feeder
The R-115 constant speed
semi-automatic wire feeder
REGISTERED
QUALITY SYSTEM
utilizes 115 VAC input power.
The R-115 offers easy
connection to older Miller and competitive welding
power sources supplying 115 VAC power.
ISO 9001
Shown with
optional
carrying handle
Feeders are not shipped with an interconnecting
cord. An optional cord is required (see page 2) or an
existing interconnecting cord can be used.
Processes
MIG (GMAW)
Welding
Flux Cored (FCAW) Welding
(Gas and Self-shielded)
Description
Use with CV
Power Sources
Features
Benefits
Universal 115V feeder power
Adapts to a wide variety of older Miller and competitive power sources.
Industrial 4 drive roll system
Offers exceptional feed performance and reliability.
Optional interconnecting cords
Quick and easy installation to a variety of power sources. (Refer to page 2 for power
source control cord and drive roll kits.)
Convienent terminal block
Easily adapts to existing feeder innerconnecting cords.
Heavy duty industrial design
16 gauge sheet metal enclosure for durability in harsh environments.
Motor ramp and burnback
control
Aids in starting and stopping performance to match power source characteristics.
Trigger hold
Allows operator to make long extended welds without having to hold gun trigger.
Wire feed speed range is
75-750 IPM
Covers a wide variety of wire sizes (.030-3/32).
Gas solenoid
Accommodates self-shielded and gas-shielded wires.
Quick change drive rolls
Four gear driven rolls are easy to change – no tools required.
Optional run-In control
A separate wire feed speed adjustment to control wire speed prior to arc initiation.
Miller True Blue Warranty
Wire feeder is warranted for 3 years - parts and labor.
®
Specifications
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters–USA
USA Phone: 920-735-4505 (Auto-Attended)
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
Web Site–www.MillerWelds.com
The R-115 will work on the following power sources:
• Older Style Miller w/hubble connectors
• Hobart
• Lincoln
• Thermal Arc
• Airco
• L-Tech
. . . and other power sources supplying 115V
(see optional cords).
Input Power
Electrode Wire
Diameter Capacity
Wire Speed
Dimensions
115 VAC, 2 A,
50/60 Hz
.030– 3/32 in
(0.8 – 2.4 mm)
75 – 750 IPM
(1.9 – 19 m/min)
L: 23-1/2 in (597 mm)
W: 10-3/4 in (273 mm)
H: 11 in (279 mm)
®
Certified by Canadian Standards Association to both Canadian and U.S. Standards.
NRTL/C
Ordering Information
#193 164 R-115 Wire Feeder
Note: Refer to page 2 for power source control cord
and drive roll kits (must be ordered separately).
#193 164-01-1 R-115 Wire Feeder
Includes run-in control.
(Use with
CV Power
Sources.)
Industrial
(Subject to change without notice.)
Net
Weight
40 lb (18 kg)
Typical Installations
Old Miller CV or CV/CC and
competitiive power source with
115 VAC power supply.
To wire feeder terminal block
➔
R-115
*Optional hubble cord shown.
Feeder to Power Source Control Cords – All cords are 10 ft (3 m) in length.
Select control cord from list below for the type of power source being used.
Cords shown reflect connection at the power source.
#193 387
Old style Miller and Airco power
source with two and three prong
(Hubbell style) twistlock
connectors.
#193 381
Hobart power source with 19-pin
plug.
#193 385
Lincoln power source with five wire terminal
strip connection.
#193 384
Lincoln power source with 14-pin
connector.
#193 379
L-tec power source with 7-pin
connector.
#193 383
Hobart power source with 115 volt
wall type plug and 5-pin plug.
#193 382
L-tec power source with 19-pin
connector.
#193 386
Airco power source with straight
blade 115 volt wall type plug and
two prong twistlock.
Drive Roll Kits Select drive roll kits from chart below according to type and wire size being used. Kit includes drive rolls and inlet guide.
“U” cogged for
extremely soft
wire or softshelled cored
wires (i.e., hard
facing types)
Wire size
“V” groove
for hard wire
“U” groove for
soft wire or
soft-shelled
cored wires
.030 in (0.8 mm)
#046 780
—
—
—
.035 in (0.9 mm)
#046 781
#044 750
#046 792
—
.040 in (1.0 mm)
#161 190
—
—
—
.045 in (1.1/1.2 mm)
#046 782
#046 785
#046 793
#083 319
.052 in (1.3/1.4 mm)
#046 783
#046 786
#046 794
#083 320
1/16 in (1.6 mm)
#046 784
#046 787
#046 795
#046 800
.068/.072 in (1.8 mm)
—
—
#089 985
—
5/64 in (2.0 mm)
—
#046 788
#046 796
#046 801
3/32 in. (2.4 mm)
—
#046 789*
#046 797*
#046 802*
* 194 264 - 3/32 inlet guide is required when using 3/32 drive rolls.
2
“V” knurled
for hard-shelled
cored wires
Control Panel
Wire Drive Assembly
1. Gun Connection
2. Trigger Receptacle
3. Wire Speed Control
4. Jog/Purge
5. Trigger Hold
Power On/Off (on rear panel)
3
1
2
4
5
Options and Accessories
Skill Level Index
The bracketed entry to the right of the stock number of
field-installed options contains a letter and number. The
letter indicates the skill level required to install the option.
The number indicates the approximate time required for
installation (see legend).
Run-In Control
#193 391 Field [ A: 25 ]
A separate wire feed speed adjustment to
control wire speed prior to arc initiation. This
control may be beneficial to aid arc starting
with certain types of power sources.
Hanging Bail
A– Easy. No previous experience needed.
B– Average. Requires removal of service panels.
Mechanical ability is helpful.
C– Difficult. May require the use of an ohmmeter and/or
splicing of electrical wires. Repair or replacement of
component parts is more difficult.
Wire Reel
Assembly
Example:
[ B: 30 ] Skill Level: B, Time: 30 minutes
Carrying
Handle
Turntable
Assembly
Wire Reel Assembly #108 008
For 60 lb (27.2 kg) coil of wire.
Feeder
Cart
[ A: 05 ]
Turntable Assembly #146 236 [ B: 20 ]
Allows rotation of feeder as operator changes
work positions. This reduces strain and
bending on gun cable.
Reel or
Spool Cover
D– Technical. May require the use of an ohmmeter and the
ability to read a circuit diagram. Repair or replacement
of component parts is complex.
Carrying Handle #193 762 [ A: 05 ]
For lifting and moving feeder.
Feeder Cart #043 698 Field only [ A: 25 ]
A low-profile creeper cart with high-quality
rubber casters, front swivel and rear rigid.
Spool Adapter #047 141 [ A: 05 ]
For use with 14 lb (6.4 kg) spool of Lincoln
self-shielding wire.
Hanging Bail #058 435 [ A: 05 ]
Suspends feeder over the work area.
Reel Cover #058 256
For 60 lb (27.2 kg) coil
[ A: 05 ]
Spool Cover #057 607 [ A: 05 ]
For 12 in (304 mm) spool
3
Distributed by:
Litho in USA
S-22P12 and Super S-32P
Index No. M/6.3
Issued Dec. 1999
Lightweight, Portable Wire Feeders
Processes
They handle a wide variety of wire sizes and types,
and include professional features for tough portable
welding jobs.
MIG (GMAW)
Welding
Select either the Super S-32P for CC or CV-type
voltage-sensing welding, or the S-22P12, for CV-type
constant-speed welding with low-voltage 24 VAC
operation. Their rugged portability makes these
feeders great choices for all environments.
Flux Cored (FCAW) Welding
(Gas and Self-shielded)
Applications
Lightweight and portable, these feeders are also
durable, enclosed in steel-reinforced, impactresistant and flame-retardant molded plastic cases.
Features
Shipbuilding
Construction
Pipe welding
Field maintenance and repair
In-plant maintenance
Outdoor equipment repair
Benefits
For Both Wire Feeders
Impact-resistant, flame-retardant case
Totally enclosed
Non-conductive case
Quick-change drive rolls
Gas purge
Wire jog control
Insulated gun-holding bracket
Overload protection
Solid-state speed control and brake circuit
Lightweight, suitcase-type feeder
Industrial, high-torque, 24 VDC drive motor
Provides strength in a portable, lightweight package. Impact resistant case protects internal components from damage.
Protects components and welding wire from moisture, dust and other contaminants.
Eliminates high voltage lines and the potential of welding current shorting to the workpiece.
Two gear-driven drive rolls are easy to change — no tools required.
Purges gas line without feeding wire.
Feeds welding wire without energizing contactor.
Convenient place for holding gun when not welding or when transporting the feeder.
Protects motor and control circuit against possible damage due to overloading conditions.
Excellent speed control and regulation. Eliminates the need for electrical/mechanical relays. Increases service life.
Allows improved mobility and ease of carrying to remote welding sites.
Excellent positive and accurate wire feeding performance.
S-22P12 Only
Low voltage control—operates off 24 VAC
remote control
Eliminates need for internal grounding of the feeder. Reduces the number of conductors required in the control cord from
the power source to the feeder. Use with Miller CV power sources having a 14-pin receptacle and 24 VAC supply.
Super S-32P Only
Operates on open-circuit and arc voltages
Voltage-sensing control circuit with
CC/CV switch
Only requires the secondary weld cable to power feeder. No control cord required.
Allows the feeder to be used with most constant-current and constant-voltage DC power sources.
S-22P12 Specifications (Subject to change without notice.)
Industrial
(Use with CV Power
Sources.)
Input Power
Electrode Wire Diameter Capacity
Maximum Spool Size Capacity*
Wire Speed
Dimensions
Net Weight
24 VAC, 3.5 A,
50/60 Hz
.023–5/64 in
(0.6 – 2.0 mm)
30 lb (13.6 kg)
12 in (304 mm)
75–630 IPM
(1.9–16 m/min)
H: 15-3/4 in (400 mm)
W: 8-3/4 in (222 mm)
D: 22-1/2 in (572 mm)
29 lb (13.1 kg)
Super S-32P Specifications (Subject to change without notice.)
Heavy Industrial
(Use with CC/CV,
DC Power Sources.)
Input Power
Electrode Wire Diameter Capacity
Maximum Spool Size Capacity*
Wire Speed
Dimensions
Net Weight
Operates on open-circuit
voltage and arc voltage
15 to 100 V
.023 –5/64 in
(0.6 – 2.0 mm)
30 lb (13.6 kg)
12 in (304 mm)
50–700 IPM (1.3 –17.8 m/min)
Actual range in CC mode is
dependent on arc voltage applied.
H: 15-3/4 in (400 mm)
W: 8-3/4 in (222 mm)
D: 22-1/2 in (572 mm)
32 lb (15 kg)
®
Certified by Canadian Standards Association to both Canadian and U.S. Standards.
NRTL/C
Ordering Information
*When using an 8 in (203 mm) diameter spool of welding
wire, compression spring #057 745 is required.
☞ See back page.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
S-22P12 Typical Installations
Miller CV power source
equipped with a 14-pin
receptacle and 24 VAC
supply.
S-22P12 Control Panel
304 mm (12 in) cord with 14-pin plug
hard-wired to feeder
Connection/Extension Cord
(order separately – see
Ordering Information)
1
4
2
5
3
6
S-22P12
Weld Power Cable and gas hose not supplied
Connection/Extension Cord
(order separately – see Ordering Information)
PSA-2 Control
Miller CV or competitive
CV power source with
115 VAC power or
competitive power
sources requiring
contact closure for
contactor control.
1. Wire Speed Meter*
2. Jog/Purge Switch
3. Wire Speed Control
4. Voltage Meter*
5. Power Control Switch
6. Remote Voltage Control*
304 mm (12 in) cord with 14-pin plug
hard-wired to feeder
Contactor
115 VAC
S-22P12
*Optional
Weld Power Cable and gas hose not supplied
Note: If using the S-22P12 Ultra-Lite feeder with a power source having only 115 VAC supply, the PSA-2 (power supply adapter) is
required. Refer to Optional Controls and Accessories section.
Super S-32P Control Panel
Super S-32P Typical Installations
Super S-32P Voltage Sensing Feeder
BASIC SET-UP — HOT WIRE
For MIG welding, use the optional Gas Solenoid Valve.
1
Constant Current and
Constant Voltage DC
Power Sources
4
Super S-32P
Electrode/Welding Cable
40
2
60
HIGH
5
OFF
20
80
ON
Work
LOW
3
MILLER ELECTRIC MFG. CO., APPLETON,WI. USA
OPTIONAL SECONDARY CONTACTOR — COLD WIRE
For MIG welding, use the optional Gas Solenoid Valve.
Constant Current
DC Power Sources
Not Having a Weld
Output Contactor
Electrode/Welding Cable
6
7
8
Super S-32P
Work
Inlet Guide
#151 203
#151 205
9
1. Wire Speed Meter*
2. Wire Speed
Control
3. Wire Speed Range
Switch
4. Voltage Meter*
5. Power Control
Switch
6. CC/CV Switch
Nylon Wire Guides for Feeding Aluminum Wire (Order from Miller Service Parts.)
Wire Size
.047 in (1.2 mm)
1/16 in (1.6 mm)
10
Note: “U” groove drive rolls
are recommended when
feeding aluminum wire.
7. Flowmeter*
8. Gas Solenoid*
9. Secondary
Contactor*
10. Purge Switch*
*Optional
Drive Roll Kits
(Order from Miller Service Parts.)
Select drive roll kits from chart below according to type and wire size being used. Kit includes drive rolls and inlet guide.
Wire size
“V” groove
for hard wire
“U” groove for
soft wire or
soft-shelled
cored wires
“V” knurled
for hard-shelled
cored wires
“U” cogged for
extremely soft
wire or softshelled cored
wires (i.e., hard
facing types)
.023 / .025 in (0.6 mm)
#087 131
—
—
—
.030 in (0.8 mm)
#079 594
—
—
—
.035 in (0.9 mm)
#079 595
#044 749
#079 606
—
.040 in (1.0 mm)
#161 189
—
—
—
.045 in (1.1/1.2 mm)
#079 596
#079 599
#079 607
#083 318
.052 in (1.3/1.4 mm)
#079 597
#079 600
#079 608
#083 317
1/16 in (1.6 mm)
#079 598
#079 601
#079 609
#079 614
.068/.072 in (1.8 mm)
—
—
#089 984
—
5/64 in (2.0 mm)
—
#079 602
#079 610
#079 615
2
Skill Level Index
The bracketed entry to the right of the stock number of
field-installed options contains a letter and number. The
letter indicates the skill level required to install the option.
The number indicates the approximate time required for
installation (see legend).
A– Easy. No previous experience needed.
B– Average. Requires removal of service panels.
Mechanical ability is helpful.
C– Difficult. May require the use of an ohmmeter and/or
splicing of electrical wires. Repair or replacement of
component parts is more difficult.
D– Technical. May require the use of an ohmmeter and the
ability to read a circuit diagram. Repair or replacement
of component parts is complex.
Remote Voltage Control
#121 569 Field [ A: 10 ]
Installs in front panel of feeder to allow remote
voltage control of most Miller electronically
controlled CV or CC/CV power sources having
a 14-pin receptacle.
Spot/Burnback Control #121 562 [ B: 20 ]
Installs inside feeder. Provides up to 5 seconds
of spot weld time in two ranges. Time starts
with depression of gun trigger switch. Burnback
control up to 0.25 seconds. Can be used in the
spot or continuous mode.
Meter Kit – Voltage/Wire Feed Speed
#121 568 Field [ B: 25 ]
Analog DC voltmeter and wire feed speed
meter. The design of the meter and the S-22P12
circuit allow the wire feed speed to be pre-set.
The voltage is displayed only while welding.
Notes: The standard Connection/Extension Cord listed under
ordering information is also designed for use with the
Remote Voltage Control.
Note: Cannot be installed if Pre-Flow/Post-Flow Control is used.
Example:
[ B: 30 ] Skill Level: B, Time: 30 minutes
S-22P12 Options
When using the PSA-2 control, the optional Remote Voltage
Control is not functional.
Preflow/Postflow Gas Control #121 563 [ B: 20 ]
Installs inside feeder. An adjustable timer
(0.25 to 5 seconds) for controlling gas flow prior
to arc initiation and after completion of weld.
Gas Flowmeter
#161 812 Field [ A: 15 ]
Allows the shielding gas flow rate
to be adjusted and monitored at
the wire feeder.
Note: Cannot be installed if Spot Control is used.
S-22P12 Accessories
Extension Cords
#122 973 25 ft (7.6 m)
#122 974 50 ft (15 m)
#122 975 75 ft (23 m)
These cords are used as interconnecting cords
(between the feeder and the power source)
and extension cords. For example, two 25 ft
(7.6 m) cords can be used together to make a
50 ft (15 m) cord.
MIG Accessory Kit #173 856
25 ft (7.6 m) 2/0 cable. Includes gas hose, weld
cable, and ground cable with clamp.
PSA-2 Control
#141 604 [ A: 10 ]
Required when using the
S-22P12 with power sources
having only 115 VAC available.
Mounts at power source and
includes a 10 ft (3 m) 115 VAC
cord and contactor cord with
Hubbell connectors. A simple
modification in the PSA-2
control also allows it to be used with
competitive constant-voltage power sources
requiring a contact closure for contactor
control. The PSA-2 includes a 14-pin
receptacle for direct connection of the standard
interconnecting cord and optional extension
cords. Bracket included for side mounting to
the power source.
When using the PSA-2 control, the optional Remote
Voltage Control is not functional.
GW-500 Gun
Refer to gun Lit. Index No. M/13.4.
Spool Adapter #047 141 [ A: 05 ]
For use with 14 lb (6.4 kg) spool of Lincoln
self-shielding wire.
Super S-32P Options
Secondary Contactor
#156 464 Field [ A: 15 ]
Conveniently installs
inside the feeder,
allowing the welding
wire to be electrically
cold until the operator is
ready to weld. Operates
with straight or reverse
polarity and features magnetic blow-outs to help
preserve and extend service life of the contactor.
Contactor Rating:
400 amps at 30% duty cycle
330 amps at 60% duty cycle
250 amps at 100% duty cycle
Gas Solenoid Valve #161 810 Field [ A: 10 ]
Required when using gas-shielded type wires.
Includes purge control.
Note: Can be ordered factory installed in option package.
Gas Flowmeter
#161 812 Field [ A: 15 ]
Allows the shielding gas flow rate
to be adjusted and monitored at
the wire feeder.
Meter Kit – Voltage/Wire Feed Speed
#161 242 Field [ B: 25 ]
DC voltmeter and wire feed speed meter.
Note: Can be ordered factory installed in option package.
Note: Can be ordered factory installed in option package.
Super S-32P Accessories
M-25 and M-40 Guns
For gas-shielded applications. Refer to gun
Lit. Index No. M/10.0.
GA-40GL Gun
For self-shielded applications. Refer to gun
Lit. Index No. M/9.0.
Spool Adapter #047 141 [ A: 05 ]
For use with 14 lb (6.4 kg) spool of Lincoln
self-shielding wire.
GW-500 Gun
Refer to gun Lit. Index No. M/13.4.
3
Recommended Power
Sources
For S-22P12
Regency ® 250
XMT® 304 CC/CV
Shopmaster™
CP-252TS
CP-302
Deltaweld® 302
Trailblazer ® 251 DT
Trailblazer ® 300D NT
For Super S-32P
Dimension™
Gold Star ®
Mark VI®
®
Mark VIII -2
™
Bobcat
Trailblazer® 251 NT
Big 40® G
Big 40® Diesel
Big Blue® 251D
Big Blue® 600D
Miller Air Pak™
For Both Models
Big Blue® 402
Pipe Pro 304
Miller Du-Op
Lit. Index No. DC/12.6
Lit. Index No. DC/18.8
Lit. Index No. AD/2.3
Lit. Index No. DC/13.0
Lit. Index No. DC/13.0
Lit. Index No. DC/16.2
Lit. Index No. ED/4.5
Lit. Index No. ED/4.6
Ordering Information and System Checklist
Equipment
Stock No.
Description
S-22P12
#125 616
#125 616-01-2
#125 616-02-8
Standard
With meter kit (volt/wfs)
With meter kit (volt/wfs), voltage control
Remote Voltage Control
#121 569
Field
Spot/Burnback Control
#121 562
Field
Pre-Flow/Post-Flow Gas Control
#121 563
Field
Meter Kit (volt/wfs)
#121 568
Field
Gas Flowmeter
#161 812
Field
Extension Cords
(one required)
#122 973
#122 974
#122 975
25 ft (7.6 m)
50 ft (15 m)
75 ft (23 m)
MIG Accessory Kit
#173 856
25 ft (7.6 m) 2/0 cable. Includes gas hose,
weld cable and ground cable with clamp.
PSA-2 Control
#141 604
Drive Roll Kit
Qty.
See Drive Roll Kit table on page 2
S-22P12 Accessories
Lit. Index No. DC/19.2
Lit. Index No. DC/8.1
Lit. Index No. DC/9.8
Lit. Index No. DC/10
Lit. Index No. ED/4.31
Lit. Index No. ED/4.5
Lit. Index No. ED/8.1
Lit. Index No. ED/9.6
Lit. Index No. ED/5.2
Lit. Index No. ED/10.3
Lit. Index No. ED/10.5
Lit. Index No. ED/10.8
Lit. Index No. ED/10.6
Lit. Index No. ED/10.9
GW-500 Gun
Field
See Lit. Index No. M/13.4
Spool Adapter
#047 141
Super S-32P
#159 928
#159 928-02-1
#159 928-03-1
Standard
With contactor, gas valve
With contactor, gas valve, meters
Secondary Contactor
#156 464
Field
Gas Solenoid Valve
#161 810
Field
Meter Kit
#161 242
Field
Gas Flowmeter
#161 812
Field
Drive Roll Kit
See Drive Roll Kit table on page 2
Super S-32P Accessories
GA-40GL Gun
See Lit. Index No. M/9.0
M-25, M-40 Gun
See Lit. Index No. M/10.0
GW-500 Gun
See Lit. Index No. M/13.4
Spool Adapter
#047 141
Miscellaneous
Consumables
Primary Power Cable
Secondary Power Cable
Ground Cable with Clamp
Gas Cylinder (if required)
Gas Hose with Fittings (if required)
Regulator/Flowmeter (if required)
Welding Wire
Compression Spring
#057 745
For 8 in (203 mm) spool of wire
Helmet/Gloves
Date:
Distributed by:
Litho in USA
Total Quoted Price:
Price
S-22P12 and Super S-32P
Index No. M/6.3
Issued Dec. 1999
Lightweight, Portable Wire Feeders
Processes
They handle a wide variety of wire sizes and types,
and include professional features for tough portable
welding jobs.
MIG (GMAW)
Welding
Select either the Super S-32P for CC or CV-type
voltage-sensing welding, or the S-22P12, for CV-type
constant-speed welding with low-voltage 24 VAC
operation. Their rugged portability makes these
feeders great choices for all environments.
Flux Cored (FCAW) Welding
(Gas and Self-shielded)
Applications
Lightweight and portable, these feeders are also
durable, enclosed in steel-reinforced, impactresistant and flame-retardant molded plastic cases.
Features
Shipbuilding
Construction
Pipe welding
Field maintenance and repair
In-plant maintenance
Outdoor equipment repair
Benefits
For Both Wire Feeders
Impact-resistant, flame-retardant case
Totally enclosed
Non-conductive case
Quick-change drive rolls
Gas purge
Wire jog control
Insulated gun-holding bracket
Overload protection
Solid-state speed control and brake circuit
Lightweight, suitcase-type feeder
Industrial, high-torque, 24 VDC drive motor
Provides strength in a portable, lightweight package. Impact resistant case protects internal components from damage.
Protects components and welding wire from moisture, dust and other contaminants.
Eliminates high voltage lines and the potential of welding current shorting to the workpiece.
Two gear-driven drive rolls are easy to change — no tools required.
Purges gas line without feeding wire.
Feeds welding wire without energizing contactor.
Convenient place for holding gun when not welding or when transporting the feeder.
Protects motor and control circuit against possible damage due to overloading conditions.
Excellent speed control and regulation. Eliminates the need for electrical/mechanical relays. Increases service life.
Allows improved mobility and ease of carrying to remote welding sites.
Excellent positive and accurate wire feeding performance.
S-22P12 Only
Low voltage control—operates off 24 VAC
remote control
Eliminates need for internal grounding of the feeder. Reduces the number of conductors required in the control cord from
the power source to the feeder. Use with Miller CV power sources having a 14-pin receptacle and 24 VAC supply.
Super S-32P Only
Operates on open-circuit and arc voltages
Voltage-sensing control circuit with
CC/CV switch
Only requires the secondary weld cable to power feeder. No control cord required.
Allows the feeder to be used with most constant-current and constant-voltage DC power sources.
S-22P12 Specifications (Subject to change without notice.)
Industrial
(Use with CV Power
Sources.)
Input Power
Electrode Wire Diameter Capacity
Maximum Spool Size Capacity*
Wire Speed
Dimensions
Net Weight
24 VAC, 3.5 A,
50/60 Hz
.023–5/64 in
(0.6 – 2.0 mm)
30 lb (13.6 kg)
12 in (304 mm)
75–630 IPM
(1.9–16 m/min)
H: 15-3/4 in (400 mm)
W: 8-3/4 in (222 mm)
D: 22-1/2 in (572 mm)
29 lb (13.1 kg)
Super S-32P Specifications (Subject to change without notice.)
Heavy Industrial
(Use with CC/CV,
DC Power Sources.)
Input Power
Electrode Wire Diameter Capacity
Maximum Spool Size Capacity*
Wire Speed
Dimensions
Net Weight
Operates on open-circuit
voltage and arc voltage
15 to 100 V
.023 –5/64 in
(0.6 – 2.0 mm)
30 lb (13.6 kg)
12 in (304 mm)
50–700 IPM (1.3 –17.8 m/min)
Actual range in CC mode is
dependent on arc voltage applied.
H: 15-3/4 in (400 mm)
W: 8-3/4 in (222 mm)
D: 22-1/2 in (572 mm)
32 lb (15 kg)
®
Certified by Canadian Standards Association to both Canadian and U.S. Standards.
NRTL/C
Ordering Information
*When using an 8 in (203 mm) diameter spool of welding
wire, compression spring #057 745 is required.
☞ See back page.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
S-22P12 Typical Installations
Miller CV power source
equipped with a 14-pin
receptacle and 24 VAC
supply.
S-22P12 Control Panel
304 mm (12 in) cord with 14-pin plug
hard-wired to feeder
Connection/Extension Cord
(order separately – see
Ordering Information)
1
4
2
5
3
6
S-22P12
Weld Power Cable and gas hose not supplied
Connection/Extension Cord
(order separately – see Ordering Information)
PSA-2 Control
Miller CV or competitive
CV power source with
115 VAC power or
competitive power
sources requiring
contact closure for
contactor control.
1. Wire Speed Meter*
2. Jog/Purge Switch
3. Wire Speed Control
4. Voltage Meter*
5. Power Control Switch
6. Remote Voltage Control*
304 mm (12 in) cord with 14-pin plug
hard-wired to feeder
Contactor
115 VAC
S-22P12
*Optional
Weld Power Cable and gas hose not supplied
Note: If using the S-22P12 Ultra-Lite feeder with a power source having only 115 VAC supply, the PSA-2 (power supply adapter) is
required. Refer to Optional Controls and Accessories section.
Super S-32P Control Panel
Super S-32P Typical Installations
Super S-32P Voltage Sensing Feeder
BASIC SET-UP — HOT WIRE
For MIG welding, use the optional Gas Solenoid Valve.
1
Constant Current and
Constant Voltage DC
Power Sources
4
Super S-32P
Electrode/Welding Cable
40
2
60
HIGH
5
OFF
20
80
ON
Work
LOW
3
MILLER ELECTRIC MFG. CO., APPLETON,WI. USA
OPTIONAL SECONDARY CONTACTOR — COLD WIRE
For MIG welding, use the optional Gas Solenoid Valve.
Constant Current
DC Power Sources
Not Having a Weld
Output Contactor
Electrode/Welding Cable
6
7
8
Super S-32P
Work
Inlet Guide
#151 203
#151 205
9
1. Wire Speed Meter*
2. Wire Speed
Control
3. Wire Speed Range
Switch
4. Voltage Meter*
5. Power Control
Switch
6. CC/CV Switch
Nylon Wire Guides for Feeding Aluminum Wire (Order from Miller Service Parts.)
Wire Size
.047 in (1.2 mm)
1/16 in (1.6 mm)
10
Note: “U” groove drive rolls
are recommended when
feeding aluminum wire.
7. Flowmeter*
8. Gas Solenoid*
9. Secondary
Contactor*
10. Purge Switch*
*Optional
Drive Roll Kits
(Order from Miller Service Parts.)
Select drive roll kits from chart below according to type and wire size being used. Kit includes drive rolls and inlet guide.
Wire size
“V” groove
for hard wire
“U” groove for
soft wire or
soft-shelled
cored wires
“V” knurled
for hard-shelled
cored wires
“U” cogged for
extremely soft
wire or softshelled cored
wires (i.e., hard
facing types)
.023 / .025 in (0.6 mm)
#087 131
—
—
—
.030 in (0.8 mm)
#079 594
—
—
—
.035 in (0.9 mm)
#079 595
#044 749
#079 606
—
.040 in (1.0 mm)
#161 189
—
—
—
.045 in (1.1/1.2 mm)
#079 596
#079 599
#079 607
#083 318
.052 in (1.3/1.4 mm)
#079 597
#079 600
#079 608
#083 317
1/16 in (1.6 mm)
#079 598
#079 601
#079 609
#079 614
.068/.072 in (1.8 mm)
—
—
#089 984
—
5/64 in (2.0 mm)
—
#079 602
#079 610
#079 615
2
Skill Level Index
The bracketed entry to the right of the stock number of
field-installed options contains a letter and number. The
letter indicates the skill level required to install the option.
The number indicates the approximate time required for
installation (see legend).
A– Easy. No previous experience needed.
B– Average. Requires removal of service panels.
Mechanical ability is helpful.
C– Difficult. May require the use of an ohmmeter and/or
splicing of electrical wires. Repair or replacement of
component parts is more difficult.
D– Technical. May require the use of an ohmmeter and the
ability to read a circuit diagram. Repair or replacement
of component parts is complex.
Remote Voltage Control
#121 569 Field [ A: 10 ]
Installs in front panel of feeder to allow remote
voltage control of most Miller electronically
controlled CV or CC/CV power sources having
a 14-pin receptacle.
Spot/Burnback Control #121 562 [ B: 20 ]
Installs inside feeder. Provides up to 5 seconds
of spot weld time in two ranges. Time starts
with depression of gun trigger switch. Burnback
control up to 0.25 seconds. Can be used in the
spot or continuous mode.
Meter Kit – Voltage/Wire Feed Speed
#121 568 Field [ B: 25 ]
Analog DC voltmeter and wire feed speed
meter. The design of the meter and the S-22P12
circuit allow the wire feed speed to be pre-set.
The voltage is displayed only while welding.
Notes: The standard Connection/Extension Cord listed under
ordering information is also designed for use with the
Remote Voltage Control.
Note: Cannot be installed if Pre-Flow/Post-Flow Control is used.
Example:
[ B: 30 ] Skill Level: B, Time: 30 minutes
S-22P12 Options
When using the PSA-2 control, the optional Remote Voltage
Control is not functional.
Preflow/Postflow Gas Control #121 563 [ B: 20 ]
Installs inside feeder. An adjustable timer
(0.25 to 5 seconds) for controlling gas flow prior
to arc initiation and after completion of weld.
Gas Flowmeter
#161 812 Field [ A: 15 ]
Allows the shielding gas flow rate
to be adjusted and monitored at
the wire feeder.
Note: Cannot be installed if Spot Control is used.
S-22P12 Accessories
Extension Cords
#122 973 25 ft (7.6 m)
#122 974 50 ft (15 m)
#122 975 75 ft (23 m)
These cords are used as interconnecting cords
(between the feeder and the power source)
and extension cords. For example, two 25 ft
(7.6 m) cords can be used together to make a
50 ft (15 m) cord.
MIG Accessory Kit #173 856
25 ft (7.6 m) 2/0 cable. Includes gas hose, weld
cable, and ground cable with clamp.
PSA-2 Control
#141 604 [ A: 10 ]
Required when using the
S-22P12 with power sources
having only 115 VAC available.
Mounts at power source and
includes a 10 ft (3 m) 115 VAC
cord and contactor cord with
Hubbell connectors. A simple
modification in the PSA-2
control also allows it to be used with
competitive constant-voltage power sources
requiring a contact closure for contactor
control. The PSA-2 includes a 14-pin
receptacle for direct connection of the standard
interconnecting cord and optional extension
cords. Bracket included for side mounting to
the power source.
When using the PSA-2 control, the optional Remote
Voltage Control is not functional.
GW-500 Gun
Refer to gun Lit. Index No. M/13.4.
Spool Adapter #047 141 [ A: 05 ]
For use with 14 lb (6.4 kg) spool of Lincoln
self-shielding wire.
Super S-32P Options
Secondary Contactor
#156 464 Field [ A: 15 ]
Conveniently installs
inside the feeder,
allowing the welding
wire to be electrically
cold until the operator is
ready to weld. Operates
with straight or reverse
polarity and features magnetic blow-outs to help
preserve and extend service life of the contactor.
Contactor Rating:
400 amps at 30% duty cycle
330 amps at 60% duty cycle
250 amps at 100% duty cycle
Gas Solenoid Valve #161 810 Field [ A: 10 ]
Required when using gas-shielded type wires.
Includes purge control.
Note: Can be ordered factory installed in option package.
Gas Flowmeter
#161 812 Field [ A: 15 ]
Allows the shielding gas flow rate
to be adjusted and monitored at
the wire feeder.
Meter Kit – Voltage/Wire Feed Speed
#161 242 Field [ B: 25 ]
DC voltmeter and wire feed speed meter.
Note: Can be ordered factory installed in option package.
Note: Can be ordered factory installed in option package.
Super S-32P Accessories
M-25 and M-40 Guns
For gas-shielded applications. Refer to gun
Lit. Index No. M/10.0.
GA-40GL Gun
For self-shielded applications. Refer to gun
Lit. Index No. M/9.0.
Spool Adapter #047 141 [ A: 05 ]
For use with 14 lb (6.4 kg) spool of Lincoln
self-shielding wire.
GW-500 Gun
Refer to gun Lit. Index No. M/13.4.
3
Recommended Power
Sources
For S-22P12
Regency ® 250
XMT® 304 CC/CV
Shopmaster™
CP-252TS
CP-302
Deltaweld® 302
Trailblazer ® 251 DT
Trailblazer ® 300D NT
For Super S-32P
Dimension™
Gold Star ®
Mark VI®
®
Mark VIII -2
™
Bobcat
Trailblazer® 251 NT
Big 40® G
Big 40® Diesel
Big Blue® 251D
Big Blue® 600D
Miller Air Pak™
For Both Models
Big Blue® 402
Pipe Pro 304
Miller Du-Op
Lit. Index No. DC/12.6
Lit. Index No. DC/18.8
Lit. Index No. AD/2.3
Lit. Index No. DC/13.0
Lit. Index No. DC/13.0
Lit. Index No. DC/16.2
Lit. Index No. ED/4.5
Lit. Index No. ED/4.6
Ordering Information and System Checklist
Equipment
Stock No.
Description
S-22P12
#125 616
#125 616-01-2
#125 616-02-8
Standard
With meter kit (volt/wfs)
With meter kit (volt/wfs), voltage control
Remote Voltage Control
#121 569
Field
Spot/Burnback Control
#121 562
Field
Pre-Flow/Post-Flow Gas Control
#121 563
Field
Meter Kit (volt/wfs)
#121 568
Field
Gas Flowmeter
#161 812
Field
Extension Cords
(one required)
#122 973
#122 974
#122 975
25 ft (7.6 m)
50 ft (15 m)
75 ft (23 m)
MIG Accessory Kit
#173 856
25 ft (7.6 m) 2/0 cable. Includes gas hose,
weld cable and ground cable with clamp.
PSA-2 Control
#141 604
Drive Roll Kit
Qty.
See Drive Roll Kit table on page 2
S-22P12 Accessories
Lit. Index No. DC/19.2
Lit. Index No. DC/8.1
Lit. Index No. DC/9.8
Lit. Index No. DC/10
Lit. Index No. ED/4.31
Lit. Index No. ED/4.5
Lit. Index No. ED/8.1
Lit. Index No. ED/9.6
Lit. Index No. ED/5.2
Lit. Index No. ED/10.3
Lit. Index No. ED/10.5
Lit. Index No. ED/10.8
Lit. Index No. ED/10.6
Lit. Index No. ED/10.9
GW-500 Gun
Field
See Lit. Index No. M/13.4
Spool Adapter
#047 141
Super S-32P
#159 928
#159 928-02-1
#159 928-03-1
Standard
With contactor, gas valve
With contactor, gas valve, meters
Secondary Contactor
#156 464
Field
Gas Solenoid Valve
#161 810
Field
Meter Kit
#161 242
Field
Gas Flowmeter
#161 812
Field
Drive Roll Kit
See Drive Roll Kit table on page 2
Super S-32P Accessories
GA-40GL Gun
See Lit. Index No. M/9.0
M-25, M-40 Gun
See Lit. Index No. M/10.0
GW-500 Gun
See Lit. Index No. M/13.4
Spool Adapter
#047 141
Miscellaneous
Consumables
Primary Power Cable
Secondary Power Cable
Ground Cable with Clamp
Gas Cylinder (if required)
Gas Hose with Fittings (if required)
Regulator/Flowmeter (if required)
Welding Wire
Compression Spring
#057 745
For 8 in (203 mm) spool of wire
Helmet/Gloves
Date:
Distributed by:
Litho in USA
Total Quoted Price:
Price
S-32S and S-32SL
Index No. M/6.21
Issued Dec. 1999
Voltage-Sensing Wire Feeders
Processes
strength and flexibility to handle the strenuous work
loads of field and fabrication shops, the S-32S and
S-32SL delivers proven reliability and performance.
Flux Cored (FCAW) Welding
(Gas and Self-shielded)
These feeders operate off arc voltage, so a control
cord is not required. Operates with most CV and CC
DC-type power sources.
MIG (GMAW)
Welding
The S-32S and S-32SL handle the necessary highend speed for small diameter wires, and the lowend speed and power for the more demanding larger
diameter wires.
Applications
Simple to use but with all the features needed for
heavy-duty wire feed applications... that’s the S-32S
and S-32SL wire feeders from Miller. Built with the
Structural steel
Building construction
Bridge construction
Field maintenance and repair
Outdoor equipment repair and build-up work
Features
Benefits
Operates on open-circuit and arc voltages
Requires only the secondary weld cable to power feeder, no control cord needed.
Voltage-sensing control circuit with
CC/CV switch
Allows the feeder to be used with most constant-current and constant-voltage DC power sources.
S-32S wire speed range:
50 – 700 IPM (1.3 – 18 m/min)
Accommodates a wide variety of wire sizes and types, .023 – 5/64 in (0.6 – 2.0 mm).
S-32SL wire speed range:
25 – 325 IPM (0.6 – 8.2 m/min)
Designed for 5/64– 7/64 in (2.0 – 2.8 mm) diameter wire.
Polarity insensitive
Operates on straight (electrode negative) or reverse (electrode positive) polarity.
High-torque, 24 VDC drive motor with two
gear-driven drive rolls
Offers excellent wire feeding performance and long uninterrupted service life.
Solid-state speed control and brake circuit
Exceptional speed control and regulation; eliminates the need for electrical/mechanical relays and increases service life.
Overload protection
Protects motor and control circuit against possible damage due to overloading conditions.
Quick-change drive rolls and quick connect
for Miller guns
No tools required. Easy attachment.
Insulated gun-holding bracket
Convenient place for holding gun when not welding or when transporting the feeder.
Specifications
Model
Input Power
S-32S
Operates on open-circuit
voltage and arc voltage
15 to 100 V
S-S32SL*
Heavy Industrial
(Subject to change without notice.)
Electrode Wire
Diameter Capacity
Maximum Spool Size
Capacity
Wire Feed Speed**
Dimensions
.023–5⁄64 in (0.6–2.0 mm)
60 lb (27 kg) coil
50–700 IPM (1.3–18 m/min)
L: 221⁄2 in (572 mm)
W: 103⁄4 in (273 mm)
H: 10 in (254 mm)
5⁄64–7⁄64 in (2.0–2.8 mm)
25–325 IPM (0.6–8.2 m/min)
*When using an 8 in (203 mm) diameter spool of welding wire, compression spring #057 745 is required. **Actual range is dependent on arc voltage applied.
® Certified by Canadian Standards Association to both Canadian and U.S. Standards.
NRTL/C
Ordering Information
☞ See back page.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
(Use with CC/CV,
DC Power Sources.)
Net
Weight
33 lb (15 kg)
Typical Installations
BASIC SET-UP -– HOT WIRE
For MIG welding, use the
optional Gas Solenoid Valve.
Constant-Current
and Constant-Voltage
DC Power Sources
Electrode/Welding Cable
Work
WITH OPTIONAL EXTERNAL SECONDARY CONTACTOR -– COLD WIRE
Note: The secondary contactor can be wired to operate off 115 VAC or powered
off a 12 VDC battery of an engine driven welder.
10 ft. (3 m) 115 VAC Primary Cord (Connect to power source 115 VAC supply, if available.)
115 VAC/12 VDC
Secondary Contactor
Constant-Current
DC Power Sources
Not Having a Weld
Output Contactor
To Wire Feeder Trigger Receptacle
For MIG welding, use the
optional Gas Solenoid Valve.
To Gun Trigger
Remote Contactor Cord
Electrode/Welding Cable
Work
Electrode/Welding Cable
Control Panel
1. Power Control Switch
2. Wire Speed Control
3. CC/CV Switch
1
2
2
Drive Roll Kits (Order from Miller Service Parts.)
Select drive roll kits from chart below according to type and wire size being used. Kit includes drive rolls and inlet guide.
Wire size
“V” groove
for hard wire
“U” groove for
soft wire or
soft-shelled
cored wires
“V” knurled
for hard-shelled
cored wires
“U” cogged for
extremely soft
wire or softshelled cored
wires (i.e., hard
facing types)
.023 / .025 in (0.6 mm)
#087 131
—
—
—
.030 in (0.8 mm)
#079 594
—
—
—
.035 in (0.9 mm)
#079 595
#044 749
#079 606
—
.040 in (1.0 mm)
#161 189
—
—
—
.045 in (1.1/1.2 mm)
#079 596
#079 599
#079 607
#083 318
.052 in (1.3/1.4 mm)
#079 597
#079 600
#079 608
#083 317
1/16 in (1.6 mm)
#079 598
#079 601
#079 609
#079 614
.068/.072 in (1.8 mm)
—
—
#089 984
—
5/64 in (2.0 mm)
—
#079 602
#079 610
#079 615
3/32 in (2.4 mm)
—
#079 603
#079 611
#079 616
7/64 in (2.8 mm)
—
#079 604
#079 612
#079 617
Options and Accessories
Skill Level Index
The box following the stock number of field-installed
options contains a letter and number. The letter indicates
the skill level required to install the option. The number
indicates the approximate time required for installation (see
legend).
A– Easy. No previous experience needed.
B– Average. Requires removal of service panels.
Mechanical ability is helpful.
C– Difficult. May require the use of an ohmmeter and/or
splicing of electrical wires. Repair or replacement of
component parts is more difficult.
Gas Solenoid Valve
#093 768 Field [ A: 15 ]
Required when using gas-shielded type wires.
Includes purge control. Operates off the arc
voltage and is designed for use with hot wire
set-up or when using an external secondary
contactor.
External Secondary Contactor
#108 921 [ A: 10 ]
Contactor rating:
400 amps at 30% duty cycle
330 amps at 60% duty cycle
250 amps at 100% duty cycle
Allows the welding wire to be electrically
cold until the operator is ready to weld. The
contactor can be used with direct current
(DC) power sources operating in either reverse
(electrode positive) or straight (electrode
negative) polarity. The contactor will operate
off 115 VAC or can be connected to a 12 VDC
battery of an engine driven welder not having
115 VAC auxiliary power available. The gun
trigger switch controls the contactor and must
remain closed while welding.
D– Technical. May require the use of an ohmmeter and the
ability to read a circuit diagram. Repair or replacement
of component parts is complex.
Example:
[ B: 30 ] Skill Level: B, Time: 30 minutes
Compression Spring #057 745
Required when using 8 in (203 mm) diameter
10 lb (4.5 kg) and 15 lb (6.8 kg) spools of wire.
Spool Adapter #047 141
For use with 14 lb (6.4 kg) spool of Lincoln
self-shielding wire.
Wire Reel Assembly #108 008
For 60 lb (27.2 kg) coil of wire.
Remote Contactor Cables
#108 925 25 ft (7.6 m)
#108 926 50 ft (15.2 m)
Spool Cover #090 389
For 12 in (305 mm) spool only.
Reel Cover #091 668
For 60 lb (27 kg) coil.
Note: 25 ft (7.6 m), #108 925, or 50 ft (15.2 m), #108 926,
remote contactor cord required.
3
Ordering Information and System Checklist
Equipment and Options
Stock No.
S-32S
#088 816
S-32SL
#109 294
Drive Roll Kit
Gas Solenoid Valve
Description
Qty.
See table on page 3
#093 768
Power Sources
Dimension™
See Lit. Index No. DC/19.2
Gold Star ®
See Lit. Index No. DC/8.1
Mark VI®, VIII®-2
See Lit. Index No. DC/9.8, DC/10
Bobcat™
See Lit. Index No. ED/4.31
Trailblazer® 251
See Lit. Index No. ED/4.5
Big 40®G or Diesel
See Lit. Index No. ED/8.1, ED/9.6
Big Blue® 251D
See Lit. Index No. ED/5.2
Big Blue® 600D
See Lit. Index No. ED/10.3
Miller Air Pak™
Accessories
External Secondary Contactor
#108 921
Wire Reel Assembly
#108 008
Spool Cover
#090 389
Reel Cover
#091 668
Compression Spring
#057 745
Spool Adapter
#047 141
Remote Contactor Cables
#108 925
#108 926
For 8 in spool of wire
25 ft (7.6 m)
50 ft (15.2 m)
GA-40GL Gun
See Lit. Index No. M/9.0
M-25, M-40 Guns
See Lit. Index No. M/10.0
GW-500 Gun
See Lit. Index No. M/13.4
Miscellaneous
Primary Power Cable
Secondary Power Cable
Ground Cable with Clamp
Gas Cylinder (if required)
Gas Hose with Fittings (if required)
Regulator/Flowmeter (if required)
Welding Wire
Helmet
Welding Gloves
Date:
Distributed by:
Litho in USA
Total Quoted Price:
Price
70 Series
Quick
Specs
Issued Feb. 2002 • Index No. M/3.0
Constant-Speed
Wire Feeder
Heavy Industrial Applications
Processes
Heavy Manufacturing
Metal Fabrication
Construction
Light Manufacturing
MIG (GMAW)
Flux Cored (FCAW)
(Gas- and Self-Shielded)
Input Power 24 VAC, 10 A, 50/60 Hz
Electrode Wire Diameter Capacity .023 –1/8 in (0.6– 3.2 mm)
Wire Speed 50 –780 IPM (1.3 –19.8 m/min)
Weight 58 lb (26 kg)
The next generation of industrial-class wire feeders. All the features
of the 60 Series, plus enhanced flexibility and additional features.
The Power of Blue .
®
Models:
74S: Standard, basic design
74D: Digital meters
74DX: Deluxe — digital, full-feature
Toolless
rotatable
drive
assembly
allows
operator
to rotate
the drive
housing, eliminating severe bends
in the wire feed path which reduce
gun liner life. Also aids in feeding
difficult wires.
S-74D
Model
S-74DX
Model
Easy access on/off switch
Trigger receptacle oriented in a downward position to reduce potential damage.
Trigger hold reduces operator fatigue by allowing the operator to make long
welds without having to energize the trigger continuously.
Automatic run-in control significantly improves arc starting performance.
Posifeed™ Wire Drive Assembly Features
24 VDC high-torque, permanent-magnet motor.
Quick-change drive rolls.
Quick-release, calibrated drive-roll pressure adjustment arm allows
drive roll change without losing spring preload setting.
Four sealed ball bearing all-gear-driven drive-roll carriers for smooth,
positive and accurate wire feed with long uninterrupted service life.
Easy loading and threading of welding wire without having to release
the drive-roll pressure arm.
Solid-state speed control and brake circuit eliminates the need for
electrical/ mechanical relays and increases service life.
Uses Miller standard 1-5/8 in (41 mm) diameter drive rolls.
Quick-connect for all Miller guns.
Covered drive rolls — easy access, heavy-duty, molded composite
cover over drive assembly.
Floating positive drive systems provide trouble-free feeding on a
variety of wires.
10 ft, 14-pin
interconnecting cord
for the operator to
hook up.
Dual
tension
control
adds
flexibility
for the
operator to fine-tune the pressure
on the wire independently when
feeding a variety of wires.
DX Models Additional Features
Dual schedule allows operator to switch between two welding parameters
without readjusting machine, eliminating downtime and enhancing quality.
Adjustable weld sequence control gives operator complete control of the
welding parameters: preflow, run-in, weld time, crater, burnback and postflow.
Welding process range control locks parameters at a set percentage of
welding parameters to ensure welding procedures and quality standards
are maintained on the shop floor.
Four weld programs allow the operators to store four independent
welding parameters reducing welding setup time. (Four programs
available per side on dual model.)
Wire feeder is warranted for
3 years, parts and labor.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
Specifications
Input Power
24 VAC, 10 A,
50/60 Hz
(Use with CV
Power Sources.)
(Subject to change without notice.)
Electrode Wire
Diameter Capacity
Wire Speed
Dimensions
S-74 (Single)
D-74 (Dual)
Net Weight
S-74 (Single) D-74 (Dual)
.023–1/8 in (0.6 – 3.2 mm)
(1/8 in wires may require
low-speed motor)
50 –780 IPM (1.3 –19.8 m/min)
Optional High Speed Motor:
90 –1440 IPM (2.3 – 36.6 m/min)
H: 14 in (356 mm)
W: 12 in (305 mm)
D: 26-1/2 in (673 mm)
H: 14 in (356 mm)
W: 12-1/2 in (318 mm)
D: 35 in (889 mm)
58 lb (26 kg)
87 lb (35.5 kg)
Control Panel
S-74DX Model
1. Program Display
2. Program # Select
3. Weld Sequence
4. Voltage/Time Select
5. Voltage/Time
Display Meter
6. Wire Feed/
Amperage Select
7. Wire Speed/
Amperage Display
Meter
8. Control Knob
9. Trigger Hold/Dual
Schedule Control
10. Jog/Purge
S-74S and S-74D Model
1
2
4
5
6
7
3
8
9
1. Voltage Display
Meter*
2. Wire Speed
Display Meter*
3. Wire Feed
Speed Select
4. Trigger Hold
5. Voltage Select**
6. Jog/Purge
1
2
3
5
*S-74D model only
**Optional on S-74S
4
70 Series
®
Drive Roll Kits and Guides
6
10
24V Wire Feeder
70 Series
24V Wire Feeder
(Order from Miller Service Parts.)
Select drive roll kits from chart below according to type and wire size being used. Drive roll kits include 4 drive rolls, the necessary guides and feature an
anti-wear sleeve for inlet guide.
Wire Size
“U” groove for
soft wire or
soft-shelled
cored wires
“V” groove
for hard wire
.023/.025 in (0.6 mm)
.030 in (0.8 mm)
.035 in (0.9 mm)
.040 in (1.0 mm)
.045 in (1.1/1.2 mm)
.052 in (1.3/1.4 mm)
1/16 in (1.6 mm)
.068/.072 in (1.8 mm)
5/64 in (2.0 mm)
3/32 in (2.4 mm)
7/64 in (2.8 mm)
1/8 in (3.2 mm)
#151 024
#151 025
#151 026
#161 190
#151 027
#151 028
#151 029
—
—
—
—
—
*Accommodates .045 and .047 (3/64 in) wire.
“U” cogged
for extremely soft
wire or soft-shelled
cored wires (i.e.,
hard facing types)
“V” knurled for
hard-shelled
cored wires
—
—
#151 036
—
#151 037*
#151 038
#151 039
—
#151 040
#151 041
#151 042
#151 043**
—
—
#151 052
—
#151 053
#151 054
#151 055
#151 056
#151 057
#151 058
#151 059
#151 060**
—
—
—
—
#151 070
#151 071
#151 072
—
#151 073
#151 074
#151 075
#151 076**
** May require a low-speed, wire-feed drive-roll option.
Nylon Wire Guides for Feeding Aluminum Wire
Wire Guides
Wire Size
Inlet Guide
Intermediate Guide
Wire Size
Inlet Guide
Intermediate Guide
.047 in (1.2 mm)
#151 203
#151 204
.023 – .040 in (0.6 – 1.0 mm)
#150 993
#149 518
1/16 in (1.6 mm)
#151 205
#151 206
.045 – .052 in (1.1 – 1.4 mm)
#150 994
#149 519
3/32 in (2.4 mm)
#151 207
#151 208
1/16 – 5/64 in (1.6 – 2 mm)
#150 995
#149 520
3/32 – 7/64 in (2.4 – 2.8 mm)
#150 996
#149 521
1/8 in (3.2 mm)
#150 997
#149 522
Note: “U” groove drive rolls are recommended when feeding aluminum wire.
2
Genuine Miller Options and Accessories
Dual Schedule Switches
Remote Voltage Control
#194 988 Field Non-digital for S-74S
#194 991 Field Non-digital for D-74S
Conversion Kit
#194 989 Field
#194 992 Field
#195 010 Field
#195 041 Field
S-74S to S-74D
D-74S to D-74D
S-74S to S-74DX
D-74S to D-74DX
Control Detachment Kit
#194 914 Field 10 ft (3 m) for S-74
#194 913 Field 25 ft (7.6 m) for S-74
#194 995 Field 25 ft (7.6 m) for D-74
Allows separation of the control module
from the wire drive assembly and base.
Spool Covers
#057 607 For S-74 and left side of
D-74 models
#090 389 For right side of D-74 models
For 12 in (305 mm) spool.
Carrying Cart #056 301
A utility cart for the wire feeder and
other miscellaneous welding supplies.
Height: 34 in (863 mm). Lower tray height:
9 in (228 mm). Shipped disassembled.
DSS-9 #071 833
A two-position slide switch which attaches
to the gun handle and is used to select the
desired welding condition for dual schedule
purposes. The gun trigger operates as a standard gun trigger. (For 74DX models only.)
Feeder Cart #142 382
A low-profile, creeper cart which allows the
operator to easily move the feeder around
the work area. Shipped disassembled.
Turntable Assembly #146 236
Allows rotation of the feeder as the operator
changes work positions. Reduces strain
and bending on the gun cable.
Hanging Bail (Electrically Isolated)
#058 435
Used for suspending feeder over work area.
Wire Reel Assembly #108 008
For 60 lb (27 kg) coil of wire.
Reel Covers
#058 256 For S-74 and left side of
D-74 models
#091 668 For right side of D-74 models
For 60 lb (27 kg) coil. Helps to protect
the welding wire from dust and other
contaminants.
Note: Reel and Spool Covers cannot be installed if
the wire drive assembly is in a rotated position.
Spool Adapter #047 141
For use with 14 lb (6.4 kg) spool of Lincoln
self-shielding wire.
Wire Straightener
#141 580 For .035 –.045 in (0.9 –1.1 mm)
diameter wire.
#141 581 For 1/16 –1/8 in (1.6 – 3.2 mm)
diameter wire.
Helps reduce the cast in wire to improve
wire feeding performance and increase the
service life of the gun liner and contact tip.
DSS-8 #079 693
A two-position trigger switch which
attaches to the gun handle and is used in
place of the standard trigger for dual
scheduling. (For 74DX models only.)
2/0 MIG Welding Accessory Kit #173 856
25 ft (7.6 m). Includes gas hose, weld
cable and ground cable with clamp.
Swingarc™ Boom-Mounted Wire Feeders
Swingarc boom-mounted semiautomatic
wire feeders bring an extra dimension of
flexibility and efficiency to high-production
wire welding stations. You get an effective
solution that maximizes output, especially
when dealing with large weldments and
hard-to-reach places. See Lit. Index No.
M/13.1.
Extension Cords
#122 973 25 ft (7.6 m)
#122 974 50 ft (15 m)
#122 975 75 ft (23 m)
Provides 14-pin, 24 VAC, contactor and
voltage control. Add to the standard 10 ft
(3 m) feeder cord to extend feeder farther
from power source.
3
Typical Installation
10 ft (3 m) 24 VAC, Contactor and
Voltage Control Cord (supplied with feeder)
Miller electrically controlled
CV and CC/CV power source
with a 14-pin receptacle and
24 VAC supply
Weld Power Cable and Gas Hose
(not supplied with feeder)
70 Series Feeder
Ordering Information
Equipment and Options
Stock No.
S-74S
#195 057
#195 057-02-1
#195 058
#195 058-01-1
#195 058-02-1
#195 058-03-1
#195 059
#195 059-01-1
#195 059-02-1
#195 059-03-1
#195 060
#195 060-02-1
#195 061
#195 061-01-1
#195 061-02-1
#195 061-03-1
#195 062
#195 062-01-1
#195 062-02-1
#195 062-03-1
#194 988
#194 991
#194 989
#194 992
#195 010
#195 041
#194 914
#194 913
#194 995
S-74D
S-74DX
D-74S (available January 2002)
D-74D (available January 2002)
D-74DX (available January 2002)
Remote Voltage Control
Conversion Kit
Control Detachment Kit
Power Sources
CP-252TS and CP-302
Invision™ 354 MP and 456MP, 456P
Deltaweld® Series
XMT® Series
Dimension™ Series
Accessories
Adapter Kit
Carrying Cart
Feeder Cart
Turntable Assembly
Hanging Bail
Wire Straightener
Spool Covers
Wire Reel Assembly
Reel Covers
Spool Adapter
2/0 MIG Welding Accessory Kit
Extension Cords
Dual Schedule Switches
Description
With CE, Euro
With high-speed motor
With CE, Euro
With CE, Euro, high-speed motor
With high-speed motor
With CE, Euro
With CE, Euro, high-speed motor
With CE, Euro
With high-speed motor
With CE, Euro
With CE, Euro, high-speed motor
With high-speed motor
With CE, Euro
With CE, Euro, high-speed motor
Field. Non-digital control (S-74S model only)
Field. Non-digital control (D-74S model only)
Field. S-74S to S-74D
Field. D-74S to D-74D
Field. S-74S to S-74DX
Field. D-74S to D-74DX
Field. 10 ft (3 m) (S-74S model only)
Field. 25 ft (7.6 m) (S-74S model only)
Field. 25 ft (7.6 m) (D-74S model only)
See Lit. Index No. DC/31 and DC/13.0
See Lit. Index No. DC/23, DC/20
See Lit. Index No. DC/16.2
See Lit. Index No. DC/18.8
See Lit. Index No. DC/19.2
#195 043
#056 301
#142 382
#146 236
#058 435
#057 607
#090 389
#108 008
#058 256
#091 668
#047 141
#173 856
#079 693
#071 833
Makes 70 Series feeder compatible with older-style power sources
Electrically isolated
See page 3
For S-74 and left side of D-74 models
For right side of D-74 models
For S-74 and left side of D-74 models
For right side of D-74 models
See page 3
DSS-8 (74DX models only)
DSS-9 (74DX models only)
Date:
Total Quoted Price:
Distributed by:
Litho in USA
Qty.
Price
Spool
Guns
and
Controls
Spoolmate 3035, Spoolmate 3545, and Spoolmatic 30A
™
Quick
Specs
™
Light and Heavy
Industrial Applications
Processes
Aluminum
Wire Feeder
®
Weight
MIG (GMAW) with
aluminum and other
soft alloy wires
Aluminum Fabrication
Sign Manufacturing
Trailers
Auto and Marine Repair
Issued Dec. 2001 • Index No. M/1.5
Spoolmate 3035: 9 lb (4.1 kg) with cable assembly
Spoolmate 3545: 10 lb (4.5 kg) with cable assembly
Spoolmatic 30A: 14 lb (6.4 kg) with cable assembly
The Power of Blue .
®
Spoolmate™ 3035
Spoolmatic® 30A
These reliable yet economical Spoolmate spool guns provide 20 ft
cable reach and accessibility, with smooth feeding of aluminum wire.
Industrial, well-balanced Spoolmatic 30A spool gun features a built-in gas
valve, rotatable canister, reversible drive roll and 30 ft cable reach.
Selecting a Spool Gun
What wire sizes
are you running?
Spoolmate™ 3545
What welding output?
Recommended gun
.023 – .035 in
150 A at 60% duty cycle —
light industrial applications
Spoolmate 3035
.030 – .047 in
200 A at 60% duty cycle —
light industrial applications
Spoolmate 3545
.023 – 1/16 in
200 A at 100% duty cycle —
light and heavy industrial
applications
Spoolmatic 30A
Spoolmate guns warranted for 90 days,
parts and labor. Spoolmatic 30A gun
warranted for 1 year, parts and labor.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
Specifications
(Use with CC/CV, DC
Power Sources.)
(Subject to change without notice.)
Spool Gun Specifications
Wire Speed
Maximum Spool
Size Capacity
.023 –.035 in (0.6 – 0.9 mm)
aluminum, steel and stainless steel
115–715 IPM
4 in (102 mm)
200 A at
60% Duty Cycle
.030 –.047 in (0.8 – 1.2 mm) aluminum,
steel and stainless steel
200–1200 IPM
200 A at
100% Duty Cycle
.023 – 1/16 in (0.6 – 1.6 mm) aluminum
and hard wires up to .045 in (1.1 mm)
70–875 IPM
Model
Welding
Output Rating
Electrode Wire
Diameter Capacity
Spoolmate
3035
150 A at
60% Duty Cycle
Spoolmate
3545
Spoolmatic
30A
Net Weight with
Cable Assembly
Dimensions
H: 11-1/2 in (291 mm)
W: 2-1/4 in (57 mm)
L: 8 in (203 mm)
9.1 lb (4.1 kg)
H: 10-1/4 in (260 mm)
W: 2-1/2 in (64 mm)
L: 15-1/8 in (384 mm)
14 lb (6.4 kg)
10 lb (4.5 kg)
Spool Gun Control Specifications
Usage
Model
Input Power
Dimensions
Net Weight
For Spoolmate
3035 and 3545
SGA 100
115 VAC, 50/60 Hz
H: 4-1/4 in (108 mm) W: 6-3/8 in (162 mm) L: 10-1/2 in (267 mm)
9.1 lb (4.1 kg)
SGA 100C
115 VAC, 50/60 Hz
H: 8-1/4 in (210 mm) W: 6-3/8 in (162 mm) L: 10-1/2 in (267 mm)
12 lb (5.4 kg)
For Spoolmatic 30A
WC-24
24 VAC, 50/60 Hz
H: 7 in (178 mm) W: 5-1/2 in (140 mm) L: 2 in (51 mm)
2 lb (0.9 kg)
WC-115A
115 VAC, 50/60 or 100 Hz
H: 10 in (254 mm) W: 9-1/2 in (241 mm) L: 13 in (330 mm)
20 lb (9 kg)
Spool Gun Hook-Up Recommendations
Power Source
Effective
Serial Number
Spoolmate 3035 #195 016
150 A, 60% Duty Cycle
Spoolmate 3545 #195 015
200 A, 60% Duty Cycle
Spoolmatic 30A #130 831
200 A, 60% Duty Cycle
Millermatic® 130 XP, 135
All
Limited to 14 gauge–1/8 in material
SGA 100 required #043 856
Not recommended
Not recommended
Millermatic®
Challenger 172, 175
All
SGA 100 required #043 856
Not recommended
Not recommended
Millermatic® 185
Prior to #KH376829
Retrofit Kit required #186 871
Retrofit Kit required #186 871
Not recommended
After #KH376829
Direct hook-up with toggle switch
Direct hook-up with toggle switch
®
™
Not recommended
Not recommended
Millermatic 210
All
Direct hook-up, Gun-On-Demand
Millermatic® Vintage, 250
All
Not recommended
SGA 100 required #043 856
Module required #043 084
All
Not recommended
Not recommended
Direct hook-up
®
Millermatic 250X, 251
2
™
Direct hook-up, Gun-On-Demand
Spoolmate Spool Gun Controls
SGA 100 #043 856
Required to connect Spoolmate spool gun
to the Millermatic 135 or 175. Allows you to
connect a Spoolmate gun to virtually any
similar MIG welder — Miller or other brands.
Includes 10 ft (3 m) 115 VAC power cable
and plug, 6 ft (1.8 m) interconnecting cable,
and 5 ft (1.5 m) gas hose.
Note: For CV engine drives like Miller Bobcat ™,
use the SGA 100C with contactor (#043 857).
SGA 100C #043 857
SGA with contactor required to connect
Spoolmate spool gun to CV engine drives
like Miller’s Bobcat ™.
Includes 10 ft (3 m) 115 VAC power cable
and plug, 6 ft (1.8 m) interconnecting cable,
and 5 ft (1.5 m) gas hose.
Genuine Miller Spoolmate Consumables and Accessories (Order Consumables from Miller Service Parts.)
Consumables For Spoolmate 3035
Consumables For Spoolmate 3545
Accessories
Note: When using with a Spoolmate 3545, ratings are
reduced to 150A, 60% Duty Cycle.
Contact Tips (5 per package)
#199 730 For .023 in (0.6 mm) wire.
#186 419 For .030 in (0.8 mm) wire.
#186 406 For .035 in (0.9 mm) wire.
Contact Tips (5 per package)
#199 387 For .030 in (0.8 mm) wire.
#199 388 For .035 in (0.9 mm) wire.
#199 389 For .047 in (1.2 mm) wire.
Spoolmate™ Curved Barrel Assembly
#198 371
Nozzle #186 405
Nozzle #199 386
Drive Roll (1)
#199 731 For .023 in
(0.6 mm) wire.
#186 413 For .030/.035 in
(0.8/0.9 mm) wire.
Drive Roll (1)
#186 413 For .030/.035 in
(0.8/0.9 mm) wire.
#199 396 For .047 in
(1.2 mm) wire.
Push Roll (1)
#199 732 For .023 in
(0.6 mm) wire.
#186 414 For .030/.035 in
(0.8/0.9 mm) wire.
Push Roll (1)
#186 414 For .030/.035 in
(0.8/0.9 mm) wire.
#199 397 For .047 in
(1.2 mm) wire.
Spoolmate™ 9-in Straight Barrel Assembly
#198 372
25 ft Extension Cable #194 996
3
Spoolmatic 30A Spool Gun Controls
Standard features include a wire run-in
control and a drive motor acceleration
control which ensure optimum arc starting
performance, regardless of the type of
power source being used. The WC-115A
comes with a 10 ft (3 m), wall-type plug
power cord.
WC-24 Weld Control #137 549
Packaged in a compact, lightweight, nonmetallic enclosure, the WC-24 easily mounts
directly on the power source. It’s designed
for use with Miller CV power sources
supplying 24 VAC and 14-pin receptacles.
The control includes a board-mounted
potentiometer which can alter the drive
motor acceleration rate to optimize arc
starting performance.
WC-115A Weld Control
#137 546 Without contactor
#137 546-01-1 With contactor
This control operates on 115 VAC, and is
designed primarily for CC DC power sources.
It can also be used with CV power sources
or DC engine drives supplying 115 VAC.
When used with a CC source, the control
circuit functions in a voltage-sensing mode.
When used with a CV source, it functions
as a constant-speed circuit.
Genuine Miller Spoolmatic 30A Consumables
WC-115 Contactor Kit #137 548 Field
Recommended when using the Spoolmatic
gun and WC-115A control with power
sources that do not have a weld output
contactor. (This is installed in the WC-115A.)
Contactor Rating:
400 amps at 30% duty cycle
330 amps at 60% duty cycle
250 amps at 100% duty cycle
(Order from Miller Service Parts.)
Contact Tips
Drive Rolls
Dual Groove for One
Dual Groove for All Wire
Wire Size (Optional)
Sizes (Supplied with Gun)
Wire Size
Standard
Tip I.D.
Optional
Tip I.D.
Gun Head
Tube Liner
.023 in (0.6 mm)
#136 171
.031 in (0.8 mm)
–
–
#136 682
#136 135 (use small groove)
#183 357 (.023 in / 0.6 mm)
.030 in (0.8 mm)
#135 428
.041 in (1.0 mm)
#135 427
.036 in (0.9 mm)
#136 682
#136 135 (use small groove)
#183 357 (.030 in / 0.8 mm)
.035 in (0.9 mm)
#135 430
.052 in (1.3 mm)
#147 314
.041 in (1.0 mm)
#136 682
#136 135 (use small groove)
#183 357 (.035 in / 0.9 mm)
.047 in (1.2 mm)
#135 424
.061 in (1.5 mm)
#135 429
.052 in (1.3 mm)
#136 683
#136 135 (use large groove)
#183 358 (.047 in / 1.2 mm)
.062 in (1.6 mm)
#135 425
.081 in (2.1 mm)
#135 426
.073 in (1.9 mm)
#136 683
#136 135 (use large groove)
#183 358 (.062 in / 1.6 mm)
Each gun is shipped with (3) .035 in and (3) .047 in standard tips. The optional contact tips listed are for those applications where a smaller I.D. tip is preferred.
All contact tips are stamped with wire size and the tip I.D. For example: .035/52 designates .035 in wire and .052 in tip I.D.
Contact Tip Conversion Kits
Standard Nozzles
#050 622
5/8 in (16 mm)
orifice (Standard
with gun)
#050 116
13/16 in (21mm)
orifice
#050 115
1/2 in (13 mm)
orifice
Spot Nozzles
#009 925
Outside
corner
4
#000 443
Inside
corner
#000 442
Flat 15/16 in
(24 mm)
orifice
#004 466
Flat 1-3/8 in
(35 mm)
orifice
Note: Both kits include liners and contact tips for
all wire sizes.
For Older-Style Spoolmatic Guns
#156 485
Allows older-style Spoolmatic guns to use
the new Spoolmatic 30A 1-7/16 in (37 mm)
long contact tips.
For Newer-Style Spoolmatic Guns
#164 603
Allows newer-style Spoolmatic guns to use
the older-style Spoolmatic 4 in (102 mm)
long contact tips.
Genuine Miller Spoolmatic 30A Accessories
SX-A 50-Degree Curved Barrel
#147 175 6 in (152 mm)
#147 176 10 in (254 mm)
Used with .030 –1/16 in (0.8 –1.6 mm)
wire. Kits supplied with two liners that
accommodate all wire sizes.
Note: Uses standard Spoolmatic contact tips. (Refer to
Spoolmatic Gun Consumables chart for contact tips.)
SX-A 50-Degree Curved Nozzle Kit
#147 174
Attaches to standard gun barrel assembly
and is ideal for access to confined weld
joint areas. Used with .030 –1/16 in
(0.8 –1/6 mm) wire. Kit includes two of
each size contact tips to accommodate all
wire sizes. Uses standard straight barrel
head tube liner.
3 in Head Tube Extension #137 787
Extends the standard gun barrel 3 in
(72 mm) when a longer reach is required.
The head tube extension is supplied with
two liners to accommodate all wire sizes.
Note: Uses standard Spoolmatic contact tips. (Refer to
Spoolmatic Gun Consumables chart for contact tips.)
Cable Cover #118 678
Protects gun hose and cable assembly
from wear and abrasion. Features a fulllength zipper.
Hose and Cable Extension Kits
#132 228 25 ft (7.6 m)
#132 229 50 ft (15 m)
Extends Spoolmatic 30A away from the
control box. Convenient plug-in connections.
Includes gas hose, control cord, and weld
power cable with International-style
insulated connector.
Replacement Parts
Teflon Liners for Curved Barrels
For 6 in Barrel
#144 858 .030–.035 in (0.8–0.9 mm) wire
#144 859 .047–1/16 in (1.2–1.6 mm) wire
For 10 in Barrel
#144 854 .030–.035 in (0.8–0.9 mm) wire
#144 855 .047–1/16 in (1.2–1.6 mm) wire
Contact Tips for Curved Nozzle
#148 155 .030–.035 in (0.8–0.9 mm) wire
#148 154 .047 in (1.2 mm) wire
#148 156 1/16 in (1.6 mm) wire
SX Heat Shield #131 103
Helps protect operator’s hand from spatter
and reflected heat.
Liners for Flex Head
#138 255 .030–.035 in (0.8–0.9 mm) wire
#132 682 .047–1/16 in (1.2–1.6 mm) wire
Liners for Head Tube Extension
#138 223 .030–.035 in (0.8–0.9 mm) wire
#138 224 .047–1/16 in (1.2–1.6 mm) wire
SX Flex Head Kit #131 104
For .030 –1/16 in (0.8 –1.6 mm) wire. Used
in place of the standard straight barrel.
Flexible head tube bends 60 degrees in
any direction for easier joint access and
improved operator comfort. Supplied with
two Teflon liners and one contact tip for
each wire size listed.
Spare Spool Canister #132 230
Canister accommodates 4 in (102 mm)
spools of wire. Can be loaded with other
popular wires to save time in changeover.
5
Typical Installations
Spoolmate Gun to Welder Requiring a SGA Spool Gun Adapter
Note: Refer to SGA Owner’s Manual for complete installation instructions.
For Millermatic 135, combine Spoolmate 3035 with
SGA 100 to weld 14 gauge to 1/8 in aluminum.
Gas Hose to Gas Regulator
115 VAC Power Cord
For Millermatic 175, combine Spoolmate 3035 with
SGA 100 to weld 14 gauge to 1/4 in aluminum.
To weld aluminum with comparable, competitive
power sources, the Spoolmate may also be used with
one of the SGA units.
The SGA 100C is necessary when connecting
Spoolmate spool guns to CV engine drive units.
Thickness will depend on engine drive.
For Miller’s Bobcat 225NT, combine Spoolmate 3545
with SGA 100C to weld 14 gauge to 3/16 in aluminum.
To weld aluminum with comparable, competitive
power sources, the Spoolmate may also be used with
one of the SGA units.
SGA-100
Control Box
Typical MIG welder such as the
Millermatic 135
Typical CV engine drive, without
output contactor, such as the
Miller Bobcat
Spoolmate
Spool Gun Trigger
Control Cord
Spool Gun Gas Hose
Interconnecting Cord
Spool Gun Weld Cable
Weld Cable (customer supplied)
OR
Spool Gun
Weld Cable
Spoolmate
Spool Gun Trigger
Control Cord
SGA-100C
(with contactor)
115 VAC Power Cord
Spool Gun
Gas Hose
Gas Hose to Gas Regulator
Spoolmatic 30A
Note: Cords and cables are supplied unless noted otherwise on drawings below. Refer to Owner’s Manual for complete installation instructions.
To connect the Spoolmatic 30A and WC-24 control to
older-style Miller or competitive CV power sources
that do not have a 24 VAC supply, the PSA-2 control
#141 604 is required.
To connect Spoolmatic 30A gun and WC-24 control
to Millermatic® 200 and Spoolmate™ 200 power
sources that have a 4-pin receptacle, order adapter
cord #042 236.
To connect the WC-115A control to older-style Miller
power sources having Hubbell or 5-pin contactor
control receptacles, the appropriate connector must
be ordered separately:
To connect to older-style Miller CC power sources having
a two-socket Hubbell connector, order plug #039 618.
If power source has a 5-pin receptacle, order #039 273
and #039 685.
To connect to older-style Miller CV power sources having
a two-prong Hubbell connector, order plug #039 635.
Note: These connectors are to replace the 14-pin connector
on the 10 ft interconnect contactor cord.
6
Miller CV, DC
power source
with a 14-pin
receptacle and
24 VAC supply
WC-24
Control
10 ft (3 m)
Control Cord
30 ft (9 m)
Control Cord
30 ft (9 m)
Weld Power
Cable
Spoolmatic 30A
40 ft (12 m) Gas Hose
40 ft (12 m) Gas Hose
WC-115A
Control
30 ft (9 m) Control Cord
30 ft (9 m) Weld Power Cable
Miller and competitive CC and/or CV,
DC power source/generator. If the
power source does not have a weld
output contactor, order the optional
WC-115 contactor.
Spoolmatic 30A
Weld Power Cable (not included)
10 ft (3 m) Contactor Cord (supplied)
10 ft (3 m) 115 VAC Power Cord (supplied)
Notes
7
Ordering Information
Equipment
Stock No.
Description
Spoolmate 3035 Spool Gun
#195 016
Includes 20 ft (6 m) cable
Spoolmate™ 3545 Spool Gun
#195 015
Includes 20 ft (6 m) cable
Spoolmatic® 30A Spool Gun
#130 831
Includes 30 ft (9 m) cable
SGA 100
#043 856
For Spoolmates
SGA 100C
#043 857
For Spoolmates
™
Qty.
Spoolmate Controls
Spoolmate Consumables and Accessories
Consumables
See page 3
Spoolmate Curved Barrel Assembly
#198 371
Spoolmate 9-in Straight Barrel Assembly
#198 372
25 ft Extension Cable
#194 996
Spoolmatic 30A Controls
WC-24 Weld Control
#137 549
For Spoolmatic 30A
WC-115A Weld Control
#137 546
#137 546-01-1
Without contactor. For Spoolmatic 30A
With contactor. For Spoolmatic 30A
WC-115 Contactor Kit
#137 548
Field
SX-A 50-Degree Curved Barrel
#147 175
#147 176
6 in (152 mm)
10 in (254 mm)
SX-A 50-Degree Curved Nozzle Kit
#147 174
SX Flex Head Kit
#131 104
3 in Head Tube Extension
#137 787
Cable Cover
#118 678
SX Heat Shield
#131 103
Spare Spool Canister
#132 230
Hose and Cable Extension Kits
#132 228
#132 229
Spoolmatic 30A Consumables and Accessories
Consumables
See page 4
Date:
Total Quoted Price:
Distributed by:
Litho in USA
25 ft (7.6 m)
50 ft (15 m)
Price
Spool
Guns
and
Controls
Spoolmate 3035, Spoolmate 3545, and Spoolmatic 30A
™
Quick
Specs
™
Light and Heavy
Industrial Applications
Processes
Aluminum
Wire Feeder
®
Weight
MIG (GMAW) with
aluminum and other
soft alloy wires
Aluminum Fabrication
Sign Manufacturing
Trailers
Auto and Marine Repair
Issued Dec. 2001 • Index No. M/1.5
Spoolmate 3035: 9 lb (4.1 kg) with cable assembly
Spoolmate 3545: 10 lb (4.5 kg) with cable assembly
Spoolmatic 30A: 14 lb (6.4 kg) with cable assembly
The Power of Blue .
®
Spoolmate™ 3035
Spoolmatic® 30A
These reliable yet economical Spoolmate spool guns provide 20 ft
cable reach and accessibility, with smooth feeding of aluminum wire.
Industrial, well-balanced Spoolmatic 30A spool gun features a built-in gas
valve, rotatable canister, reversible drive roll and 30 ft cable reach.
Selecting a Spool Gun
What wire sizes
are you running?
Spoolmate™ 3545
What welding output?
Recommended gun
.023 – .035 in
150 A at 60% duty cycle —
light industrial applications
Spoolmate 3035
.030 – .047 in
200 A at 60% duty cycle —
light industrial applications
Spoolmate 3545
.023 – 1/16 in
200 A at 100% duty cycle —
light and heavy industrial
applications
Spoolmatic 30A
Spoolmate guns warranted for 90 days,
parts and labor. Spoolmatic 30A gun
warranted for 1 year, parts and labor.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
Specifications
(Use with CC/CV, DC
Power Sources.)
(Subject to change without notice.)
Spool Gun Specifications
Wire Speed
Maximum Spool
Size Capacity
.023 –.035 in (0.6 – 0.9 mm)
aluminum, steel and stainless steel
115–715 IPM
4 in (102 mm)
200 A at
60% Duty Cycle
.030 –.047 in (0.8 – 1.2 mm) aluminum,
steel and stainless steel
200–1200 IPM
200 A at
100% Duty Cycle
.023 – 1/16 in (0.6 – 1.6 mm) aluminum
and hard wires up to .045 in (1.1 mm)
70–875 IPM
Model
Welding
Output Rating
Electrode Wire
Diameter Capacity
Spoolmate
3035
150 A at
60% Duty Cycle
Spoolmate
3545
Spoolmatic
30A
Net Weight with
Cable Assembly
Dimensions
H: 11-1/2 in (291 mm)
W: 2-1/4 in (57 mm)
L: 8 in (203 mm)
9.1 lb (4.1 kg)
H: 10-1/4 in (260 mm)
W: 2-1/2 in (64 mm)
L: 15-1/8 in (384 mm)
14 lb (6.4 kg)
10 lb (4.5 kg)
Spool Gun Control Specifications
Usage
Model
Input Power
Dimensions
Net Weight
For Spoolmate
3035 and 3545
SGA 100
115 VAC, 50/60 Hz
H: 4-1/4 in (108 mm) W: 6-3/8 in (162 mm) L: 10-1/2 in (267 mm)
9.1 lb (4.1 kg)
SGA 100C
115 VAC, 50/60 Hz
H: 8-1/4 in (210 mm) W: 6-3/8 in (162 mm) L: 10-1/2 in (267 mm)
12 lb (5.4 kg)
For Spoolmatic 30A
WC-24
24 VAC, 50/60 Hz
H: 7 in (178 mm) W: 5-1/2 in (140 mm) L: 2 in (51 mm)
2 lb (0.9 kg)
WC-115A
115 VAC, 50/60 or 100 Hz
H: 10 in (254 mm) W: 9-1/2 in (241 mm) L: 13 in (330 mm)
20 lb (9 kg)
Spool Gun Hook-Up Recommendations
Power Source
Effective
Serial Number
Spoolmate 3035 #195 016
150 A, 60% Duty Cycle
Spoolmate 3545 #195 015
200 A, 60% Duty Cycle
Spoolmatic 30A #130 831
200 A, 60% Duty Cycle
Millermatic® 130 XP, 135
All
Limited to 14 gauge–1/8 in material
SGA 100 required #043 856
Not recommended
Not recommended
Millermatic®
Challenger 172, 175
All
SGA 100 required #043 856
Not recommended
Not recommended
Millermatic® 185
Prior to #KH376829
Retrofit Kit required #186 871
Retrofit Kit required #186 871
Not recommended
After #KH376829
Direct hook-up with toggle switch
Direct hook-up with toggle switch
®
™
Not recommended
Not recommended
Millermatic 210
All
Direct hook-up, Gun-On-Demand
Millermatic® Vintage, 250
All
Not recommended
SGA 100 required #043 856
Module required #043 084
All
Not recommended
Not recommended
Direct hook-up
®
Millermatic 250X, 251
2
™
Direct hook-up, Gun-On-Demand
Spoolmate Spool Gun Controls
SGA 100 #043 856
Required to connect Spoolmate spool gun
to the Millermatic 135 or 175. Allows you to
connect a Spoolmate gun to virtually any
similar MIG welder — Miller or other brands.
Includes 10 ft (3 m) 115 VAC power cable
and plug, 6 ft (1.8 m) interconnecting cable,
and 5 ft (1.5 m) gas hose.
Note: For CV engine drives like Miller Bobcat ™,
use the SGA 100C with contactor (#043 857).
SGA 100C #043 857
SGA with contactor required to connect
Spoolmate spool gun to CV engine drives
like Miller’s Bobcat ™.
Includes 10 ft (3 m) 115 VAC power cable
and plug, 6 ft (1.8 m) interconnecting cable,
and 5 ft (1.5 m) gas hose.
Genuine Miller Spoolmate Consumables and Accessories (Order Consumables from Miller Service Parts.)
Consumables For Spoolmate 3035
Consumables For Spoolmate 3545
Accessories
Note: When using with a Spoolmate 3545, ratings are
reduced to 150A, 60% Duty Cycle.
Contact Tips (5 per package)
#199 730 For .023 in (0.6 mm) wire.
#186 419 For .030 in (0.8 mm) wire.
#186 406 For .035 in (0.9 mm) wire.
Contact Tips (5 per package)
#199 387 For .030 in (0.8 mm) wire.
#199 388 For .035 in (0.9 mm) wire.
#199 389 For .047 in (1.2 mm) wire.
Spoolmate™ Curved Barrel Assembly
#198 371
Nozzle #186 405
Nozzle #199 386
Drive Roll (1)
#199 731 For .023 in
(0.6 mm) wire.
#186 413 For .030/.035 in
(0.8/0.9 mm) wire.
Drive Roll (1)
#186 413 For .030/.035 in
(0.8/0.9 mm) wire.
#199 396 For .047 in
(1.2 mm) wire.
Push Roll (1)
#199 732 For .023 in
(0.6 mm) wire.
#186 414 For .030/.035 in
(0.8/0.9 mm) wire.
Push Roll (1)
#186 414 For .030/.035 in
(0.8/0.9 mm) wire.
#199 397 For .047 in
(1.2 mm) wire.
Spoolmate™ 9-in Straight Barrel Assembly
#198 372
25 ft Extension Cable #194 996
3
Spoolmatic 30A Spool Gun Controls
Standard features include a wire run-in
control and a drive motor acceleration
control which ensure optimum arc starting
performance, regardless of the type of
power source being used. The WC-115A
comes with a 10 ft (3 m), wall-type plug
power cord.
WC-24 Weld Control #137 549
Packaged in a compact, lightweight, nonmetallic enclosure, the WC-24 easily mounts
directly on the power source. It’s designed
for use with Miller CV power sources
supplying 24 VAC and 14-pin receptacles.
The control includes a board-mounted
potentiometer which can alter the drive
motor acceleration rate to optimize arc
starting performance.
WC-115A Weld Control
#137 546 Without contactor
#137 546-01-1 With contactor
This control operates on 115 VAC, and is
designed primarily for CC DC power sources.
It can also be used with CV power sources
or DC engine drives supplying 115 VAC.
When used with a CC source, the control
circuit functions in a voltage-sensing mode.
When used with a CV source, it functions
as a constant-speed circuit.
Genuine Miller Spoolmatic 30A Consumables
WC-115 Contactor Kit #137 548 Field
Recommended when using the Spoolmatic
gun and WC-115A control with power
sources that do not have a weld output
contactor. (This is installed in the WC-115A.)
Contactor Rating:
400 amps at 30% duty cycle
330 amps at 60% duty cycle
250 amps at 100% duty cycle
(Order from Miller Service Parts.)
Contact Tips
Drive Rolls
Dual Groove for One
Dual Groove for All Wire
Wire Size (Optional)
Sizes (Supplied with Gun)
Wire Size
Standard
Tip I.D.
Optional
Tip I.D.
Gun Head
Tube Liner
.023 in (0.6 mm)
#136 171
.031 in (0.8 mm)
–
–
#136 682
#136 135 (use small groove)
#183 357 (.023 in / 0.6 mm)
.030 in (0.8 mm)
#135 428
.041 in (1.0 mm)
#135 427
.036 in (0.9 mm)
#136 682
#136 135 (use small groove)
#183 357 (.030 in / 0.8 mm)
.035 in (0.9 mm)
#135 430
.052 in (1.3 mm)
#147 314
.041 in (1.0 mm)
#136 682
#136 135 (use small groove)
#183 357 (.035 in / 0.9 mm)
.047 in (1.2 mm)
#135 424
.061 in (1.5 mm)
#135 429
.052 in (1.3 mm)
#136 683
#136 135 (use large groove)
#183 358 (.047 in / 1.2 mm)
.062 in (1.6 mm)
#135 425
.081 in (2.1 mm)
#135 426
.073 in (1.9 mm)
#136 683
#136 135 (use large groove)
#183 358 (.062 in / 1.6 mm)
Each gun is shipped with (3) .035 in and (3) .047 in standard tips. The optional contact tips listed are for those applications where a smaller I.D. tip is preferred.
All contact tips are stamped with wire size and the tip I.D. For example: .035/52 designates .035 in wire and .052 in tip I.D.
Contact Tip Conversion Kits
Standard Nozzles
#050 622
5/8 in (16 mm)
orifice (Standard
with gun)
#050 116
13/16 in (21mm)
orifice
#050 115
1/2 in (13 mm)
orifice
Spot Nozzles
#009 925
Outside
corner
4
#000 443
Inside
corner
#000 442
Flat 15/16 in
(24 mm)
orifice
#004 466
Flat 1-3/8 in
(35 mm)
orifice
Note: Both kits include liners and contact tips for
all wire sizes.
For Older-Style Spoolmatic Guns
#156 485
Allows older-style Spoolmatic guns to use
the new Spoolmatic 30A 1-7/16 in (37 mm)
long contact tips.
For Newer-Style Spoolmatic Guns
#164 603
Allows newer-style Spoolmatic guns to use
the older-style Spoolmatic 4 in (102 mm)
long contact tips.
Genuine Miller Spoolmatic 30A Accessories
SX-A 50-Degree Curved Barrel
#147 175 6 in (152 mm)
#147 176 10 in (254 mm)
Used with .030 –1/16 in (0.8 –1.6 mm)
wire. Kits supplied with two liners that
accommodate all wire sizes.
Note: Uses standard Spoolmatic contact tips. (Refer to
Spoolmatic Gun Consumables chart for contact tips.)
SX-A 50-Degree Curved Nozzle Kit
#147 174
Attaches to standard gun barrel assembly
and is ideal for access to confined weld
joint areas. Used with .030 –1/16 in
(0.8 –1/6 mm) wire. Kit includes two of
each size contact tips to accommodate all
wire sizes. Uses standard straight barrel
head tube liner.
3 in Head Tube Extension #137 787
Extends the standard gun barrel 3 in
(72 mm) when a longer reach is required.
The head tube extension is supplied with
two liners to accommodate all wire sizes.
Note: Uses standard Spoolmatic contact tips. (Refer to
Spoolmatic Gun Consumables chart for contact tips.)
Cable Cover #118 678
Protects gun hose and cable assembly
from wear and abrasion. Features a fulllength zipper.
Hose and Cable Extension Kits
#132 228 25 ft (7.6 m)
#132 229 50 ft (15 m)
Extends Spoolmatic 30A away from the
control box. Convenient plug-in connections.
Includes gas hose, control cord, and weld
power cable with International-style
insulated connector.
Replacement Parts
Teflon Liners for Curved Barrels
For 6 in Barrel
#144 858 .030–.035 in (0.8–0.9 mm) wire
#144 859 .047–1/16 in (1.2–1.6 mm) wire
For 10 in Barrel
#144 854 .030–.035 in (0.8–0.9 mm) wire
#144 855 .047–1/16 in (1.2–1.6 mm) wire
Contact Tips for Curved Nozzle
#148 155 .030–.035 in (0.8–0.9 mm) wire
#148 154 .047 in (1.2 mm) wire
#148 156 1/16 in (1.6 mm) wire
SX Heat Shield #131 103
Helps protect operator’s hand from spatter
and reflected heat.
Liners for Flex Head
#138 255 .030–.035 in (0.8–0.9 mm) wire
#132 682 .047–1/16 in (1.2–1.6 mm) wire
Liners for Head Tube Extension
#138 223 .030–.035 in (0.8–0.9 mm) wire
#138 224 .047–1/16 in (1.2–1.6 mm) wire
SX Flex Head Kit #131 104
For .030 –1/16 in (0.8 –1.6 mm) wire. Used
in place of the standard straight barrel.
Flexible head tube bends 60 degrees in
any direction for easier joint access and
improved operator comfort. Supplied with
two Teflon liners and one contact tip for
each wire size listed.
Spare Spool Canister #132 230
Canister accommodates 4 in (102 mm)
spools of wire. Can be loaded with other
popular wires to save time in changeover.
5
Typical Installations
Spoolmate Gun to Welder Requiring a SGA Spool Gun Adapter
Note: Refer to SGA Owner’s Manual for complete installation instructions.
For Millermatic 135, combine Spoolmate 3035 with
SGA 100 to weld 14 gauge to 1/8 in aluminum.
Gas Hose to Gas Regulator
115 VAC Power Cord
For Millermatic 175, combine Spoolmate 3035 with
SGA 100 to weld 14 gauge to 1/4 in aluminum.
To weld aluminum with comparable, competitive
power sources, the Spoolmate may also be used with
one of the SGA units.
The SGA 100C is necessary when connecting
Spoolmate spool guns to CV engine drive units.
Thickness will depend on engine drive.
For Miller’s Bobcat 225NT, combine Spoolmate 3545
with SGA 100C to weld 14 gauge to 3/16 in aluminum.
To weld aluminum with comparable, competitive
power sources, the Spoolmate may also be used with
one of the SGA units.
SGA-100
Control Box
Typical MIG welder such as the
Millermatic 135
Typical CV engine drive, without
output contactor, such as the
Miller Bobcat
Spoolmate
Spool Gun Trigger
Control Cord
Spool Gun Gas Hose
Interconnecting Cord
Spool Gun Weld Cable
Weld Cable (customer supplied)
OR
Spool Gun
Weld Cable
Spoolmate
Spool Gun Trigger
Control Cord
SGA-100C
(with contactor)
115 VAC Power Cord
Spool Gun
Gas Hose
Gas Hose to Gas Regulator
Spoolmatic 30A
Note: Cords and cables are supplied unless noted otherwise on drawings below. Refer to Owner’s Manual for complete installation instructions.
To connect the Spoolmatic 30A and WC-24 control to
older-style Miller or competitive CV power sources
that do not have a 24 VAC supply, the PSA-2 control
#141 604 is required.
To connect Spoolmatic 30A gun and WC-24 control
to Millermatic® 200 and Spoolmate™ 200 power
sources that have a 4-pin receptacle, order adapter
cord #042 236.
To connect the WC-115A control to older-style Miller
power sources having Hubbell or 5-pin contactor
control receptacles, the appropriate connector must
be ordered separately:
To connect to older-style Miller CC power sources having
a two-socket Hubbell connector, order plug #039 618.
If power source has a 5-pin receptacle, order #039 273
and #039 685.
To connect to older-style Miller CV power sources having
a two-prong Hubbell connector, order plug #039 635.
Note: These connectors are to replace the 14-pin connector
on the 10 ft interconnect contactor cord.
6
Miller CV, DC
power source
with a 14-pin
receptacle and
24 VAC supply
WC-24
Control
10 ft (3 m)
Control Cord
30 ft (9 m)
Control Cord
30 ft (9 m)
Weld Power
Cable
Spoolmatic 30A
40 ft (12 m) Gas Hose
40 ft (12 m) Gas Hose
WC-115A
Control
30 ft (9 m) Control Cord
30 ft (9 m) Weld Power Cable
Miller and competitive CC and/or CV,
DC power source/generator. If the
power source does not have a weld
output contactor, order the optional
WC-115 contactor.
Spoolmatic 30A
Weld Power Cable (not included)
10 ft (3 m) Contactor Cord (supplied)
10 ft (3 m) 115 VAC Power Cord (supplied)
Notes
7
Ordering Information
Equipment
Stock No.
Description
Spoolmate 3035 Spool Gun
#195 016
Includes 20 ft (6 m) cable
Spoolmate™ 3545 Spool Gun
#195 015
Includes 20 ft (6 m) cable
Spoolmatic® 30A Spool Gun
#130 831
Includes 30 ft (9 m) cable
SGA 100
#043 856
For Spoolmates
SGA 100C
#043 857
For Spoolmates
™
Qty.
Spoolmate Controls
Spoolmate Consumables and Accessories
Consumables
See page 3
Spoolmate Curved Barrel Assembly
#198 371
Spoolmate 9-in Straight Barrel Assembly
#198 372
25 ft Extension Cable
#194 996
Spoolmatic 30A Controls
WC-24 Weld Control
#137 549
For Spoolmatic 30A
WC-115A Weld Control
#137 546
#137 546-01-1
Without contactor. For Spoolmatic 30A
With contactor. For Spoolmatic 30A
WC-115 Contactor Kit
#137 548
Field
SX-A 50-Degree Curved Barrel
#147 175
#147 176
6 in (152 mm)
10 in (254 mm)
SX-A 50-Degree Curved Nozzle Kit
#147 174
SX Flex Head Kit
#131 104
3 in Head Tube Extension
#137 787
Cable Cover
#118 678
SX Heat Shield
#131 103
Spare Spool Canister
#132 230
Hose and Cable Extension Kits
#132 228
#132 229
Spoolmatic 30A Consumables and Accessories
Consumables
See page 4
Date:
Total Quoted Price:
Distributed by:
Litho in USA
25 ft (7.6 m)
50 ft (15 m)
Price
ST 44 Ultra-Lite
Industrijske primjene
održavanje, reparatura
proizvodnja, brodogradnja
Postupci
MIG/MAG
punjena žica
Dodavač žice
konstantne brzine
Ulaz
Promjer žice
Brzina žice
Težina
24VAC, 3A, 50/60Hz
0,6 – 2,0 mm
0 – 20m/min
15kg
Standardni 14-pinski priključak
Omogućava spajanje sa bilo kojim
CV (konstantni napon) izvorom
Težina od samo 15 kg i
potpuno zatvoreni 4-rolni
sklop dodavanja žice
Digitalni pokazivači pokazuju jasno
i precizno očitavanje napona luka i
brzine žice
2T/4T prekidač omogućava
dvotaktni i četverotaktni rad
Daljinska regulacija napona omogućava
preciznu daljinsku regulaciju napona luka
izvora struje zavarivanja**
Brze spojnice za vodeno
hlađenje*-brzo spajanje
vodom hlađenog polikabela
Hladna dobava žice-omogućava pogon
žice bez da je ista „energizirana“
Precizna kontrola protoka
plina sa ugrađenim
protokometrom osigurava
točan protok plina
Industrijski 4-rolni pogonski kotačići
Snažan motor sa pogonskim sklopom
sa brzinom žice od 0-20m/min i za najzahtjevnije
aplikacije; euro ili US priključak
Podesivo početak zavara
i dužina slobodnog kraja
žice za optimalni početak i
završetak luka
Brzo izmjenjivi dualni pogonski kotačići
*opcija
**Potreban je izvor struje koji ima daljinsku regulaciju napona
A.M.I.-COMMERCE LOVREKOVIĆ d.o.o.
Maksimirska 100
tel:
01-2300-333
10000 ZAGREB
fax: 01-2300-222
web adresa
www.ami-lovrekovic.hr
www.tehnologija-zavarivanja.com
karakteristike
Ulaz
24 VAC, 3A,
50/60 Hz
koristiti sa CV izvorima
Promjer žice
Brzina žice
0,6-2,0 mm
0 – 20 m/min
Dimenzije
v=420mm
š=220mm
d=650mm
Težina
15kg
Zastupstvo i prodaja:
A.M.I.-COMMERCE LOVREKOVIĆ d.o.o.
Maksimirska 100
tel:
01-2300-333
10000 ZAGREB
fax: 01-2300-222
web adresa
www.ami-lovrekovic.hr
www.tehnologija-zavarivanja.com
SuitCase 8RC and 12RC
Issued March 2003 • Index No. M/6.5
™
Quick
Specs
Wire Feeder with
Remote Control
Industrial Applications
Processes
Input Power
Shipbuilding
Construction
Heavy Manufacturing
Rental
MIG (GMAW)
Flux Cored (FCAW)
Weight
24 VAC, 7 A/10 A
8RC: 22.0 lb (9.9 kg)
12RC: 25.5 lb (11.6 kg)
Drive roll accessibility
makes it easy to install
wire, adjust tension and
change drive rolls.
The Power of Blue .
®
Remote voltage control — standard.
Versatile feeders can
run wire diameters up to
5/64 in (2.0 mm).
Standard gas solenoid
controlling gas flow.
Totally enclosed, impactresistant, flame-retardant
case provides strength
and durability, protecting
components and weld wire
from moisture, dust and
contaminants.
Gas purge purges gas
line without feeding wire,
or energizing weld wire
with OCV.
Thermal overload
protection protects motor
and control circuit against
possible damage due to
overloading conditions,
or loose cable connections.
Component
assembly is
easily removed
for servicing.
Digital meter option
available for wirefeed
speed or voltage display.
Quick-change drive rolls are easy
to change — no tools required.
Specifications
Model
Input
Power
8RC
24 VAC,
7 A,
50/60 Hz
12RC
24 VAC,
10 A,
50/60 Hz
(Use with CC/CV,
DC Power Sources.)
(Subject to change without notice.)
Welding
Power
Source Type
Constant
Voltage (CV)
Input Welding
Circuit Rating
500 A
at 100%
Duty Cycle
Electrode Wire Diameter Capacity
Maximum
Spool Size
Capacity
Solid Wire: .023– 5/64 in (0.6–2.0 mm)
Flux Cored: .030– 5/64 in (0.8–2.0 mm)
8 in (203 mm)
14 lb (6.4 kg)
Solid Wire: .023– 5/64 in (0.6–2.0 mm)
Flux Cored: .030– 5/64 in (0.8–2.0 mm)
12 in
(305 mm)
Up to 44 lb
(20 kg)
Net
Weight
Wire Speed
Dimensions
75–700 IPM
(1.9–17.7
m/min)
H: 14-1/2 in (368 mm)
W: 6-1/2 in (165 mm)
D: 15-5/8 in (397 mm)
22 lb
(9.9 kg)
H: 16 in (406 mm)
W: 7-1/4 in (184 mm)
D: 20 in (508 mm)
25.5 lb
(11.6 kg)
Wire feeder is warranted for 3 years, parts and labor.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
Drive Roll Kits
(1 kit required, order from Miller Service Parts.)
Select drive roll kits from chart below according to type and wire size being used. Drive roll kits include 2 drive rolls, the necessary guides and feature an
anti-wear sleeve for inlet guide.
Wire size
“V” groove
for hard wire
“U” groove for
soft wire or
soft-shelled
cored wires
.023/.025 in (0.6 mm)
#087 131
—
—
—
.030 in (0.8 mm)
#079 594
—
—
—
.035 in (0.9 mm)
#079 595
#044 749
#079 606
—
.040 in (1.0 mm)
#161 189
—
—
—
.045 in (1.1/1.2 mm)
#079 596
#079 599
#079 607
#083 318
.052 in (1.3/1.4 mm)
#079 597
#079 600
#079 608
#083 317
1/16 in (1.6 mm)
#079 598
#079 601
#079 609
#079 614
.068/.072 in (1.8 mm)
—
—
#089 984
—
5/64 in (2.0 mm)
—
#079 602
#079 610
#079 615
Control Panels
ON
2
3
4
OFF
1
ON
3
RC
2
4
1.
2.
3.
4.
Purge Switch
Voltage Control
Power Control Switch
Wire Speed Control
Power Source and Options
Stock No.
Description
SuitCase™ 8RC
(Remote Extension Cord
required.)
Meter Kit
#194 938
#194 938-01-1
#194 938-03-1
#195 165
With remote voltage
With meters, remote voltage, and trigger hold
With CE, meters, remote voltage, and trigger hold
Field. For SuitCase 8RC
SuitCase™ 12RC
(Remote Extension Cord
required.)
Meter Kit
#194 940
#194 940-01-1
#194 940-03-1
#195 169
With remote voltage
With meters, remote voltage, and trigger hold
With CE, meters, remote voltage, and trigger hold
Field. For SuitCase 12RC
Volt/Current Sensor Kit
#122 973
#122 974
#122 975
#195 194
Flowmeter Kit
Shielding Gas Filter
#195 217
#195 189
25 ft (7.6 m)
50 ft (15.2 m)
75 ft (22.9 m)
Field. For both SuitCase 8RC and 12RC. Required for
digital meter operation with power sources not having
pins F and H in the 14-pin receptacle. (PipePro 304
is the only Miller engine drive with pins F and H.)
Field. For both SuitCase 8RC and 12RC
Field. For both SuitCase 8RC and 12RC
Accessories
Remote Extension Cords
(One required.)
Qty.
Guns
Ironmate™ 1260
Roughneck® C-Series
Flux cored (FCAW) gun. See Lit. Index No. AY/16.0
MIG (GMAW) gun. See Lit. Index No. AY/17.0
Power Sources
XMT® 304
Dimension™
Invision™ MP
Mark VI™
Big Blue® 600D
Big Blue® 402
Big Blue® Air Pak™
PipePro™
Trailblazer®
See Lit. Index No. DC/18.8
See Lit. Index No. DC/19.2
See Lit. Index No. DC/23
See Lit. Index No. DC/9.8
See Lit. Index No. DC/10.3
See Lit. Index No. DC/10.8
See Lit. Index No. DC/10.5
See Lit. Index No. ED/10.6
See Lit. Index No. DC/4.5
Consumables
Drive Rolls/Wire
Date:
Distributed by:
Litho in USA
“U” cogged for
extremely soft wire or
soft- shelled cored wires
(i.e., hard facing types)
Ordering Information
OFF
1
“V” knurled
for hard-shelled
cored wires
Total Quoted Price:
Price
SuitCase 8VS and 12VS
Issued Sept. 2002 • Index No. M/6.4
™
Quick
Specs
Voltage-Sensing
Wire Feeder
Industrial Applications
Processes
Input Power
15 – 100 VDC
Shipbuilding
Construction
Heavy Manufacturing
Rental
MIG (GMAW)
Flux Cored (FCAW)
Weight 8VS
12VS
23.5 lb (10.7 kg)
28.5 lb (12.9 kg)
The Power of Blue .
®
Ergonomically sound, lightweight
unit is well balanced, for ease of
carrying to remote welding sites.
Carrying handle folds down out
of way, yet is large enough for a
gloved hand.
Quick-change drive rolls are easy
to change — no tools required.
Drive roll accessibility makes it
easy to install wire, adjust tension
and change drive rolls.
Quick-connect sense lead
disconnects if pulled excessively —
prevents damage to internal
components.
Versatile feeder can run wire
diameters up to .062 in for the 8VS
and up to 5/64 in for the 12VS.
Standard contactor and gas
solenoid control OCV and gas flow.
Simple control panel eliminates
operator confusion.
Totally enclosed, impact-resistant,
flame-retardant case provides
strength and durability, protecting
components and weld wire from
moisture, dust and contaminants.
Gas purge purges gas line without
feeding wire, or energizing weld
wire with OCV.
Operates on open-circuit or arc
voltages, eliminating the need for
a power supply cord between the
power source and feeder.
Overload protection protects motor
and control circuit against possible
damage due to overloading conditions.
Universal feeder operates with
most Miller and competitive
CV/CC DC power sources.
Component assembly is easily
removed for servicing.
Specifications
(Use with CC/CV,
DC Power Sources.)
(Subject to change without notice.)
Welding Power Input Welding
Model Input Power Source Type
Circuit Rating Electrode Wire Diameter Capacity
Maximum Spool
Size Capacity
Wire Speed
8VS
Solid Wire: .023–.062 in (0.6–1.6 mm)
Flux Cored: .030–.062 in (0.8–1.3 mm)
8 in (203 mm)
14 lb (6.4 kg)
Solid Wire: .023– 5/64 in (0.6–2.0 mm)
Flux Cored: .030– 5/64 in (0.8–2.0 mm)
12 in (305 mm)
Up to 44 lb (20 kg)
12VS
Open-Circuit Constant
Arc Voltage Voltage (CV)
15 –100 VDC or Constant
Current (CC) DC
330 A at
60% Duty
Cycle w/
Secondary
Contactor
Dimensions
Net
Weight
50–700 IPM
H: 14-1/2 in (368 mm) 23.5 lb
(1.3–18 m/min) W: 6-1/2 in (165 mm) (10.7 kg)
dependent on
D: 15-5/8 in (397 mm)
arc voltage
H: 16 in (406 mm)
28.5 lb
W: 7-1/4 in (184 mm) (12.9 kg)
D: 20 in (508 mm)
Wire feeder is warranted for 3 years, parts and labor.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
Control Panels
Drive Roll Kits
(Order from Miller Service Parts.)
Select drive roll kits from chart below according to type and wire size being used. Drive roll kits
include 2 drive rolls, the necessary guides and feature an anti-wear sleeve for inlet guide.
1
2
3
1
2
Wire size
“V” groove
for hard wire
“U” groove for
soft wire or
soft-shelled
cored wires
“V” knurled
for hard-shelled
cored wires
“U” cogged for
extremely soft wire
or soft- shelled cored
wires (i.e., hard
facing types)
.023 / .025 in (0.6 mm)
#087 131
—
—
—
.030 in (0.8 mm)
#079 594
—
—
—
.035 in (0.9 mm)
#079 595
#044 749
#079 606
—
.040 in (1.0 mm)
#161 189
—
—
—
.045 in (1.1/1.2 mm)
#079 596
#079 599
#079 607
#083 318
.052 in (1.3/1.4 mm)
#079 597
#079 600
#079 608
#083 317
1/16 in (1.6 mm)
#079 598
#079 601
#079 609
#079 614
.068/.072 in (1.8 mm)
—
—
#089 984
—
5/64 in (2.0 mm)
—
#079 602
#079 610
#079 615
Ordering Information
Power Source and Options
Stock No.
SuitCase 8VS™
#194 890
#194 890-01-1
#194 890-01-2
#194 890-01-3
#194 890-02-1
#195 029
#194 941
#194 941-01-1
#194 941-01-2
#194 941-02-2
#195 167
3
Conversion Kit
SuitCase 12VS™
Conversion Kit
1. Purge Switch
2. Power Control Switch
3. Wire Speed Control
Description
Qty.
With trigger hold
With CE and trigger hold
With meters (factory)
With meters and trigger hold
Meters (field)
With trigger hold
With meters (factory)
With meters and trigger hold
Meters (field)
Guns
Ironmate™ 1260 (FCAW)
Roughneck® C-Series (GMAW)
See Lit. Index No. AY/16.0
See Lit. Index No. AY/17.0
Power Sources
XMT® 304
Dimension™
Gold Star®
Mark VI™
Big Blue® 251D
Big Blue® 600D
Big Blue® 402
Big Blue® Air Pak™
Bobcat™
Trailblazer®
See Lit. Index No. DC/18.8
See Lit. Index No. DC/19.2
See Lit. Index No. DC/8.1
See Lit. Index No. DC/9.8
See Lit. Index No. ED/5.2
See Lit. Index No. DC/10.3
See Lit. Index No. DC/10.8
See Lit. Index No. DC/10.5
See Lit. Index No. DC/4.31
See Lit. Index No. DC/4.5
Consumables
Drive Rolls
Wire
Date:
Distributed by:
Litho in USA
Total Quoted Price:
Price
SuitCase X-TREME 12VS
Brza
spec.
Izdanje travanj 2005 • Index No. M/6.41
™
™
Industrijske primjene
Ulaz:
Postupci
Brodogradnja
Konstrukcije
Teška proizvodnja
Rental
MIG (GMAW)
Punjene žice (FCAW)
Naponsko-osjetljivi
dodavač žice
14 – 48 VDC radni napon
110 VDC Maximum napon praznog hoda
Brzina žice
Težina:
5 0 – 780 IPM (1. 3 – 19.8 m/min)
35 lb (15.9 kg)
The Power of Blue.
®
NOVO! Polipropilen kučište sa
ugrađenim kliznim šinama i mogućnošću
otvaranja vrata za izmjenu žice sa dodavačem
u vertikalnom položaju.
Poboljšani kontaktor i opća
intermitencija za visoko strujne
aplikacije (425 A uz 60%).
Taktovi prekidača, hladna dobava
žice i protok plina su standardni i
smješteni na prednjem panelu.
™
Digitalni pokazivači sa SunVision
tehnologijom za prikaz napona i
brzine žice, te također prikaz jačine struje
ukoliko se želi. Display ima jasan prikaz
i na direktnoj sunčevoj svjetlosti.
Širi opseg napona za male i velike
žice bez promjene kontaktora
ili promjena luka.
Izmjenjiva i klizna glavna elektronička
upravljačka za najzahtjevnija okruženja
daje izuzetnu pouzdanost. Ploča ima
punu izolaciju prekidača tako da kratki spoj
prekidača neće ometati rad dodavača.
NOVO! Duplo-filtrirani plinski ventil
pomaže da nečistoće ne utječu
na protok plina.
Odličan start i poboljšane superiorne
osobine luka za sve vrste i veličine
žica bez obzira koristi li se
CV ili CC izvor struje. Najbolji završni
CC luk u industriji.
Specifikacija
Ulazni napon
Radni napon:
14– 48 VDC
Max NPH: 110 VDC
(Sa CC/CV,
DC izvorima struje.)
Izvor struje
zavarivanja
Opterećenje
CC ili CV DC
izvori struje.
AC tip se ne
preporučuje.
425 A uz
60% intermit.
Promjer žice
Veličina koluta
Brzina žice
Puna žica: .023 – 5/64 in
(0.6–2.0 mm)
Punjena žica:
(0.8–2.0 mm)
12 in (305 mm)
50–780 IPM
Sve do 45 lb (20.4 kg) (1.3 –19.8 m/min)
zavisno od
napona luka
Dimenzije
H: 21 in (533 mm)
W: 9 in (229 mm)
D: 15-1/2 in (394 mm)
Dodavač žice ima garanciju od 3 (tri) godine.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX:920-735-4125
www.MillerWelds.com
A.M.I.-Commerce, d.o.o.
Maksimirska 100
10000 Zagreb
tel:01/2300-333; fax:01/2300-222
Net
težina
35 lb
(15.9 kg)
Upravljački panel
Pogonski kotači - kompleti
5
Odrediti pogonske kotačiće prema donjoj tablici. Kompleti pogonskih kotačića
uključuju 2 pogonska kotačića , potrebne vodilice .
OFF
1
6
2
3
4
“U” nazubljene za
extremno meke žice
“V” žlijeb
ili meke punjene
za tvrdo obložene žice (i.e., žice za
punjene žice
tvrdo navarivanje)
Veličina žice
“V” žlijeb
za tvrdu žicu
“U” žlijeb za
meku žicu ili
mekše punjene
žice
.023 /.025 in (0.6 mm)
#087 131
—
—
—
.030 in (0.8 mm)
#079 594
—
—
—
.035 in (0.9 mm)
#079 595
#044 749
#079 606
—
.040 in (1.0 mm)
#161 189
—
—
—
.045 in (1.1/1.2 mm)
#079 596
#079 599
#079 607
#083 318
.052 in (1.3/1.4 mm)
#079 597
#079 600
#079 608
#083 317
1/16 in (1.6 mm)
#079 598
#079 601
#079 609
#079 614
.068/.072 in (1.8 mm)
—
—
#089 984
—
5/64 in (2.0 mm)
—
#079 602
#079 610
#079 615
Front Panel
1.
2.
3.
4.
5.
6.
Prekidač hladne dobave/protok plina
Voltmetar
Brzina žice/Pokazivač struje
Kontrola brzine žice
Prekidač za taktove prekidača
Glavni prekidač
Informacije za narudžbu
Izvor struje i opcije
art.br.
Opis
SuitCase ™ X-TREME ™ 12VS
Flowmeter Kit
Inline Filter
Lincoln® Spool Adapter
#195 500
#195 217
#195 189
#047 141
For 14 lb spools
Kol.
Gorionici
Ironmate™ 1260 (FCAW)
Roughneck® C-Series (GMAW)
See Lit. Index No. AY/16.0
See Lit. Index No. AY/17.0
Izvori struje
XMT® Series
Dimension™
Gold Star®
Mark VI™
Big Blue® Turbo
Big Blue® 400 & 500
Big Blue® Air Pak™
Bobcat™
Trailblazer®
See Lit. Index No. DC/18.8
See Lit. Index No. DC/19.2
See Lit. Index No. DC/8.1
See Lit. Index No. DC/9.8
See Lit. Index No. ED/10.3
See Lit. Index No. ED/10.8
See Lit. Index No. ED/10.5
See Lit. Index No. ED/4.4
See Lit. Index No. ED/4.77
Potrošni dijelovi
Drive Rolls
Wire
Datum:
Litho in USA
Zastupstvo i prodaja: A.M.I.-COMMERCE LOVREKOVIĆ, d.o.o.
Maksimirska 100
10000 Zagreb
tel: 01/2300-333
fax: 01/2300-222
e-mail: [email protected]
www.ami-lovrekovic.hr
www.tehnologija-zavarivanja.com
Ukupna cijena:
Cijena
70 Series Swingarc
Quick
Specs
Heavy Industrial Applications
Processes
Heavy Manufacturing
Metal Fabrication
Construction
Light Manufacturing
MIG (GMAW)
Flux Cored (FCAW)
(Gas- and Self-Shielded)
Submerged Arc (SAW)
Issued Dec. 2001 • Index No. M/13.1
™
Boom-Mounted
Wire Feeder
Input Power 24 VAC, 10 A, 50/60 Hz
Electrode Wire Diameter Capacity .023 –1/8 in (0.6– 3.2 mm)
Wire Speed 50 –780 IPM (1.3 –19.8 m/min)
Weight 160–280 lb (73–127 kg) depending upon feeder and boom
The Power of Blue .
®
Available in single- and dual-wire models with 12 or 16 ft booms
to accommodate a wide variety of semiautomatic wire feed
applications, including large weldments and hard to reach areas.
In-boom cable routing organizes
hoses and cables, preventing
damage and maintaining an
orderly work cell.
360˚ rotation and 60˚ lift angle maximizes your work area
(24 or 32 ft diameter work area).
Unique counterbalanced boom
makes it easy to raise and lower boom
and automatically holds its position.
Additional 10 ft, 14-pin
interconnecting cord,
10 ft gas hose and
10 ft weld cable
provided for the
operator to hook up.
Control features
on page 2.
One of the following is
required for mounting the
boom:
Swingpak 12 base and
pipe post with base plate
(for 12 ft Swingarcs only)
4 or 6 ft (1.2 or 1.8 m)
pipe post with base plate
(for 12 or 16 ft Swingarcs).
Pipe post base plates
allow post to be bolted to
Swingpak base or floor.
See page 4 for details.
Single-wire Swingarc shown with pipe post, power source,
welding gun, and optional Swingpak ™ 12 base.
Wire feeder and boom are warranted
for 3 years, parts and labor.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
70 Series Control Features
The next generation of industrial-class wire
feeders. All the features of the 60 Series
controls, plus enhanced flexibility and
additional features.
Models: 74S: Standard, basic design
74D: Digital meters
74DX: Deluxe — digital, full-feature
Dual tension control adds flexibility for the
operator to fine-tune the pressure on the wire
independently when feeding a variety of wires.
Trigger receptacle oriented in a downward
position to reduce potential damage.
Trigger hold reduces operator fatigue by allowing
the operator to make long welds without having
to energize the trigger continuously.
Automatic run-in control significantly improves
arc starting performance.
10 ft, 14-pin interconnecting cord, 10 ft gas
hose and 10 ft weld cable provided for the
operator to hook up.
Specifications
Input Power
SS-74
24 VAC, 10 A, 50/60 Hz
2
DX Models Additional Features
Dual schedule allows operator to switch
between two welding parameters without
readjusting machine, eliminating downtime
and enhancing quality.
Adjustable weld sequence control gives
operator complete control of the welding
parameters: preflow, run-in, weld time,
crater, burnback and postflow.
Welding process range control locks
parameters at a set percentage of welding
parameters to ensure welding procedures
and quality standards are maintained on the
shop floor.
Four weld programs allow the operators to
store four independent welding parameters
reducing welding setup time. (Four
programs available per side on dual model.)
(Use with CV
Power Sources.)
(Subject to change without notice.)
Model
DS-74
Posifeed™ Wire Drive Assembly Features
24 VDC high-torque, permanent-magnet motor.
Quick-change drive rolls.
Quick-release, calibrated drive-roll pressure
adjustment arm allows drive roll change
without losing spring preload setting.
Four sealed ball bearing all-gear-driven
drive-roll carriers for smooth, positive and
accurate wire feed with long uninterrupted
service life.
Easy loading and threading of welding wire
without having to release the drive-roll
pressure arm.
Solid-state speed control and brake circuit
eliminates the need for electrical/ mechanical
relays and increases service life.
Uses Miller standard 1-5/8 in (41 mm)
diameter drive rolls.
Quick-connect for all Miller guns.
Covered drive rolls — easy access, heavy-duty,
molded composite cover over drive assembly.
Floating positive drive systems provide
trouble-free feeding on a variety of wires.
Electrode Wire
Diameter Capacity
Wire Speed
.023 –1/8 in (0.6 – 3.2 mm)
(1/8 in wires may require
low-speed motor)
50–780 IPM (1.3–19.8 m/min)
Optional High Speed Motor:
90–1440 IPM (2.3–36.6 m/min)
12 ft Boom
Net Weight
16 ft Boom
Net Weight
160 lb (73 kg)
210 lb (95 kg)
207 lb (94 kg)
280 lb (127 kg)
Control Panels
1
4
5
2
6
7
8
3
9
70 Series
®
S-74DX Model
1. Program Display
2. Program # Select
3. Weld Sequence
4. Voltage/Time Select
5. Voltage/Time Display Meter
6. Wire Feed/Amperage Select
7. Wire Speed/Amperage Display Meter
8. Control Knob
9. Trigger Hold/Dual Schedule Control
10. Jog/Purge
10
24V Wire Feeder
1
2
S-74S and S-74D Model
3
5
1. Voltage Display Meter*
2. Wire Speed Display Meter*
3. Wire Feed Speed Select
4. Trigger Hold
5. Voltage Select
6. Jog/Purge
*S-74D model only
4
6
70 Series
24V Wire Feeder
3
Drive Roll Kits and Guides
(Order from Miller Service Parts.)
Select drive roll kits from chart below according to type and wire size being used. Drive roll kits include 4 drive rolls, the necessary guides and feature an
anti-wear sleeve for inlet guide.
“U” groove for
soft wire or
soft-shelled
cored wires
“V” groove
for hard wire
Wire Size
.023/.025 in (0.6 mm)
.030 in (0.8 mm)
.035 in (0.9 mm)
.040 in (1.0 mm)
.045 in (1.1/1.2 mm)
.052 in (1.3/1.4 mm)
1/16 in (1.6 mm)
.068/.072 in (1.8 mm)
5/64 in (2.0 mm)
3/32 in (2.4 mm)
7/64 in (2.8 mm)
1/8 in (3.2 mm)
#151 024
#151 025
#151 026
#161 190
#151 027
#151 028
#151 029
—
—
—
—
—
*Accommodates .045 and .047 (3/64 in) wire.
“U” cogged
for extremely soft
wire or soft-shelled
cored wires (i.e.,
hard facing types)
“V” knurled for
hard-shelled
cored wires
—
—
#151 036
—
#151 037*
#151 038
#151 039
—
#151 040
#151 041
#151 042
#151 043**
—
—
#151 052
—
#151 053
#151 054
#151 055
#151 056
#151 057
#151 058
#151 059
#151 060**
—
—
—
—
#151 070
#151 071
#151 072
—
#151 073
#151 074
#151 075
#151 076**
** May require a low-speed, wire-feed drive-roll option.
Nylon Wire Guides for Feeding Aluminum Wire
Wire Guides
Wire Size
Inlet Guide
Intermediate Guide
Wire Size
Inlet Guide
Intermediate Guide
.047 in (1.2 mm)
#151 203
#151 204
.023 – .040 in (0.6 –1.0 mm)
#150 993
#149 518
1/16 in (1.6 mm)
#151 205
#151 206
.045 – .052 in (1.1 –1.4 mm)
#150 994
#149 519
3/32 in (2.4 mm)
#151 207
#151 208
1/16 – 5/64 in (1.6 – 2 mm)
#150 995
#149 520
3/32 – 7/64 in (2.4 – 2.8 mm)
#150 996
#149 521
1/8 in (3.2 mm)
#150 997
#149 522
Note: “U” groove drive rolls are recommended when feeding aluminum wire.
Mounting Equipment for Swingarc Booms
™
Specifications and Usage
(Subject to change without notice.)
Usage
Model
Stock No.
Dimensions
Net Weight
For 12 ft
Swingarc only
Swingpak 12 Base
#183 997
L: 65 in (1.7 m)
W: 50-7/8 in (1.3 m)
285 lb (129 kg)
4 ft Pipe Post w/o Base
#075 078
H: 4 ft (1.2 m)
56 lb (25.4 kg)
6 ft Pipe Post w/o Base
#079 217
H: 6 ft (1.8 m)
82 lb (37.2 kg)
4 ft Pipe Post with Base
#149 838
H: 4 ft (1.2 m)
110 lb (49.9 kg)
6 ft Pipe Post with Base
#149 839
H: 6 ft (1.8 m)
130 lb (59 kg)
For 12 or 16 ft
Swingarc
garc
Swin
The Swingpak 12 Base
™
For use with 12 ft (3.7 m) Swingarc only.
Each base accommodates a power source,
12 ft Swingarc feeder system, water
coolant system, and gas cylinder. The base
plate is solid to help better organize
components and cables. The entire unit can
be moved with a forklift truck.
Pipe Post,
required
MIG Gun,
required
Power Source,
required
Optional Swingpak 12 Base
4
Genuine Miller Options and Accessories
Remote Voltage Control
#194 988 Field Non-digital for S-74S
#194 991 Field Non-digital for D-74S
2/0 MIG Welding Accessory Kit #173 856
25 ft (7.6 m). Includes gas hose, weld
cable and ground cable with clamp.
Conversion Kit
#194 989 Field
#194 992 Field
#195 010 Field
#195 041 Field
Extension Cords
#122 973 25 ft (7.6 m)
#122 974 50 ft (15 m)
#122 975 75 ft (23 m)
Provides 14-pin, 24 VAC, contactor and
voltage control. Add to the standard 10 ft
(3 m) feeder cord to extend feeder farther
from power source.
S-74S to S-74D
D-74S to D-74D
S-74S to S-74DX
D-74S to D-74DX
Control Detachment Kit
#194 914 Field 10 ft (3 m) for S-74S
#194 913 Field 25 ft (7.6 m) for S-74S
#194 995 Field 25 ft (7.6 m) for D-74S
Allows separation of the control module
from the wire drive assembly and base.
Wire Straightener
#141 580 For .035 –.045 in (0.9 –1.1 mm)
diameter wire.
#141 581 For 1/16 –1/8 in (1.6 – 3.2 mm)
diameter wire.
Helps reduce the cast in wire to improve
wire feeding performance and increase the
service life of the gun liner and contact tip.
Spool Covers
#057 607 For S-74 and left side of
D-74 models
#090 389 For right side of D-74 models
For 12 in (305 mm) spool.
Dual Schedule Switches
DSS-8 #079 693
A two-position trigger switch which
attaches to the gun handle and is used in
place of the standard trigger for dual
scheduling. (For 74DX models only.)
Wire Reel Assembly #108 008
For 60 lb (27 kg) coil of wire.
Reel Covers
#058 256 For S-74 and left side of
D-74 models
#091 668 For right side of D-74 models
For 60 lb (27 kg) coil. Helps to protect
the welding wire from dust and other
contaminants.
Note: Reel and Spool Covers cannot be installed if
the wire drive assembly is in a rotated position.
DSS-9 #071 833
A two-position slide switch which attaches
to the gun handle and is used to select the
desired welding condition for dual schedule
purposes. The gun trigger operates as a standard gun trigger. (For 74DX models only.)
Spool Adapter #047 141
For use with 14 lb (6.4 kg) spool of Lincoln
self-shielding wire.
5
Typical Installations
Models: 74S: Standard, basic design
74D: Digital meters
74DX: Deluxe — digital, full-feature
10 ft (3 m) Gas Hose (supplied with feeder)
Miller CV power source
equipped with a 14-pin
receptacle, 24 VAC
supply, and voltage and
current feedback
74S, 74D or 74DX Models
10 ft (3 m) 24 VAC, Contactor, and
Voltage Control Cord (supplied with feeder)
Note: D and DX models
are not compatible with
CP Series power sources.
10 ft (3 m) Weld Power Cable (supplied with feeder)
10 ft (3 m) Gas Hose (supplied with feeder)
Miller electrically
controlled CV and CC/CV
power source with a
14-pin receptacle, 24 VAC
supply, and voltage and
current feedback
74S, 74D* or 74DX Models
10 ft (3 m) 24 VAC, Contactor, and
Voltage Control Cord (supplied with feeder)
10 ft (3 m) Weld Power Cable (supplied with feeder)
10 ft (3 m) interconnecting cord included with
PSA-2 control. Includes a 4-pin connector for
connecting to PSA-2 control and Hubbell
connectors on older-style Miller CV power sources.
Optional PSA-2 Control**
10 ft (3 m) Gas Hose (supplied with feeder)
1 ft (305 mm)
4-pin Connector
Miller CV power source
with only 115 VAC power
requiring contact closure
for contactor control
74S, 74D* or 74DX Models
Note: 74D and 74DX models
require Adapter Kit #195 043
to be compatible with
older-style power sources.
10 ft (3 m) Weld Power Cable (supplied with feeder)
*When using the D model with Miller power sources that DO NOT have remote voltage
control capabilities, i.e., CP type, the voltage control in the feeder IS NOT functional.
See Operator’s Manual for operating instructions.
6
**If using the 70 Series feeders with a power source having only 115 VAC supply, the
PSA-2 (Power Source Adapter) is required. When using the PSA control, optional
remote voltage is not functional. See Operator’s Manual for operating instructions.
Notes
7
Ordering Information
Equipment and Options
Stock No.
Description
Single-Wire Models
SS-74S12
SS-74S16
SS-74D12
SS-74D16
SS-74DX12
SS-74DX16
#195 063
#195 064
#195 065
#195 066
#195 067
#195 068
12 ft. With S-74S model wire feeder
16 ft. With S-74S model wire feeder
12 ft. With S-74D model wire feeder
16 ft. With S-74D model wire feeder
12 ft. With S-74DX model wire feeder
16 ft. With S-74DX model wire feeder
Dual-Wire Models (available January 2002)
DS-74S12
DS-74S16
DS-74D12
DS-74D16
DS-74DX12
DS-74DX16
#195 069
#195 070
#195 071
#195 072
#195 073
#195 074
12 ft. With D-74S model wire feeder
16 ft. With D-74S model wire feeder
12 ft. With D-74D model wire feeder
16 ft. With D-74D model wire feeder
12 ft. With D-74DX model wire feeder
16 ft. With D-74DX model wire feeder
Remote Voltage Control
#194 988
#194 991
Field. Non-digital control (S-74S model only)
Field. Non-digital control (D-74S model only)
Conversion Kit
#194 989
#194 992
#195 010
#195 041
Field. S-74S to S-74D
Field. D-74S to D-74D
Field. S-74S to S-74DX
Field. D-74S to D-74DX
Control Detachment Kit
#194 914
#194 913
#194 995
Field. 10 ft (3 m) (S-74S model only)
Field. 25 ft (7.6 m) (S-74S model only)
Field. 25 ft (7.6 m) (D-74S model only)
Qty.
Control Options
Power Sources
Invision™ 354 MP and 456MP
See Lit. Index No. DC/23
Invision™ 456P
See Lit. Index No. DC/20
Deltaweld ® Series
See Lit. Index No. DC/16.2
XMT ® Series
See Lit. Index No. DC/18.8
Dimension™ Series
See Lit. Index No. DC/19.2
Mounting Equipment
Swingpak™ 12 Base
#183 997
For 12 ft boom only
Pipe Posts
#075 078
#079 217
#149 838
#149 839
4 ft without base, for 12 ft boom only
6 ft without base, for 12 ft boom only
4 ft with base, for 12 ft or 16 ft boom
6 ft with base, for 12 ft or 16 ft boom
Adapter Kit
#195 043
Makes 70 Series feeder compatible with older-style power sources
Wire Straightener
#141 580
#141 581
For .035 – .045 in (0.9 – 1.1 mm) diameter wire
For 1/16 – 1/8 in (1.6 – 3.2 mm) diameter wire
Spool Covers
#057 607
#090 389
For S-74 and left side of D-74 models
For right side of D-74 models
Wire Reel Assembly
#108 008
Reel Covers
#058 256
#091 668
Spool Adapter
#047 141
2/0 MIG Welding Accessory Kit
#173 856
Accessories
Extension Cords
Dual Schedule Switches
See page 5
#079 693
#071 833
Date:
DSS-8 (74DX models only)
DSS-9 (74DX models only)
Total Quoted Price:
Distributed by:
Litho in USA
For S-74 and left side of D-74 models
For right side of D-74 models
Price
™
Index No. M/1.7
Issued June 2000
XR Control
Push-Pull Wire Feed System
Process
MIG (GMAW)
Welding
Note: Drive
roll kit must
be ordered
separately.
1-year warranty on gun
The XR-A and XR-W Pistol guns have been
redesigned with a quick-connect, similar to the
XR-Edge guns, for easy connection to the XR Control.
The XR-Pistol guns are available in 15 and 30 ft
lengths, and the XR-Edge gooseneck-style guns are
available in 15, 30 and 50 ft lengths. All guns are
available in both air- and water-cooled models.
The wire drive kits are to be ordered separately from
the guns because the drive rolls are wire size dependent. All wire drive kits consist of gun drive rolls, two
push feeder drive rolls, head tube liner, five contact
tips, collet nut and a contact tip wrench
A unique solid-state control circuit permits the XR
systems to work with most CC, CV, or CC/CV DC
welding power sources, giving you true adaptability.
Applications
XR-Edge Gun
XR-Pistol Gun
The XR Control push-pull wire feed system now offers
the ability to select either an XR-Edge gooseneckstyle gun or an XR-Pistol gun for a truly customized
system that delivers optimum performance for your
desired application.
Emergency vehicles
Boat building
Shipbuilding
Trucks and trailers
Railcars
Snowmobiles
Watercraft
Recreational vehicles
Tool boxes
Heat exchangers
Overhead doors
Sign manufacturers
Automotive
components
Features
Benefits
Air-cooled and water-cooled models
Whether your application is light gauge metals or demanding, high-amperage heavy plate, we’ve got the model for you.
All gear-driven drive rolls
Both rolls are driving the wire for positive feeding performance, reducing burnbacks and improving arc starts.
Smooth groove drive-roll design
Prevents shaving the wire, which causes build-up in the drive-roll grooves, liner and contact tip. Improved feeding
performance, helping to eliminate burnbacks and enhancing arc starts.
True push-pull design
The push feeder motor provides continuous torque to the wire. The gun motor controls the actual wire feed speed at the arc.
Each motor works in concert to provide accurate and positive wire feed speed.
Arc starting control
The control has wire run-in speed, which can be adjusted to tune arc starting. This prevents wire stubbing or arc flaring
which leads to burnbacks to the contact tip.
Wire jog control
Allows you to thread wire through gun cable without energizing weld output.
Master/gun wire-feed-speed control
Improves resolution, by limiting speed range available at the gun. This makes it easier to fine-tune arc conditions.
Trigger hold
Reduces fatigue by allowing the operator to weld without holding the gun trigger.
XR Control Specifications
Heavy Industrial
(Subject to change without notice.)
(Use with
CC/CV, DC
Power Sources.)
Input Power
Wire Speed
Maximum Spool Size Capacity
Dimensions
Net Weight
24 VAC, 50/60 or 100 Hz
70 – 875 IPM (1.8 – 22.2 m/min)
12 in (305 mm)
H: 16 in (406 mm)
W: 9-1/4 in (235 mm)
D: 21-1/4 in (540 mm)
38 lb (17.2 kg)
®
Certified by Canadian Standards Association to both Canadian and U.S. Standards.
Conforms to European standards.
NRTL/C
Ordering Information
☞ See back page.
Miller Electric Mfg. Co.
International Headquarters
Web Site
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Phone: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
www.MillerWelds.com
XR Control
Control Panels
17
13
2
18
3
1
4
5
14
6
19
7
8
15
9
10
16
11
Side Panel
12
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Gas Flowmeter*
Voltage/Wire Speed Meter*
Voltage/Wire Speed Switch*
Voltage Control*
Wire Speed Control
Schedule A Indicator LED*
Press To Set Push Button*
Schedule B Indicator LED*
Wire Speed B Control*
Remote Volts B Control*
Wire Jog/Gas Purge Switch
Trigger Hold Switch
13.
14.
15.
16.
17.
18.
19.
Run-In Speed Control
Burnback Time Control*
Continuous/Spot Time Control*
Spot Time Range Switch*
Fuse F1
Circuit Breaker CB1
Motor Torque Switch
*Optional
Front Panel
XR Control Drive Roll Kits (Order from Miller Service Parts.)
Wire Size
.030 in (0.8 mm)
#194 118
.035 in (0.9 mm)
#194 118
.040 in (1.0 mm)
#196 301
.047 in (1.2 mm)
#194 119
.062 in (1.6 mm)
#194 119
Drive roll kits consist of
two control drive rolls,
insulating washers and
installation instructions.
Typical Installations Refer to Owner’s Manual for complete installation instructions.
10 ft (3 m) 24 VAC
and contactor cord supplied with feeder
Miller CV or CV/CC power
source equipped with a 14-pin
receptacle and 24 VAC power.
XR
Control
or
10 ft (3 m) gas hose included
15 or 30 ft cable
(50 ft available for XR-Edge Gun)
PSA-2
115 / 24 VAC
10 ft (3 m) 24 VAC
and contactor cord supplied with feeder
Miller CV or competitive
CV power source with
115 VAC power
2
Contactor
115 VAC
XR
Control
or
10 ft (3 m) gas hose included
15 or 30 ft cable
(50 ft available for XR-Edge Gun)
XR-Edge Gun
(Note: Air-cooled gun shown)
4
1.
2.
3.
4.
5.
6.
3
2
1
5
6
7
8
9
10
Head Tube Liner (See chart below)
Liner O-Ring
#164 485
Head Tube O-Ring
#191 191
Head Tube (Air-cooled) #191 180
Lock Nut
#185 111
Insulator
#185 097
11
12
7. Gas Defuser
#185 110
8. Collet Nut
#136 748
9. Contact Tip
(See chart below)
10. Adapter Jam Nut
#185 102
11. Nozzle Adapter
#185 105
12. Nozzle (Standard)
#185 100
Features
Benefits
All gear-driven drive rolls
Both rolls are driving the wire for positive feeding performance, reducing burnbacks and improving arc starts.
Smooth groove drive-roll design
Prevents shaving the wire, which causes build-up in the drive-roll grooves, liner and contact tip. Improved feeding
performance, helping to eliminate burnbacks and enhancing arc starts.
Patent-pending gas delivery
Reduce weld clean-up and repair by improving shielding gas coverage. This is accomplished through reduction of
atmospheric contamination in the gas delivery system.
Gun head tube rotates 360 degrees
Reduces operator fatigue by providing a simple means to position the gun comfortably for various welding positions.
Quick-connect of gun to controller
Reduces time to set-up the welding equipment and reduces maintenance.
Replaceable feed cable liner
Reduces parts cost and service time by providing a simple means of removing and replacing the cable liner and not the
complete feed cable.
Easy access to drive assembly
Reduces service time by providing a simple means of removing and replacing the drive rolls or performing routine
maintenance without disassembly of the gun.
Replaceable head tube
Reduces service time by providing a simple means of replacing the head tube or performing routine maintenance
without disassembly of the gun.
Adjustable gun barrel
Allows operator to easily vary contact tip-to-nozzle position.
Quick-change, collet-type contact tip
Easy to change contact tip when the need arises.
XR-Edge Gun Specifications
(Subject to change without notice.)
Model
Welding Output Range
Electrode Wire Diameter Capacity
Wire Speed
Maximum Spool Size Capacity
Dimensions
Net Weight
XR-A Edge Gun
Air: 200 A at 100% duty cycle
H: 5 in (127 mm)
W: 2-1/2 in (64 mm)
L: 17 in (432mm)
2.5 lb (1.1 kg)
Water: 400 A at 100% duty cycle
70 – 875 IPM
(1.8 – 22.2 m/min)
12 in (305 mm)
XR-W Edge Gun
.030 – .047 in (0.8 – 1.2 mm)
aluminum wire
®
A=Air-Cooled W=Water-Cooled
Certified by Canadian Standards Association to both Canadian and U.S. Standards.
Conforms to European standards.
NRTL/C
XR-Edge Gun Consumables
(Order from Miller Service Parts.)
Contact Tips
Wire Size
Standard Tip I.D.
Optional (Smaller) Tip I.D.
.030 in (0.8 mm) .041 in (1.0 mm) #135 428
.036 in (0.9 mm) #135 427
.035 in (0.9 mm) .052 in (1.3 mm) #135 430
.041 in (1.0 mm) #147 314
.040 in (1.0 mm) .052 in (1.3 mm) #135 430
—
.047 in (1.2 mm) .061 in (1.5 mm) #135 424
.052 in (1.3 mm) #135 429
.062 in (1.6 mm)
Gun Head
Tube Liner
#193 793 Air
#197 729 Water
#193 792 Air
#197 730 Water
Wire Drive Kits (One Required)
Gun Drive Gun Drive Roll
Roll Kits Kits (Insulated) Standard Optional (Insulated)
Feed Cable Liners
Length
Aluminum
#194 114
#198 434
#193 520 #198 385
15 ft (4.6 m)
#191 064
#194 115
#198 435
#193 521 #198 376
30 ft (9 m)
#191 065
#196 302
#198 436
#196 300 #198 375
50 ft (15.2 m) #191 066
#194 116
#198 437
#193 522 #198 374
#194 117
#198 438
#198 373
The optional contact tips listed are for applications where a smaller I.D. tip is preferred. All contact tips are stamped with wire size and the tip I.D. For example: .035/52 designates .035 in wire and .052 in tip I.D.
Drive roll kits consist of drive rolls, idler roll screw and conductive grease. Wire drive kits consist of gun drive rolls, two control drive rolls, two head tube liners (one air liner [7.18 in] and one
water liner [7.8 in]), five contact tips, collet nut, and contact tip wrench.
XR-Edge Gun Standard Nozzles
#185 100
5/8 in (16 mm) orifice
(Standard with
air-cooled gun)
XR-Edge Gun Spot Nozzles
(Order from Miller Service Parts.)
NEW!
#197 728
5/8 in (16 mm) orifice
(Standard with
water-cooled gun)
#193 790
1/2 in
(13 mm) orifice
#050 116
13/16 in (21 mm) orifice
#000 442
Flat 15/16 in
(24 mm) orifice
#004 466
Flat 1-3/8 in
(35 mm) orifice
Note: Nozzle adapter kit
#193 794 required.
Note: Nozzle adapter kit
#193 794 required.
Note: Nozzle adapter kit
#193 794 required.
(Order from Miller Service Parts.)
#009 925
Outside corner
#000 443
Inside corner
Note: Nozzle adapter kit
#193 794 required.
Note: Nozzle adapter kit
#193 794 required.
3
XR-Pistol Gun
(Note: Air-cooled gun shown)
3
1
1.
2.
3.
4.
5.
6.
7.
2
4
5
6
7 8
Head Tube Liner
(See chart below)
O-Ring .614 ID
#134 800
O-Ring .176 ID
#164 485
Head Tube Adapter (Air-cooled) #164 423
Set Screw
#602 172
Jam Nut (Air-cooled)
#058 685
Head Tube (Air-cooled)
#164 422
9
12
13
14
8. Set Screw (Air-cooled)
#604 612
9. Contact Tip Adapter
#136 680
10. Collet Nut
#136 748
11. Contact Tip
(See chart below)
12. Barrel Extension (Air-cooled)
#156 821
13. Nozzle Extension (Air-cooled)
#144 862
14. Nozzle (Standard)
#050 622
Features
Benefits
New!
Reduces time to set-up the welding equipment and reduces maintenance.
Quick-connect of gun to controller
10 11
Replaceable head tube
Reduces service time by providing a simple means of replacing the head tube or performing routine maintenance
without disassembly of the gun.
Adjustable gun barrel
Allows operator to easily vary contact tip-to-nozzle position.
Quick-change, collet-type contact tip
Easy to change contact tip when the need arises.
Replaceable feed cable liner
Reduces parts cost and service time by providing a simple means of removing and replacing the cable liner and not the
complete feed cable.
Easy access to drive assembly
Reduces service time by providing a simple means of removing and replacing the drive rolls or performing routine
maintenance without disassembly of the gun.
XR-Pistol Gun Specifications
(Subject to change without notice.)
Model
Welding Output Range
Electrode Wire Diameter Capacity
Wire Speed
Maximum Spool Size Capacity
Dimensions
Net Weight
XR-A Gun
Air: 200 A at 100% duty cycle
H: 7-3/8 in (187 mm)
W: 1-7/8 in (48 mm)
L: 10-5/8 in (270 mm)
2.4 lb (1.1 kg)
Water: 400 A at 100% duty cycle
70 – 875 IPM
(1.8 – 22.2 m/min)
12 in (305 mm)
XR-W Gun
.030 – 1/16 in (0.8 – 1.6 mm)
aluminum wire
®
A=Air-Cooled W=Water-Cooled
Certified by Canadian Standards Association to both Canadian and U.S. Standards.
2.9 lb (1.3 kg)
Conforms to European standards.
NRTL/C
XR-Pistol Gun Consumables
(Order from Miller Service Parts.)
Contact Tips
Drive Rolls
Dual Groove for
One Wire Size
Feed Cable Liners
Wire Drive Kits
(One Required)
Length
Aluminum
15 ft (4.6 m)
#191 064
Wire Size
Standard Tip I.D.
Optional (Smaller) Tip I.D.
Gun Head
Tube Liner
.030 in (0.8 mm)
.041 in (1.0 mm) #135 428
.036 in (0.9 mm) #135 427
#136 682
#183 357
#198 384
30 ft (9 m)
#191 065
.035 in (0.9 mm)
.052 in (1.3 mm) #135 430
.041 in (1.0 mm) #147 314
#136 682
#183 357
#198 384
50 ft (15.2 m)
#191 066
—
#198 383
—
—
.040 in (0.9 mm)
—
.047 in (1.2 mm)
.061 in (1.5 mm) #135 424
.052 in (1.3 mm) #135 429
#136 683
#183 358
#198 382
.062 in (1.6 mm)
.081 in (2.1 mm) #135 425
.073 in (1.9 mm) #135 426
#136 683
#183 358
#198 381
Other size tips must be ordered separately. The optional contact tips listed are for those applications where a smaller I.D. tip is preferred. All contact tips are stamped with wire size and the tip I.D.
For example: .035/52 designates .035 in wire and .052 in tip I.D. Wire drive kits consist of gun drive rolls, two control drive rolls, head tube liner, five contact tips, collet nut, and contact tip wrench.
XR-Pistol Gun Standard Nozzles
#050 622
5/8 in (16 mm) orifice
(Standard with gun)
XR-Pistol Gun Spot Nozzles
#009 925
Outside corner
4
(Order from Miller Service Parts.)
#050 116
13/16 in
(21 mm) orifice
#050 115
1/2 in
(13 mm) orifice
(Order from Miller Service Parts.)
#000 443
Inside corner
#000 442
Flat 15/16 in
(24 mm) orifice
#004 466
Flat 1-3/8 in
(35 mm) orifice
XR Gun Accessories
Cable Cover
#118 677 15 ft
#118 678 30 ft
Protects gun hose and cable assembly from
wear and abrasion. Features a full length zipper.
50 ft Cable Cover
Not available for 50 ft gun.
Hardwire Liner Kits for Steel and Stainless
#198 380 For 15 ft air-cooled gun
#198 379 For 30 ft air-cooled gun
#198 378 For 15 ft water-cooled gun
#198 377 For 30 ft water-cooled gun
For XR-Pistol and XR-Edge gun. Kits consist of
gun head tube liner and feed cable liner.
Recommend using .030–.045 in mild steel,
flux cored, or stainless steel electrode wire.
SX Heat Shield #131 103
For XR-Pistol. Helps protect operator’s hand
from spatter and reflected heat.
1 lb (0.5 kg) Spool Canister #132 230
Ideal for use with XR guns if a small job arises
requiring a different wire size and/or wire type
that does not justify a 12 in (305 mm) spool of
wire. The XR feed cable is removed if the spool
canister is being used. (Canister accommodates
4 in [102 mm] spools of wire.)
XR-Pistol Gun Barrels (Air-Cooled)
SX-A 50 Degree Curved Barrels
#147 175 6 in (152 mm)
#147 176 10 in (254 mm)
Used with .030–1/16 in (0.8–1.6 mm) wire. Kits
supplied with two liners that accommodate all
wire sizes.
3 in Head Tube Extension #137 787
Extends the standard gun barrel 3 in (72 mm)
when a longer reach is required. The head tube
extension is supplied with two liners to accommodate all wire sizes.
Replacement Teflon Liners for Air-Cooled
Barrels (Order from Miller Service Parts.)
For 6 in Curved Barrel
#144 858 .030 and .035 in (0.8 and 0.9 mm) wire
#144 859 .047 and 1/16 in (1.2 and 1.6 mm) wire
For 10 in Curved Barrel
#144 854 .030 and .035 in (0.8 and 0.9 mm) wire
#144 855 .047 and 1/16 in (1.2 and 1.6 mm) wire
SX 12 in Flex Head Kit #131 104
For .030–1/16 in (0.8–1.6 mm) wire. Used in
place of the standard straight barrel. Flexible
head tube bends 60 degrees in any direction
for easier joint access and improved operator
comfort. Supplied with two Teflon liners and
one contact tip for each wire size listed.
SX-A 50 Degree Curved Nozzle Kit #147 174
Attaches to standard gun barrel assembly and
is ideal for access to confined weld joint areas.
Used with .030–1/16 in (0.8–1.6 mm) wire.
Kit includes two of each size contact tips to
accommodate all wire sizes. Uses standard
straight barrel head tube liner.
Replacement Contact Tips for Curved Nozzle
(Order from Miller Service Parts.)
#148 155 .030 and .035 in (0.8 and 0.9 mm) wire
#148 154 .047 in (1.2 mm) wire
#148 156 1/16 in (1.6 mm) wire
For Flex Head
#138 255 .030 and .035 in(0.8 and 0.9 mm) wire
#132 682 3/64 and 1/16 in (1.2 and 1.6 mm) wire
For Head Tube Extension
#138 223 .030 and .035 in (0.8 and 0.9 mm) wire
#138 224 3/64 and 1/16 in (1.2 and 1.6 mm) wire
XR-Pistol Gun Barrels (Water-Cooled)
Replacement Teflon Liners for Water-Cooled
Barrels (Order from Miller Service Parts.)
SX-W 50 Degree Curved Barrels
#130 843 6 in (152 mm)
#130 842 10 in (254 mm)
Used with .030–1/16 in (0.8–1.6 mm) wire. Kits
supplied with two liners that accommodate all
wire sizes.
SX-W 10 in Straight Barrel #130 841
Used with .030–1/16 in (0.8–1.6 mm) wire. Kits
supplied with two liners that accommodate all
wire sizes.
For 6 in Curved Barrel
#144 858 .030 and .035 in (0.8 and 0.9 mm) wire
#144 859 .047 and 1/16 in (1.2 and 1.6 mm) wire
For 10 in Curved Barrel
#144 854 .030 and .035 in (0.8 and 0.9 mm) wire
#144 855 .047 and 1/16 in (1.2 and 1.6 mm) wire
For 10 in Straight Barrel
#144 857 .030 and .035 in (0.8 and 0.9 mm) wire
#144 856 .047 and 1/16 in (1.2 and 1.6 mm) wire
5
XR Control Options
*Factory option available only in XR Control packages — see Ordering Information on page 8.
Voltage Control* #194 027 Field
Allows voltage adjustment at the current
XR Control when used with Miller electrically
controlled, constant-voltage DC power sources
that have a 14-pin receptacle.
Digital Display V/WFS* #193 274 Field
Allows wire feed speed to be preset and
displayed. Will also monitor voltage while
welding. If used with current manufactured
Miller CV or CC/CV power sources (excluding
CPs) and the optional voltage control or dual
schedule control is used, the arc voltage can
also be preset on the digital display. Includes
back-lit LCD digital display that is easy to read
in virtually any lighting condition. A selector
switch allows the display to switch between
wire feed speed and voltage.
Gas Flowmeter*
#193 278 Field
#197 793 Field w/CE
Monitors and adjust gas flow
at the XR Control.
Note: Gas pressure must be controlled
at the primary gas supply with the use
of a regulator.
Dual Schedule Control* #193 276 Field
Allows two different welding conditions
(voltage and wire feed speed) to be used on the
same wire. This is ideal when different heat
settings are required or when the need arises to
change conditions while welding, i.e. different
material thickness, out of position welding, etc.
Is also ideal for use as a start control or crater
fill control.
Spot Weld/Burnback
Control #193 279 Field
Provides up to 5 seconds
of spot weld time and
0 (zero) to 0.25 seconds of
burnback time.
Note: The Digital Display option is required to use the Dual
Schedule. Only for use with Miller CV or CC/CV power
sources. Dual Schedule Switch required.
Dual Schedule Switch
DSS-30 #193 271 Field
For 15 ft (4.6 m) and 30 ft (9 m) guns
DSS-50 #193 272 Field
For 50 ft (15.2 m) gun
Required to operate the dual schedule control.
A two position slide switch that can be
positioned at the XR-Edge gun to remotely
select schedule A or B conditions.
Water Flow Shutdown Switch #194 039 Field
For use with water cooled guns only. Protects
the water-cooled gun from overheating if water
is not present or water stops flowing to the gun.
XR Control Accessories
Optima™ MIG (GMAW) Pulse Control
#043 389
For Invision, Phoenix 456P and XMT 304 CC/CV.
A multipurpose, microprocessor-based pulse
control for synergic MIG (wire welding or
GMAW), manual MIG pulsing or standard MIG
welding. Use this control with all above power
sources and any Miller wire feeder. Includes
25 ft (7.6 m) cord with 14-pin plug.
PSA-2 Control #141 604
Required when using the XR
control with power sources
having only 115 VAC available.
Mounts at power source and
includes a 10 ft (3 m) 115 VAC
cord and contactor cord with
Hubbell connectors. A simple
modification in the PSA-2 control also allows it
to be used with competitive constant voltage
power sources requiring a contact closure for
contactor control. The PSA-2 includes a 14-pin
receptacle for direct connection of the
standard interconnecting cord and optional
extension cords. Bracket included for side
mounting to the power source.
Note: When using the PSA-2 control, the optional Remote
Voltage Control is not functional.
Extension Cords
#122 973 25 ft (7.6 m)
#122 974 50 ft (15.2 m)
#122 975 75 ft (22.9 m)
Provides 14-pin, 24 VAC, contactor and voltage
control. Can be added to the standard 10 ft (3 m)
feeder cord to extend feeder farther from
power source.
6
Water Coolant Systems
Coolmate V3
Coolmate 4
Coolmate 3
Coolmate™ 3
Coolmate™ 3
Coolmate™ V3
Coolmate™ 4
#043 007
#043 008
#043 009
#042 288
115 VAC
230 VAC
115 VAC
115 VAC
For use with water-cooled guns. Refer to
Lit. Index No. AY/7.2 for additional coolant
system information.
Coolant #043 810
Sold in cases of four 1-gallon recyclable plastic
bottles.
Typical Welding Systems for Aluminum MIG Welding
Conventional Aluminum MIG System
CP-252TS with XR™ Control
and 30 ft XR-A Edge Gun
#950 704
Aluminum MIG and Pulsed MIG System
Invision™ 354MP with XR™ Control
and 30 ft XR-A Edge Gun
#950 705
Note: For high-current pulse welding,
water-cooled system recommended.
7
Ordering Information and System Checklist
How to Assemble a System
Equipment
Stock No.
Description
Qty.
Important: The XR Control and specific type and length gun must be ordered separately.
Also order proper wire drive kit below for the size wire being used.
1
XR™ Control
#181 538
#181 538-01-1
#181 538-03-3
#181 538-04-2
#181 538-03-2
#181 538-04-1
Standard model
Standard model w/CE
W/digital display, voltage control & gas flow meter
W/digital display, voltage control & gas flow meter w/CE
W/digital display, dual schedule & gas flow meter
W/digital display, dual schedule & gas flow meter w/CE
XR-A Edge Gun (Air-Cooled)
#181 534
#181 534-01-1
#181 535
#181 535-01-1
#181 537
#181 537-01-1
15 ft (4.6 m) cable
15 ft (4.6 m) cable w/CE
30 ft (9 m) cable
30 ft (9 m) cable w/CE
50 ft (15.2 m) cable
50 ft (15.2 m) cable w/CE
XR-W Edge Gun (Water-Cooled)
#181 531
#181 531-01-1
#181 532
#181 532-01-1
#181 533
#181 533-01-1
15 ft (4.6 m) cable
15 ft (4.6 m) cable w/CE
30 ft (9 m) cable
30 ft (9 m) cable w/CE
50 ft (15.2 m) cable
50 ft (15.2 m) cable w/CE
XR-A Pistol Gun (Air-Cooled)
#198 127
#198 128
15 ft (4.6 m) cable. New with quick-disconnect
30 ft (9 m) cable. New with quick-disconnect
XR-W Pistol Gun (Water-Cooled)
#198 129
#198 130
15 ft (4.6 m) cable. New with quick-disconnect
30 ft (9 m) cable. New with quick-disconnect
XR-Edge Gun Wire Drive Kits
(One Required — See page 3
for Insulated Wire Drive Kits)
#193 520
#193 521
#196 300
#193 522
.030 in (0.8 mm)
.035 in (0.9 mm)
.040 in (1.0 mm)
.047 in (1.2 mm)
XR-Pistol Gun Wire Drive Kits
(One Required)
#198 384
#198 383
#198 382
#198 381
.030/.035 in (0.8/0.9 mm)
.040 in (1.0 mm)
.047 in (1.2 mm)
.062 in (1.6 mm)
CP-252TS with XR Control
and XR-Edge Gun Package
#950 704
Complete conventional aluminum MIG package
Invision 354MP with XR Control
and XR-Edge Gun Package
#950 705
Complete aluminum MIG and pulsed MIG package
Voltage Control
#194 027
Field
Digital Display V/WFS
#193 274
Field
Dual Schedule Control
#193 276
Field
Dual Schedule Switch
#193 271
#193 272
Field. For 15 ft (4.6 m) and 30 ft (9 m) guns
Field. For 50 ft (15.2 m) gun
Gas Flowmeter
#193 278
#193 278-01-1
Field
Field w/CE
Spot Weld/Burnback Control
#193 279
Field
Water Flow Shutdown Switch
#194 039
Field
Pick a Control
Standard or
with Options
2
Pick a Gun Style
Gooseneck or Pistol
15, 30 or 50 ft Cable
Air- or Water-Cooled
or
3
Pick a Wire Drive Kit
.030, .035, .040, .047 or .062 in
Wire drive kits consist of gun drive
rolls, two push feeder drive rolls,
head tube liner, five contact tips,
collet nut and a contact tip wrench.
Options
Recommended Power
Sources*
Regency® 250
Lit. Index No. DC/12.6
CP-252TS
Lit. Index No. DC/13
Lit. Index No. DC/16.2
Deltaweld ® Series
Shopmaster ™
Lit. Index No. AD/2.3
Lit. Index No. DC/18.8
XMT® 304
Lit. Index No. DC/23
Invision™ 354 MP
Lit. Index No. ED/4.5
Trailblazer ® 251
Miller Air Pak™
Lit. Index No. ED/10.5
PipePro™
Lit. Index No. ED/10.6
Trailblazer ® 300D NT Lit. Index No. ED/4.6
*other power sources may be used
Accessories
Optima MIG Pulse Control
#043 389
PSA-2 Control
#141 604
Extension Cords
Important note: The products and
descriptions mentioned in this literature
are for use with XR Control systems with
serial #KK309906 or higher. To confirm
compatibility of any products listed here
with older equipment, please contact
the factory.
Water Coolant Systems
See Lit. Index No. AY/7.2
Cable Cover
#118 677
#118 678
15 ft (4.5 m)
30 ft (9 m)
SX Heat Shield
#131 103
For XR-Pistol gun only
Spool Canister
#132 230
XR-Pistol Gun Barrels
Date:
Distributed by:
Litho in USA
For use with older 115 V power sources
See XR Control Accessories on page 6
See page 5
Total Quoted Price:
Price
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